Removing The Front Brake Master Cylinder; Checking The Front Brake Master Cylinder; Assembling The Front Brake Master Cylinder; Installing The Front Brake Master Cylinder - Yamaha YZF-R1 Series Service Manual

EAS30179
REMOVING THE FRONT BRAKE MASTER
CYLINDER
TIP
Before removing the front brake master cylinder,
drain the brake fluid from the entire brake sys-
tem.
1. Disconnect:
• Brake light switch connectors
(from the front brake light switch)
2. Remove:
• Brake hose union bolt
• Brake hose gaskets
• Brake hose
TIP
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
EAS30725
CHECKING THE FRONT BRAKE MASTER
CYLINDER
1. Check:
• Brake master cylinder
Damage/scratches/wear → Replace.
• Brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed air.
2. Check:
• Brake master cylinder kit
Damage/scratches/wear → Replace.
3. Check:
• Brake fluid reservoir
• Brake fluid reservoir diaphragm holder
Cracks/damage → Replace.
• Brake fluid reservoir diaphragm
Damage/wear → Replace.
4. Check:
• Brake hoses
Cracks/damage/wear → Replace.
EAS30181
ASSEMBLING THE FRONT BRAKE MASTER
CYLINDER
EWA13520
WARNING
• 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.
Specified brake fluid
DOT 4
EAS30182
INSTALLING THE FRONT BRAKE MASTER
CYLINDER
1. Install:
• Front brake master cylinder
• Front brake master cylinder holder
Front brake master cylinder hold-
er bolt
16 N·m (1.6 kgf·m, 12 lb·ft)
TIP
• Install the front brake master cylinder holder
with the "UP" mark "a" facing up.
• Align the end of the front brake master cylinder
with the punch mark "b" on the handlebar.
• First, tighten the upper bolt, then the lower bolt.
b
2. Install:
• Brake hose gaskets
• Brake hose
• Brake hose union bolt
Front brake hose union bolt
32 N·m (3.2 kgf·m, 24 lb·ft)
EWA13531
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation.
TIP
• When installing the brake hose onto the master
cylinder, make sure the projection "a" on the
brake hose touches the projection "b" on the
master cylinder.
• While holding the brake hose, tighten the union
bolt as shown.
4-61
FRONT BRAKE
a
New