7. Check:
Brake lever operation
Soft or spongy feeling
→
Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-18.
REMOVING THE FRONT BRAKE MASTER
CYLINDER
NOTE:
Before removing the front brake master cylinder,
drain the brake fluid from the entire brake sys-
tem.
1. Disconnect:
Front brake light switch“1”
Push the fastener to remove the front brake light
switch from the brake master cylinder.
2. Remove:
Brake hose union bolt
Copper washers
Brake hose
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
CHECKING THE FRONT BRAKE MASTER
CYLINDER
1. Check:
Brake master cylinder“1”
Damage/scratches/wear
→
Replace.
Brake fluid delivery passages“2”
(brake master cylinder body)
Obstruction
→
Blow out with compressed air.
2. Check:
Brake master cylinder kit
Damage/scratches/wear
→
Replace.
3. Check:
Brake master cylinder reservoir
Cracks/damage
→
Replace.
Brake master cylinder reservoir diaphragm
Damage/wear
→
Replace.
4. Check:
Brake hose
Cracks/damage/wear
→
Replace.
ASSEMBLING THE FRONT BRAKE MASTER
CYLINDER
WARNING
INSTALLING THE FRONT BRAKE MASTER
CYLINDER
1. Install:
Brake master cylinder“1”
Brake master cylinder holder“2”
Recommended fluid
DOT 3 or
4
DOT
Brake master cylinder holder bolt
7 Nm (0.7 m·kg, 5.1 ft·lb)
4-22
4-23
FRONT BRAKE
FRONT BRAKE
NOTE:
Install the brake master cylinder holder with the
“UP” mark facing up.
Align the end of the brake master cylinder hold-
er with the punch mark “a” on the handlebar.
First, tighten the upper bolt, then the lower bolt.
2. Install:
Copper washers“1”
Brake hose “2”
Brake hose union bolt“3”
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to “CABLE
ROUTING” on page 2-33.
NOTE:
Install the brake hose to the front brake master
cylinder within the angle shown in the illustra-
tion.
While holding the brake hose, tighten the brake
hose union bolt as shown.
Turn the handlebar to the left and right to make
sure the brake hose does not touch other parts
(e.g., wire harness, cables, leads). Correct if
necessary.
3. Fill:
Brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)
WARNING
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 performance.
When refilling, be careful that water does
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts.Therefore, always clean up
any spilt brake fluid immediately.
4. Bleed:
Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-18.
5. 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” on page 3-17.
6. Check:
Brake lever operation
Soft or spongy feeling
→
Bleed the brake sys-
tem.
T
R
.
.
Brake hose union bolt
26 Nm (2.6 m·
kg, 19 ft
·lb)
a
UP
1
2
New
1
3
2
New
Recommended fluid
DOT 3 or
4
DOT
a
60-80
º
Summary of Contents for YZF-R15
Page 1: ...2008 SERVICE MANUAL YZF R15 20P F8197 E0 ...
Page 33: ...2 14 ELECTRICAL SPECIFICATIONS Coil resistance 54 0 66 0 Fuse 20 0A Ω Fuse ...
Page 46: ...2 27 LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION DIAGRAMS A 1 2 3 4 5 6 7 ...
Page 48: ...2 29 LUBRICATION POINTS AND LUBRICANT TYPES 1 2 3 4 ...
Page 49: ...2 30 LUBRICATION POINTS AND LUBRICANT TYPES 1 Camshaft 2 Crankshaft 3 Main axle 4 Drive axle ...
Page 50: ...2 31 COOLING SYSTEM DIAGRAMS COOLING SYSTEM DIAGRAMS 1 2 3 4 1 5 7 6 4 ...
Page 52: ...2 33 CABLE ROUTING CABLE ROUTING 1 5 2 3 6 4 8 7 ...
Page 54: ...2 35 CABLE ROUTING A A B B C C A A C C B B A B C 1 2 3 4 5 4 5 6 6 7 8 9 10 11 10 11 12 12 ...
Page 56: ...2 37 CABLE ROUTING 1 2 5 4 3 ...
Page 60: ...2 41 CABLE ROUTING A A B C D E 1 2 3 4 5 6 7 8 9 10 A ...
Page 121: ...4 24 FRONT BRAKE Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 18 ...
Page 249: ...7 8 THROTTLE BODY ...
Page 250: ...7 9 AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM 1 2 5 4 5 6 3 2 1 6 4 3 ...
Page 257: ......
Page 269: ...8 12 CHARGING SYSTEM 1 AC magneto 2 Rectifier regulator 3 Battery 42 Fuse ...
Page 271: ...8 14 CHARGING SYSTEM ...
Page 275: ...8 18 LIGHTING SYSTEM ...
Page 285: ...8 28 COOLING SYSTEM ...
Page 311: ...8 54 FUEL PUMP SYSTEM ...