Yamaha R1 2004 ServiceManual
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5-69 OIL PAN AND OIL PUMPENG NOTE: 15 Nm (1.5 mkg, 11 ftlb) NOTE: 12 Nm (1.2 mkg, 8.7 ftlb) 2. Install: pin 1 inner rotor 2 outer rotor 3 oil pump housing 4 When installing the inner rotor, align the pin 1 in the oil pump shaft with the groove a in the inner rotor 2. 3. Install: oil / water pump driven sprocket 1 LOCTITE 5VY mark of the oil / water pump driven gear is installed at oil pump side. 4. Check: oil pump operation Refer to “CHECKING THE OIL PUMP”. INSTALLING THE OIL / WATER PUMP ASSEMBLY 1. Install: O-ring New oil / water pump assembly 1 dowel pin bolts 2 LOCTITE
5-70 OIL PAN AND OIL PUMPENG NOTE: CAUTION: 10 Nm (1.0 mkg, 7.2 ftlb) NOTE: 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 2. Install: washer oil / water pump assembly drive chain 1 oil / water pump assembly drive sprocket 2 collar Install the oil / water pump assembly drive chain 1 onto the oil / water pump assembly drive sprocket 2. After installing the oil / water pump assem- bly drive chain and drive sprocket, make sure the oil / water pump turns smoothly. 3. Install: oil / water pump assembly drive chain guide 1 LOCTITE “UP” mark of the oil / water pump assembly drive chain guide is upward. 4. Install: oil delivery pipe 1 LOCTITE 5. Install: relief valve 1 O-ring New oil strainer 2 LOCTITE O-ring New oil pipe 3 O-ring New drain pipe 4 O-ring New
5-71 OIL PAN AND OIL PUMPENG 12 Nm (1.2 mkg, 8.7 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 43Nm (4.3 mkg, 31 ftlb) WARNING NOTE: EAS00380 INSTALLING THE OIL PAN 1. Install: dowel pins gasket New oil pan 1 oil level switch 2 engine oil drain bolt 3 Always use new copper washers. Tighten the oil pan bolts in stages and in a crisscross pattern. Lubricate the oil level switch O-ring with en- gine oil.
5-72 Order Job / Part Q’ty Remarks Removing the crankcase Air filter case Throttle body assembly Engine Cylinder head Starter clutch and generator Shift shaft Crankshaft position sensor Clutch Oil pan and oil pump Starter motorRemove the parts in the order listed. Refer to “AIR FILTER CASE” in chapter 3. Refer to “THROTTLE BODIES” in chapter 7. Refer to “ENGINE”. Refer to “CYLINDER HEAD”. Refer to “STARTER CLUTCH AND GENERATOR”. Refer to “SHIFT SHAFT”. Refer to “CRANKSHAFT POSITION SENSOR”. Refer to “CLUTCH”. Refer to “OIL PAN AND OIL PUMP”. Refer to “STARTING SYSTEM” in chapter 8. 12 Nm (1.2 mkg, 8.7 ftlb)12 Nm (1.2 mkg, 8.7 ftlb) 24 Nm (2.4 mkg, 17 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 24 Nm (2.4 mkg, 17 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) 20 Nm (2.0 mkg, 14 ftlb) +60 CRANKCASEENG CRANKCASE
5-73 CRANKCASEENG Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9Timing chain Timing chain guide (intake side) Pin Timing chain guide (exhaust side) Left side cover O-ring Lower crankcase Dowel pin Damper1 1 2 1 1 1 1 3 1 For installation, reverse the removal procedure. 12 Nm (1.2 mkg, 8.7 ftlb)12 Nm (1.2 mkg, 8.7 ftlb) 24 Nm (2.4 mkg, 17 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 24 Nm (2.4 mkg, 17 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) 20 Nm (2.0 mkg, 14 ftlb) +60
5-74 CRANKCASEENG NOTE: CAUTION: NOTE: EAS00384 DISASSEMBLING THE CRANKCASE 1. Place the engine upside down. 2. Remove: crankcase bolts 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. Loosen the bolts in decreasing numerical or- der (refer to the numbers in the illustration). The numbers embossed on the crankcase in- dicate the crankcase tightening sequence. M9 105 mm (4.1 in) bolts: 1 10 M8 60 mm (2.4 in) bolt: 11 LOCTITE M8 60 mm (2.4 in) bolts: 12, 16 M6 70 mm (2.8 in) bolts: 19, 21, 23 M6 65 mm (2.5 in) bolts: 17, 18 M6 60 mm (2.4 in) bolts: 22, 24, 25 M6 50 mm (2.0 in) bolts: 20, 26 M8 50 mm (2.0 in) bolts: 13 15 3. Remove: lower crankcase Tap on one side of the crankcase with a soft- face hammer. Tap only on reinforced por- tions of the crankcase, not on the crankcase mating surfaces. Work slowly and carefully and make sure the crankcase halves sepa- rate evenly. 4. Remove: dowel pins 5. Remove: crankshaft journal lower bearing (from the lower crankcase) Identify the position of each crankshaft journal lower bearing so that it can be reinstalled in its original place.
