Yamaha R1 2004 ServiceManual
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5-39 STARTER CLUTCH AND GENERATORENG REMOVING THE STARTER CLUTCH 1. Remove: spacer 1 O-ring 2 washer 3 2. Remove: Starter clutch drive gear 1 collar 2 washer 3 3. Remove: driven gear 1 dampers 2 generator rotor 3 CHECKING THE DAMPER 1. Check: dampers 1 Damage / wear Replace.
5-40 STARTER CLUTCH AND GENERATORENG EAS00351 CHECKING THE STARTER CLUTCH 1. Check: starter clutch rollers 1 Damage / wear Replace. 2. Check: starter clutch idle gear 1 starter clutch drive gear 2 Burrs / chips / roughness / wear Replace the defective part(s). 3. Check: starter clutch gear’s contacting surfaces a Damage / pitting / wear Replace the starter clutch gear. 4. Check: starter clutch operation a. Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch. b. When turning the starter clutch drive gear counterclockwise A, the starter clutch and the starter clutch drive gear should engage, otherwise the starter clutch is faulty and must be replaced. c. When turning the starter clutch drive gear clockwise B, it should turn freely, otherwise the starter clutch is faulty and must be re- placed.
5-41 STARTER CLUTCH AND GENERATORENG NOTE: NOTE: 10 Nm (1.0 mkg, 7.2 ftlb) INSTALLING THE STARTER CLUTCH 1. Install: generator rotor 1 damper 2 driven gear 3 The hole side of the damper is installed to the generator side. Lubricate the engine oil 4. 2. Install: starter clutch drive gear 1 collar 2 washer 3 Refer to “CHECKING THE STARTER CLUTCH”. 3. Install: washer 1 O-ring 2 New spacer 3 Lubricate the engine oil to O-ring. INSTALLING THE GENERATOR 1. Install: idle gear shaft idle gear 1 washer idle gear shaft bolt 2 LOCTITE 2. Install: generator rotor and starter clutch assembly 1
5-42 STARTER CLUTCH AND GENERATORENG 12 Nm (1.2 mkg, 8.7 ftlb) 22 Nm (2.2 mkg, 16 ftlb) NOTE: 3. Install: generator cover gasket generator cover 1 (M6 bolts) (M8 bolts) First tighten the M8 bolts and then tighten the M6 bolts. Tighten the generator rotor cover bolts in stages and in a crisscross pattern. 4. Fill: engine oil Refer to “CHANGING THE ENGINE OIL” in chapter 3. 5. Install: bottom cowling left side cowling Refer to “COWLINGS” in chapter 3. 6. Install: fuel tank rider seat Refer to “SEATS” and “FUEL TANK” in chap- ter 3.
5-43 Order Job / Part Q’ty Remarks 1 2 3 4 5 6Removing the crankshaft position sensor Rider seat Fuel tank Side cowlings Bottom cowlings Engine oil Crankshaft position sensor lead coupler Crankshaft position sensor O-ring Pickup rotor cover Gasket Cover1 1 1 1 1 1Remove 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. Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Disconnect. For installation, reverse the removal procedure. 10 Nm (1.0 mkg, 7.2 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) CRANKSHAFT POSITION SENSORENG CRANKSHAFT POSITION SENSOR
5-44 CRANKSHAFT POSITION SENSORENG NOTE: 12 Nm (1.2 mkg, 8.7 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) REMOVING THE CRANKSHAFT POSITION SENSOR 1. Remove: rider seat fuel tank Refer to “SEATS” and “FUEL TANK” in chap- ter 3. 2. Remove: right side cowling bottom cowlings Refer to “COWLINGS” in chapter 3. 3. Drain: engine oil Refer to “CHANGING THE ENGINE OIL” in chapter 3. 4. Disconnect: crankshaft position sensor lead coupler 5. Remove: crankshaft position sensor O-ring pickup rotor cover 1 Loosen each bolt 1 / 4 of a turn a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. INSTALLING THE CRANKSHAFT POSITION SENSOR 1. Install: gasket New pickup rotor cover 1 O-ring New crankshaft position sensor LOCTITE 2. Connect: crankshaft position sensor lead coupler 3. Fill: engine oil Refer to “CHANGING THE ENGINE OIL” in chapter 3. 4. Install: right side cowling bottom cowlings Refer to “COWLINGS” in chapter 3.
5-45 CRANKSHAFT POSITION SENSORENG 5. Install: rider seat fuel tank Refer to “SEATS” and “FUEL TANK” in chap- ter 3.
5-46 Order Job / Part Q’ty Remarks 1 2 3 4 5 6Removing the clutch cover Right side cowling Bottom cowling Engine oil Cover Clutch cable Clutch cover Clutch cover gasket Dowel pin Oil filler cap1 1 1 1 2 1Remove the parts in the order listed. Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Disconnect. For installation, reverse the removal procedure. Refer to “COWLINGS” in chapter 3. 12 Nm (1.2 mkg, 8.7 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) CLUTCHENG CLUTCH CLUTCH COVER
5-47 CLUTCHENG Order Job / Part Q’ty Remarks 1 2 3 4 5 6Removing the pull lever shaft Circlip Pull lever Pull lever spring Pull lever shaft Oil seal Bearing2 1 1 1 1 2Remove the parts in the order listed. For installation, reverse the removal procedure. PULL LEVER SHAFT
5-48 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12Removing the clutch Compression spring Pressure plate Pull rod Bearing Friction plate 1 Clutch plate 1 Friction plate 2 Wire clip Clutch plate 2 Friction plate 3 Clutch damper spring Clutch damper spring seat6 1 1 1 1 7 7 1 1 1 1 1Remove the parts in the order listed. 10 Nm (1.0 mkg, 7.2 ftlb) 95 Nm (9.5 mkg, 69 ftlb) CLUTCHENG CLUTCH