Yamaha R1 2004 ServiceManual

							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 m
kg, 7.2 ft
lb)
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 m
kg, 8.7 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
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 m
kg, 7.2 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
CRANKSHAFT POSITION SENSORENG
CRANKSHAFT POSITION SENSOR 
						

							5-44
CRANKSHAFT POSITION SENSORENG
NOTE:
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
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 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
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 m
kg, 7.2 ft
lb)
95 Nm (9.5 m
kg, 69 ft
lb)
CLUTCHENG
CLUTCH