Yamaha R1 2004 ServiceManual

							4-24
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
Disassembling the front brake 
master cylinder
Brake master cylinder kit
Bleed screw
Brake master cylinder body1
1
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly 
procedure.
1
2
3
6 Nm (0.6 m
kg, 4.3 ft
lb)
EAS00585 
						

							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 
						

							4-26
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
Disassembling the rear brake master
cylinder
Brake master cylinder kit
Hose joint
Bush
Brake master cylinder body1
1
1
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly
procedure.
1
2
3
4 
						

							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 
						

							4-28
A
B
A
B
BA
FRONT AND REAR BRAKESCHAS
EAS00593
CHECKING THE FRONT AND REAR BRAKE 
MASTER CYLINDERS
The following procedure applies to both of the
brake master cylinders.
1. Check:

brake master cylinder
Damage / scratches / wear 
 Replace.

brake fluid delivery passages
(brake master cylinder body)
Obstruction 
 Blow out with compressed air.
AFront
BRear
2. Check:

brake master cylinder kit
Damage / scratches / wear 
 Replace.
AFront
BRear
3. Check:

brake fluid reservoir 
1
Cracks / damage 
 Replace.

brake fluid reservoir diaphragm 
2
Cracks / damage 
 Replace.
AFront
BRear
4. Check:

brake hoses
Cracks / damage / wear 
 Replace. 
						

							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”. 
						

							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. 
						

							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 
						

							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. 
						

							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