2004 YAMAHA YZF-R1SC Service Manual

4-22
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the front brake master
cylinder
Brake fluid
Stopper
Brake fluid reservoir cap
Brake fluid reservoir diaphragm holder
Brake fluid reservoir diaphragm
Brake fluid reservoir tank
Brake fluid reservoir hose
Brake lever
Front brake switch connector
Union bolt1
1
1
1
1
1
1
2
1Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE BRAKE
FLUID” in chapter 3.
Disconnect.
3.8 Nm (0.38 m
kg, 2.7 ft
lb)
1.2 Nm (0.12 m
kg, 0.9 ft
lb)
13 Nm (1.3 m
kg, 9.4 ft
lb)
30 Nm (3.0 m
kg, 22 ft
lb)
EAS00584
FRONT BRAKE MASTER CYLINDER
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4-23
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
10
11
12
13
14Copper washer
Brake hose
Brake master cylinder bracket
Brake master cylinder
Front brake light switch2
1
1
1
1
For installation, reverse the removal
procedure.
3.8 Nm (0.38 m
kg, 2.7 ft
lb)
1.2 Nm (0.12 m
kg, 0.9 ft
lb)
13 Nm (1.3 m
kg, 9.4 ft
lb)
30 Nm (3.0 m
kg, 22 ft
lb)
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4-24
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
Disassembling the front brake
master cylinder
Brake master cylinder kit
Bleed screw
Brake master cylinder body1
1
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly
procedure.
1
2
3
6 Nm (0.6 m
kg, 4.3 ft
lb)
EAS00585
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4-25
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11Removing the rear brake master
cylinder
Brake fluid
Brake fluid reservoir cap
Brake fluid reservoir diaphragm holder
Brake fluid reservoir diaphragm
Brake fluid reservoir tank
Brake fluid reservoir hose
Hose joint
Bush
Union bolt
Copper washer
Brake hose
Brake master cylinder1
1
1
1
1
1
1
1
2
1
1Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE BRAKE
FLUID” in chapter 3.
For installation, reverse the removal
procedure.
30 Nm (3.0 m
kg, 22 ft
lb)18 Nm (1.8 m
kg, 13 ft
lb)
EAS00586
REAR BRAKE MASTER CYLINDER
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4-26
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
Disassembling the rear brake master
cylinder
Brake master cylinder kit
Hose joint
Bush
Brake master cylinder body1
1
1
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly
procedure.
1
2
3
4
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4-27
FRONT AND REAR BRAKESCHAS
NOTE:
NOTE:
NOTE:
EAS00588
DISASSEMBLING THE FRONT BRAKE
MASTER CYLINDER
Before disassembling the front brake master
cylinder, drain the brake fluid from the entire
brake system.
1. Disconnect:

brake light switch connector
1
(from the brake light switch)
2. Remove:

union bolt
2

copper washers 3

brake hose 4
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
3. Remove :

brake master cylinder bracket

brake master cylinder assembly
4. Remove :

dust boot

circlip
EAS00589
DISASSEMBLING THE REAR BRAKE
MASTER CYLINDER
1. Remove:

union bolt
1

copper washers 2

brake hose 3
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
2. Remove :

brake master cylinder assembly
3. Remove :

dust boot

circlip
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4-28
A
B
A
B
BA
FRONT AND REAR BRAKESCHAS
EAS00593
CHECKING THE FRONT AND REAR BRAKE
MASTER CYLINDERS
The following procedure applies to both of the
brake master cylinders.
1. Check:

brake master cylinder
Damage / scratches / wear
Replace.

brake fluid delivery passages
(brake master cylinder body)
Obstruction
Blow out with compressed air.
AFront
BRear
2. Check:

brake master cylinder kit
Damage / scratches / wear
Replace.
AFront
BRear
3. Check:

brake fluid reservoir
1
Cracks / damage
Replace.

brake fluid reservoir diaphragm
2
Cracks / damage
Replace.
AFront
BRear
4. Check:

brake hoses
Cracks / damage / wear
Replace.
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4-29
FRONT AND REAR BRAKESCHAS
WARNING
13 Nm (1.3 m
kg, 9.4 ft
lb)
NOTE:
30 Nm (3.0 m
kg, 22 ft
lb)
WARNING
EAS00607
ASSEMBLING AND INSTALLING THE
FRONT BRAKE MASTER CYLINDER

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.
Recommended brake fluid
DOT 4
1. Install :

brake master cylinder kit

circlip
New

dust boot
2. Install:

brake master cylinder
1

Install the brake master cylinder holder with
the “UP” mark
a facing up.

Align the end of the brake master cylinder
holder with the punch mark
b on the right han-
dlebar.

First, tighten the upper bolt, then the lower bolt.
There should be 2
2.5 mm (0.08
0.10 in)
for clearance between the right handlebar
switch and the brake master cylinder holder.
3. Install:

copper washers
New

brake hose

union bolt

brake light switch coupler
Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
“CABLE ROUTING”.
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