Removing The Front Brake Calipers; Disassembling The Front Brake Calipers; Checking The Front Brake Calipers; Assembling The Front Brake Calipers - Yamaha YZF-R1 Series Service Manual

8. Check:
• Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
tem.
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)" on page 3-16.
EAS30171

REMOVING THE FRONT BRAKE CALIPERS

The following procedure applies to both of the
brake calipers.
TIP
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
• Brake hose union bolts
• Brake hose gaskets
• Brake hoses
TIP
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
EAS30172
DISASSEMBLING THE FRONT BRAKE
CALIPERS
The following procedure applies to both of the
brake calipers.
1. Remove:
• Brake caliper pistons
• Brake caliper piston dust seals
• Brake caliper piston seals
a. Secure the right side 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
pistons from the brake caliper.
EWA17060
WARNING
• Never try to pry out the brake caliper pis-
tons.
• Do not loosen the bolts "4".
4
a
c. Remove the brake caliper piston dust
seals and brake caliper piston seals.
d. Repeat the previous steps to force out the
right side pistons from the brake caliper.
EAS30173

CHECKING THE FRONT BRAKE CALIPERS

The following procedure applies to both of the
brake calipers.
Brake pads
Piston seals
Piston dust seals
Brake hoses
Brake fluid
1. Check:
• Brake caliper pistons
Rust/scratches/wear → Replace the brake
caliper pistons.
• Brake caliper cylinders
Scratches/wear → Replace the brake caliper
assembly.
• Brake caliper body
Cracks/damage → Replace the brake caliper
assembly.
• Brake fluid delivery passages
(brake caliper body)
Obstruction → Blow out with compressed air.
EWA13611
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seals
and brake caliper piston seals.
EAS30174
ASSEMBLING THE FRONT BRAKE
CALIPERS
EWA16560
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 as they will cause the brake caliper
piston dust seals and brake caliper piston
seals to swell and distort.
b
• Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seals
and brake caliper piston seals.
4-59
FRONT BRAKE
Recommended brake component
replacement schedule
If necessary
Every two years
Every two years
Every four years
Every two years and
whenever the brake is
disassembled