washer fluid YAMAHA YZF-R1S 2004 Service Manual

3-39
CHANGING THE COOLANT
CHK
ADJ
CAUTION:
EAS00105
CHANGING THE COOLANT
1. Remove:

bottom cowlings

side cowlings
Refer to “COWLINGS”.

rider seat
Refer to “SEATS”.
2. Remove:

coolant reservoir tank

coolant reservoir hose
3. Disconnect:

coolant reservoir cap
1
4. Drain:

coolant
(from the coolant reservoir tank)
5. Remove:

radiator cap
1
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious in-
jury. When the engine has cooled, open the
radiator cap as follows:
Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap coun-
terclockwise toward the detent to allow any
residual pressure to escape. When the his-
sing sound has stopped, press down on the
radiator cap and turn it counterclockwise to
remove.
The following procedure applies to all of the
coolant drain bolts and copper washers.
6. Remove:

coolant drain bolts
1
(along with the copper washers)
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4-25
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11Removing the rear brake master
cylinder
Brake fluid
Brake fluid reservoir cap
Brake fluid reservoir diaphragm holder
Brake fluid reservoir diaphragm
Brake fluid reservoir tank
Brake fluid reservoir hose
Hose joint
Bush
Union bolt
Copper washer
Brake hose
Brake master cylinder1
1
1
1
1
1
1
1
2
1
1Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE BRAKE
FLUID” in chapter 3.
For installation, reverse the removal
procedure.
30 Nm (3.0 m
kg, 22 ft
lb)18 Nm (1.8 m
kg, 13 ft
lb)
EAS00586
REAR BRAKE MASTER CYLINDER
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4-27
FRONT AND REAR BRAKESCHAS
NOTE:
NOTE:
NOTE:
EAS00588
DISASSEMBLING THE FRONT BRAKE
MASTER CYLINDER
Before disassembling the front brake master
cylinder, drain the brake fluid from the entire
brake system.
1. Disconnect:

brake light switch connector
1
(from the brake light switch)
2. Remove:

union bolt
2

copper washers 3

brake hose 4
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
3. Remove :

brake master cylinder bracket

brake master cylinder assembly
4. Remove :

dust boot

circlip
EAS00589
DISASSEMBLING THE REAR BRAKE
MASTER CYLINDER
1. Remove:

union bolt
1

copper washers 2

brake hose 3
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
2. Remove :

brake master cylinder assembly
3. Remove :

dust boot

circlip
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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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4-31
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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4-33
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
1
2
3
4Removing the front brake calipers
Brake fluid
Union bolt
Copper washer
brake hose
brake caliper1
2
1
1Remove the parts in the order listed.
The following procedure applies to both of
the front brake calipers.
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
For installation, reverse the removal
procedure.
NOTE:
6 Nm (0.6 m
kg, 4.3 ft
lb)
30 Nm (3.0 m
kg, 22 ft
lb)
35 Nm (3.5 m
kg, 25 ft
lb)
EAS00613
FRONT BRAKE CALIPERS
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4-35
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
1
2
3
4Removing the rear brake caliper
Brake fluid
Union bolt
Copper washer
Brake hose
Brake caliper1
2
1
1Remove the parts in the order listed.
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
For installation, reverse the removal
procedure.
30 Nm (3.0 m
kg, 22 ft
lb)
27 Nm (2.7 m
kg, 20 ft
lb)22 Nm (2.2 m
kg, 16 ft
lb)
EAS00616
REAR BRAKE CALIPER
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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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4-40
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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