Yamaha R1 2004 ServiceManual

5-19
CAMSHAFTENG
NOTE:
NOTE:
NOTE:
EAS00215
INSTALLING THE CAMSHAFTS
1. 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, align the “T” mark
a with the crankcase mating surface b.
2. Install:

intake camshaft sprocket 
1

exhaust camshaft sprocket 2
(with the camshaft sprockets temporarily
tightened)
Install the camshaft sprockets as a illustration.
3. Install:

exhaust camshaft 
1

intake camshaft 2
(with the...

5-20
CAMSHAFTENG
10 Nm (1.0 m
kg, 7.2 ft
lb)
NOTE:
CAUTION:
24 Nm (2.4 m
kg, 17 ft
lb)
CAUTION:
5. Install:

camshaft cap bolts
Tighten the camshaft cap bolts in stages and in
a crisscross pattern, working from the inner
caps out.

Lubricate the camshaft cap bolts with the
engine oil.

The camshaft cap bolts must be tightened
evenly or damage to the cylinder head,
camshaft caps, and camshafts will result.

Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing....

5-21
CAMSHAFTENG
10 Nm (1.0 m
kg, 7.2 ft
lb)
CAUTION:
WARNING
8. Install:

O-ring 
New

timing chain tensioner 
1

timing chain tensioner bolts 2
The “arrow” mark a on the timing chain ten-
sioner should face up.
Always use a new O-ring.
9. Turn:

crankshaft
(several full turns clockwise)
10. Check:

“T” mark 
a
Make sure the “T” mark on the pickup rotor is
aligned with the crankcase mating sure face
b.

camshaft punch mark 
c
Make sure the punch mark c on the cam-
shaft is aligned with the camshaft cap...

5-22
Order Job / Part Q’ty Remarks
1
2
3
4
5
6Removing the cylinder head
Engine
Intake camshaft
Exhaust camshaft
Cylinder head
Cylinder head gasket
Dowel pin
Coolant pipe
O-ring
Thermo wax out let hose1
1
2
1
1
1Remove the parts in the order listed.
Refer to “ENGINE”.
Refer to “CAMSHAFTS”.
For installation, reverse the removal 
procedure.
18 Nm (1.8 m
kg, 13 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
19 Nm (1.9 m
kg, 14 ft
lb)
67 Nm (6.7 m
kg, 48 ft
lb)
1st
2nd
10 Nm (1.0 m
kg, 7.2 ft
lb)
CYLINDER HEADENG...

5-23
CYLINDER HEADENG
NOTE:
NOTE:
NOTE:
EAS00222
REMOVING THE CYLINDER HEAD
1. Remove:

intake camshaft

exhaust camshaft
Refer to “REMOVING THE CAMSHAFTS”.
2. Remove:

cylinder head nuts

cylinder head bolts

Loosen the nuts in the proper sequence as
shown.

Loosen each nut 1 / 2 of a turn at a time. After all
of the nuts are fully loosened, remove them.
EAS00227
CHECKING THE CYLINDER HEAD
1. Eliminate:

combustion chamber carbon deposits
(with a rounded scraper)
Do not use a sharp instrument to avoid...

5-24
CYLINDER HEADENG
8 Nm (0.8 m
kg, 5.8 ft
lb)
NOTE:
NOTE:
19 Nm (1.9 m
kg, 14 ft
lb)
67 Nm (6.7 m
kg, 48 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
NOTE:
EAS00233
INSTALLING THE CYLINDER HEAD
1. Check:

cylinder head bolts 
1
Retighten the cylinder head bolts to specifica-
tion, before installing the cylinder head.
2. Install:

gasket 
New
 1

dowel pins
3. Install:

cylinder head
Pass the timing chain through the timing chain
cavity.
4. Tighten:

cylinder head nuts 
1 
 10
1st
2nd

cylinder head bolts 
11...

5-25
VALVES AND VALVE SPRINGSENG
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the valves and valve
springs
Cylinder head
Intake valve lifter
Intake valve pad
Intake valve cotter
Intake valve upper spring seat
Intake valve spring
Intake valve oil seal
Intake valve lower spring seat
Intake valve
Intake valve guide12
12
24
12
12
12
12
12
12Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
EAS00236
VALVES AND VALVE SPRINGS 

5-26
Order Job / Part Q’ty Remarks
10
11
12
13
14
15
16
17
18Exhaust valve lifter
Exhaust valve pad
Exhaust valve cotter
Exhaust valve upper spring seat
Exhaust valve spring
Exhaust valve oil seal
Exhaust valve lower spring seat
Exhaust valve
Exhaust valve guide8
8
16
8
8
8
8
8
8
For installation, reverse the removal
procedure.
VALVES AND VALVE SPRINGSENG 

5-27
VALVES AND VALVE SPRINGSENG
NOTE:
NOTE:
NOTE:
NOTE:
EAS00237
REMOVING THE VALVES
The following procedure applies to all of the
valves and related components.
Before removing the internal parts of the cylin-
der head (e.g., valves, valve springs, valve
seats), make sure the valves properly seal.
1. Remove:

valve lifter 
1

valve pad 2
Make a note of the position of each valve lifter
and valve pad so that they can be reinstalled in
their original place.
2. Check:

valve sealing
Leakage at the valve...

5-28
VALVES AND VALVE SPRINGSENG
NOTE:
NOTE:
4. Remove:

upper spring seat 
1

valve spring 2

valve stem seal 3

lower spring seat 4

valve 5
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
EAS00239
CHECKING THE VALVES AND VALVE 
GUIDES
The following procedure applies to all of the
valves and valve guides.
1. Measure:

valve-stem-to-valve-guide clearance
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter 
A –
Valve stem diameter 
B...