Yamaha R1 2004 ServiceManual

6-3
RADIATORCOOL
NOTE:
EAS00455
CHECKING THE RADIATOR
1. Check:

radiator fins
Obstruction 
 Clean.
Apply compressed air to the rear of the radia-
tor.
Damage 
 Repair or replace.
Straighten any flattened fins with a thin, flat-
head screwdriver.
2. Check:

radiator hoses

radiator pipes
Cracks / damage 
 Replace.
3. Measure:

radiator cap opening pressure
Below the specified pressure 
 Replace the
radiator cap.
Radiator cap opening pressure
108 
 137 kPa
(1.08 
 1.37 kg / cm
2, 
1.0 
 1.3 bar, 15.6 
...

6-4
RADIATORCOOL
EAS00456
INSTALLING THE RADIATOR
1. Fill:

cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
2. Check:

cooling system
Leaks 
 Repair or replace any faulty part.
3. Measure:

radiator cap opening pressure
Below the specified pressure 
 Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR”. 

6-5
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the oil cooler
Engine oil
Oil cooler inlet hose
Bolt
Washer
Oil cooler
O-ring
Water pump outlet pipe
O-ring
Water jacket joint inlet hose
O-ring1
1
1
1
1
1
1
1
1Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
63 Nm (6.3 m
kg, 46 ft
lb)
OIL COOLERCOOL
EAS00457
OIL COOLER 

6-6
OIL COOLERCOOL
Order Job / Part Q’ty Remarks
10
11
12Water jacket joint
Stay
O-ring1
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)
63 Nm (6.3 m
kg, 46 ft
lb) 

6-7
OIL COOLERCOOL
63 Nm (6.3 m
kg, 46 ft
lb)
NOTE:
EAS00458
CHECKING THE OIL COOLER
1. Check:

oil cooler
Cracks / damage 
 Replace.
2. Check:

oil cooler inlet hose

oil cooler outlet hose
Cracks / damage / wear 
 Replace.
EAS00459
INSTALLING THE OIL COOLER
1. Clean:

mating surfaces of the oil cooler and the
crankcase
(with a cloth dampened with lacquer thinner)
2. Install:

O-ring 
New

oil cooler 
1

washer 2 New

bolt 
3

Before installing the oil cooler, lubricate the oil
cooler bolt and O-ring...

6-8
Order Job / Part Q’ty Remarks
1
2
3
4
5Removing the thermostat assembly
Rider seat
Fuel tank
Air filter case
Coolant
Thermostat assembly outlet hose
Thermostat assembly breather hose
Thermostat assembly
Thermostat assembly inlet hose
Band1
1
1
1
2Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “AIR FILTER CASE” in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter3.
For installation, reverse the removal 
procedure....

6-9
THERMOSTATCOOL
Order Job / Part Q’ty Remarks
Disassembling the thermostat 
housing
Thermostat housing cover
Thermostat
Thermostat housing
O-ring1
1
1
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly 
procedure.
1
2
3
4
10 Nm (1.0 m
kg, 7.2 ft
lb) 

6-10
THERMOSTATCOOL
NOTE:
EAS00462
CHECKING THE THERMOSTAT
1. Check:

thermostat
Does not open at 71 
 85C (160 
 185F)

 Replace.
a. Suspend the thermostat in a container filled
with water.
b. Slowly heat the water.
c. Place a thermometer in the water.
d. While stirring the water, observe the thermo-
stat and thermometer’s indicated tempera-
ture.
1Thermometer
2Water
3Thermostat
4Container
AFully closed
BFully open
If the accuracy of the thermostat is in doubt, re-
place it. A faulty thermostat could...

6-11
THERMOSTATCOOL
10 Nm (1.0 m
kg, 7.2 ft
lb)
NOTE:
EAS00464
ASSEMBLING THE THERMOSTAT 
ASSEMBLY
1. Install:

thermostat housing 
1

thermostat 2

O-ring New 3

thermostat housing cover 4
Install the thermostat with its breather hole a
facing up.
EAS00466
INSTALLING THE THERMOSTAT 
ASSEMBLY
1. Fill:

cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
2. Check:

cooling system
Leaks 
 Repair or replace any faulty part.
3. Measure:...

6-12
WATER PUMPCOOL
Order Job / Part Q’ty Remarks
1
2
3
4Removing the impeller shaft
Oil / water pump assembly and oil
pump rotor
Water pump cover
O-ring
Pin
Impeller shaft (along with the impeller)1
1
2
1
Remove the parts in the order listed.

The water pump and oil pump are com-
bined into one unit (oil / water pump as-
sembly).

It is not necessary to remove the impeller
shaft unless the coolant level is extreme-
ly low or coolant leaks from the oil pan.
Refer to “OIL PAN AND OIL PUMP” in
chapter 5....