Yamaha R1 2004 ServiceManual
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5-9 ENGINEENG NOTE: 7 Nm (0.7 mkg, 5.1 ftlb) NOTE: INSTALLING THE ENGINE 1. Install: engine mounting adjust bolts (temporary tighten) 2. Install: engine 3. Install: lower engine mounting bolt 1 upper engine mounting bolt 2 self locking nuts Lubricate the lower and upper engine mounting bolts threads with lithium-soap-based grease. 4. Install: left front engine mount bolt 1 (temporary tighten) 5. Install: engine mount collar (inside) 1 engine mount collar (outside) 2 right front engine mount bolt 3 (temporary tighten) 6. Tighten: engine mounting adjust bolts Use the pivot shaft wrench 1 and pivot shaft wrench adapter 2 to tighten the engine mount- ing adjust bolts.
5-10 ENGINEENG 51 Nm (5.1 mkg, 37 ftlb) NOTE: 45 Nm (4.5 mkg, 33 ftlb) 45 Nm (4.5 mkg, 33 ftlb) Pivot shaft wrench 90890-01471, YM-01471 Pivot shaft wrench adapter 90890-01476 7. Tighten: upper self-locking nut 1 lower self-locking nut 2 First tighten the lower self-locking nut, and then tighten the upper self-locking nut. 8. Tighten: left front engine mounting bolt 1 9. Tighten: right front engine mounting bolt 1
5-11 Order Job / Part Q’ty Remarks 1 2 3 4Removing the cylinder head cover Fuel tank Side and bottom cowlings Throttle body assembly Radiator assembly Air cut-off valve Ignition coil Spark plug Cylinder head cover Cylinder head cover gasket4 4 1 1Remove the parts in the order listed. Refer to “FUEL TANK” in chapter 3. Refer to “COWLINGS” in chapter 3. Refer to “THROTTLE BODIES” in chapter 7. Refer to “RADIATOR” in chapter 3. Refer to “AIR INDUCTION SYSTEM” in chapter 7. 13 Nm (1.3 mkg, 9.4 ftlb) 8 Nm (0.8 mkg, 5.7 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) CAMSHAFTENG EAS00194 CAMSHAFT CYLINDER HEAD COVER
5-12 CAMSHAFTENG Order Job / Part Q’ty Remarks 5 6 7Timing chain guide (top side) Cylinder identification sensor O-ring1 1 1 For installation, reverse the removal procedure. 13 Nm (1.3 mkg, 9.4 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) 8 Nm (0.8 mkg, 5.7 ftlb)
5-13 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10Removing the camshafts Pickup rotor cover Camshaft sprocket bolt Timing chain tensioner Timing chain tensioner O-ring Intake camshaft cap Dowel pin Exhaust camshaft cap Dowel pin Intake camshaft Exhaust camshaft Camshaft sprocket4 1 1 3 6 3 6 1 1 2Remove the parts in the order listed. Refer to “CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR”. Loosen. Refer to “REMOVING THE CAMSHAFTS”. For installation, reverse the removal procedure. During removal, the dowel pins may still be connected to the camshaft caps. NOTE: 10 Nm (1.0 mkg, 7.2 ftlb) 24 Nm (2.4 mkg, 17 ftlb) 24 Nm (2.4 mkg, 17 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb)10 Nm (1.0 mkg, 7.2 ftlb) CAMSHAFTENG EAS00196 CAMSHAFTS
5-14 CAMSHAFTENG NOTE: CAUTION: EAS00198 REMOVING THE CAMSHAFTS 1. Remove: pickup rotor cover Refer to “CRANKSHAFT POSITION SEN- SOR AND PICKUP ROTOR”. 2. Align: “T” mark a on the pickup rotor (with the crankcase mating surface b) a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the “T” mark a on the pick- up rotor with the crankcase mating surface b. TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. 3. Loosen: camshaft sprocket bolts 1 Camshaft wrench 90890-04143 4. Remove: timing chain tensioner 1 O-ring 5. Remove: camshaft caps 1 dowel pins To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in.
