2004 YAMAHA YZF-R1SC brake pads

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)
ProCarManuals.com

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.
ProCarManuals.com

4-20
FRONT AND REAR BRAKESCHAS
NOTE:
NOTE: REPLACING THE REAR BRAKE PADS
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the brake caliper.
1. Remove :

screw plug
1

brake pad pin 2

brake caliper 3

brake pad spring
2. Remove :

brake pads
1
(along with the brake pad shims 2)
3. Measure :

brake pad wear limit
a
Out of specification
Replace the brake
pads as a set.
Brake pad wear limit
1.0 mm (0.04 in)
4. 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.
ProCarManuals.com

4-39
A
B
FRONT AND REAR BRAKESCHAS
WARNING
EAS00633
CHECKING THE FRONT AND REAR BRAKE
CALIPERS
Recommended brake component
p
replacement schedule
Brake padsIf necessary
Piston sealsEvery two years
Brake hosesEvery four years
Brake fluidEvery two years
and whenever the
brake is disas-
sembled
1. Check:

brake caliper pistons
1
Rust / scratches / wear
Replace the brake
caliper pistons.

brake caliper cylinders
2
Scratches / wear
Replace the brake cali-
per assembly.

brake caliper body
3
Cracks / damage
Replace the brake cali-
per assembly.

brake fluid delivery passages
(brake caliper body)
Obstruction
Blow out with compressed air.
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
AFront
BRear
2. Check:

brake caliper bracket
1
Cracks / damage
Replace.
ProCarManuals.com

4-40
FRONT AND REAR BRAKESCHAS
WARNING
35 Nm (3.5 m
kg, 25 ft
lb)
30 Nm (3.0 m
kg, 22 ft
lb)
6 Nm (0.6 m
kg, 4.3 ft
lb)
WARNING
CAUTION:
EAS00640
ASSEMBLING AND INSTALLING THE
FRONT BRAKE CALIPERS
The following procedure applies to both of the
brake calipers.

Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.

Never use solvents on internal brake com-
ponents as they will cause the piston seals
to swell and distort.

Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
Recommended brake fluid
DOT 4
1. Install :

brake pads

brake pad spring

brake pad pin
2. Install:

brake caliper
1

copper washers New

brake hose
2

union bolt 3

brake hose holder
Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
“CABLE ROUTING”.
When installing the brake hose onto the
brake caliper
1, make sure the brake pipe a
touches the projection b on the brake cali-
per.
ProCarManuals.com