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Yamaha R1 2004 ServiceManual

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Page 321

5-99
Order Job / Part Q’ty Remarks
Disassembling the main axle 
assembly
2nd pinion gear
Toothed lock washer
Toothed lock washer retainer
6th pinion gear
Collar
Washer
Circlip
3rd pinion gear
Circlip
Washer
5th pinion gear
Collar
Main axle1
1
1
1
1
1
1
1
1
1
1
1
1Disassemble the parts in the order listed.
1
2
3
4
5
6
7
8
9
10
11
12
13
TRANSMISSIONENG 

Page 322

5-100
Order Job / Part Q’ty Remarks
Bearing housing
Bearing1
1
For installation, reverse the removal 
procedure.
14
15
TRANSMISSIONENG 

Page 323

5-101
Order Job / Part Q’ty Remarks
Disassembling the drive axle
assembly
Washer
1st wheel gear
Collar
5th wheel gear
Circlip
Washer
3rd wheel gear
Collar
Toothed lock washer
Toothed lock washer retainer
4th wheel gear
Collar
Washer
Circlip1
1
1
1
1
1
1
1
1
1
1
1
1
1Disassemble the parts in the order listed.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
TRANSMISSIONENG 

Page 324

5-102
TRANSMISSIONENG
Order Job / Part Q’ty Remarks
6th wheel gear
Circlip
Washer
Collar
2nd wheel gear
Collar
Oil seal
Bearing
Drive axle1
1
1
1
1
1
1
1
1
For installation, reverse the removal 
procedure.
15
16
17
18
19
20
21
22
23 

Page 325

5-103
TRANSMISSIONENG
REMOVING THE TRANSMISSION
1. Remove:
drive axle assembly 
1
shift drum retainers 2
shift fork guide bars
shift fork “L” and “R”
shift drum assembly
shift fork “C”
2. Remove:
bearing housing 
1
main axle assembly 2
a. Insert two bolts 3 of the proper size, as
shown in the illustration, into the main axle
assembly bearing housing.
b. Tighten the bolts until they contact the crank-
case surface.
c. Continue tightening the bolts until the main
axle assembly comes free from the...

Page 326

5-104
TRANSMISSIONENG
WARNING
2. Check:
shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends  Replace.
Do not attempt to straighten a bent shift fork
guide bar.
3. Check:
shift fork movement
(along the shift fork guide bar)
Rough movement  Replace the shift forks
and shift fork guide bar as a set.
EAS00422
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
shift drum grooves 
1
Damage / scratches / wear  Replace the
shift drum assembly.
shift drum segment 
2
Damage / wear  Replace...

Page 327

5-105
TRANSMISSIONENG
NOTE:
12 Nm (1.2 mkg, 8.7 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)
NOTE: 2. Measure:
drive axle runout
(with a centering device and dial gauge 
1)
Out of specification  Replace the drive
axle.
Drive axle runout limit
0.08 mm (0.0032 in)
3. Check:
transmission gears
Blue discoloration / pitting / wear  Replace
the defective gear(s).
transmission gear dogs
Cracks / damage / rounded edges  Replace
the defective gear(s).
INSTALLING THE TRANSMISSION
1. Install:
bearing 
1
Make the seal...

Page 328

5-106
TRANSMISSIONENG
10 Nm (1.0 mkg, 7.2 ftlb)
NOTE:
NOTE: 3. Install:
shift fork “L” 
1 and “R” 2
drive axle assembly 3
shift fork guide bar
shift fork guide bar retainer 
4
LOCTITE
Install shift fork “L” into the groove in the 6th
wheel gear and shift fork “R” into the groove in
the 5th wheel gear on the drive axle.
Make sure that the drive axle bearing circlip 
a
is inserted into the grooves in the upper crank-
case.
4. Check:
transmission
Rough movement  Repair.
Oil each gear, shaft, and...

Page 329

6-1
Order Job / Part Q’ty Remarks
1
2
3
4
5Removing the radiator
Rider seat
Fuel tank
Air filter case
Side cowlings
Bottom cowling
Coolant
Fuse box stay
Coolant reservoir hose
Radiator
Radiator fan motor
Radiator inlet hose1
1
1
2
1Remove the parts in the order listed.
Refer to “AIR FILTER CASE” in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Disconnect.
Refer to “COWLINGS” in chapter 3.
Refer to “SEATS” in chapter 3.
10 Nm (1.0 mkg, 7.2 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)
5 Nm (0.5...

Page 330

6-2
6
RADIATORCOOL
Order Job / Part Q’ty Remarks
6
7
8
9
10
11Radiator inlet pipe
Oil cooler outlet hose
Water pump breather hose
Radiator outlet hose
Water pump inlet pipe
O-ring1
1
1
1
1
1
For installation, reverse the removal 
procedure.
10 Nm (1.0 mkg, 7.2 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)
5 Nm (0.5 mkg, 3.6 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb) 
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