Yamaha R1 2004 ServiceManual

							5-19
CAMSHAFTENG
NOTE:
NOTE:
NOTE:
EAS00215
INSTALLING THE CAMSHAFTS
1. 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, align the “T” mark
a with the crankcase mating surface b.
2. Install:

intake camshaft sprocket 
1

exhaust camshaft sprocket 2
(with the camshaft sprockets temporarily
tightened)
Install the camshaft sprockets as a illustration.
3. Install:

exhaust camshaft 
1

intake camshaft 2
(with the camshaft sprockets temporarily
tightened)
Make sure the punch mark 
a faces up.
4. Install:

dowel pins

exhaust camshaft caps

intake camshaft caps

Make sure each camshaft cap is installed in its
original place.

Make sure the arrow mark 
a on each cam-
shaft cap points towards the right side of the
engine.
L: Left side camshaft cap mark
R: Right side camshaft cap mark
I: Intake side camshaft cap mark
E: Exhaust side camshaft cap mark 
						

							5-20
CAMSHAFTENG
10 Nm (1.0 m
kg, 7.2 ft
lb)
NOTE:
CAUTION:
24 Nm (2.4 m
kg, 17 ft
lb)
CAUTION:
5. Install:

camshaft cap bolts
Tighten the camshaft cap bolts in stages and in
a crisscross pattern, working from the inner
caps out.

Lubricate the camshaft cap bolts with the
engine oil.

The camshaft cap bolts must be tightened
evenly or damage to the cylinder head,
camshaft caps, and camshafts will result.

Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
6. Tighten:

camshaft sprocket bolts 
1
Camshaft wrench
90890-04143
Be sure to tighten the camshaft sprocket
bolts to the specified torque to avoid the
possibility of the bolts coming loose and
damaging the engine.
7. Align:

camshaft punch mark 
a
Align the camshaft punch mark a and the
camshaft cap arrow mark 
b.
Camshaft wrench
90890-04143 
						

							5-21
CAMSHAFTENG
10 Nm (1.0 m
kg, 7.2 ft
lb)
CAUTION:
WARNING
8. Install:

O-ring 
New

timing chain tensioner 
1

timing chain tensioner bolts 2
The “arrow” mark a on the timing chain ten-
sioner should face up.
Always use a new O-ring.
9. Turn:

crankshaft
(several full turns clockwise)
10. Check:

“T” mark 
a
Make sure the “T” mark on the pickup rotor is
aligned with the crankcase mating sure face
b.

camshaft punch mark 
c
Make sure the punch mark c on the cam-
shaft is aligned with the camshaft cap arrow
mark 
d.
Out of alignment 
 Adjust.
Refer to the installation steps above.
11. Measure:

valve clearance
Out of specification 
 Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” in chapter 3.
12. Install:

pickup coil rotor cover
Refer to “CRANKSHAFT POSITION SEN-
SOR”. 
						

							5-22
Order Job / Part Q’ty Remarks
1
2
3
4
5
6Removing the cylinder head
Engine
Intake camshaft
Exhaust camshaft
Cylinder head
Cylinder head gasket
Dowel pin
Coolant pipe
O-ring
Thermo wax out let hose1
1
2
1
1
1Remove the parts in the order listed.
Refer to “ENGINE”.
Refer to “CAMSHAFTS”.
For installation, reverse the removal 
procedure.
18 Nm (1.8 m
kg, 13 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
19 Nm (1.9 m
kg, 14 ft
lb)
67 Nm (6.7 m
kg, 48 ft
lb)
1st
2nd
10 Nm (1.0 m
kg, 7.2 ft
lb)
CYLINDER HEADENG
EAS00221
CYLINDER HEAD 
						

							5-23
CYLINDER HEADENG
NOTE:
NOTE:
NOTE:
EAS00222
REMOVING THE CYLINDER HEAD
1. Remove:

intake camshaft

exhaust camshaft
Refer to “REMOVING THE CAMSHAFTS”.
2. Remove:

cylinder head nuts

cylinder head bolts

Loosen the nuts in the proper sequence as
shown.

Loosen each nut 1 / 2 of a turn at a time. After all
of the nuts are fully loosened, remove them.
EAS00227
CHECKING THE CYLINDER HEAD
1. Eliminate:

combustion chamber carbon deposits
(with a rounded scraper)
Do not use a sharp instrument to avoid damag-
ing or scratching:

spark plug bore threads

valve seats
2. Check:

cylinder head
Damage / scratches 
 Replace.
3. Measure:

cylinder head warpage
Out of specification 
 Resurface the cylin-
der head.
Maximum cylinder head warpage
0.10 mm (0.0039 in)
a. Place a straightedge 
1 and a thickness
gauge 
2 across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder
head as follows.
d. Place a 400 
 600 grit wet sandpaper on the
surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
To ensure an even surface, rotate the cylinder
head several times. 
						

