Yamaha R1 2004 ServiceManual
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3-4 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11Removing the fuel tank Rider sear Fuel tank side cover Fuel hose connector cover Fuel hose Fuel return hose Fuel sender coupler Fuel pump coupler Fuel tank over flow hose Fuel tank breather hose Fuel tank Fuel tank cover Fuel pump2 1 1 1 1 1 1 1 1 1 1Remove the parts in the order listed. Refer to “SEATS”. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. For installation, reverse the removal procedure. 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 4 Nm (0.4 mkg, 2.9 ftlb) 4 Nm (0.4 mkg, 2.9 ftlb) FUEL TANK CHK ADJ EAS00040 FUEL TANK
3-5 FUEL TANK CHK ADJ CAUTION: NOTE: NOTE: CAUTION: REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: fuel hose connector cover fuel return hose fuel hose fuel sender coupler fuel pump coupler fuel tank breather hose fuel tank over flow hose Although the fuel has been removed from the fuel tank, be careful when removing the fuel hoses, since there may be fuel remain- ing in it. Before removing the hoses, place a few rags in the area under where it will be removed. 3. Remove: fuel tank Do not set the fuel tank down so that the installa- tion surface of the fuel pump is directly under the tank. Be sure to lean the fuel tank in an upright position. REMOVING THE FUEL PUMP 1. Remove: fuel pump Do not drop the fuel pump or give it a strong shock. Do not touch the base section of the fuel sender.
3-6 FUEL TANK CHK ADJ 4 Nm (0.4 mkg, 2.9 ftlb) NOTE: CAUTION: INSTALLING THE FUEL PUMP 1. Install: fuel pump Do not damage the installation surfaces of the fuel tank when installing the fuel pump. Always use a new fuel pump gasket. Install the fuel pump as shown in the illustra- tion. Tighten the fuel pump bolts in stages in a criss- cross pattern and to the specified torque. INSTALLING THE FUEL TANK 1. Install: fuel hose fuel return hose fuel hose connector cover When installing the fuel hose, make sure that it is securely connected, and that the fuel hose holder is in the correct position, otherwise the fuel hose will not be properly installed.
3-7 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 13Removing the front cowling and side cowlings Rider seat Side cowling Front turn signal light lead coupler Side cowling inner panel Bottom cowling Bottom cowing front cover Frame side cover Frame side panel Headlight panel Front cowling Rear view mirror Windshield Air intake duct Air intake duck mount2 2 2 2 1 2 2 2 1 2 1 2 2Remove the parts in the order listed. Refer to “SEATS”. Disconnect. For installation, reverse the removal procedure. 7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 16 Nm (1.6 mkg, 12 ftlb) COWLINGS CHK ADJ COWLINGS FRONT COWLING AND SIDE COWLINGS
3-8 Order Job / Part Q’ty Remarks 1 2 3 4 5 6Removing the rear cowling Rider seat and passenger seat Muffler Rear cowling (upper) Tail / brake light lead coupler Rear turn signal light lead coupler Tail / brake light License plate bracket assembly Rear cowling (lower)1 1 4 1 1 1Remove the parts in the order listed. Refer to “SEATS”. Refer to “EXHAUST PIPE” in chapter 5. Disconnect. Disconnect. For installation, reverse the removal procedure. 4 Nm (0.4 mkg, 2.9 ftlb)10 Nm (1.0 mkg, 7.2 ftlb) COWLINGS CHK ADJ REAR COWLING
3-9 COWLINGS CHK ADJ NOTE: NOTE: REMOVAL 1. Remove: rear cowling side cowlings To remove the quick fastener, push its center with a screwdriver, then pull the fastener out. INSTALLATION 1. Install: side cowlings rear cowling To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the cowling and push the pin a in with a screwdriver. Make sure that the pin is flush with the fastener’s head.
3-10 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10Removing the air filter case Rider sear Fuel tank Plug Air temperature sensor lead coupler Spacer Air temperature sensor Air filter case cover Air filter Funnel Air filter case Air induction system hose Crankcase breather hose1 1 1 1 1 1 2 1 1 1Remove the parts in the order listed. Refer to “SEATS”. Refer to “FUEL TANK”. Disconnect. Disconnect. Disconnect. For installation, reverse the removal procedure. 2 Nm (0.2 mkg, 1.4 ftlb) 3.4 Nm (0.34 mkg, 2.5 ftlb) AIR FILTER CASE CHK ADJ AIR FILTER CASE
3-11 ADJUSTING THE VALVE CLEARANCE CHK ADJ NOTE: EAS00045 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. Valve clearance adjustment should be made on a cold engine, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1. Remove rider seat Refer to “SEATS”. fuel tank Refer to “FUEL TANK”. air filter case Refer to “AIR FILTER CASE”. bottom cowlings side cowlings Refer to “COWLINGS”. throttle body assembly Refer to “THROTTLE BODIES” in chapter 7. air cut-off valve Refer to “AIR INDUCTION SYSTEM” in chapter 7. radiator radiator fan motor Refer to “RADIATOR” in chapter 6. 2. Remove ignition coils spark plugs cylinder head cover cylinder head cover gasket Refer to “CAMSHAFT” in chapter 5. 3. Remove pickup rotor cover 1
3-12 ADJUSTING THE VALVE CLEARANCE CHK ADJ NOTE: NOTE: 4. Measure: valve clearance Out of specification Adjust. Valve clearance (cold) Intake valve 0.11 0.20 mm (0.0043 0.0079 in) Exhaust valve 0.21 0.25 mm (0.0083 0.0098 in) a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the TDC mark a on the pickup rotor with the crankcase mating sur- face b. TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. c. Measure the valve clearance with a thick- ness gauge 1. If the valve clearance is incorrect, record the measured reading. Measure the valve clearance in the following sequence. Valve clearance measuring sequence Cylinder #1 #2 #4 #3 AFront d. To measure the valve clearances of the other cylinders, starting with cylinder #1 at TDC, turn the crankshaft counterclockwise as spe- cified in the following table. BDegrees that the crankshaft is turned counter- clockwise CCylinder DCombustion cycle Cylinder #2180 Cylinder #4360 Cylinder #3540
3-13 ADJUSTING THE VALVE CLEARANCE CHK ADJ NOTE: NOTE: NOTE: 5. Remove: camshafts Refer to “DISASSEMBLING THE ENGINE – CAMSHAFT AND CYLINDER HEAD” in chap- ter 5. When removing the timing chain and cam- shafts, fasten the timing chain with a wire to re- trieve it if it falls into the crankcase. 6. Adjust: valve clearance a. Remove the valve lifter 1 and the valve pad 2 with a valve lapper 3. Valve lapper 90890-04101 Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. Make a note of the position of each valve lifter 2 and valve pad 1 so that they can be installed in the correct place. b. Select the proper valve pad from the follow- ing table. Valve pad thickness range Available valve pads Nos. 120 2401.20 (0.0472) 2.40 mm (0.0945 in)25 thicknesses in 0.05 mm (0.002 in) increments The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter. Since valve pads of various sizes are originally installed, the valve pad number must be rounded in order to reach the closest equiva- lent to the original.