Yamaha R1 2004 ServiceManual

5-59
SHIFT SHAFTENG
Order Job / Part Q’ty Remarks
10
11
12
13Oil seal
Bearing
Bearing
Stopper lever spring1
1
1
1
For installation, reverse the removal 
procedure.
22 Nm (2.2 m
kg, 16 ft
lb) 

5-60
SHIFT SHAFTENG
REMOVING THE SHIFT SHAFT
1. Remove:

left and right side cowlings

bottom cowlings
Refer to “COWLINGS” in chapter 3.
2. Remove:

clutch assembly
Refer to “CLUTCH”.
3. Remove:

shift arm

shift rod
Refer to “ENGINE”.
4. Remove:

circlip 
1

Washer 2
(left side of the engine)
5. Remove:

shift shaft 
1

shift shaft spring 2

collar

washer
6. Remove:

stopper lever spring 
1

stopper screw 2

stopper lever 3

washer 

5-61
SHIFT SHAFTENG
22 Nm (2.2 m
kg, 16 ft
lb)
NOTE: CHECKING THE SHIFT SHAFT
1. Check:

shift shaft 
1
Bends / damage / wear 
 replace.

shift shaft spring 
2

collar 3
Damage / wear 
 Replace.
CHECKING THE STOPPER LEVER
1. Check:

stopper lever 
1
Bends / damage 
 Replace.
Roller turns roughly 
 Replace the stopper
lever.
INSTALLING THE SHIFT SHAFT
1. Install:

washer

stopper lever 
1

stopper screw 2
LOCTITE

stopper lever spring 3
2. Install:

washer

collar

shift shaft spring 
1

shift shaft 2...

5-62
SHIFT SHAFTENG
4. Install:

shift rod

shift arm
Refer to “ENGINE”.
5. Install:

clutch assembly
Refer to “CLUTCH”.
6. Install:

left and side cowling

bottom cowlings
Refer to “COWLING” in chapter 3. 

5-63
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8Removing the oil pan and oil pump
Side cowlings
Bottom cowlings
Engine oil
Exhaust pipe and exhaust valve pipe
Clutch assembly
Water pump inlet pipe
Water pump outlet pipe
Oil level switch lead coupler
Oil level switch
Oil level switch lead holder
Oil pan
Oil pan gasket
Dowel pin
Drain pipe
Oil strainer1
1
1
1
1
2
1
1Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “EXHAUST PIPE”.
Refer to “CLUTCH”....

5-64
OIL PAN AND OIL PUMPENG
Order Job / Part Q’ty Remarks
9
10
11
12
13
14
15
16
17
18Oil pipe
Oil delivery pipe
Relief valve assembly
Oil / water pump assembly drive 
chain guide
Collar
Oil / water pump assembly drive 
sprocket
Washer
Oil / water pump assembly drive chain
Dowel pin
Oil / water pump assembly1
1
1
1
1
1
1
1
1
1
For installation, reverse the removal 
procedure.
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)10 Nm (1.0 m
kg, 7.2 ft
lb)
12 Nm (1.2 m
kg,...

5-65
Order Job / Part Q’ty Remarks
Disassembling the oil pump
Oil / water pump driven sprocket
Collar
Oil pump housing
Bearing
Pin
Oil pump outer rotor
Oil pump inner rotor
Pin1
1
1
1
2
1
1
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly
procedure.
1
2
3
4
5
6
7
8
15 Nm (1.5 m
kg, 11 ft
lb)
OIL PAN AND OIL PUMPENG
EAS00360 

5-66
OIL PAN AND OIL PUMPENG
NOTE:
EAS00362
REMOVING THE OIL PAN
1. Remove:

oil level switch 
1

oil pan 2

oil pan gasket

dowel pins
Loosen each bolt 1 / 4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
CHECKING THE SPROCKET AND CHAIN
1. Check:

oil / water pump assembly drive sprocket 
1
Cracks / damage / wear 
 Replace the de-
fective part(-s).
2. Check:

oil / water pump assembly drive chain 
1
Damage / stiffness 
 Replace the oil...

5-67
OIL PAN AND OIL PUMPENG
EAS00364
CHECKING THE OIL PUMP
1. Check:

oil pump driven gear 
1

oil pump rotor housing 2

oil pump cover 
Cracks / damage / wear 
 Replace the de-
fective part(s).
2. Measure:

inner-rotor-to-outer-rotor-tip clearance 
a

outer-rotor-to-oil-pump-housing clearance
b
1Inner rotor
2Outer rotor
3Oil pump housing
Inner-rotor-to-outer-rotor-tip 
clearance
0.01 
 0.10 mm
(0.0004 
 0.0039 in)
: 0.18 mm (0.0071 in)
Outer-rotor-to-oil-pump-housing 
clearance
0.09 
 0.15 mm
(0.0035 
...

5-68
OIL PAN AND OIL PUMPENG
EAS00367
CHECKING THE OIL DELIVERY PIPE AND
OIL PIPE
1. Check:

oil delivery pipe 
1

oil pipe 2
Damage 
 Replace.
Obstruction 
 Wash and blow out with com-
pressed air.
EAS00368
CHECKING THE OIL STRAINER
1. Check:

oil strainer 
1
Damage 
 Replace.
Contaminants 
 Clean with solvent.
EAS00373
CHECKING THE OIL NOZZLES
The following procedure applies to all of the oil
nozzles.
1. Check:

oil nozzle 
1
Damage / wear 
 Replace the oil nozzle.

O-ring 
2
Damage / wear 
 Replace....