Yamaha R1 2004 ServiceManual
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6-3 RADIATORCOOL NOTE: EAS00455 CHECKING THE RADIATOR 1. Check: radiator fins Obstruction Clean. Apply compressed air to the rear of the radia- tor. Damage Repair or replace. Straighten any flattened fins with a thin, flat- head screwdriver. 2. Check: radiator hoses radiator pipes Cracks / damage Replace. 3. Measure: radiator cap opening pressure Below the specified pressure Replace the radiator cap. Radiator cap opening pressure 108 137 kPa (1.08 1.37 kg / cm 2, 1.0 1.3 bar, 15.6 19.9 psi) a. Install the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator cap 3. Radiator cap tester 90890-01325, YU-24460-01 Radiator cap tester adapter 90890-01352, YU-33984 b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure. 4. Check: radiator fan Damage Replace. Malfunction Check and repair. Refer to “COOLING SYSTEM” in chapter 8.
6-4 RADIATORCOOL EAS00456 INSTALLING THE RADIATOR 1. Fill: cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: cooling system Leaks Repair or replace any faulty part. 3. Measure: radiator cap opening pressure Below the specified pressure Replace the radiator cap. Refer to “CHECKING THE RADIATOR”.
6-5 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9Removing the oil cooler Engine oil Oil cooler inlet hose Bolt Washer Oil cooler O-ring Water pump outlet pipe O-ring Water jacket joint inlet hose O-ring1 1 1 1 1 1 1 1 1Remove the parts in the order listed. Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 63 Nm (6.3 mkg, 46 ftlb) OIL COOLERCOOL EAS00457 OIL COOLER
6-6 OIL COOLERCOOL Order Job / Part Q’ty Remarks 10 11 12Water jacket joint Stay O-ring1 1 1 For installation, reverse the removal procedure. 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 63 Nm (6.3 mkg, 46 ftlb)
6-7 OIL COOLERCOOL 63 Nm (6.3 mkg, 46 ftlb) NOTE: EAS00458 CHECKING THE OIL COOLER 1. Check: oil cooler Cracks / damage Replace. 2. Check: oil cooler inlet hose oil cooler outlet hose Cracks / damage / wear Replace. EAS00459 INSTALLING THE OIL COOLER 1. Clean: mating surfaces of the oil cooler and the crankcase (with a cloth dampened with lacquer thinner) 2. Install: O-ring New oil cooler 1 washer 2 New bolt 3 Before installing the oil cooler, lubricate the oil cooler bolt and O-ring with a thin coat of engine oil. Make sure that the O-ring is positioned proper- ly. Align the projection a on the oil cooler with the slot b in the crankcase. 3. Fill: cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. crankcase (with the specified amount of the recom- mended engine oil) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 4. Check: cooling system Leaks Repair or replace any faulty part. 5. Measure: radiator cap opening pressure Below the specified pressure Replace the radiator cap. Refer to “CHECKING THE RADIATOR”.
6-8 Order Job / Part Q’ty Remarks 1 2 3 4 5Removing the thermostat assembly Rider seat Fuel tank Air filter case Coolant Thermostat assembly outlet hose Thermostat assembly breather hose Thermostat assembly Thermostat assembly inlet hose Band1 1 1 1 2Remove the parts in the order listed. Refer to “SEATS” in chapter 3. Refer to “FUEL TANK” in chapter 3. Refer to “AIR FILTER CASE” in chapter 3. Drain. Refer to “CHANGING THE COOLANT” in chapter3. For installation, reverse the removal procedure. THERMOSTATCOOL EAS00460 THERMOSTAT
6-9 THERMOSTATCOOL Order Job / Part Q’ty Remarks Disassembling the thermostat housing Thermostat housing cover Thermostat Thermostat housing O-ring1 1 1 1Disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 10 Nm (1.0 mkg, 7.2 ftlb)
6-10 THERMOSTATCOOL NOTE: EAS00462 CHECKING THE THERMOSTAT 1. Check: thermostat Does not open at 71 85C (160 185F) Replace. a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d. While stirring the water, observe the thermo- stat and thermometer’s indicated tempera- ture. 1Thermometer 2Water 3Thermostat 4Container AFully closed BFully open If the accuracy of the thermostat is in doubt, re- place it. A faulty thermostat could cause serious overheating or overcooling. 2. Check: thermostat housing cover 1 thermostat housing 2 Cracks / damage Replace.
6-11 THERMOSTATCOOL 10 Nm (1.0 mkg, 7.2 ftlb) NOTE: EAS00464 ASSEMBLING THE THERMOSTAT ASSEMBLY 1. Install: thermostat housing 1 thermostat 2 O-ring New 3 thermostat housing cover 4 Install the thermostat with its breather hole a facing up. EAS00466 INSTALLING THE THERMOSTAT ASSEMBLY 1. Fill: cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: cooling system Leaks Repair or replace any faulty part. 3. Measure: radiator cap opening pressure Below the specified pressure Replace the radiator cap. Refer to “CHECKING THE RADIATOR”.
6-12 WATER PUMPCOOL Order Job / Part Q’ty Remarks 1 2 3 4Removing the impeller shaft Oil / water pump assembly and oil pump rotor Water pump cover O-ring Pin Impeller shaft (along with the impeller)1 1 2 1 Remove the parts in the order listed. The water pump and oil pump are com- bined into one unit (oil / water pump as- sembly). It is not necessary to remove the impeller shaft unless the coolant level is extreme- ly low or coolant leaks from the oil pan. Refer to “OIL PAN AND OIL PUMP” in chapter 5. 12 Nm (1.2 mkg, 8.7 ftlb) NOTE: EAS00468 WATER PUMP IMPELLER SHAFT