Yamaha R1 2004 ServiceManual
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3-44 A B CHECKING THE BRAKE FLUID LEVEL CHK ADJ NOTE: WARNING CAUTION: NOTE: EAS00115 CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. Place the motorcycle on a suitable stand. Make sure the motorcycle is upright. 2. Check: brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level. Recommended brake fluid DOT 4 AFront brake BRear brake 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. In order to ensure a correct reading of the brake fluid level, make sure the top of the brake fluid reservoir is horizontal.
3-45 ADJUSTING THE REAR BRAKE LIGHT SWITCH / CHECKING THE FRONT AND REAR BRAKE PADSCHK ADJ NOTE: a b EAS00128 ADJUSTING THE REAR BRAKE LIGHT SWITCH The rear brake light switch is operated by move- ment of the brake pedal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts. 1. Check: rear brake light operation timing Incorrect Adjust. 2. Adjust: rear brake light operation timing a. Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time. Direction Brake light comes on sooner. DirectionBrake light comes on later. EAS00122 CHECKING THE FRONT AND REAR BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake.
3-46 B A B A CHECKING THE FRONT AND REAR BRAKE PADS/ CHECKING THE FRONT AND REAR BRAKE HOSESCHK ADJ 2. Check: front brake pad rear brake pad Brake pad wear limit a, b Wear limit reached Replace the brake pads as a set. Refer to “FRONT AND REAR BRAKES” in chapter 7. Brake pad wear limit a 0.5 mm (0.02 in) b 1.0 mm (0.04 in) AFront brake BRear brake EAS00131 CHECKING THE FRONT AND REAR BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps. 1. Check: brake hose 1 Cracks / damage / wear Replace. AFront BRear 2. Check: brake hose clamp 2 Loose Tighten the clamp bolt. 3. Hold the motorcycle upright and apply the brake several times. 4. Check: brake hose Brake fluid leakage Replace the damaged hose. Refer to “FRONT AND REAR BRAKES” in chapter 4.
3-47 B C A BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ WARNING NOTE: NOTE: EAS00135 BLEEDING THE HYDRAULIC BRAKE SYSTEM Bleed the hydraulic brake system whenev- er: the system is disassembled. a brake hose is loosened, disconnected or replaced. the brake fluid level is very low. brake operation is faulty. Be careful not to spill any brake fluid or allow the brake fluid reservoir to overflow. When bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake. Ignoring this pre- caution could allow air to enter the hydraulic brake system, considerably lengthening the bleeding procedure. If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared. 1. Bleed: hydraulic brake system a. Fill the brake fluid reservoir to the proper lev- el with the recommended brake fluid. b. Install the brake fluid reservoir diaphragm. c. Connect a clear plastic hose 1 tightly to the bleed screw 2. AFront brake master cylinder BFront brake caliper CRear brake caliper Bleeding order of the front hydraulic brake sys- tem is the following order: 1. front brake master cylinder. 2. front brake calipers. 3. front brake master cylinder. d. Place the other end of the hose into a con- tainer. e. Slowly apply the brake several times. f. Fully pull the brake lever or fully press down the brake pedal and hold it in position. g. Loosen the bleed screw.
3-48 BLEEDING THE HYDRAULIC BRAKE SYSTEM / ADJUSTING THE SHIFT PEDALCHK ADJ NOTE: WARNING NOTE: a b Loosening the bleed screw will release the pres- sure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend. h. Tighten the bleed screw and then release the brake lever or brake pedal. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose. j. Tighten the bleed screw to specification. Bleed screw 6 Nm (0.6 mkg, 4.3 ftlb) k. Fill the brake fluid reservoir to the proper lev- el with the recommended brake fluid. Refer to “CHECKING THE BRAKE FLUID LEVEL”. After bleeding the hydraulic brake system, check the brake operation. After bleeding air, the brake fluid may ooze around the thread section of each bleed screw. This phenomenon does not show the leakage but the brake fluid that has been accumulated in the thread of screw while bleeding air. Please wipe off to make the parts clean. EAS00136 ADJUSTING THE SHIFT PEDAL 1. Adjust: shift pedal position a. Loosen both locknuts 1. b. Turn the shift rod 2 in direction a or b to obtain the correct shift pedal position. Direction Shift pedal is raised. DirectionShift pedal is lowered. c. Tighten both locknuts.