5-15 CAMSHAFTENG NOTE: 6. Remove: intake camshaft 1 exhaust camshaft 2 To prevent the timing chain from falling into the crankcase, fasten it with a wire 3. 7. Remove: camshaft sprockets EAS00204 CHECKING THE CAMSHAFTS 1. Check: camshaft lobes Blue discoloration / pitting / scratches Re- place the camshaft. 2. Measure: camshaft lobe dimensions a and b Out of specification Replace the cam- shaft. Camshaft lobe dimension limit Intake camshaft a 32.85 32.95 mm (1.293 1.297 in) : 32.75 mm (1.289 in) b 25.14 25.24 mm (0.990 0.994 in) : 25.04 mm (0.986 in) Exhaust camshaft a 30.75 30.85 mm (1.211 1.215 in) : 30.65 mm (1.207 in) b 23.09 23.19 mm (0.909 0.913 in) : 22.99 mm (0.905 in)
5-16 CAMSHAFTENG NOTE: 3. Measure: camshaft runout Out of specification Replace. Camshaft runout limit 0.03 mm (0.0012 in) 4. Measure: camshaft-journal-to-camshaft-cap clear- ance Out of specification Measure the camshaft journal diameter. Camshaft-journal-to-camshaft- cap clearance 0.028 0.062 mm (0.0011 0.0024 in) a. Install the camshaft into the cylinder head (without the dowel pins and camshaft caps). b. Position strip of Plastigauge 1 onto the camshaft journal as shown. c. Install the dowel pins and camshaft caps. Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance with the Plastigauge . Camshaft cap bolt 10 Nm (1.0 mkg, 7.2 ftlb) d. Remove the camshaft caps and then mea- sure the width of the Plastigauge 1. 5. Measure: camshaft journal diameter a Out of specification Replace the cam- shaft. Within specification Replace the cylinder head and the camshaft caps as a set. Camshaft journal diameter 22.459 22.472 mm (0.8842 0.8847 in)
5-17 CAMSHAFTENG NOTE: EAS00208 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides. 1. Check: timing chain 1 Damage / stiffness Replace the timing chain and camshaft sprockets as a set. 2. Check: camshaft sprocket More than 1 / 4 tooth wear a Replace the camshaft sprockets and the timing chain as a set. a1 / 4 tooth bCorrect 1Timing chain roller 2Camshaft sprocket 3. Check: timing chain guide (exhaust side) 1 timing chain guide (intake side) 2 timing chain guide (top side) 3 Damage / wear Replace the defective part(s). CHECKING THE TIMING CHAIN TENSIONER 1. Remove: timing chain tensioner housing 1 timing chain tensioner rod 2 timing chain tensioner spring 3 Squeeze the timing chain tensioner clip, and then remove the timing chain tensioner spring and timing chain tensioner rod. 2. Check: timing chain tensioner housing timing chain tensioner rod timing chain tensioner spring Damage / wear Replace.
5-18 CAMSHAFTENG NOTE: NOTE: NOTE: 3. Install: timing chain tensioner spring timing chain tension rod 1 Prior to installing the timing chain tensioner rod, drain the engine oil from the timing chain ten- sioner housing. a. Install the timing chain tensioner spring and timing chain tensioner rod 1. b. Squeeze the timing chain tensioner clip 2 and push the timing chain tensioner rod 3. When the timing chain tensioner rod 3 is pushed while holding the grip of the timing chain tensioner clip 2, make sure not to release the timing chain tensioner rod 3 before releasing the timing chain tensioner clip 2. (Otherwise, the timing chain tensioner rod 3 may run off.) c. Hook the clip 4 to the timing chain tensioner rod 3. Hook the timing chain tensioner rod pin 5 to the center of the clip 4. After the installation, check that the clip 4 can come off by its own weight by pushing the timing chain tensioner rod 3 at the position of installation.