ECU YAMAHA YZF-R1S 2004 User Guide

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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4-12
REAR WHEEL AND BRAKE DISCCHAS
WARNING
NOTE:
NOTE:
NOTE:
EAS00561
REMOVING THE REAR 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 rear wheel is elevated.
2. Remove:

brake caliper
1
Do not depress the brake pedal when removing
the brake caliper.
3. Loosen:

locknut
1

adjusting bolt 2
4. Remove:

wheel axle nut
1

wheel axle

rear wheel
Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
5. Remove:

left collar
1

rear wheel drive hub 2

rear wheel drive hub damper

right collar
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4-37
FRONT AND REAR BRAKESCHAS
NOTE:
NOTE:
WARNING
EAS00625
DISASSEMBLING THE FRONT BRAKE
CALIPERS
The following procedure applies to both of the
brake calipers.
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:

union bolt
1

copper washers 2

brake hose 3
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:

brake caliper pistons
1

brake caliper piston seals 2
a. Secure the brake caliper pistons with a piece
of wood
a.
b. Blow compressed air into the brake hose
joint opening
b to force out the left side pis-
tons from the brake caliper.

Never try to pry out the brake caliper pis-
tons.

Do not loosen the bolts
3.
c. Remove the brake caliper piston seals.
d. Repeat the previous steps to force out the
right side pistons from the brake caliper.
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4-38
FRONT AND REAR BRAKESCHAS
NOTE:
NOTE:
WARNING
EAS00626
DISASSEMBLING THE REAR BRAKE
CALIPER
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:

union bolt
1

copper washers 2

brake hose 3

brake caliper 4
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:

brake caliper piston
1

brake caliper piston seals 2
a. Secure the brake caliper piston with a piece
of wood
a.
b. Blow compressed air into the brake hose
joint opening
b to force out the piston from
the brake caliper.

Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.

Never try to pry out the brake caliper pis-
ton.
c. Remove the brake caliper piston seals.
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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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4-58
HANDLEBARSCHAS
WARNING
NOTE:
NOTE:
WARNING
WARNING
EAS00667
REMOVING THE HANDLEBARS
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:

handlebar grip
1
Blow compressed air between the left handle-
bar and the handlebar grip, and gradually push
the grip off the handlebar.
3. Remove:

throttle cable housing
1

throttle grip 2
While removing the throttle cable housing, pull
back the rubber cover
3.
EAS00669
CHECKING THE HANDLEBARS
1. Check:

left handlebar
1

right handlebar 2
Bends / cracks / damage
Replace.
Do not attempt to straighten bent handle-
bars as this may dangerously weaken them.
EAS00674
INSTALLING THE HANDLEBARS
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
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4-63
STEERING HEADCHAS
WARNING
WARNING
EAS00677
REMOVING THE UNDER BRACKET
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:

ring nut
1
(with the steering nut wrench 2)
Steering nut wrench
90890–01403, YU-33975
Securely support the lower bracket so that
there is no danger of it falling.
EAS00681
CHECKING THE STEERING HEAD
1. Wash:

bearings

bearing races
Recommended cleaning solvent
Kerosene
2. Check:

bearings
1

bearing races 2
Damage / pitting
Replace.
3. Replace:

bearings

bearing races
a. Remove the bearing races
1 from the steer-
ing head pipe with a long rod
2 and hammer.
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4-67
REAR SHOCK ABSORBER ASSEMBLYCHAS
WARNING
NOTE:
NOTE:
NOTE:
EAS00690
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Stand the motorcycle on a level surface.
Becurely support the motorcycle so that
there is no danger of it falling over.
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Remove:

bottom cowling
Refer to “COWLINGS” in chapter 3.

servo motor
Refer to “EXHAUST PIPE” in chapter 5.
3. Remove:

rear shock absorber assembly lower bolt
1

relay arm-to-swingarm bolt 2
While removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.
4. Remove:

rear shock absorber assembly upper bolt
1

rear shock absorber assembly
Raise the swingarm and then remove the rear
shock absorber assembly from between the
swingarm.
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4-71
SWINGARM AND DRIVE CHAINCHAS
WARNING
NOTE:
NOTE:
EAS00703
REMOVING THE SWINGARM
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 rear wheel is elevated.
2. Remove:

relay arm-to-swingarm bolt
1

connecting arm bolt 2

rear shock absorber assembly lower bolt 3
When removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.
3. Measure:

swingarm side play

swingarm vertical movement
a. Measure the tightening torque of the pivot
shaft nut.
Pivot shaft nut
105 Nm (10.5 m
kg, 76 ft
lb)
b. Measure the swingarm side play
A by mov-
ing the swingarm from side to side.
c. If the swingarm side play is out of specifica-
tion, check the spacers, bearings, washers,
and dust covers.
Swingarm side play
(at the end of the swingarm)
1.0 mm (0.04 in)
d. Check the swingarm vertical movement
B
by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers,
bearings, washers, and dust covers.
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4-72
SWINGARM AND DRIVE CHAINCHAS
WARNING
NOTE:
NOTE:
WARNING
EAS00704
REMOVING THE DRIVE CHAIN
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 rear wheel is elevated.
2. Remove:

drive chain
(with the drive chain cutter)
Only cut the drive chain if it or the swingarm is to
be replaced.
EAS00707
CHECKING THE SWINGARM
1. Check:

swingarm
Bends / cracks / damage
Replace.
2. Check:

pivot shaft
Roll the pivot shaft on a flat surface.
Bends
Replace.
Do not attempt to straighten a bent pivot
shaft.
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