Yamaha R1 2004 ServiceManual
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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 mkg, 3.6 ftlb) 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 mkg, 22 ftlb) 27 Nm (2.7 mkg, 20 ftlb)22 Nm (2.2 mkg, 16 ftlb) 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 mkg, 3.6 ftlb) 17 Nm (1.7 mkg, 12 ftlb) 3 Nm (0.3 mkg, 2.2 ftlb) 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 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.
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.
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 / damage Replace the brake cali- per assembly. brake fluid delivery passages (brake caliper body) Obstruction Blow out with compressed air. Whenever a brake caliper is disassembled, replace the brake caliper piston seals. AFront BRear 2. Check: brake caliper bracket 1 Cracks / damage Replace.
4-40 FRONT AND REAR BRAKESCHAS WARNING 35 Nm (3.5 mkg, 25 ftlb) 30 Nm (3.0 mkg, 22 ftlb) 6 Nm (0.6 mkg, 4.3 ftlb) 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.
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 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. Check: brake lever operation Soft or spongy feeling Bleed the brake system. Refer to ”BLEEDING THE HYDRAULIC BRAKE SYSTEM“ in chapter 3.
4-42 FRONT AND REAR BRAKESCHAS WARNING 27 Nm (2.7 mkg, 20 ftlb) 22 Nm (2.2 mkg, 16 ftlb) 30 Nm (3.0 mkg, 22 ftlb) 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. Recommended brake fluid DOT 4 1. Install: brake caliper 1 (front) (rear) brake pad pin screw plug copper washers New brake hose 2 union bolt 3 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.
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 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. 3. Bleed: brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 4. 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. 5. Check: brake pedal operation Soft or spongy feeling Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.