Yamaha R1 2004 ServiceManual

4-64
STEERING HEADCHAS
CAUTION:
NOTE:
NOTE:
NOTE: b. Remove the bearing race 
3 from the lower
bracket with a floor chisel 
4 and hammer.
c. Install a new rubber seal and new bearing
races.
If the bearing race is not installed properly,
the steering head pipe could be damaged.

Always replace the bearings and bearing
races as a set.

Whenever the steering head is disassembled,
replace the rubber seal.
4. Check:

upper bracket

lower bracket
(along with the steering stem)
Bends / cracks / damage 
...

4-65
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the rear shock absorber 
assembly
EXUP servo motor
Self-locking nut / bolt
Self-locking nut / bolt
Self-locking nut / bolt
Self-locking nut
Rear shock absorber assembly
Oil seal / bearing / collar
Collar / self-locking nut / bolt
Connecting arm
Oil seal / bearing / collar
Relay arm1/1
1/1
1/1
1
1
6/3/3
1/1/1
2
2/1/1
1Remove the parts in the order listed.
Refer to “EXHAUST PIPE” in chapter 5.
For installation, reverse the removal 
procedure....

4-66
REAR SHOCK ABSORBER ASSEMBLYCHAS
WARNING
WARNING
EAS00687
HANDLING THE REAR SHOCK ABSORBER
AND GAS CYLINDER
This rear shock absorber and gas cylinder
contain highly compressed nitrogen gas.
Before handling the rear shock absorber or
gas cylinder, read and make sure you under-
stand the following information. The
manufacturer cannot be held responsible
for property damage or personal injury that
may result from improper handling of the
rear shock absorber and gas cylinder.

Do not tamper or attempt...

4-67
REAR SHOCK ABSORBER ASSEMBLYCHAS
WARNING
NOTE:
NOTE:
NOTE:
EAS00690
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Stand the motorcycle on a level surface.
Becurely support the motorcycle so that
there is no danger of it falling over.
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Remove:

bottom cowling
Refer to “COWLINGS” in chapter 3.

servo motor
Refer to “EXHAUST PIPE” in chapter 5.
3. Remove:

rear shock absorber assembly lower bolt 
1

relay arm-to-swingarm bolt...

4-68
REAR SHOCK ABSORBER ASSEMBLYCHAS
NOTE:
44 Nm (4.4 m
kg, 32 ft
lb)
44 Nm (4.4 m
kg, 32 ft
lb)
44 Nm (4.4 m
kg, 32 ft
lb)
EAS00695
CHECKING THE REAR SHOCK ABSORBER 
ASSEMBLY
1. Check:

rear shock absorber rod
Bends / damage 
 Replace the rear shock
absorber assembly.

rear shock absorber
Gas leaks / oil leaks 
 Replace the rear
shock absorber assembly.

spring
Damage / wear 
 Replace the rear shock ab-
sorber assembly.

bushings
Damage / wear 
 Replace.

dust seals
Damage / wear 
 Replace.

bolts...

4-69
SWINGARM AND DRIVE CHAINCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7Removing the swingarm and drive
chain
Rear wheel
Rear shock absorber
Drive sprocket
Muffler
Catalyst pipe assembly
Right footrest bracket
Adjusting bolt / locknut
Drive chain guard
Rear fender
Brake hose holder
Pivot shaft nut / washer
Pivot shaft1
2/2
1
1
1
1/1
1Remove the parts in the order listed.
Refer to “REAR WHEEL AND BRAKE
DISC”.
Refer to “REAR SHOCK ABSORBER
ASSEMBLY”.
Refer to “ENGINE REMOVAL” in chapter
5.
Refer to...

4-70
SWINGARM AND DRIVE CHAINCHAS
Order Job / Part Q’ty Remarks
8
9
10
11
12
13Swingarm
Drive chain
Dust cover
Drive chain guide
Spacer
Bearing1
1
2
1
1
2
For installation, reverse the removal
procedure.
28 Nm (2.8 m
kg, 20 ft
lb)
7 Nm (0.7 m
kg, 5.1 ft
lb)
7 Nm (0.7 m
kg, 5.1 ft
lb)
105 Nm (10.5 m
kg, 76 ft
lb)
2 Nm (0.2 m
kg, 1.4 ft
lb)
16 Nm (1.6 m
kg, 12 ft
lb) 

4-71
SWINGARM AND DRIVE CHAINCHAS
WARNING
NOTE:
NOTE:
EAS00703
REMOVING THE SWINGARM
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 rear wheel is elevated.
2. Remove:

relay arm-to-swingarm bolt 
1

connecting arm bolt 2

rear shock absorber assembly lower bolt 3
When removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.
3....

4-72
SWINGARM AND DRIVE CHAINCHAS
WARNING
NOTE:
NOTE:
WARNING
EAS00704
REMOVING THE DRIVE CHAIN
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 rear wheel is elevated.
2. Remove:

drive chain
(with the drive chain cutter)
Only cut the drive chain if it or the swingarm is to
be replaced.
EAS00707
CHECKING THE SWINGARM
1. Check:

swingarm
Bends / cracks / damage 
 Replace.
2....

4-73
SWINGARM AND DRIVE CHAINCHAS
NOTE: 3. Wash:

pivot shaft

dust covers

spacer

washers

bearings
Recommended cleaning solvent
Kerosene
4. Check:

dust covers 
1

spacer 2
Damage / wear 
 Replace.

bearings 
3
Damage / pitting 
 Replace.
5. Check:

connecting arms 
1

relay arm 2
Damage / wear 
 Replace.
6. Check:

bearings 
3

oil seals 4
Damage / pitting 
 Replace.
7. Check:

collars 
5
Damage / scratches 
 Replace.
EAS00709
CHECKING THE DRIVE CHAIN
1. Measure:

ten-link section 
a of the drive...