3-49 ADJUSTING THE DRIVE CHAIN SLACK CHK ADJ NOTE: CAUTION: WARNING NOTE: EAS00140 ADJUSTING THE DRIVE CHAIN SLACK The drive chain slack must be checked at the tightest point on the chain. A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swin- garm or cause an accident. Therefore, keep the drive chain slack within the specified limits. 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Spin the rear wheel several times and find the tightest position of drive chain. 3. Check: drive chain slack a Out of specification Adjust. Drive chain slack 25 35 mm (0.98 1.38 in) 4. Adjust: drive chain slack a. Loosen the wheel axle nut 1. b. Loosen both locknuts 2. c. Turn both adjusting bolts 3 in direction a or b until the specified drive chain slack is ob- tained.
3-50 a b ADJUSTING THE DRIVE CHAIN SLACK / LUBRICATING THE DRIVE CHAINCHK ADJ NOTE: DirectionDrive chain is tightened. DirectionDrive chain is loosened. To maintain the proper wheel alignment, adjust both sides evenly. d. Tighten both locknuts to specification. Locknut 16 Nm (1.6 mkg, 12 ftlb) e. Tighten the wheel axle nut to specification. Wheel axle nut 150 Nm (15 mkg, 108 ftlb) EAS00142 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained proper- ly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the motorcycle is used in dusty areas. This motorcycle has a drive chain with small rubber O-rings between each side plate. Steam cleaning, high-pressure washing, certain sol- vents, and the use of a coarse brush can dam- age these O-rings. Therefore, use only kero- sene to clean the drive chain. Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O-ring chains. Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O-rings. Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains
3-51 CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ WARNING NOTE: NOTE: EAS00146 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Check: steering head Grasp the bottom of the front fork legs and gently rock the front fork. Binding / looseness Adjust the steering head. 3. Remove: upper bracket Refer to “HANDLEBAR” and “STEERING HEAD” in chapter 4. 4. Adjust: steering head a. Remove the lock washer 1, the upper ring nut 2, and the rubber washer 3. b. Loosen the lower ring nut 4 and then tighten it to specification with a steering nut wrench 5. Set the torque wrench at a right angle to the steering nut wrench. Steering nut wrench 90890-01403, YU-33975 Lower ring nut (initial tightening torque) 52 Nm (5.2 mkg, 38 ftlb)
3-52 CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ WARNING NOTE: NOTE: c. Loosen the lower ring nut 4 completely, then tighten it to specification. Do not overtighten the lower ring nut. Lower ring nut (final tightening torque) 18 Nm (1.8 mkg, 13 ftlb) d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the under bracket and check the upper and lower bearings. Refer to “STEERING HEAD” in chapter 4. e. Install the rubber washer 3. f. Install the upper ring nut 2. g. Finger tighten the upper ring nut 2, then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned. h. Install the lock washer 1. Make sure the lock washer tabs a sit correctly in the ring nut slots b. 5. Install: upper bracket Refer to “HANDLEBAR” and “STEERING HEAD” in chapter 4. 6. Measure: steering head tension Make sure all of the cables and wires are prop- erly routed. a. Point the front wheel straight ahead. b. Install a plastic locking tie 1 loosely around the end of the handlebar as shown. c. Hook a spring gauge 2 onto the plastic lock- ing tie. d. Hold the spring gauge at a 90 angle from the handlebar, pull the spring gauge, and then record the measurement when the handle- bar starts to run.
3-53 CHECKING AND ADJUSTING THE STEERING HEAD / CHECKING THE FRONT FORKCHK ADJ WARNING Steering head tension 200 500 g e. Repeat the above procedure on the opposite handlebar. f. If the steering head tension is out of specifi- cation (both handlebars should be within specification), remove the upper bracket and loosen or tighten the upper ring nut. g. Reinstall the upper bracket and measure the steering head tension again as described above. h. Repeat the above procedure until the steer- ing head tension is within specification. i. Grasp the bottom of the front fork legs and gently rock the front fork. Binding / looseness Adjust the steering head. EAS00150 CHECKING THE FRONT FORK 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. 2. Check: inner tube 1 Damage / scratches Replace. oil seal 2 Oil leakage Replace. 3. Hold the motorcycle upright and apply the front brake. 4. Check: front fork operation Push down hard on the handlebars several times and check if the front fork rebounds smoothly. Rough movement Repair. Refer to “FRONT FORK” in chapter 4.