2004 YAMAHA YZF-R1S brakes

FRONT AND REAR BRAKES4-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE PADS 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE PADS 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE FRONT BRAKE PADS 4-18. . . . . . . . . . . . . . . . . . . . .
REPLACING THE REAR BRAKE PADS 4-20. . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE MASTER CYLINDER 4-22. . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE MASTER CYLINDER 4-25. . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT BRAKE MASTER
CYLINDER 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE REAR BRAKE MASTER
CYLINDER 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE MASTER
CYLINDERS 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING AND INSTALLING THE FRONT BRAKE
MASTER CYLINDER 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4-31. . . . . . .
FRONT BRAKE CALIPERS 4-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE CALIPER 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT BRAKE CALIPERS 4-37. . . . . . . . . . .
DISASSEMBLING THE REAR BRAKE CALIPER 4-38. . . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE CALIPERS 4-39. . . . . .
ASSEMBLING AND INSTALLING THE FRONT BRAKE
CALIPERS 4-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING AND INSTALLING THE REAR
BRAKE CALIPER 4-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK4-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK LEGS 4-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT FORK LEGS 4-47. . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT FORK LEGS 4-48. . . . . . . . . . . . . . . . .
CHECKING THE FRONT FORK LEGS 4-49. . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE FRONT FORK LEGS 4-50. . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT FORK LEGS 4-55. . . . . . . . . . . . . . . . . . . . . .
HANDLEBARS4-56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE HANDLEBARS 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE HANDLEBARS 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE HANDLEBARS 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STEERING DAMPER 4-60. . . . . . . . . . . . . . . . . . . . . . .
STEERING HEAD4-61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNDER BRACKET 4-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE UNDER BRACKET 4-63. . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STEERING HEAD 4-63. . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE STEERING HEAD 4-64. . . . . . . . . . . . . . . . . . . . . . . . .
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2-12
CHASSIS SPECIFICATIONSSPEC
ItemStandardLimit
Front brakes
Brake type
Operation
Recommended fluid
Brake lever free play
Brake discs
Diameter
thickness
Min. thickness
Max. deflection
Brake pad lining thickness (inner)
Brake pad lining thickness (outer)
Master cylinder inside diameter
Caliper cylinder inside diameter
Dual disc brake
Right hand operation
DOT 4
2.3  11.5 mm (0.09  0.45 in)
320
4.5 mm (12.60
0.18 in)








4.5 mm (0.18 in)
4.5 mm (0.18 in)
14 mm (0.55 in)
30.1 mm and 27 mm (1.19 in and 1.06 in)



















4.0 mm
(0.16 in)
0.1 mm
(0.004 in)
0.5 mm
(0.02 in)
0.5 mm
(0.02 in)








Rear brake
Brake type
Operation
Recommended fluid
Brake pedal freeplay
Brake discs
Diameter
thickness
Min. thickness
Max. deflection
Brake pad lining thickness (inner)
Brake pad lining thickness (outer)
Master cylinder inside diameter
Caliper cylinder inside diameter
Single disc brake
Right foot operation
DOT 4
4.3  9.3 mm (0.17  0.37 in)
220
5 mm (8.66
0.20 in)








6.0 mm (0.24 in)
6.0 mm (0.24 in)
12.7 mm (0.5 in)
31.8 mm (1.25 in)



















4.5 mm
(0.18 in)
0.15 mm
(0.006 in)
1.0 mm
(0.04 in)
1.0 mm
(0.04 in)








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3-46
B
A
B
A
CHECKING THE FRONT AND REAR BRAKE PADS
/
CHECKING THE FRONT AND REAR BRAKE HOSESCHK
ADJ
2. Check:

front brake pad

rear brake pad
Brake pad wear limit
a, b
Wear limit reached
Replace the brake
pads as a set.
Refer to “FRONT AND REAR BRAKES” in
chapter 7.
Brake pad wear limit
a 0.5 mm (0.02 in)
b 1.0 mm (0.04 in)
AFront brake
BRear brake
EAS00131
CHECKING THE FRONT AND REAR BRAKE
HOSES
The following procedure applies to all of the
brake hoses and brake hose clamps.
1. Check:

brake hose
1
Cracks / damage / wear
Replace.
AFront
BRear
2. Check:

brake hose clamp
2
Loose
Tighten the clamp bolt.
3. Hold the motorcycle upright and apply the
brake several times.
4. Check:

brake hose
Brake fluid leakage
Replace the damaged
hose.
Refer to “FRONT AND REAR BRAKES” in
chapter 4.
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4-15
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7Removing the front brake pads
Brake hose holder
Front brake caliper
Brake pad clip
Brake pad pin
Brake pad spring
Brake pad
Bleed screw1
1
2
1
1
2
1Remove the parts in the order listed.
The following procedure applies to both of
the front brake calipers.
For installation, reverse the removal
procedure.
NOTE:
5 Nm (0.5 m
kg, 3.6 ft
lb)
35 Nm (3.5 m
kg, 25 ft
lb)
6 Nm (0.6 m
kg, 4.3 ft
lb)
FRONT AND REAR BRAKESCHAS
EAS00577
FRONT AND REAR BRAKES
FRONT BRAKE PADS
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4-16
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7Removing the rear brake pads
Screw plug
Brake pad pin
Rear brake caliper
Brake pad shim
Brake pad
Bleed screw
Brake pad spring1
1
1
4
2
1
1Remove the parts in the order listed.
For installation, reverse the removal
procedure.
5 Nm (0.5 m
kg, 3.6 ft
lb)
27 Nm (2.7 m
kg, 20 ft
lb)
3 Nm (0.3 m
kg, 2.2 ft
lb)
17 Nm (1.7 m
kg, 12 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
REAR BRAKE PADS
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4-17
FRONT AND REAR BRAKESCHAS
CAUTION:
WARNING
EAS00579
Disc brake components rarely require dis-
assembly.
Therefore, always follow these preventive
measures:

Never disassemble brake components un-
less absolutely necessary.

If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly.

Never use solvents on internal brake com-
ponents.

Use only clean or new brake fluid for clean-
ing brake components.

Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.

Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:

Flush with water for 15 minutes and get im-
mediate medical attention.
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4-18
FRONT AND REAR BRAKESCHAS
NOTE:
EAS00582
REPLACING THE FRONT BRAKE PADS
The following procedure applies to both brake
calipers.
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the brake caliper.
1. Remove:

brake hose holder
1

brake caliper 2
2. Remove:

brake pad clips
1

brake pad pin 2

brake pad spring 3
3. Remove:

brake pads
1
(along with the brake pad shims)
4. Measure:

brake pad wear limit
a
Out of specification
Replace the brake
pads as a set.
Brake pad wear limit
0.5 mm (0.02 in)
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4-19
FRONT AND REAR BRAKESCHAS
NOTE:
NOTE:
35 Nm (3.5 m
kg, 25 ft
lb)
5. Install:

brake pad shims
(onto the brake pads)

brake pads

brake pad spring
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.
a. Connect a clear plastic hose
1 tightly to the
bleed screw
2. Put the other end of the hose
into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
Bleed screw
5 Nm (0.5 m
kg, 3.6 ft
lb)
d. Install a new brake pad shim onto each new
brake pad.
Install the brake pad spring pointing
a toward
the bleed screw.
e. Install new brake pads and a new brake pad
spring.
6. Install:

brake pad pins

brake pad clips

brake caliper
7. Check:

brake fluid level
Below the minimum level mark
a
Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
8. Check:

brake lever operation
Soft or spongy feeling
Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
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