Yamaha R1 2004 ServiceManual

5-9
ENGINEENG
NOTE:
7 Nm (0.7 m
kg, 5.1 ft
lb)
NOTE: INSTALLING THE ENGINE
1. Install:

engine mounting adjust bolts
(temporary tighten)
2. Install:

engine
3. Install:

lower engine mounting bolt 
1

upper engine mounting bolt 2

self locking nuts
Lubricate the lower and upper engine mounting
bolts threads with lithium-soap-based grease.
4. Install:

left front engine mount bolt 
1
(temporary tighten)
5. Install:

engine mount collar (inside) 
1

engine mount collar (outside) 2

right front engine mount...

5-10
ENGINEENG
51 Nm (5.1 m
kg, 37 ft
lb)
NOTE:
45 Nm (4.5 m
kg, 33 ft
lb)
45 Nm (4.5 m
kg, 33 ft
lb)
Pivot shaft wrench
90890-01471, YM-01471
Pivot shaft wrench adapter
90890-01476
7. Tighten:

upper self-locking nut 
1

lower self-locking nut 2
First tighten the lower self-locking nut, and then
tighten the upper self-locking nut.
8. Tighten:

left front engine mounting bolt 
1
9. Tighten:

right front engine mounting bolt 
1 

5-11
Order Job / Part Q’ty Remarks
1
2
3
4Removing the cylinder head cover
Fuel tank
Side and bottom cowlings
Throttle body assembly
Radiator assembly
Air cut-off valve
Ignition coil
Spark plug
Cylinder head cover
Cylinder head cover gasket4
4
1
1Remove the parts in the order listed.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Refer to “THROTTLE BODIES” in
chapter 7.
Refer to “RADIATOR” in chapter 3.
Refer to “AIR INDUCTION SYSTEM” in 
chapter 7.
13 Nm (1.3 m
kg, 9.4 ft
lb)
8 Nm...

5-12
CAMSHAFTENG
Order Job / Part Q’ty Remarks
5
6
7Timing chain guide (top side)
Cylinder identification sensor
O-ring1
1
1
For installation, reverse the removal 
procedure.
13 Nm (1.3 m
kg, 9.4 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
8 Nm (0.8 m
kg, 5.7 ft
lb) 

5-13
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the camshafts
Pickup rotor cover
Camshaft sprocket bolt
Timing chain tensioner
Timing chain tensioner O-ring
Intake camshaft cap
Dowel pin
Exhaust camshaft cap
Dowel pin
Intake camshaft
Exhaust camshaft
Camshaft sprocket4
1
1
3
6
3
6
1
1
2Remove the parts in the order listed.
Refer to “CRANKSHAFT POSITION 
SENSOR AND PICKUP ROTOR”.
Loosen.
Refer to “REMOVING THE 
CAMSHAFTS”.
For installation, reverse the removal 
procedure.
During removal,...

5-14
CAMSHAFTENG
NOTE:
CAUTION:
EAS00198
REMOVING THE CAMSHAFTS
1. Remove:

pickup rotor cover
Refer to “CRANKSHAFT POSITION SEN-
SOR AND PICKUP ROTOR”.
2. Align:

“T” mark 
a on the pickup rotor
(with the crankcase mating surface 
b)
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compres-
sion stroke, align the “T” mark 
a on the pick-
up rotor with the crankcase mating surface
b.
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
3....

5-15
CAMSHAFTENG
NOTE:
6. Remove:

intake camshaft 
1

exhaust camshaft 2
To prevent the timing chain from falling into the
crankcase, fasten it with a wire 
3.
7. Remove:

camshaft sprockets
EAS00204
CHECKING THE CAMSHAFTS
1. Check:

camshaft lobes
Blue discoloration / pitting / scratches 
 Re-
place the camshaft.
2. Measure:

camshaft lobe dimensions 
a and b
Out of specification 
 Replace the cam-
shaft.
Camshaft lobe dimension limit
Intake camshaft
a 32.85 
 32.95 mm
(1.293 
 1.297 in)
: 32.75 mm...

5-16
CAMSHAFTENG
NOTE:
3. Measure:

camshaft runout
Out of specification 
 Replace.
Camshaft runout limit
0.03 mm (0.0012 in)
4. Measure:

camshaft-journal-to-camshaft-cap clear-
ance
Out of specification 
 Measure the camshaft
journal diameter.
Camshaft-journal-to-camshaft-
cap clearance
0.028 
 0.062 mm 
(0.0011 
 0.0024 in)
a. Install the camshaft into the cylinder head
(without the dowel pins and camshaft caps).
b. Position strip of Plastigauge
 1 onto the
camshaft journal as shown.
c. Install the...

5-17
CAMSHAFTENG
NOTE:
EAS00208
CHECKING THE TIMING CHAIN, CAMSHAFT
SPROCKETS, AND TIMING CHAIN GUIDES
The following procedure applies to all of the
camshaft sprockets and timing chain guides.
1. Check:

timing chain 
1
Damage / stiffness 
 Replace the timing
chain and camshaft sprockets as a set.
2. Check:

camshaft sprocket
More than 1 / 4 tooth wear 
a 
 Replace the
camshaft sprockets and the timing chain as a
set.
a1 / 4 tooth
bCorrect
1Timing chain roller
2Camshaft sprocket
3. Check:

timing chain...

5-18
CAMSHAFTENG
NOTE:
NOTE:
NOTE:
3. Install:

timing chain tensioner spring

timing chain tension rod 
1
Prior to installing the timing chain tensioner rod,
drain the engine oil from the timing chain ten-
sioner housing.
a. Install the timing chain tensioner spring and
timing chain tensioner rod 
1.
b. Squeeze the timing chain tensioner clip 
2
and push the timing chain tensioner rod 3.
When the timing chain tensioner rod 
3 is
pushed while holding the grip of the timing chain
tensioner clip 
2, make...