Yamaha R1 2004 ServiceManual
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5-49 CLUTCHENG Order Job / Part Q’ty Remarks 13 14 15 16 17 18Clutch boss nut Washer Clutch boss Thrust plate Clutch housing Bearing1 1 1 1 1 1 For installation, reverse the removal procedure. 10 Nm (1.0 mkg, 7.2 ftlb) 95 Nm (9.5 mkg, 69 ftlb)
5-50 CLUTCHENG NOTE: EAS00276 REMOVING THE CLUTCH 1. Remove: clutch cover 1 gasket Loosen each bolt 1 / 4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: compression spring bolts 1 compression springs pressure plate 2 pull rod 3 3. Remove: friction plate 1 4. Remove: clutch plate 1 1 friction plate 2 5. Straighten the clutch boss nut rib 1.
5-51 CLUTCHENG NOTE: NOTE: 6. Loosen: clutch boss nut 1 While holding the clutch boss 2 with the univer- sal clutch holder 3, loosen the clutch boss nut. Universal clutch holder 90890-04086, YM-91042 7. Remove: clutch boss nut washer clutch boss assembly thrust plate 8. Remove: wire clip 1 There is a built-in damper between the clutch boss and the clutch plate. It is not necessary to remove the wire circlip 1 and disassemble the built-in damper unless there is serious clutch chattering. 9. Remove: clutch plate 2 1 friction plate 3 2 10. Remove: clutch damper spring 1 clutch damper spring seat 2
5-52 CLUTCHENG NOTE: EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric- tion plates. 1. Check: friction plate Damage / wear Replace the friction plates as a set. 2. Measure: friction plate thickness Out of specification Replace the friction plates as a set. Measure the friction plate at four places. Friction plate thickness 2.9 3.1 mm (0.114 0.122 in) : 2.8 mm (0.110 in) EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: clutch plate Damage Replace the clutch plates as a set. 2. Measure: clutch plate warpage (with a surface plate and thickness gauge 1) Out of specification Replace the clutch plates as a set. Clutch plate warpage limit 0.1 mm (0.0039 in)
5-53 CLUTCHENG NOTE: NOTE: EAS00282 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: clutch spring Damage Replace the clutch springs as a set. 2. Measure: clutch spring free length a Out of specification Replace the clutch springs as a set. Clutch spring free length 52.5 mm (2.07 in) : 49.9 mm (1.96 in) EAS00284 CHECKING THE CLUTCH HOUSING 1. Check: clutch housing dogs Damage / pitting / wear Deburr the clutch housing dogs or replace the clutch housing. Pitting on the clutch housing dogs will cause er- ratic clutch operation. 2. Check: bearing Damage / wear Replace the bearing and clutch housing. EAS00285 CHECKING THE CLUTCH BOSS 1. Check: clutch boss splines Damage / pitting / wear Replace the clutch boss. Pitting on the clutch boss splines will cause er- ratic clutch operation.
5-54 CLUTCHENG NOTE: EAS00286 CHECKING THE PRESSURE PLATE 1. Check: pressure plate 1 Cracks / damage Replace. bearing 2 Damage / wear Replace. EAS00287 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1. Check: pull lever shaft pinion gear teeth 1 pull rod teeth 2 Damage / wear Replace the pull rod and pull lever shaft pinion gear as a set. 2. Check: pull rod bearing Damage / wear Replace. INSTALLING THE CLUTCH 1. Install: clutch damper spring seat 1 clutch damper spring 2 2. Install: friction plate 3 1 clutch plate 2 2 Lubricate the engine oil.
5-55 CLUTCHENG NOTE: 95 Nm(9.5 mkg, 69 ftlb) NOTE: 3. Install: wire clip 1 4. Install: clutch housing 1 Align the projection of clutch housing a and hollow of the oil pump drive gear b. 5. Install: thrust plate clutch boss assembly 1 washer clutch boss nut 2 New Install the washer on the main axle with the “OUT” mark facing away from the motorcycle. Lock the threads on the clutch boss nut by staking them with a drift punch at the point aligned with the groove in the axle. While holding the clutch boss assembly 1 with the clutch holding tool 3, tighten the clutch boss nut. Universal clutch holder 90890-04089, YM-91042
5-56 CLUTCHENG NOTE: 10 Nm (1.0 mkg, 7.2 ftlb) NOTE: NOTE: 6. Lubricate: friction plates clutch plates (with the recommended lubricant) Recommended lubricant Engine oil 7. Install: friction plate 2 clutch plate 1 1 8. Install: friction plate 1 1 Install the last friction plate shifting half phase. 9. Install: bearing pull rod 1 pressure plate 2 clutch springs clutch spring bolts 3 Tighten the clutch spring bolts in stages and in a crisscross pattern. 10. Install: pull lever In stall the pull lever with the “” mark facing to- ward upper side.
5-57 CLUTCHENG NOTE: 12 Nm (1.2 mkg, 8.7 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) NOTE: 11. Install: clutch cover clutch cover gasket New Install the pull rod so that the teeth a face to- wards the rear of the motorcycle. Then, install the clutch cover. Apply oil onto the bearing. Apply molybdenum disulfide grease onto the pull rod. When installing the clutch cover, push the pull lever and check that the punch mark a on the pull lever aligns with the mark b on the clutch cover. Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged. Tighten the clutch cover bolts in stages and in a crisscross pattern. 12. Tighten: clutch cover bolts 1 clutch cover bolt 2 LOCTITE Tighten the clutch cover bolts in a stages and in a crisscross pattern. 13. Adjust: clutch cable free play Refer to “ADJUSTING THE CLUTCH CABLE FREE PLAY” in chapter 3.
5-58 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9Removing the shift shaft and stopper lever Side cowlings Bottom cowlings Clutch assembly Sift arm and shift rod Circlip Washer Shift shaft Collar Shift shaft spring Washer Stopper screw Stopper lever Washer1 1 1 1 1 1 1 1 1Remove the parts in the order listed. Refer to “CLUTCH”. Refer to “ENGINE”. Refer to “COWLINGS” in chapter 3. 22 Nm (2.2 mkg, 16 ftlb) SHIFT SHAFTENG EAS00327 SHIFT SHAFT SHIFT SHAFT AND STOPPER LEVER