Yamaha R1 2004 ServiceManual
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4-74 SWINGARM AND DRIVE CHAINCHAS CAUTION: 2. Check: drive chain Stiffness Clean and lubricate or replace. 3. Clean: drive chain a. Wipe the drive chain with a clean cloth. b. Put the drive chain in kerosene and remove any remaining dirt. c. Remove the drive chain from the kerosene and completely dry it. This motorcycle has a drive chain with small rubber O-rings 1 between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain. High-pressure methods could force dirt or water into the drive chain’s in- ternals, and solvents will deteriorate the O- rings. A coarse brush can also damage the O-rings. Therefore, use only kerosene to clean the drive chain. Don’t soak drive chain in kerosine more them ten minutes. O-ring is damage by kerosine. 4. Check: O-rings 1 Damage Replace the drive chain. drive chain rollers 2 Damage / wear Replace the drive chain. drive chain side plates 3 Damage / wear Replace the drive chain. Cracks Replace the drive chain and make sure the battery breather hose is properly routed away from the drive chain and below the swingarm. 5. Lubricate: drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains
4-75 SWINGARM AND DRIVE CHAINCHAS 6. Check: drive sprocket rear wheel sprocket More than 1 / 4 tooth a wear Replace the drive chain sprockets as a set. Bent teeth Replace the drive chain sprock- ets as a set. bCorrect 1Drive chain roller 2Drive chain sprocket EAS00711 INSTALLING THE SWINGARM 1. Lubricate: bearings spacers dust covers pivot shaft Recommended lubricant Lithium-soap-based grease 2. Install: swingarm pivot shaft 1 pivot shaft nut 2 3. Install: rear shock absorber assembly rear wheel Refer to “INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY” and “INSTAL- LING THE REAR WHEEL”. 4. Adjust: drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3. Drive chain slack 25 35 mm (0.98 1.38 in)
5-1 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8Removing the drive sprocket Bottom cowlings Lock nut Shift rod Sift arm Drive sprocket cover Drive sprocket nut Lock washer Drive sprocket Plate2 1 1 1 1 1 1 1Remove the parts in the order listed. Refer to “COWLINGS” in chapter 3. Loosen. For installation, reverse the removal procedure. 10 Nm (1.0 mkg, 7.2 ftlb) 85 Nm (8.5 mkg, 61 ftlb) 7 Nm (0.7 mkg, 5 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) ENGINEENG ENGINE ENGINE DRIVE SPROCKET
5-2 5 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10Removing the exhaust pipe Rider seat and passenger seat Fuel tank Side cowlings and bottom cowlings EXUP pulley cover EXUP cable Exhaust pipe assembly Exhaust pipe gasket Exhaust valve pipe gasket Exhaust valve pipe assembly Catalyst pipe assembly Gasket Muffler Gasket1 2 1 4 1 1 1 1 2 2Remove the parts in the order listed. Refer to “SEATS” in chapter 3. Refer to “FUEL TANK” in chapter 3. Refer to “COWLINGS” in chapter 3. 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 20 Nm (2.0 mkg, 14 ftlb) 20 Nm (2.0 mkg, 14 ftlb) 20 Nm (2.0 mkg, 14 ftlb) 23 Nm (2.3 mkg, 17 ftlb) ENGINEENG EXHAUST PIPE
5-3 Order Job / Part Q’ty Remarks 11 12 13 14Muffler cover EXUP servo motor EXUP servo motor bracket Protector2 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) 10 Nm (1.0 mkg, 7.2 ftlb) 20 Nm (2.0 mkg, 14 ftlb) 20 Nm (2.0 mkg, 14 ftlb) 20 Nm (2.0 mkg, 14 ftlb) 23 Nm (2.3 mkg, 17 ftlb) ENGINEENG
5-4 ENGINEENG Order Job / Part Q’ty Remarks Disassembling the exhaust valve pipe Washer Pulley Collar Plate Spring Housing Gasket Shaft arm Exhaust valve pipe EXUP pulley bracket1 1 1 1 1 1 1 1 1 1Disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 5 6 7 8 9 10 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 7 Nm (0.7 mkg, 5 ftlb)
5-5 Order Job / Part Q’ty Remarks 1 2Disconnecting the leads and hoses Fuel tank Air filter case Throttle body assembly Engine oil Oil cooler Air cut-off valve Starter motor Battery negative lead Battery positive lead1 1Disconnect the parts in the order listed. Refer to “FUEL TANK” in chapter 3. Refer to “AIR FILTER CASE” in chapter 3. Refer to “THROTTLE BODIES” in chapter 7. Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Refer to “OIL COOLER” in chapter 6. Refer to “AIR INDUCTION SYSTEM” in chapter 7. Refer to “STARTING SYSTEM” in chapter 7. ENGINEENG LEADS AND HOSES
5-6 Order Job / Part Q’ty Remarks 3 4 5 6 7 8 9 10Clutch cable Ground lead Stator coil assembly coupler Crankshaft position sensor lead coupler Oil level switch connector Neutral switch connector Speed sensor coupler Cylinder identification sensor coupler1 2 1 1 1 1 1 1First, disconnect the negative battery lead, and then the positive battery lead. For connecting, reverse the disconnec- tion procedure. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. For installation, reverse the removal procedure. CAUTION: ENGINEENG
5-7 ENGINEENG Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8Removing the engine Right front engine mounting bolt Engine mount collar (inside) Engine mount collar (outside) Left front engine mounting bolt Lower self locking nut Lower engine mounting bolt Upper self locking nut Upper engine mounting bolt1 1 1 1 1 1 1 1Remove the parts in the order listed. Place a suitable stand under the frame and engine. NOTE: 51 Nm (5.1 mkg, 37 ftlb) 51 Nm (5.1 mkg, 37 ftlb) 45 Nm (4.5 mkg, 33 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 45 Nm (4.5 mkg, 33 ftlb) ENGINE
5-8 ENGINEENG Order Job / Part Q’ty Remarks 9 10Engine mounting adjust bolt Engine2 1 Use the pivot shaft wrench and adapter to loosen the engine mounting adjust bolts. For installation, reverse the removal pro- cedure. NOTE: 51 Nm (5.1 mkg, 37 ftlb) 51 Nm (5.1 mkg, 37 ftlb) 45 Nm (4.5 mkg, 33 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 45 Nm (4.5 mkg, 33 ftlb)