Yamaha R1 2004 ServiceManual
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4-14 REAR WHEEL AND BRAKE DISCCHAS NOTE: 150 Nm (15 mkg, 108 ftlb) 27 Nm (2.7 mkg, 20 ftlb) 22 Nm (2.2 mkg, 16 ftlb) NOTE: 2. Replace: rear wheel sprocket a. Remove the self-locking nuts and the rear wheel sprocket. b. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the sprocket. c. Install the new rear wheel sprocket. Rear wheel sprocket self-locking nut 100 Nm (10 mkg, 72 ftlb) Tighten the self-locking nuts in stages and in a crisscross pattern. EAS00572 INSTALLING THE REAR WHEEL 1. Lubricate: wheel axle wheel bearings oil seal lips Recommended lubricant Lithium-soap-based grease 2. Tighten: wheel axle nut brake caliper bolts (front) (rear) EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1. Adjust: rear wheel static balance Refer to “ADJUSTING THE FRONT WHEEL STATIC BALANCE”.
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
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
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.
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)
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.
4-20 FRONT AND REAR BRAKESCHAS NOTE: NOTE: REPLACING THE REAR BRAKE PADS When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disas- semble the brake caliper. 1. Remove : screw plug 1 brake pad pin 2 brake caliper 3 brake pad spring 2. Remove : brake pads 1 (along with the brake pad shims 2) 3. Measure : brake pad wear limit a Out of specification Replace the brake pads as a set. Brake pad wear limit 1.0 mm (0.04 in) 4. 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.
4-21 FRONT AND REAR BRAKESCHAS 27 Nm (2.7 mkg, 20 ftlb) 22 Nm (2.2 mkg, 16 ftlb) 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 3 onto each new brake pad 4. 5. Install: rear brake caliper (front) rear brake caliper (rear) brake pad pin screw plug 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 pedal operation Soft or spongy feeling Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
4-22 FRONT AND REAR BRAKESCHAS Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9Removing the front brake master cylinder Brake fluid Stopper Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir tank Brake fluid reservoir hose Brake lever Front brake switch connector Union bolt1 1 1 1 1 1 1 2 1Remove the parts in the order listed. Drain. Refer to “CHANGING THE BRAKE FLUID” in chapter 3. Disconnect. 3.8 Nm (0.38 mkg, 2.7 ftlb) 1.2 Nm (0.12 mkg, 0.9 ftlb) 13 Nm (1.3 mkg, 9.4 ftlb) 30 Nm (3.0 mkg, 22 ftlb) EAS00584 FRONT BRAKE MASTER CYLINDER
4-23 FRONT AND REAR BRAKESCHAS Order Job / Part Q’ty Remarks 10 11 12 13 14Copper washer Brake hose Brake master cylinder bracket Brake master cylinder Front brake light switch2 1 1 1 1 For installation, reverse the removal procedure. 3.8 Nm (0.38 mkg, 2.7 ftlb) 1.2 Nm (0.12 mkg, 0.9 ftlb) 13 Nm (1.3 mkg, 9.4 ftlb) 30 Nm (3.0 mkg, 22 ftlb)