Yamaha R1 2004 ServiceManual

5-69
OIL PAN AND OIL PUMPENG
NOTE:
15 Nm (1.5 m
kg, 11 ft
lb)
NOTE:
12 Nm (1.2 m
kg, 8.7 ft
lb)
2. Install:

pin 
1

inner rotor 2

outer rotor 3

oil pump housing 4
When installing the inner rotor, align the pin 1 in
the oil pump shaft with the groove 
a in the inner
rotor 
2.
3. Install:

oil / water pump driven sprocket 
1
LOCTITE
5VY mark of the oil / water pump driven gear is
installed at oil pump side.
4. Check:

oil pump operation
Refer to “CHECKING THE OIL PUMP”.
INSTALLING THE OIL / WATER PUMP...

5-70
OIL PAN AND OIL PUMPENG
NOTE:
CAUTION:
10 Nm (1.0 m
kg, 7.2 ft
lb)
NOTE:
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
2. Install:

washer

oil / water pump assembly drive chain 
1

oil / water pump assembly drive sprocket 2

collar
Install the oil / water pump assembly drive chain
1 onto the oil / water pump assembly drive
sprocket 
2.
After installing the oil / water pump assem-
bly drive chain and drive sprocket, make
sure the oil / water pump turns smoothly.
3. Install:

oil / water...

5-71
OIL PAN AND OIL PUMPENG
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
43Nm (4.3 m
kg, 31 ft
lb)
WARNING
NOTE:
EAS00380
INSTALLING THE OIL PAN
1. Install:

dowel pins

gasket 
New

oil pan 
1

oil level switch 2

engine oil drain bolt 3
Always use new copper washers.

Tighten the oil pan bolts in stages and in a
crisscross pattern.

Lubricate the oil level switch O-ring with en-
gine oil. 

5-72
Order Job / Part Q’ty Remarks
Removing the crankcase
Air filter case
Throttle body assembly
Engine
Cylinder head
Starter clutch and generator
Shift shaft
Crankshaft position sensor
Clutch
Oil pan and oil pump
Starter motorRemove the parts in the order listed.
Refer to “AIR FILTER CASE” in chapter 3.
Refer to “THROTTLE BODIES” in 
chapter 7.
Refer to “ENGINE”.
Refer to “CYLINDER HEAD”.
Refer to “STARTER CLUTCH AND 
GENERATOR”.
Refer to “SHIFT SHAFT”.
Refer to “CRANKSHAFT POSITION 
SENSOR”.
Refer to...

5-73
CRANKCASEENG
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Timing chain
Timing chain guide (intake side)
Pin
Timing chain guide (exhaust side)
Left side cover
O-ring
Lower crankcase
Dowel pin
Damper1
1
2
1
1
1
1
3
1
For installation, reverse the removal
procedure.
12 Nm (1.2 m
kg, 8.7 ft
lb)12 Nm (1.2 m
kg, 8.7 ft
lb)
24 Nm (2.4 m
kg, 17 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
24 Nm (2.4 m
kg, 17 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb) +60 

5-74
CRANKCASEENG
NOTE:
CAUTION:
NOTE:
EAS00384
DISASSEMBLING THE CRANKCASE
1. Place the engine upside down.
2. Remove:

crankcase bolts

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.

Loosen the bolts in decreasing numerical or-
der (refer to the numbers in the illustration).

The numbers embossed on the crankcase in-
dicate the crankcase tightening sequence.
M9  105 mm (4.1 in) bolts: 
1 
 10
M8  60 mm (2.4...

5-75
CRANKCASEENG
NOTE:
EAS00399
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
3. Check:

crankcase
Cracks / damage 
 Replace.

oil delivery passages
Obstruction 
 Blow out with compressed air.
EAS00401
CHECKING THE BEARINGS AND OIL
SEALS
1. Check:

bearings
Clean and lubricate the bearings, then rotate
the inner race with your finger.
Rough movement 
 Replace.
2. Check:

oil seals
Damage / wear...

5-76
CRANKCASEENG
CAUTION:
NOTE:
3. Install:

dowel pin
4. Set the shift drum assembly and transmis-
sion gears in the neutral position.
5. Install:

lower crankcase 
1
(onto the upper crankcase 2)
Before tightening the crankcase bolts, make
sure that the transmission gears shift cor-
rectly when the shift drum assembly is
turned by hand.
6. Install:

crankcase bolts

Lubricate the bolt threads with engine oil.

Install a washer on bolts 
1 
 10 and 22.

Seal bolt 
18

Tighten the bolts in the tightening...

5-77
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11
12Removing the connecting rods and
pistons
Lower crankcase
Connecting rod cap
Big end lower bearing
Big end upper bearing
Piston pin clip
Piston pin
Piston
Connecting rod
Top ring
2nd ring
Oil ring
Cylinder
Cylinder gasket4
4
4
8
4
4
4
4
4
4
1
1Remove the parts in the order listed.
Refer to “CRANKCASE”.
For installation, reverse the removal 
procedure.
20 Nm (2.0 m
kg, 14 ft
lb) +150
8 Nm (0.8 m
kg, 5.8 ft
lb)
CONNECTING RODS AND PISTONSENG...

5-78
CONNECTING RODS AND PISTONSENG
NOTE:
CAUTION:
NOTE:
NOTE:
EAS00393
REMOVING THE CONNECTING RODS AND
PISTONS
The following procedure applies to all of the
connecting rods and pistons.
1. Remove:

connecting rod cap 
1

big end bearings

Identify the position of each big end bearing so
that it can be reinstalled in its original place.

After removing the connecting rods and con-
necting rod caps, care should be taken not to
damage the mating surfaces of the connecting
rods and connecting rod caps.
2....