Yamaha R1 2004 ServiceManual

							4-4
FRONT WHEEL AND BRAKE DISCSCHAS
NOTE:
CAUTION:
NOTE:
3. Measure:

radial wheel runout 
1

lateral wheel runout 2
Over the specified limits 
 Replace.
Radial wheel runout limit
1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
4. Check:

wheel bearings
Front wheel turns roughly or is loose 
 Re-
place the wheel bearings.

oil seals
Damage / wear 
 Replace.
5. Replace:

wheel bearings 
New

oil seals 
New
a. Clean the outside of the front wheel hub.
b. Remove the oil seals 
1 with a flat-head
screwdriver.
To prevent damaging the wheel, place a rag 
2
between the screwdriver and the wheel surface.
c. Remove the wheel bearings 
3 with a gener-
al bearing puller.
d. Install the new wheel bearings and oil seals
in the reverse order of disassembly.
Do not contact the wheel bearing inner race
1 or balls 2. Contact should be made only
with the outer race 
3.
Use a socket 
4 that matches the diameter of
the wheel bearing outer race and oil seal. 
						

							4-5
FRONT WHEEL AND BRAKE DISCSCHAS
NOTE:
EAS00533
CHECKING THE BRAKE DISCS
The following procedure applies to all of the
brake discs.
1. Check:

brake disc
Damage / galling 
 Replace.
2. Measure:

brake disc deflection
Out of specification 
 Correct the brake disc
deflection or replace the brake disc.
Brake disc deflection limit 
(maximum)
Front : 0.1 mm (0.004 in)
Rear : 0.15 mm (0.006 in)
a. Place the motorcycle on a suitable stand so
that the wheel is elevated.
b. Before measuring the front brake disc deflec-
tion, turn the handlebars to the left or right to
ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 1.5 mm (0.06 in) be-
low the edge of the brake disc.
3. Measure:

brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification 
 Replace.
Brake disc thickness limit 
(minimum)
Front : 4.0 mm (0.16 in)
Rear : 4.5 mm (0.18 in)
4. Adjust:

brake disc deflection
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
Tighten the brake disc bolts in stages and in a
crisscross pattern. 
						

							4-6
FRONT WHEEL AND BRAKE DISCSCHAS
NOTE:
91 Nm (9.1 m
kg, 66 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb)
CAUTION:
Brake disc bolt
Front : 18 Nm (1.8 m
kg, 13 ft
lb)
Rear : 30 Nm (3.0 m
kg, 22 ft
lb)
LOCTITE

d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be brought
within specification, replace the brake disc.
EAS00545
INSTALLING THE FRONT WHEEL
The following procedure applies to both brake
discs.
1. Lubricate:

wheel axle

oil seal lips
Recommended lubricant
Lithium-soap-based grease
2. Lift the wheel up between the fork legs.
3. Insert the wheel axle.
Install the tire and wheel with the mark 
1 point-
ing in the direction of wheel rotation.
4. Lower the front wheel so that it is on the
ground.
5. Tighten:

wheel axle

wheel axle pinch bolt
Before tightening the wheel axle nut, push
down hard on the handlebars several times
and check if the front fork rebounds smooth-
ly. 
						

							4-7
FRONT WHEEL AND BRAKE DISCSCHAS
35 Nm (3.5 m
kg, 25 ft
lb)
NOTE:
WARNING
NOTE:
NOTE:
6. Install:

brake caliper (left and right)
Make sure that there is enough space between
the brake pads before installing the brake cali-
pers onto the brake discs.
Make sure the brake hose is routed properly.
EAS00549
ADJUSTING THE FRONT WHEEL STATIC 
BALANCE

After replacing the tire, wheel or both, the front
wheel static balance should be adjusted.

Adjust the front wheel static balance with the
brake discs installed.
1. Remove:

balancing weight(s)
2. Find:

front wheel’s heavy spot
Place the front wheel on a suitable balancing
stand.
a. Spin the front wheel.
b. When the front wheel stops, put an “X
1” mark
at the bottom of the wheel.
c. Turn the front wheel 90 so that the “X
1” mark
is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an “X
2” mark at
the bottom of the wheel.
f. Repeat steps (d) through (f) several times
until all the marks come to rest at the same
spot.
g. The spot where all the marks come to rest is
the front wheel’s heavy spot “X”. 
						

