warning YAMAHA YZF-R1S 2004 Owner's Guide

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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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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4-17
FRONT AND REAR BRAKESCHAS
CAUTION:
WARNING
EAS00579
Disc brake components rarely require dis-
assembly.
Therefore, always follow these preventive
measures:

Never disassemble brake components un-
less absolutely necessary.

If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly.

Never use solvents on internal brake com-
ponents.

Use only clean or new brake fluid for clean-
ing brake components.

Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.

Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:

Flush with water for 15 minutes and get im-
mediate medical attention.
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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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4-30
FRONT AND REAR BRAKESCHAS
NOTE:
WARNING
CAUTION:

While holding the brake hose, tighten the
union bolt.

Turn the handlebars to the left and right to
make sure the brake hose does not touch oth-
er parts (e.g., wire harness, cables, leads).
Correct if necessary.
4. 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.
5. Bleed:

brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
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4-31
FRONT AND REAR BRAKESCHAS
30 Nm (3.0 m
kg, 22 ft
lb)
WARNING
CAUTION:
6. 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.
7. Check:

brake lever operation
Soft or spongy feeling
Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00608
ASSEMBLING THE REAR BRAKE MASTER
CYLINDER
1. Install:

brake master cylinder kit

circlip

dust boot
2. Install:

copper washers
New

brake hoses

union bolt
Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
“CABLE ROUTING”.
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection
a as shown.
3. Fill:

brake fluid reservoir
(to the maximum level mark
b)
Recommended brake fluid
DOT 4
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4-32
FRONT AND REAR BRAKESCHAS
WARNING
CAUTION:

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. Adjust:

rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” in chapter 3.
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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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4-39
A
B
FRONT AND REAR BRAKESCHAS
WARNING
EAS00633
CHECKING THE FRONT AND REAR BRAKE
CALIPERS
Recommended brake component
p
replacement schedule
Brake padsIf necessary
Piston sealsEvery two years
Brake hosesEvery four years
Brake fluidEvery two years
and whenever the
brake is disas-
sembled
1. Check:

brake caliper pistons
1
Rust / scratches / wear
Replace the brake
caliper pistons.

brake caliper cylinders
2
Scratches / wear
Replace the brake cali-
per assembly.

brake caliper body
3
Cracks / damage
Replace the brake cali-
per assembly.

brake fluid delivery passages
(brake caliper body)
Obstruction
Blow out with compressed air.
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
AFront
BRear
2. Check:

brake caliper bracket
1
Cracks / damage
Replace.
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