Yamaha R1 2004 ServiceManual

4-34
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
Disassembling the front brake 
calipers
Brake pad clip
Brake pad pin
Brake pad spring
Brake pad
Brake caliper piston
Brake caliper piston seal
Bleed screw2
1
1
2
4
8
1Disassemble the parts in the order listed.
The following procedure applies to both of
the front brake calipers.
For assembly, reverse the disassembly 
procedure.
NOTE:
1
2
3
4
5
6
7
5 Nm (0.5 m
kg, 3.6 ft
lb)
EAS00615 

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 

4-36
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
Disassembling the rear brake caliper
Screw plug
Brake pad pin
Brake pad
Brake pad shim
Brake pad spring
Brake caliper piston
Brake caliper piston seal
Bleed screw1
1
2
4
1
1
2
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly 
procedure.
1
2
3
4
5
6
7
8
5 Nm (0.5 m
kg, 3.6 ft
lb)
17 Nm (1.7 m
kg, 12 ft
lb)
3 Nm (0.3 m
kg, 2.2 ft
lb)
EAS00617 

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...

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...

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 /...

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...

4-41
FRONT AND REAR BRAKESCHAS
WARNING
CAUTION:
3. 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...

4-42
FRONT AND REAR BRAKESCHAS
WARNING
27 Nm (2.7 m
kg, 20 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
30 Nm (3.0 m
kg, 22 ft
lb)
WARNING
CAUTION:
EAS00642
ASSEMBLING AND INSTALLING THE REAR 
BRAKE CALIPER

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....

4-43
FRONT AND REAR BRAKESCHAS
WARNING
CAUTION:
2. 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...