							4-8
FRONT WHEEL AND BRAKE DISCSCHAS
NOTE:
3. Adjust:

front wheel static balance
a. Install a balancing weight 
1 onto the rim ex-
actly opposite the heavy spot “X”.
Start with the lightest weight.
b. Turn the front wheel 90 so that the heavy
spot is positioned as shown.
c. If the heavy spot does not stay in that posi-
tion, install a heavier weight.
d. Repeat steps (b) and (c) until the front wheel
is balanced.
4. Check:

front wheel static balance
a. Turn the front wheel and make sure it stays at
each position shown.
b. If the front wheel does not remain stationary
at all of the positions, rebalance it. 
						

							4-9
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the rear wheel
Rear brake caliper
Lock nut (left and right)
Adjusting bolt (left and right)
Wheel axle nut
Washer
Rear wheel axle
Left adjusting block
Right adjusting block
Rear wheel
Brake caliper bracket1
2
2
1
1
1
1
1
1
1Remove the parts in the order listed.
Place the motorcycle on a suitable stand
so that the rear wheel is elevated.
Loosen.
Loosen.
For installation, reverse the removal 
procedure.
NOTE:
22 Nm (2.2 m
kg, 16 ft
lb)
27 Nm (2.7 m
kg, 20 ft
lb)
150 Nm (15 m
kg, 108 ft
lb)
REAR WHEEL AND BRAKE DISCCHAS
EAS00551
REAR WHEEL AND BRAKE DISC
REAR WHEEL 
						

							4-10
REAR WHEEL AND BRAKE DISCCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8Removing the rear brake disc and
rear wheel sprocket
Rear brake disc
Rear wheel sprocket
Collar
Oil seal
Bearing
Rear wheel drive hub
Rear wheel drive hub damper
Rear wheel1
1
2
1
1
1
6
1Remove the parts in the order listed.
For installation, reverse the disassembly 
procedure.
100 Nm (10 m
kg, 72 ft
lb)
30 Nm (3.0 m
kg, 22 ft
lb)
EAS00560
REAR BRAKE DISC AND REAR WHEEL SPROCKET 
						

							4-11
REAR WHEEL AND BRAKE DISCCHAS
Order Job / Part Q’ty Remarks
Disassembling the rear wheel
Collar
Bearing
Spacer
Oil seal
Circlip
Bearing1
1
1
1
1
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly
procedure.
1
2
3
4
5
6 
						

							4-12
REAR WHEEL AND BRAKE DISCCHAS
WARNING
NOTE:
NOTE:
NOTE:
EAS00561
REMOVING THE REAR WHEEL
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Remove:

brake caliper 
1
Do not depress the brake pedal when removing
the brake caliper.
3. Loosen:

locknut 
1

adjusting bolt 2
4. Remove:

wheel axle nut 
1

wheel axle

rear wheel
Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
5. Remove:

left collar 
1

rear wheel drive hub 2

rear wheel drive hub damper

right collar 
						

							4-13
REAR WHEEL AND BRAKE DISCCHAS
EAS00565
CHECKING THE REAR WHEEL
1. Check:

wheel axle

rear wheel

wheel bearings

oil seals
Refer to “CHECKING THE FRONT
WHEEL”.
2. Check:

tire

rear wheel
Damage / wear 
 Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
3. Measure:

radial wheel runout

lateral wheel runout
Refer to “CHECKING THE FRONT
WHEEL”.
EAS00567
CHECKING THE REAR WHEEL DRIVE HUB
1. Check:

rear wheel drive hub 
1
Cracks / damage 
 Replace.

rear wheel drive hub dampers 
2
Damage / wear 
 Replace.
EAS00568
CHECKING AND REPLACING THE REAR 
WHEEL SPROCKET
1. Check:

rear wheel sprocket
More than 1 / 4 tooth 
a wear 
 Replace the
rear wheel sprocket.
Bent teeth 
 Replace the rear wheel sprock-
et.
bCorrect
1Drive chain roller
2Rear wheel sprocket