Yamaha R1 2004 ServiceManual
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5-99 Order Job / Part Q’ty Remarks Disassembling the main axle assembly 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip Washer 5th pinion gear Collar Main axle1 1 1 1 1 1 1 1 1 1 1 1 1Disassemble the parts in the order listed. 1 2 3 4 5 6 7 8 9 10 11 12 13 TRANSMISSIONENG
5-100 Order Job / Part Q’ty Remarks Bearing housing Bearing1 1 For installation, reverse the removal procedure. 14 15 TRANSMISSIONENG
5-101 Order Job / Part Q’ty Remarks Disassembling the drive axle assembly Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip1 1 1 1 1 1 1 1 1 1 1 1 1 1Disassemble the parts in the order listed. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 TRANSMISSIONENG
5-102 TRANSMISSIONENG Order Job / Part Q’ty Remarks 6th wheel gear Circlip Washer Collar 2nd wheel gear Collar Oil seal Bearing Drive axle1 1 1 1 1 1 1 1 1 For installation, reverse the removal procedure. 15 16 17 18 19 20 21 22 23
5-103 TRANSMISSIONENG REMOVING THE TRANSMISSION 1. Remove: drive axle assembly 1 shift drum retainers 2 shift fork guide bars shift fork “L” and “R” shift drum assembly shift fork “C” 2. Remove: bearing housing 1 main axle assembly 2 a. Insert two bolts 3 of the proper size, as shown in the illustration, into the main axle assembly bearing housing. b. Tighten the bolts until they contact the crank- case surface. c. Continue tightening the bolts until the main axle assembly comes free from the upper crankcase. 3. Remove: oil pipe 1 bearing 2 EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Check: shift fork cam follower 1 shift fork pawl 2 Bends / damage / scoring / wear Replace the shift fork.
5-104 TRANSMISSIONENG WARNING 2. Check: shift fork guide bar Roll the shift fork guide bar on a flat surface. Bends Replace. Do not attempt to straighten a bent shift fork guide bar. 3. Check: shift fork movement (along the shift fork guide bar) Rough movement Replace the shift forks and shift fork guide bar as a set. EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: shift drum grooves 1 Damage / scratches / wear Replace the shift drum assembly. shift drum segment 2 Damage / wear Replace the shift drum as- sembly. shift drum bearing 3 Damage / pitting Replace the shift drum assembly. EAS00425 CHECKING THE TRANSMISSION 1. Measure: main axle runout (with a centering device and dial gauge 1) Out of specification Replace the main axle. Main axle runout limit 0.08 mm (0.0032 in)
5-105 TRANSMISSIONENG NOTE: 12 Nm (1.2 mkg, 8.7 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) NOTE: 2. Measure: drive axle runout (with a centering device and dial gauge 1) Out of specification Replace the drive axle. Drive axle runout limit 0.08 mm (0.0032 in) 3. Check: transmission gears Blue discoloration / pitting / wear Replace the defective gear(s). transmission gear dogs Cracks / damage / rounded edges Replace the defective gear(s). INSTALLING THE TRANSMISSION 1. Install: bearing 1 Make the seal side of bearing face to the outside and install it close to the right end face of the crankcase. oil pipe 2 2. Install: main axle assembly 1 bearing housing 2 LOCTITE shift fork “C” shift drum assembly shift fork guide bar shift fork guide bar retainer LOCTITE The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence: “R”, “C”, “L”. Carefully position the shift forks so that they are installed correctly into the transmission gears. Install shift fork “C” into the groove in the 3rd and 4th pinion gear on the main axle.
5-106 TRANSMISSIONENG 10 Nm (1.0 mkg, 7.2 ftlb) NOTE: NOTE: 3. Install: shift fork “L” 1 and “R” 2 drive axle assembly 3 shift fork guide bar shift fork guide bar retainer 4 LOCTITE Install shift fork “L” into the groove in the 6th wheel gear and shift fork “R” into the groove in the 5th wheel gear on the drive axle. Make sure that the drive axle bearing circlip a is inserted into the grooves in the upper crank- case. 4. Check: transmission Rough movement Repair. Oil each gear, shaft, and bearing thoroughly.
6-1 Order Job / Part Q’ty Remarks 1 2 3 4 5Removing the radiator Rider seat Fuel tank Air filter case Side cowlings Bottom cowling Coolant Fuse box stay Coolant reservoir hose Radiator Radiator fan motor Radiator inlet hose1 1 1 2 1Remove the parts in the order listed. Refer to “AIR FILTER CASE” in chapter 3. Drain. Refer to “CHANGING THE COOLANT” in chapter 3. Disconnect. Refer to “COWLINGS” in chapter 3. Refer to “SEATS” in chapter 3. 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 5 Nm (0.5 mkg, 3.6 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) RADIATORCOOL EAS00454 COOLING SYSTEM RADIATOR
6-2 6 RADIATORCOOL Order Job / Part Q’ty Remarks 6 7 8 9 10 11Radiator inlet pipe Oil cooler outlet hose Water pump breather hose Radiator outlet hose Water pump inlet pipe O-ring1 1 1 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) 5 Nm (0.5 mkg, 3.6 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb)