2004 YAMAHA YZF-R1SC brake

3-53
CHECKING AND ADJUSTING THE STEERING HEAD /
CHECKING THE FRONT FORKCHK
ADJ
WARNING
Steering head tension
200
500 g
e. Repeat the above procedure on the opposite
handlebar.
f. If the steering head tension is out of specifi-
cation (both handlebars should be within
specification), remove the upper bracket and
loosen or tighten the upper ring nut.
g. Reinstall the upper bracket and measure the
steering head tension again as described
above.
h. Repeat the above procedure until the steer-
ing head tension is within specification.
i. Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding / looseness
Adjust the steering
head.
EAS00150
CHECKING THE FRONT FORK
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
2. Check:

inner tube
1
Damage / scratches
Replace.

oil seal
2
Oil leakage
Replace.
3. Hold the motorcycle upright and apply the
front brake.
4. Check:

front fork operation
Push down hard on the handlebars several
times and check if the front fork rebounds
smoothly.
Rough movement
Repair.
Refer to “FRONT FORK” in chapter 4.
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4-1
4
FRONT WHEEL AND BRAKE DISCSCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the front wheel and brake
discs
Side reflector (left and right)
Brake hose holder (left and right)
Side reflector bracket
Front brake caliper (left and right)
Front wheel axle pinch bolt
Front wheel axle bolt
Front wheel axle
Collar (left and right)
Front wheel
Front brake disc (left and right)2
2
2
2
4
1
1
2
1
2Remove the parts in the order listed.
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
For installation, reverse the removal
procedure.
NOTE:
35 Nm (3.5 m
kg, 25 ft
lb)
6 Nm (0.6 m
kg, 4.3 ft
lb)
91 Nm (9.1 m
kg, 66 ft
lb)
20 Nm (2.0 m
kg, 13 ft
lb)
6 Nm (0.6 m
kg, 4.3 ft
lb)
18 Nm (1.8 m
kg, 13 ft
lb)
2 Nm (0.2 m
kg, 1.4 ft
lb)
2 Nm (0.2 m
kg, 1.4 ft
lb)
EAS00514
CHASSIS
FRONT WHEEL AND BRAKE DISCS
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4-2
FRONT WHEEL AND BRAKE DISCSCHAS
Order Job / Part Q’ty Remarks
Disassembling the front wheel
Oil seal (left and right)
Wheel bearing (left and right)
Spacer2
2
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly
procedure.
1
2
3
EAS00518
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4-3
FRONT WHEEL AND BRAKE DISCSCHAS
WARNING
NOTE:
NOTE:
NOTE:
WARNING
EAS00521
REMOVING THE FRONT WHEEL
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
2. Remove:

left brake caliper

right brake caliper
Refer to “FRONT BRAKE CALIPERS”.
Do not apply the brake lever when removing the
brake calipers.
3. Elevate:

front wheel
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
4. Loosen :

front wheel axle pinch bolt
5. Remove :

front wheel axle bolt

front wheel axle

front wheel
EAS00525
CHECKING THE FRONT WHEEL
1. Check:

wheel axle
Roll the wheel axle on a flat surface.
Bends
Replace.
Do not attempt to straighten a bent wheel
axle.
2. Check:

tire

front wheel
Damage / wear
Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
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4-4
FRONT WHEEL AND BRAKE DISCSCHAS
NOTE:
CAUTION:
NOTE:
3. Measure:

radial wheel runout
1

lateral wheel runout 2
Over the specified limits
Replace.
Radial wheel runout limit
1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
4. Check:

wheel bearings
Front wheel turns roughly or is loose
Re-
place the wheel bearings.

oil seals
Damage / wear
Replace.
5. Replace:

wheel bearings
New

oil seals
New
a. Clean the outside of the front wheel hub.
b. Remove the oil seals
1 with a flat-head
screwdriver.
To prevent damaging the wheel, place a rag
2
between the screwdriver and the wheel surface.
c. Remove the wheel bearings
3 with a gener-
al bearing puller.
d. Install the new wheel bearings and oil seals
in the reverse order of disassembly.
Do not contact the wheel bearing inner race
1 or balls 2. Contact should be made only
with the outer race
3.
Use a socket
4 that matches the diameter of
the wheel bearing outer race and oil seal.
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4-5
FRONT WHEEL AND BRAKE DISCSCHAS
NOTE:
EAS00533
CHECKING THE BRAKE DISCS
The following procedure applies to all of the
brake discs.
1. Check:

brake disc
Damage / galling
Replace.
2. Measure:

brake disc deflection
Out of specification
Correct the brake disc
deflection or replace the brake disc.
Brake disc deflection limit
(maximum)
Front : 0.1 mm (0.004 in)
Rear : 0.15 mm (0.006 in)
a. Place the motorcycle on a suitable stand so
that the wheel is elevated.
b. Before measuring the front brake disc deflec-
tion, turn the handlebars to the left or right to
ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 1.5 mm (0.06 in) be-
low the edge of the brake disc.
3. Measure:

brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification
Replace.
Brake disc thickness limit
(minimum)
Front : 4.0 mm (0.16 in)
Rear : 4.5 mm (0.18 in)
4. Adjust:

brake disc deflection
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
Tighten the brake disc bolts in stages and in a
crisscross pattern.
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4-6
FRONT WHEEL AND BRAKE DISCSCHAS
NOTE:
91 Nm (9.1 m
kg, 66 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb)
CAUTION:
Brake disc bolt
Front : 18 Nm (1.8 m
kg, 13 ft
lb)
Rear : 30 Nm (3.0 m
kg, 22 ft
lb)
LOCTITE

d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be brought
within specification, replace the brake disc.
EAS00545
INSTALLING THE FRONT WHEEL
The following procedure applies to both brake
discs.
1. Lubricate:

wheel axle

oil seal lips
Recommended lubricant
Lithium-soap-based grease
2. Lift the wheel up between the fork legs.
3. Insert the wheel axle.
Install the tire and wheel with the mark
1 point-
ing in the direction of wheel rotation.
4. Lower the front wheel so that it is on the
ground.
5. Tighten:

wheel axle

wheel axle pinch bolt
Before tightening the wheel axle nut, push
down hard on the handlebars several times
and check if the front fork rebounds smooth-
ly.
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4-7
FRONT WHEEL AND BRAKE DISCSCHAS
35 Nm (3.5 m
kg, 25 ft
lb)
NOTE:
WARNING
NOTE:
NOTE:
6. Install:

brake caliper (left and right)
Make sure that there is enough space between
the brake pads before installing the brake cali-
pers onto the brake discs.
Make sure the brake hose is routed properly.
EAS00549
ADJUSTING THE FRONT WHEEL STATIC
BALANCE

After replacing the tire, wheel or both, the front
wheel static balance should be adjusted.

Adjust the front wheel static balance with the
brake discs installed.
1. Remove:

balancing weight(s)
2. Find:

front wheel’s heavy spot
Place the front wheel on a suitable balancing
stand.
a. Spin the front wheel.
b. When the front wheel stops, put an “X
1” mark
at the bottom of the wheel.
c. Turn the front wheel 90 so that the “X
1” mark
is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an “X
2” mark at
the bottom of the wheel.
f. Repeat steps (d) through (f) several times
until all the marks come to rest at the same
spot.
g. The spot where all the marks come to rest is
the front wheel’s heavy spot “X”.
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