5-75 CRANKCASEENG NOTE: EAS00399 CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: crankcase Cracks / damage Replace. oil delivery passages Obstruction Blow out with compressed air. EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1. Check: bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement Replace. 2. Check: oil seals Damage / wear Replace. ASSEMBLING THE CRANKCASE 1. Lubricate: crankshaft journal bearings (with the recommended lubricant) Recommended lubricant Engine oil 2. Apply: sealant Yamaha bond No. 1215 90890-85505, ACC-1109-05-01 Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings. Do not apply sealant to within 2 3 mm (0.08 0.12 in) of the crankshaft journal bear- ings.
5-76 CRANKCASEENG CAUTION: NOTE: 3. Install: dowel pin 4. Set the shift drum assembly and transmis- sion gears in the neutral position. 5. Install: lower crankcase 1 (onto the upper crankcase 2) Before tightening the crankcase bolts, make sure that the transmission gears shift cor- rectly when the shift drum assembly is turned by hand. 6. Install: crankcase bolts Lubricate the bolt threads with engine oil. Install a washer on bolts 1 10 and 22. Seal bolt 18 Tighten the bolts in the tightening sequence cast on the crankcase. M9 105 mm (4.1 in) bolts: 1 10 M8 60 mm (2.4 in) bolt: 11 LOCTITE M8 60 mm (2.4 in) bolts: 12, 16 M6 70 mm (2.8 in) bolts: 19, 21, 23 M6 65 mm (2.5 in) bolts: 17, 18 M6 60 mm (2.4 in) bolts: 22, 24, 25 M6 50 mm (2.0 in) bolts: 20, 26 M8 50 mm (2.0 in) bolts: 13 15 Crankcase bolt Bolt 1 10 1st: 20 Nm (2.0 mkg, 14 ftlb) 2nd*: 20 Nm (2.0 mkg, 14 ftlb) 3rd: +60 Bolt 11 16 24 Nm (2.4 mkg, 17 ftlb) Bolt 17 26 12 Nm (1.2 mkg, 8.7 ftlb) * Following the tightening order, loosen the bolt one by one and then retighten it to the specific torque.
5-77 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12Removing the connecting rods and pistons Lower crankcase Connecting rod cap Big end lower bearing Big end upper bearing Piston pin clip Piston pin Piston Connecting rod Top ring 2nd ring Oil ring Cylinder Cylinder gasket4 4 4 8 4 4 4 4 4 4 1 1Remove the parts in the order listed. Refer to “CRANKCASE”. For installation, reverse the removal procedure. 20 Nm (2.0 mkg, 14 ftlb) +150 8 Nm (0.8 mkg, 5.8 ftlb) CONNECTING RODS AND PISTONSENG EAS00252 CONNECTING RODS AND PISTONS
5-78 CONNECTING RODS AND PISTONSENG NOTE: CAUTION: NOTE: NOTE: EAS00393 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the connecting rods and pistons. 1. Remove: connecting rod cap 1 big end bearings Identify the position of each big end bearing so that it can be reinstalled in its original place. After removing the connecting rods and con- necting rod caps, care should be taken not to damage the mating surfaces of the connecting rods and connecting rod caps. 2. Remove: Cylinder Cylinder gasket Cylinder stud bolts 3. Remove: piston pin clips 1 piston pin 2 piston 3 Do not use a hammer to drive the piston pin out. For reference during installation, put identifica- tion marks on the piston crown. Before removing the piston pin, deburr the pis- ton pin clip groove and the piston pin bore area. If both areas are debarred and the piston pin is still difficult to remove, remove it with the piston pin puller set 4. Piston pin puller set 90890-01304, YU-01304 4. Remove: top ring 2nd ring oil ring When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown.