brake YAMAHA YZF-R1 2000 User Guide

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6
EAU00713
Adjusting the rear brake light
switch The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction
a. To
make the brake light come on later,
turn the adjusting nut in direction
b.
EAU00721
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU00725
Front brake pads
Each front brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator groove. If a brake
pad has worn to the point that the wear
indicator groove has almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
1. Brake light switch
2. Adjusting nut
1. Wear indicator grooveFront
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EAU01248
Rear brake pads
1. Remove the rear brake caliper by
removing the bolts.2. Check each rear brake pad for
damage and measure the lining
thickness. If a brake pad is dam-
aged or if the lining thickness is
less than 0.5 mm, have a Yamaha
dealer replace the brake pads as a
set.
3. Install the rear brake caliper by in-
stalling the bolts, then tightening
them to the specified torque.
EAU00731
Checking the brake fluid level Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake flu-
id level may indicate worn brake pads
and/or brake system leakage. If the
brake level is low, be sure to check the
brake pads for wear and the brake sys-
tem for leakage.
1. Caliper bolt (´ 2)Rear
a. Lining thickness
Tightening torque:
Brake caliper bolt:
40 Nm (4.0 m·kg)
1. Minimum level markFront
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6 Observe these precautions:
l
When checking the fluid level,
make sure that the top of the mas-
ter cylinder is level by turning the
handlebars.
l
Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.
l
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
l
Be careful that water does not en-
ter the master cylinder when refill-
ing. Water will significantly lower
the boiling point of the fluid and
may result in vapor lock.
l
Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.
l
As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU00742
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the oil seals
of the brake master cylinders and cali-
pers as well as the brake hoses re-
placed at the intervals listed below or
whenever they are damaged or leak-
ing.l
Oil seals: Replace every two
years.
l
Brake hoses: Replace every four
years.
1. Minimum level mark
Recommended brake fluid: DOT 4Rear
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6
EAU03163
Lubricating the brake pedal The operation of the brake pedal
should be checked before each ride,
and the pedal pivot should be lubricat-
ed if necessary.
EAU03164
Checking and lubricating the
brake and clutch levers The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
EAU03165
Checking and lubricating the
sidestand The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
EW000113
WARNING
@ If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. @
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6
EAU03166
Lubricating the rear
suspension The pivoting points of the rear suspen-
sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU02939
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @Check the inner tubes for scratches,
damage and excessive oil leakage.To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
EC000098
CAUTION:@ If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it. @
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-37
6
EAU01358
Replacing the tail/brake light
bulb 1. Remove the passenger seat. (See
page 3-14 for passenger seat re-
moval and installation proce-
dures.)
2. Remove the tail/brake light bulb
cover.3. Remove the socket (together with
the bulb) by turning it counter-
clockwise.
4. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
5. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
6. Install the socket (together with
the bulb) by turning it clockwise.
7. Install the bulb cover.
8. Install the passenger seat.
EAU01095
Replacing a turn signal light
bulb 1. Remove the turn signal light lens
by removing the screw.
2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw.
1. Tail/brake light bulb cover
1. Socket
1. Screw
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-39
6
EAU03167
Front wheelTo remove the front wheel
EW000122
WARNING
@ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motor-
cycle so that there is no danger
of it falling over.
@1. Remove cowling A. (See page 6-5
for cowling removal and installa-
tion procedures.)2. Loosen the front wheel axle pinch
bolt, then the wheel axle and the
brake caliper bolts.
3. Lift the front wheel off the ground
according to the procedure on
page 6-38.4. Remove the brake hose holders
on each side by removing the
bolts.
5. Remove the brake caliper on each
side by removing the bolts.
6. Pull the wheel axle out, and then
remove the wheel.
ECA00046
CAUTION:@ Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut. @
1. Wheel axle
2. Pinch bolt
1. Brake hose holder bolt
2. Caliper bolt (´ 2)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-40
6
EAU01249
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle.
3. Lower the front wheel so that it is
on the ground.
4. Push down hard on the handlebar
several times to check for proper
fork operation.
5. Install the brake calipers by install-
ing the bolts.NOTE:@ Make sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brake
discs. @6. Install the brake hose holders by
installing the bolts.
7. Install the front wheel axle pinch
bolt, and then tighten the wheel
axle, pinch bolt and brake caliper
bolts to the specified torques.8. Install the cowling.Tightening torques:
Wheel axle:
72 Nm (7.2 m·kg)
Front wheel axle pinch bolt:
23 Nm (2.3 m·kg)
Brake caliper bolt:
40 Nm (4.0 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-41
6
EAU01247
Rear wheelTo remove the rear wheel
EW000122
WARNING
@ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motor-
cycle so that there is no danger
of it falling over.
@1. Loosen the axle nut and the brake
caliper bolts.
2. Lift the rear wheel off the ground
according to the procedure on
page 6-38.3. Remove the axle nut and the
brake caliper by removing the
bolts.
4. Loosen the locknut on each side of
the swingarm.
5. Turn the drive chain adjusting
bolts fully in direction
a.6. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:@ The drive chain does not need to be
disassembled in order to remove and
install the rear wheel. @7. Pull the wheel axle out, and then
remove the wheel.
ECA00048
CAUTION:@ Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut. @
1. Axle nut
2. Drive chain adjusting bolt
3. Locknut
1. Bolt (´ 2)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-42
6
EAU01246
To install the rear wheel
1. Install the wheel by inserting the
wheel axle.
2. Install the drive chain onto the rear
sprocket, and then adjust the drive
chain slack. (See page 6-27 for
drive chain slack adjustment pro-
cedures.)
3. Install the axle nut, and then lower
the rear wheel so that it is on the
ground.
4. Install the brake caliper by install-
ing the bolts.NOTE:@ Make sure that there is enough space
between the brake pads before install-
ing the brake caliper onto the brake
disc. @
5. Tighten the axle nut and brake cal-
iper bolts to the specified torques.
EAU03087
TroubleshootingAlthough Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills. Tightening torques:
Axle nut:
150 Nm (15.0 m·kg)
Brake caliper bolt:
40 Nm (4.0 m·kg)
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