warning YAMAHA YZF-R1S 2004 Workshop Manual

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.
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4-41
FRONT AND REAR BRAKESCHAS
WARNING
CAUTION:
3. Fill:

brake fluid reservoir
(with the specified amount of the recom-
mended brake fluid)
Recommended brake fluid
DOT 4

Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.

Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.

When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:

brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM“ in chapter 3.
5. 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.
6. 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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4-42
FRONT AND REAR BRAKESCHAS
WARNING
27 Nm (2.7 m
kg, 20 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
30 Nm (3.0 m
kg, 22 ft
lb)
WARNING
CAUTION:
EAS00642
ASSEMBLING AND INSTALLING THE REAR
BRAKE CALIPER

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 caliper
1
(front)
(rear)

brake pad pin

screw plug

copper washers
New

brake hose
2

union bolt 3
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.
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4-43
FRONT AND REAR BRAKESCHAS
WARNING
CAUTION:
2. Fill:

brake fluid reservoir
(with the specified amount of the recom-
mended brake fluid)
Recommended brake fluid
DOT 4

Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.

Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.

When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
3. Bleed:

brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4. 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.
5. Check:

brake pedal operation
Soft or spongy feeling
Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
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4-47
FRONT FORKCHAS
WARNING
NOTE:
WARNING
EAS00649
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
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

front wheel

front brake caliper
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
3. Remove:

Side Cowlings
Refer to “COWLINGS” in chapter 3.

handlebar
4. Loosen:

handlebar pinch bolt
1

upper bracket pinch bolt 2

cap bolt 3

under bracket pinch bolt 4
Before loosening the upper and under
bracket pinch bolts, support the front fork
leg.
5. Remove:

front fork leg
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4-48
FRONT FORKCHAS
NOTE:
WARNING
NOTE:
CAUTION:
EAS00652
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Remove:

cap bolt
1
(from the damper adjusting rod)

spacer
2

nut 3
a. Press down on the spacer with the fork
spring compressor
4.
b. Install the rod holder
5 between the nut 3
and the spacer 2.
Fork spring compressor
90890-01441, YM-01441
Rod holder
90890-01434, YM-01434
Use the side of the rod holder that is marked “B”.
c. Loosen the nut.
d. Remove the cap bolt.
e. Remove the rod holder and fork spring com-
pressor.
The fork spring is compressed.
f. Remove the spacer and nut.
2. Drain:

fork oil
Stroke the damper rod
1 several times while
draining the fork oil.
3. Remove:

dust seal

oil seal clip
1

oil seal

washer
(with a flat-head screwdriver)
Do not scratch the inner tube.
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4-49
FRONT FORKCHAS
NOTE:
WARNING
4. Remove:

damper rod assembly bolt

damper rod assembly
While holding the damper rod assembly with the
damper rod holder
1, loosen the damper rod
assembly bolt.
Damper rod holder
90890-01423, YM-01423
EAS00656
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Check:

inner tube
1

outer tube 2
Bends / damage / scratches
Replace.
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Measure:

spring free length
a
Out of specification
Replace.
Spring free length
236.5 mm (9.31 in)
<Limit> : 231.8 mm (9.13 in)
3. Check:

damper rod
1
Damage / wear
Replace.
Obstruction
Blow out all of the oil pas-
sages with compressed air.

damper rod adjusting rod
Bends / damage
Replace.
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4-50
FRONT FORKCHAS
CAUTION:
WARNING
NOTE:
The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly
sensitive to foreign material.

When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
4. Check:

cap bolt O-ring
1
Damage / wear
Replace.
EAS00659
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.

Make sure the oil levels in both front fork
legs are equal.

Uneven oil levels can result in poor han-
dling and a loss of stability.

When assembling the front fork leg, be sure to
replace the following parts:
– outer tube bushing
– oil seal
– dust seal
– Before assembling the front fork leg, make
sure all of the components are clean.
1. Install:

inner tube
1

damper rod assembly 2

damper rod assembly bolt

copper washer
New
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4-51
FRONT FORKCHAS
WARNING
CAUTION:
23 Nm (2.3 m
kg, 17 ft
lb)
NOTE:
Always use new copper washer.
Allow the damper rod assembly to slide
slowly down the inner tube
1 until it pro-
trudes from the bottom of the inner tube. Be
careful not to damage the inner tube.
2. Lubricate:

inner tube’s outer surface
Recommended lubricant
Suspension oil “01” or
equivalent
3. Tighten:

damper rod assembly bolt
1
LOCTITE
While holding the damper rod assembly with the
damper rod holder
2, tighten the damper rod
assembly bolt.
Damper rod holder
90890-01423, YM-01423
4. Install:

dust seal
1

oil seal clip 2

oil seal 3

washer 4
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4-54
FRONT FORKCHAS
NOTE:
WARNING
d. Press down on the spacer with the fork
spring compressor
1.
e. Pull up the rod puller and install the rod hold-
er
2 between the nut 3 and the spacer 4.
Use the side of the rod holder that is marked “B”.
Fork spring compressor
90890-01441, YM-01441
Rod holder
90890-01434, YM-01434
f. Remove the rod puller and adapter.
g. Install the nut
1 and position it as specified
b.
Distance
b
11 mm (0.43 in)
h. Set the cap bolt distance
c to specification.
Distance
c
13 mm (0.51 in)
i. Install the damper adjusting rod and cap bolt,
and then finger tighten the cap bolt.
j. Hold the cap bolt and tighten the nut to speci-
fication.
Nut
15 Nm (1.5 m
kg, 11 ft
lb)
k. Remove the rod holder and fork spring com-
pressor.

The fork spring is compressed.

Always use a new cap bolt O-ring.
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