Yamaha R1 2004 ServiceManual
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4-64 STEERING HEADCHAS CAUTION: NOTE: NOTE: NOTE: b. Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer. c. Install a new rubber seal and new bearing races. If the bearing race is not installed properly, the steering head pipe could be damaged. Always replace the bearings and bearing races as a set. Whenever the steering head is disassembled, replace the rubber seal. 4. Check: upper bracket lower bracket (along with the steering stem) Bends / cracks / damage Replace. EAS00683 INSTALLING THE STEERING HEAD 1. Lubricate: upper bearing lower bearing bearing races Recommended lubricant Lithium-soap-based grease 2. Install: lower ring nut 1 rubber washer 2 upper ring nut 3 lock washer 4 Refer to “CHECKING THE STEERING HEAD” in chapter 3. 3. Install: upper bracket steering stem nut Temporarily tighten the steering stem nut. 4. Install: front fork legs Refer to “INSTALLING THE FRONT FORK LEGS”. Temporarily tighten the upper and lower bracket pinch bolts.
4-65 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10Removing the rear shock absorber assembly EXUP servo motor Self-locking nut / bolt Self-locking nut / bolt Self-locking nut / bolt Self-locking nut Rear shock absorber assembly Oil seal / bearing / collar Collar / self-locking nut / bolt Connecting arm Oil seal / bearing / collar Relay arm1/1 1/1 1/1 1 1 6/3/3 1/1/1 2 2/1/1 1Remove the parts in the order listed. Refer to “EXHAUST PIPE” in chapter 5. For installation, reverse the removal procedure. 92 Nm (9.2 mkg, 67 ftlb)44 Nm (4.4 mkg, 32 ftlb) 44 Nm (4.4 mkg, 32 ftlb)44 Nm (4.4 mkg, 32 ftlb) REAR SHOCK ABSORBER ASSEMBLYCHAS EAS00685 REAR SHOCK ABSORBER ASSEMBLY
4-66 REAR SHOCK ABSORBER ASSEMBLYCHAS WARNING WARNING EAS00687 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you under- stand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber and gas cylinder. Do not tamper or attempt to open the rear shock absorber or gas cylinder. Do not subject the rear shock absorber or gas cylinder to an open flame or any other source of high heat. High heat can cause an explosion due to excessive gas pressure. Do not deform or damage the rear shock absorber or gas cylinder in any way. If the rear shock absorber, gas cylinder or both are damaged, damping performance will suffer. EAS00689 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER Gas pressure must be released before dispos- ing of a rear shock absorber and gas cylinder. To release the gas pressure, drill a 2 3 mm (0.08 0.12 in) hole through the gas cylinder at a point 15 20 mm (0.59 0.79 in) from its end as shown. Wear eye protection to prevent eye damage from released gas or metal chips.
4-67 REAR SHOCK ABSORBER ASSEMBLYCHAS WARNING NOTE: NOTE: NOTE: EAS00690 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the motorcycle on a level surface. Becurely 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: bottom cowling Refer to “COWLINGS” in chapter 3. servo motor Refer to “EXHAUST PIPE” in chapter 5. 3. Remove: rear shock absorber assembly lower bolt 1 relay arm-to-swingarm bolt 2 While removing the rear shock absorber as- sembly lower bolt, hold the swingarm so that it does not drop down. 4. Remove: rear shock absorber assembly upper bolt 1 rear shock absorber assembly Raise the swingarm and then remove the rear shock absorber assembly from between the swingarm.
4-68 REAR SHOCK ABSORBER ASSEMBLYCHAS NOTE: 44 Nm (4.4 mkg, 32 ftlb) 44 Nm (4.4 mkg, 32 ftlb) 44 Nm (4.4 mkg, 32 ftlb) EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: rear shock absorber rod Bends / damage Replace the rear shock absorber assembly. rear shock absorber Gas leaks / oil leaks Replace the rear shock absorber assembly. spring Damage / wear Replace the rear shock ab- sorber assembly. bushings Damage / wear Replace. dust seals Damage / wear Replace. bolts Bends / damage / wear Replace. EAS00698 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: spacers bearings Recommended lubricant Lithium – soap-based grease 2. Install: rear shock absorber assembly When installing the rear shock absorber as- sembly, lift up the swingarm. Install the connecting arm front bolt from the right. 3. Tighten: rear shock absorber assembly upper nut rear shock absorber assembly lower nut relay arm-to swingarm nut 4. Install : EXUP servo motor Refer to “EXHAUST PIPE” in chapter 5. bottom cowling Refer to “COWLINGS” in chapter 3.
