Yamaha R1 2004 ServiceManual
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5-59 SHIFT SHAFTENG Order Job / Part Q’ty Remarks 10 11 12 13Oil seal Bearing Bearing Stopper lever spring1 1 1 1 For installation, reverse the removal procedure. 22 Nm (2.2 mkg, 16 ftlb)
5-60 SHIFT SHAFTENG REMOVING THE SHIFT SHAFT 1. Remove: left and right side cowlings bottom cowlings Refer to “COWLINGS” in chapter 3. 2. Remove: clutch assembly Refer to “CLUTCH”. 3. Remove: shift arm shift rod Refer to “ENGINE”. 4. Remove: circlip 1 Washer 2 (left side of the engine) 5. Remove: shift shaft 1 shift shaft spring 2 collar washer 6. Remove: stopper lever spring 1 stopper screw 2 stopper lever 3 washer
5-61 SHIFT SHAFTENG 22 Nm (2.2 mkg, 16 ftlb) NOTE: CHECKING THE SHIFT SHAFT 1. Check: shift shaft 1 Bends / damage / wear replace. shift shaft spring 2 collar 3 Damage / wear Replace. CHECKING THE STOPPER LEVER 1. Check: stopper lever 1 Bends / damage Replace. Roller turns roughly Replace the stopper lever. INSTALLING THE SHIFT SHAFT 1. Install: washer stopper lever 1 stopper screw 2 LOCTITE stopper lever spring 3 2. Install: washer collar shift shaft spring 1 shift shaft 2 Mesh the stopper lever with the shift drum seg- ment assembly. Lubricate the oil seal lips with lithium soap base grease. Install the end of the shift shaft spring onto the shift shaft spring stopper. 3. Install: Washer 1 circlip 2 New
5-62 SHIFT SHAFTENG 4. Install: shift rod shift arm Refer to “ENGINE”. 5. Install: clutch assembly Refer to “CLUTCH”. 6. Install: left and side cowling bottom cowlings Refer to “COWLING” in chapter 3.
5-63 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8Removing the oil pan and oil pump Side cowlings Bottom cowlings Engine oil Exhaust pipe and exhaust valve pipe Clutch assembly Water pump inlet pipe Water pump outlet pipe Oil level switch lead coupler Oil level switch Oil level switch lead holder Oil pan Oil pan gasket Dowel pin Drain pipe Oil strainer1 1 1 1 1 2 1 1Remove the parts in the order listed. Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Refer to “EXHAUST PIPE”. Refer to “CLUTCH”. Refer to “OIL COOLER” in chapter 6. Disconnect. Refer to “COWLINGS” in chapter 3. 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb)10 Nm (1.0 mkg, 7.2 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb)43 Nm (4.3 mkg, 31 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) OIL PAN AND OIL PUMPENG EAS00356 OIL PAN AND OIL PUMP
5-64 OIL PAN AND OIL PUMPENG Order Job / Part Q’ty Remarks 9 10 11 12 13 14 15 16 17 18Oil pipe Oil delivery pipe Relief valve assembly Oil / water pump assembly drive chain guide Collar Oil / water pump assembly drive sprocket Washer Oil / water pump assembly drive chain Dowel pin Oil / water pump assembly1 1 1 1 1 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) 10 Nm (1.0 mkg, 7.2 ftlb)10 Nm (1.0 mkg, 7.2 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb)43 Nm (4.3 mkg, 31 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb)
5-65 Order Job / Part Q’ty Remarks Disassembling the oil pump Oil / water pump driven sprocket Collar Oil pump housing Bearing Pin Oil pump outer rotor Oil pump inner rotor Pin1 1 1 1 2 1 1 1Disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 5 6 7 8 15 Nm (1.5 mkg, 11 ftlb) OIL PAN AND OIL PUMPENG EAS00360
5-66 OIL PAN AND OIL PUMPENG NOTE: EAS00362 REMOVING THE OIL PAN 1. Remove: oil level switch 1 oil pan 2 oil pan gasket dowel pins 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. CHECKING THE SPROCKET AND CHAIN 1. Check: oil / water pump assembly drive sprocket 1 Cracks / damage / wear Replace the de- fective part(-s). 2. Check: oil / water pump assembly drive chain 1 Damage / stiffness Replace the oil / water pump assembly drive chain and oil / water pump assembly drive sprocket as a set.
5-67 OIL PAN AND OIL PUMPENG EAS00364 CHECKING THE OIL PUMP 1. Check: oil pump driven gear 1 oil pump rotor housing 2 oil pump cover Cracks / damage / wear Replace the de- fective part(s). 2. Measure: inner-rotor-to-outer-rotor-tip clearance a outer-rotor-to-oil-pump-housing clearance b 1Inner rotor 2Outer rotor 3Oil pump housing Inner-rotor-to-outer-rotor-tip clearance 0.01 0.10 mm (0.0004 0.0039 in) : 0.18 mm (0.0071 in) Outer-rotor-to-oil-pump-housing clearance 0.09 0.15 mm (0.0035 0.0059 in) : 0.22 mm (0.0087 in) 3. Check: oil pump operation Rough movement Repeat steps (1) and (2) or replace the defective part(s). EAS00365 CHECKING THE RELIEF VALVE 1. Check: relief valve body 1 relief valve 2 spring 3 O-ring 4 Damage / wear Replace the defective part(s).
5-68 OIL PAN AND OIL PUMPENG EAS00367 CHECKING THE OIL DELIVERY PIPE AND OIL PIPE 1. Check: oil delivery pipe 1 oil pipe 2 Damage Replace. Obstruction Wash and blow out with com- pressed air. EAS00368 CHECKING THE OIL STRAINER 1. Check: oil strainer 1 Damage Replace. Contaminants Clean with solvent. EAS00373 CHECKING THE OIL NOZZLES The following procedure applies to all of the oil nozzles. 1. Check: oil nozzle 1 Damage / wear Replace the oil nozzle. O-ring 2 Damage / wear Replace. oil nozzle passage Obstruction Blow out with compressed air. EAS00374 ASSEMBLING THE OIL PUMP 1. Lubricate: inner rotor outer rotor oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil