brake pads YAMAHA YZF-R1S 2004 Service Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2004, Model line: YZF-R1S, Model: YAMAHA YZF-R1S 2004Pages: 457, PDF Size: 7.58 MB
Page 9 of 457
CHASSIS3-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT BRAKE 3-42. . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR BRAKE 3-43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE FLUID LEVEL 3-44. . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-45. . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE PADS 3-45. . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE HOSES 3-46. . . . . . . . .
BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-47. . . . . . . . . . . . . . .
ADJUSTING THE SHIFT PEDAL 3-48. . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE DRIVE CHAIN SLACK 3-49. . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE DRIVE CHAIN 3-50. . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE STEERING HEAD 3-51. . . . . . . . .
CHECKING THE FRONT FORK 3-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT FORK LEGS 3-54. . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-56. . . . .
CHECKING THE TIRES 3-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE WHEELS 3-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND LUBRICATING THE CABLES 3-61. . . . . . . . . . . . . . .
LUBRICATING THE LEVERS AND PEDALS 3-61. . . . . . . . . . . . . . . . . .
LUBRICATING THE SIDESTAND 3-61. . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE REAR SUSPENSION 3-61. . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM3-62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND CHARGING THE BATTERY 3-62. . . . . . . . . . . . . . . . .
CHECKING THE FUSES 3-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE HEADLIGHT BULBS 3-69. . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE HEADLIGHT BEAMS 3-70. . . . . . . . . . . . . . . . . . . . . .
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISCS4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT WHEEL 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT WHEEL 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE DISCS 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT WHEEL 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT WHEEL STATIC BALANCE 4-7. . . . . . . . .
REAR WHEEL AND BRAKE DISC4-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WHEEL 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE DISC AND REAR WHEEL SPROCKET 4-10. . . . . . . . .
REMOVING THE REAR WHEEL 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL DRIVE HUB 4-13. . . . . . . . . . . . . . . . .
CHECKING AND REPLACING THE REAR WHEEL
SPROCKET 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE REAR WHEEL 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR WHEEL STATIC BALANCE 4-14. . . . . . . . . . .
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Page 10 of 457
FRONT AND REAR BRAKES4-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE PADS 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE PADS 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE FRONT BRAKE PADS 4-18. . . . . . . . . . . . . . . . . . . . .
REPLACING THE REAR BRAKE PADS 4-20. . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE MASTER CYLINDER 4-22. . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE MASTER CYLINDER 4-25. . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT BRAKE MASTER
CYLINDER 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE REAR BRAKE MASTER
CYLINDER 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE MASTER
CYLINDERS 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING AND INSTALLING THE FRONT BRAKE
MASTER CYLINDER 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4-31. . . . . . .
FRONT BRAKE CALIPERS 4-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE CALIPER 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT BRAKE CALIPERS 4-37. . . . . . . . . . .
DISASSEMBLING THE REAR BRAKE CALIPER 4-38. . . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE CALIPERS 4-39. . . . . .
ASSEMBLING AND INSTALLING THE FRONT BRAKE
CALIPERS 4-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING AND INSTALLING THE REAR
BRAKE CALIPER 4-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK4-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK LEGS 4-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT FORK LEGS 4-47. . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT FORK LEGS 4-48. . . . . . . . . . . . . . . . .
CHECKING THE FRONT FORK LEGS 4-49. . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE FRONT FORK LEGS 4-50. . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT FORK LEGS 4-55. . . . . . . . . . . . . . . . . . . . . .
HANDLEBARS4-56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE HANDLEBARS 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE HANDLEBARS 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE HANDLEBARS 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STEERING DAMPER 4-60. . . . . . . . . . . . . . . . . . . . . . .
STEERING HEAD4-61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNDER BRACKET 4-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE UNDER BRACKET 4-63. . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STEERING HEAD 4-63. . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE STEERING HEAD 4-64. . . . . . . . . . . . . . . . . . . . . . . . .
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Page 78 of 457
3-1
3
INTRODUCTION / PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM / GENERAL MAINTENANCE AND LUBRICATION CHARTCHK
ADJ
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale, All service technicians
should be familiar with this entire chapter.
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
INITIALODOMETER READINGS
No.ITEMROUTINE600 mi
(1000 km)
or
1 month4000 mi
(7000 km)
or
6 months8000 mi
(13000 km)
or
12 months12000 mi
(19000 km)
or
18 months16000 mi
(25000 km)
or
24 months20000 mi
(31000 km)
or
30 months
1*Fuel line
(See page 3-33)Check fuel hoses for cracks or damage.
Replace if necessary.
2*Spark plugs
(See page 3-23)Check Condition.
Adjust gap and clean.
Replace every 8000 mi (13000 km) or 12
months.Replace.Replace.
3*Valve clearance
(See page 3-11)Check and adjust valve clearance when en-
gine is cold.Every 26600 mi (42000 km)
4*Crankcase breather
system
(See page 3-34)Check breather hose for cracks or damage.
Replace if necessary.
5*Electronic fuel injection
(See page 3-17, 21)Check and adjust engine idle speed and syn-
chronization.
6*Exhaust system
(See page 3-35)Check for leakage.
Tighten if necessary.
Replace gasket(s) if necessary.
7*Evaporative emission
control system
(For California only)Check control system for damage.
Replace if necessary.
8*Air induction system
(See page 7-46)Check the air cut-off valve, reed valve, and
hose for damage.
Replace any damaged parts if necessary.
GENERAL MAINTENANCE AND LUBRICATION CHART
INITIALODOMETER READINGS
No.ITEMROUTINE600 mi
(1000 km)
or
1 month4000 mi
(7000 km)
or
6 months8000 mi
(13000 km)
or
12 months12000 mi
(19000 km)
or
18 months16000 mi
(25000 km)
or
24 months20000 mi
(31000 km)
or
30 months
1*Air filter element
(See page 3-32)Check condition and damage.Replace if necessary.
2*Clutch
(See page 3-31)Check operation.Adjust or replace cable.
3*Front brake
(See page 3-42, 44, 45)Check operation, fluid level, and for fluid leak-
age.
Replace brake pads if necessary.
4*Rear brake
(See page 3-43, 44, 45)Check operation, fluid level, and for fluid leak-
age.
Replace brake pads if necessary.
5*Brake hosesCheck for cracks or damage.5*Brake hoses(See page 3-46)Replace.Every 4 years
6*Wheels
(See page 4-3)Check runout and for damage.Replace if necessary.
7*Tires
(See page 3-58)Check tread depth and for damage.Replace if necessary.Check air pressure.Correct if necessary.
8*Wheel bearings
(See page 4-3)Check bearings for smooth operation.Replace if necessary.
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Page 122 of 457
3-45
ADJUSTING THE REAR BRAKE LIGHT SWITCH /
CHECKING THE FRONT AND REAR BRAKE PADSCHK
ADJ
NOTE:
a
b
EAS00128
ADJUSTING THE REAR BRAKE LIGHT
SWITCH
The rear brake light switch is operated by move-
ment of the brake pedal.
The rear brake light switch is properly adjusted
when the brake light comes on just before the
braking effect starts.
1. Check:
rear brake light operation timing
Incorrect Adjust.
2. Adjust:
rear brake light operation timing
a. Hold the main body
1 of the rear brake light
switch so that it does not rotate and turn the
adjusting nut
2 in direction a or b until the
rear brake light comes on at the proper time.
Direction
Brake light comes on
sooner.
DirectionBrake light comes on
later.
EAS00122
CHECKING THE FRONT AND REAR BRAKE
PADS
The following procedure applies to all of the
brake pads.
1. Operate the brake.
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Page 123 of 457
3-46
B
A
B
A
CHECKING THE FRONT AND REAR BRAKE PADS/
CHECKING THE FRONT AND REAR BRAKE HOSESCHK
ADJ
2. Check:
front brake pad
rear brake pad
Brake pad wear limit
a, b
Wear limit reached Replace the brake
pads as a set.
Refer to “FRONT AND REAR BRAKES” in
chapter 7.
Brake pad wear limit
a 0.5 mm (0.02 in)
b 1.0 mm (0.04 in)
AFront brake
BRear brake
EAS00131
CHECKING THE FRONT AND REAR BRAKE
HOSES
The following procedure applies to all of the
brake hoses and brake hose clamps.
1. Check:
brake hose
1
Cracks / damage / wear Replace.
AFront
BRear
2. Check:
brake hose clamp
2
Loose Tighten the clamp bolt.
3. Hold the motorcycle upright and apply the
brake several times.
4. Check:
brake hose
Brake fluid leakage Replace the damaged
hose.
Refer to “FRONT AND REAR BRAKES” in
chapter 4.
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Page 154 of 457
4-7
FRONT WHEEL AND BRAKE DISCSCHAS
35 Nm (3.5 mkg, 25 ftlb)
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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Page 162 of 457
4-15
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7Removing the front brake pads
Brake hose holder
Front brake caliper
Brake pad clip
Brake pad pin
Brake pad spring
Brake pad
Bleed screw1
1
2
1
1
2
1Remove the parts in the order listed.
The following procedure applies to both of
the front brake calipers.
For installation, reverse the removal
procedure.
NOTE:
5 Nm (0.5 mkg, 3.6 ftlb)
35 Nm (3.5 mkg, 25 ftlb)
6 Nm (0.6 mkg, 4.3 ftlb)
FRONT AND REAR BRAKESCHAS
EAS00577
FRONT AND REAR BRAKES
FRONT BRAKE PADS
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Page 163 of 457
4-16
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7Removing the rear brake pads
Screw plug
Brake pad pin
Rear brake caliper
Brake pad shim
Brake pad
Bleed screw
Brake pad spring1
1
1
4
2
1
1Remove the parts in the order listed.
For installation, reverse the removal
procedure.
5 Nm (0.5 mkg, 3.6 ftlb)
27 Nm (2.7 mkg, 20 ftlb)
3 Nm (0.3 mkg, 2.2 ftlb)
17 Nm (1.7 mkg, 12 ftlb)
22 Nm (2.2 mkg, 16 ftlb)
REAR BRAKE PADS
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Page 165 of 457
4-18
FRONT AND REAR BRAKESCHAS
NOTE:
EAS00582
REPLACING THE FRONT BRAKE PADS
The following procedure applies to both brake
calipers.
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the brake caliper.
1. Remove:
brake hose holder
1
brake caliper 2
2. Remove:
brake pad clips
1
brake pad pin 2
brake pad spring 3
3. Remove:
brake pads
1
(along with the brake pad shims)
4. Measure:
brake pad wear limit
a
Out of specification Replace the brake
pads as a set.
Brake pad wear limit
0.5 mm (0.02 in)
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Page 166 of 457
4-19
FRONT AND REAR BRAKESCHAS
NOTE:
NOTE:
35 Nm (3.5 mkg, 25 ftlb)
5. Install:
brake pad shims
(onto the brake pads)
brake pads
brake pad spring
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.
a. Connect a clear plastic hose
1 tightly to the
bleed screw
2. Put the other end of the hose
into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
Bleed screw
5 Nm (0.5 mkg, 3.6 ftlb)
d. Install a new brake pad shim onto each new
brake pad.
Install the brake pad spring pointing
a toward
the bleed screw.
e. Install new brake pads and a new brake pad
spring.
6. Install:
brake pad pins
brake pad clips
brake caliper
7. 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.
8. 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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