Brake system of motorcycle Yamaha FZ1 (2006-2015)

Removing the front brake pads
Order Job/Parts to remove Quantity Remarks 1 Brake hose holder 1 2 Front brake caliper 1 3 Brake pad clip 2 4 Brake pad pin 1 5 Brake pad spring 1 6 Brake pad 2 7 Bleed screw 1

Removing the front brake master cylinder
Order Job/Parts to remove Quantity Remarks Brake fluid Drain. Refer to « Bleeding the hydraulic brake system ». 1 Right rear view mirror (FZ1-N(X)), (FZ1-NA) 1 2 Brake master cylinder reservoir cap 1 3 Brake master cylinder reservoir diaphragm...

Disassembling the front brake master cylinder
Order Job/Parts to remove Quantity Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1

Removing the front brake calipers
Order Job/Parts to remove Quantity Remarks Brake fluid Drain. Refer to « Bleeding the hydraulic brake system ». 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Brake caliper 1

Disassembling the front brake calipers
Order Job/Parts to remove Quantity Remarks 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston dust seal 4 7 Brake caliper piston seal 4 8 Bleed screw 1

Preventive measures
Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: Never disassemble brake components unless absolutely necessary. If any connection on the hydraulic brake system is disconnected, the entire brake...

Checking the front brake discs
The following procedure applies to both brake discs. 1. Remove: Front wheel Refer to « Front wheel ». 2. Check: Brake disc Damage/galling → Replace. 3. Measure: Brake disc deflection Out of specification → Correct the brake disc deflection or...

Replacing the front brake pads
The following procedure applies to both brake calipers. Note: When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper. 1. Measure: Brake pad wear limit «a» Out of specification → Replace the...

Removing front brake calipers
The following procedure applies to both of the brake calipers. Note: Before removing the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: Union bolt «1» Copper washers «2» Brake hose «3» Note: Put the end of the brake...

Disassembling the front brake calipers
The following procedure applies to both of the brake calipers. 1. Remove: Brake caliper pistons «1» Brake caliper piston seals «2» Brake caliper piston dust seals «3» a. Secure the brake caliper pistons with a piece of wood «a». b. Blow compressed...

Checking the front brake calipers
Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every four years Brake fluid Every two years and whenever the brake is disassembled 1. Check: Brake caliper pistons «1»....

Assembling the front brake calipers
Warnings! Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. Never use solvents on internal brake components as they will cause the piston seals to swell and distort. Whenever a brake...

Installing the front brake calipers
The following procedure applies to both of the brake calipers. 1. Install: Brake caliper «1» (temporarily) Copper washers Brake hose «2» Union bolt «3» Brake hose union bolt: 30 Nm (3.0 m·kg, 22 ft·lb). Warning! Proper brake hose routing is...

Removing front brake master cylinder
Note: Before removing the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Disconnect: Brake switch couplers «1» (from the brake switch) 2. Remove: Union bolt «1» Copper washers «2» Brake hose «3» Note: To collect...

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:...

Assembling the front brake master cylinder
Warnings! Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. Never use solvents on internal brake components. Recommended brake fluid: DOT4.

Installing the front brake master cylinder
1. Install: Brake master cylinder «1» Brake master cylinder bracket «2» Brake master cylinder bracket bolt: 10 Nm (1.0 m·kg, 7.2 ft·lb). Notes: Install the brake master cylinder holder with the «UP» mark «a» facing up. Align the end of the brake...

Removing the rear brake pads
Order Job/Parts to remove Quantity Remarks 1 Screw plug 1 2 Brake pad pin 1 3 Rear brake caliper 1 4 Brake pad shim 4 5 Brake pad 2 6 Bleed screw 1 7 Brake pad spring 1

Removing the rear brake master cylinder (FZ1-N(X)/FZ1-S(X))
Order Job/Parts to remove Quantity Remarks Brake fluid Drain. Refer to « Bleeding the hydraulic brake system ». 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir tank...

Removing the rear brake master cylinder (FZ1-SA), (FZ1-NA)
Order Job/Parts to remove Quantity Remarks Brake fluid Drain. Refer to « Bleeding the hydraulic brake system ». 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir tank...

Disassembling the rear brake master cylinder
Order Job/Parts to remove Quantity Remarks 1 Brake master cylinder kit 1 2 Hose joint 1 3 Bushing 1 4 Brake master cylinder body 1

Removing the rear brake caliper
Order Job/Parts to remove Quantity Remarks 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Brake caliper 1

Disassembling the rear brake caliper
Order Job/Parts to remove Quantity Remarks 1 Screw plug 1 2 Brake pad pin 1 3 Brake pad 2 4 Brake pad shim 4 5 Brake pad spring 1 6 Brake caliper piston 1 7 Brake caliper piston dust seal 1 8 Brake caliper piston seal 1 9 Bleed screw 1

Checking the rear brake disc
1. Remove: Rear wheel Refer to « Rear wheel ». 2. Check: Brake disc Damage/galling → Replace. 3. Measure: Brake disc deflection Out of specification → Correct the brake disc deflection or replace the brake disc. Refer to « Checking the front brake...

Replacing the rear brake pads
Note: When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper. 1. Measure: Brake pad wear limit «a» Out of specification → Replace the brake pads as a set. Brake pad thickness lining (inner):...

Removing rear brake caliper
Note: 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» Note: Put the end of the brake hose into a container and pump out the brake fluid carefully.

Disassembling rear brake caliper
1. Remove: Brake caliper piston «1» Brake caliper piston seals «2» Brake caliper piston dust seals «3» 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 piston...

Checking the rear brake caliper
Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every four years Brake fluid Every two years and whenever the brake is disassembled 1. Check: Brake caliper pistons «1»...

Assembling the rear brake caliper
Warnings! Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. Never use solvents on internal brake components as they will cause the piston seals to swell and distort. Whenever a brake...

Installing the rear brake caliper
1. Install: Brake caliper «1» (temporarily) Copper washers «2» Brake hose «3» Union bolt «4» Brake hose union bolt: 30 Nm (3.0 m·kg, 22 ft·lb). Warning! Proper brake hose routing is essential to insure safe vehicle operation. Refer to « Cable...

Removing the rear brake master cylinder
1. Remove: Union bolt «1» Copper washers «2» Brake hose «3» Note: To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose.

Checking the rear 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:...

Assembling the rear brake master cylinder
Warnings! Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. Never use solvents on internal brake components. Recommended brake fluid: DOT4.

Nstalling the rear brake master cylinder
1. Install: Copper washers Brake hose «1» Union bolt «2» Brake hose union bolt: 30 Nm (3.0 m·kg, 22 ft·lb). Warning! Proper brake hose routing is essential to insure safe vehicle operation. Refer to « Cable routing ». Caution! When installing the...

Removing the hydraulic unit ABS (FZ1-SA), (FZ1-NA)
Order Job/Parts to remove Quantity Remarks Passenger seat Refer to « General chassis ». Rider seat Refer to « General chassis ». Fuel tank Refer to « Fuel tank ». EXUP servo motor Refer to « Engine removal ». Brake fluid reservoir tank Refer to «...

Maintenance of the hydraulic unit ABS
Caution! Do not turn the crankshaft when installing the camshaft sprockets to avoid damage or improper valve. Warning! Refill with the same type of brake fluid that is already in the system. Mixing fluids may result in a harmful chemical reaction,...

Hydraulic unit operation test
The reaction-force pulsating action generated in the brake lever and brake pedal when the ABS is activated can be tested when the vehicle is stopped. The hydraulic unit operation can be tested by the following two methods. Hydraulic unit operation...