Yamaha R1 2004 ServiceManual

							4-14
REAR WHEEL AND BRAKE DISCCHAS
NOTE:
150 Nm (15 m
kg, 108 ft
lb)
27 Nm (2.7 m
kg, 20 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
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 m
kg, 72 ft
lb)
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 m
kg, 3.6 ft
lb)
35 Nm (3.5 m
kg, 25 ft
lb)
6 Nm (0.6 m
kg, 4.3 ft
lb)
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 m
kg, 3.6 ft
lb)
27 Nm (2.7 m
kg, 20 ft
lb)
3 Nm (0.3 m
kg, 2.2 ft
lb)
17 Nm (1.7 m
kg, 12 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
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 m
kg, 25 ft
lb)
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 m
kg, 3.6 ft
lb)
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 m
kg, 20 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
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 m
kg, 3.6 ft
lb)
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 m
kg, 2.7 ft
lb)
1.2 Nm (0.12 m
kg, 0.9 ft
lb)
13 Nm (1.3 m
kg, 9.4 ft
lb)
30 Nm (3.0 m
kg, 22 ft
lb)
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 m
kg, 2.7 ft
lb)
1.2 Nm (0.12 m
kg, 0.9 ft
lb)
13 Nm (1.3 m
kg, 9.4 ft
lb)
30 Nm (3.0 m
kg, 22 ft
lb)