4-69 SWINGARM AND DRIVE CHAINCHAS Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7Removing the swingarm and drive chain Rear wheel Rear shock absorber Drive sprocket Muffler Catalyst pipe assembly Right footrest bracket Adjusting bolt / locknut Drive chain guard Rear fender Brake hose holder Pivot shaft nut / washer Pivot shaft1 2/2 1 1 1 1/1 1Remove the parts in the order listed. Refer to “REAR WHEEL AND BRAKE DISC”. Refer to “REAR SHOCK ABSORBER ASSEMBLY”. Refer to “ENGINE REMOVAL” in chapter 5. Refer to “EXHAUST PIPE” in chapter 5. Refer to “EXHAUST PIPE” in chapter 5. 28 Nm (2.8 mkg, 20 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 105 Nm (10.5 mkg, 76 ftlb) 2 Nm (0.2 mkg, 1.4 ftlb) 16 Nm (1.6 mkg, 12 ftlb) EAS00700 SWINGARM AND DRIVE CHAIN
4-70 SWINGARM AND DRIVE CHAINCHAS Order Job / Part Q’ty Remarks 8 9 10 11 12 13Swingarm Drive chain Dust cover Drive chain guide Spacer Bearing1 1 2 1 1 2 For installation, reverse the removal procedure. 28 Nm (2.8 mkg, 20 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 105 Nm (10.5 mkg, 76 ftlb) 2 Nm (0.2 mkg, 1.4 ftlb) 16 Nm (1.6 mkg, 12 ftlb)
4-71 SWINGARM AND DRIVE CHAINCHAS WARNING NOTE: NOTE: EAS00703 REMOVING THE SWINGARM 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: relay arm-to-swingarm bolt 1 connecting arm bolt 2 rear shock absorber assembly lower bolt 3 When removing the rear shock absorber as- sembly lower bolt, hold the swingarm so that it does not drop down. 3. Measure: swingarm side play swingarm vertical movement a. Measure the tightening torque of the pivot shaft nut. Pivot shaft nut 105 Nm (10.5 mkg, 76 ftlb) b. Measure the swingarm side play A by mov- ing the swingarm from side to side. c. If the swingarm side play is out of specifica- tion, check the spacers, bearings, washers, and dust covers. Swingarm side play (at the end of the swingarm) 1.0 mm (0.04 in) d. Check the swingarm vertical movement B by moving the swingarm up and down. If swingarm vertical movement is not smooth or if there is binding, check the spacers, bearings, washers, and dust covers.
4-72 SWINGARM AND DRIVE CHAINCHAS WARNING NOTE: NOTE: WARNING EAS00704 REMOVING THE DRIVE CHAIN 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: drive chain (with the drive chain cutter) Only cut the drive chain if it or the swingarm is to be replaced. EAS00707 CHECKING THE SWINGARM 1. Check: swingarm Bends / cracks / damage Replace. 2. Check: pivot shaft Roll the pivot shaft on a flat surface. Bends Replace. Do not attempt to straighten a bent pivot shaft.
4-73 SWINGARM AND DRIVE CHAINCHAS NOTE: 3. Wash: pivot shaft dust covers spacer washers bearings Recommended cleaning solvent Kerosene 4. Check: dust covers 1 spacer 2 Damage / wear Replace. bearings 3 Damage / pitting Replace. 5. Check: connecting arms 1 relay arm 2 Damage / wear Replace. 6. Check: bearings 3 oil seals 4 Damage / pitting Replace. 7. Check: collars 5 Damage / scratches Replace. EAS00709 CHECKING THE DRIVE CHAIN 1. Measure: ten-link section a of the drive chain Out of specification Replace the drive chain. Ten-link drive chain section limit (maximum) 150.1 mm (5.91 in) While measuring the ten-link section, push down on the drive chain to increase its tension. Measure the length between drive chain roller 1 and 11 as shown. Perform this measurement at two or three dif- ferent places.