Yamaha R1 2004 ServiceManual

4-44
Order Job / Part Q’ty Remarks
1
2
3
4
5
6Removing the front fork legs
Front wheel
Front brake calipers
Side cowlings
Front fender
Cap bolt
Handlebar pinch bolt
Upper bracket pinch bolt
Under bracket pinch bolt
Front fork leg1
1
1
1
2
1Remove the parts in the order listed.
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
Refer to “FRONT AND REAR BRAKES”.
Refer to “COWLINGS” in chapter3.
Loosen.
Loosen.
Loosen.
Loosen.
For installation, reverse the removal 
procedure.
6 Nm (0.6 m
kg, 4.3 ft
lb)
23 Nm (2.3...

4-45
FRONT FORKCHAS
Order Job / Part Q’ty Remarks
Disassembling the front fork legs
Cap bolt
O-ring
Damper adjusting rod
Nut
Washer
Spacer
Fork spring
Dust seal
Oil seal clip
Oil seal1
1
1
1
1
1
1
1
1
1Disassemble the parts in the order listed.
The following the procedure applies to
both of the front fork legs.
NOTE:
1
2
3
4
5
6
7
8
9
10
23 Nm (2.3 m
kg, 17 ft
lb)
15 Nm (1.5 m
kg, 11 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)
EAS00648 

4-46
FRONT FORKCHAS
Order Job / Part Q’ty Remarks
Washer
Damper rod assembly bolt
Copper washer
Damper rod assembly
Inner tube
Outer tube1
1
1
1
1
1
For assembly, reverse the disassembly 
procedure.
11
12
13
14
15
16
23 Nm (2.3 m
kg, 17 ft
lb)
15 Nm (1.5 m
kg, 11 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb) 

4-47
FRONT FORKCHAS
WARNING
NOTE:
WARNING
EAS00649
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
2. Remove

front wheel

front brake caliper
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
3. Remove:

Side Cowlings
Refer to “COWLINGS” in chapter 3.

handlebar
4....

4-48
FRONT FORKCHAS
NOTE:
WARNING
NOTE:
CAUTION:
EAS00652
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Remove:

cap bolt 
1
(from the damper adjusting rod)

spacer 
2

nut 3
a. Press down on the spacer with the fork
spring compressor 
4.
b. Install the rod holder 
5 between the nut 3
and the spacer 2.
Fork spring compressor
90890-01441, YM-01441
Rod holder
90890-01434, YM-01434
Use the side of the rod holder that is marked “B”.
c. Loosen the nut.
d....

4-49
FRONT FORKCHAS
NOTE:
WARNING
4. Remove:

damper rod assembly bolt

damper rod assembly
While holding the damper rod assembly with the
damper rod holder 
1, loosen the damper rod
assembly bolt.
Damper rod holder
90890-01423, YM-01423
EAS00656
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Check:

inner tube 
1

outer tube 2
Bends / damage / scratches 
 Replace.
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2....

4-50
FRONT FORKCHAS
CAUTION:
WARNING
NOTE: 
The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly
sensitive to foreign material.

When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
4. Check:

cap bolt O-ring 
1
Damage / wear 
 Replace.
EAS00659
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.

Make sure the oil levels in...

4-51
FRONT FORKCHAS
WARNING
CAUTION:
23 Nm (2.3 m
kg, 17 ft
lb)
NOTE:
Always use new copper washer.
Allow the damper rod assembly to slide
slowly down the inner tube 
1 until it pro-
trudes from the bottom of the inner tube. Be
careful not to damage the inner tube.
2. Lubricate:

inner tube’s outer surface
Recommended lubricant
Suspension oil “01” or 
equivalent
3. Tighten:

damper rod assembly bolt 
1
LOCTITE
While holding the damper rod assembly with the
damper rod holder 
2, tighten the damper rod...

4-52
FRONT FORKCHAS
CAUTION:
NOTE:
NOTE:
Make sure the numbered side of the oil seal
faces up.

Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.

Lubricate the outer surface of the inner tube
with fork oil.

Before installing the oil seal, cover the top of
the front fork leg with a plastic bag to protect
the oil seal during installation.
5. Install :

Oil seal 
1
(with the fork seal driver 2)
Fork seal driver
90890-01442, YM-01442
6. Install:

oil seal clip 
1
Adjust the...

4-53
FRONT FORKCHAS
NOTE:
NOTE: 8. Install:

rod puller 
1

rod puller attachment 2
(onto the damper rod 3)
Rod puller
90890-01437, YM-01437
Rod puller attachment
90890-01436, YM-01436
9. Fill:

front fork leg
(with the specified amount of the recom-
mended fork oil)
Quantity (each front fork leg)
0.53 L (0.47 Imp qt, 0.56 US qt)
Recommended oil
Suspension oil “01” or 
equivalent
Front fork leg oil level (from the 
top of the outer tube, with the 
outer tube fully compressed and 
without the fork...