							5-24
CYLINDER HEADENG
8 Nm (0.8 m
kg, 5.8 ft
lb)
NOTE:
NOTE:
19 Nm (1.9 m
kg, 14 ft
lb)
67 Nm (6.7 m
kg, 48 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
NOTE:
EAS00233
INSTALLING THE CYLINDER HEAD
1. Check:

cylinder head bolts 
1
Retighten the cylinder head bolts to specifica-
tion, before installing the cylinder head.
2. Install:

gasket 
New
 1

dowel pins
3. Install:

cylinder head
Pass the timing chain through the timing chain
cavity.
4. Tighten:

cylinder head nuts 
1 
 10
1st
2nd

cylinder head bolts 
11 12

First, tighten the nuts 1 
 10 to approximate-
ly 19 Nm (1.9 m
kg, 14 ft
lb) with a torque
wrench, and then tighten the 67 Nm (6.7 m
kg,
48 ft
lb).

Lubricate the cylinder head nuts with engine
oil.

Tighten the cylinder head nuts in the proper
tightening sequence as shown and torque
them in two stages.
5. Install:

exhaust camshaft

intake camshaft
Refer to “INSTALLING THE CAMSHAFTS”. 
						

							5-25
VALVES AND VALVE SPRINGSENG
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the valves and valve
springs
Cylinder head
Intake valve lifter
Intake valve pad
Intake valve cotter
Intake valve upper spring seat
Intake valve spring
Intake valve oil seal
Intake valve lower spring seat
Intake valve
Intake valve guide12
12
24
12
12
12
12
12
12Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
EAS00236
VALVES AND VALVE SPRINGS 
						

							5-26
Order Job / Part Q’ty Remarks
10
11
12
13
14
15
16
17
18Exhaust valve lifter
Exhaust valve pad
Exhaust valve cotter
Exhaust valve upper spring seat
Exhaust valve spring
Exhaust valve oil seal
Exhaust valve lower spring seat
Exhaust valve
Exhaust valve guide8
8
16
8
8
8
8
8
8
For installation, reverse the removal
procedure.
VALVES AND VALVE SPRINGSENG 
						

							5-27
VALVES AND VALVE SPRINGSENG
NOTE:
NOTE:
NOTE:
NOTE:
EAS00237
REMOVING THE VALVES
The following procedure applies to all of the
valves and related components.
Before removing the internal parts of the cylin-
der head (e.g., valves, valve springs, valve
seats), make sure the valves properly seal.
1. Remove:

valve lifter 
1

valve pad 2
Make a note of the position of each valve lifter
and valve pad so that they can be reinstalled in
their original place.
2. Check:

valve sealing
Leakage at the valve seat 
 Check the valve
face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”.
a. Pour a clean solvent 
a into the intake and
exhaust ports.
b. Check that the valves properly seal.
There should be no leakage at the valve seat 
1.
3. Remove:

valve cotters 
1
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
2 and the valve spring compressor attachment
3.
Valve spring compressor
90890-04019, YM-04019
Valve spring compressor 
attachment
Intake valve
90890-04114, YM-4114
Exhaust valve
90890-04108, YM-4108 
						

							5-28
VALVES AND VALVE SPRINGSENG
NOTE:
NOTE:
4. Remove:

upper spring seat 
1

valve spring 2

valve stem seal 3

lower spring seat 4

valve 5
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
EAS00239
CHECKING THE VALVES AND VALVE 
GUIDES
The following procedure applies to all of the
valves and valve guides.
1. Measure:

valve-stem-to-valve-guide clearance
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter 
A –
Valve stem diameter 
B
Out of specification 
 Replace the valve
guide.
Valve-stem-to-valve-guide
clearance
Intake
0.0010 
 0.0037 mm
(0.0004 
 0.0015 in)
: 0.08 mm (0.0032 in)
Exhaust
0.025 
 0.052 mm 
(0.0010 
 0.0020 in)
: 0.10 mm (0.0039 in)
2. Replace:

valve guide
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100C (212F) in an oven.
a. Remove the valve guide with the valve guide
remover 
1.
b. Install the new valve guide with the valve
guide installer 
2 and valve guide remover
1.
c. After installing the valve guide, bore the
valve guide with the valve guide reamer 
3 to
obtain the proper valve-stem-to-valve-guide
clearance.