How To Use This Manual - Yamaha R1 Series 2015 Service Manual

EAS20004

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
"1" is shown at the top of each page.
• Sub-section titles "2" appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams "3" at the start of each
removal and disassembly section.
• Numbers "4" are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols "5" indicate parts to be lubricated or replaced.
Refer to "SYMBOLS".
• A job instruction chart "6" accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation
and assembly procedure, reverse the steps.
• Jobs "7" requiring more information (such as special tools and technical data) are described sequen-
tially.
EAS20055
CLUTCH
Removing the clutch cover
5
2
(10)
1st 6 Nm (0.6 m
2nd
Specified angle 90°
*
Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque.
Order Job/Parts to remove
Front side cowling (right)
Engine oil
1 C u l c t h c a b e l
2 C u l c t h c v o r e
3 C u l c t h c v o r e g a k s t e
4 D o w l e p n i
5 O l i l l i f r e c a p
CLUTCH
4
3
7 Nm (0.7 m kgf, 5.1 ft lbf)
• •
1
kgf, 4.3 ft Ibf)
• •
3.0 Nm (0.30 m kgf, 2.2 ft Ibf)
• •
Q'ty Remarks
Refer to "GENERAL CHASSIS (2)" on page
4-7.
Drain.
Refer to "CHANGING THE ENGINE OIL" on
page 3-30.
1 i D c s o n n e c . t
1
1
2
1
5-53
Clutch plate "1"
Part No. Thickness
2CR-16325-10 2.0 mm (0.079 in)
2CR-16325-00 2.3 mm (0.091 in)
2CR-16325-20 2.6 mm (0.102 in)
EAS30351
CHECKING THE CLUTCH SPRINGS
The following procedure applies to all of the
clutch springs.
1. Check:
• Clutch spring
Damage → Replace the clutch springs as a
set.
2. Measure:
• Clutch spring free length "a"
F W F W
D D Out of specification → Replace the clutch
springs as a set.
Clutch spring free length
47.36 mm (1.86 in)
Limit
44.99 mm (1.77 in)
EAS30352
CHECKING THE CLUTCH HOUSING
1. Check:
• Clutch housing dogs
Damage/pitting/wear → Deburr the clutch
CLUTCH
housing dogs or replace the clutch housing.
TIP
Pitting on the clutch housing dogs will cause er-
ratic clutch operation.
STD
1
2. Check:
• Bearing
Damage/wear → Replace the bearing and
clutch housing.
EAS30353
CHECKING THE CLUTCH BOSS
1. Check:
• Clutch boss splines
Damage/pitting/wear → Replace the clutch
boss.
TIP
Pitting on the clutch boss splines will cause er-
ratic clutch operation.
EAS30354
CHECKING THE PRESSURE PLATE
1. Check:
• Pressure plate 1 "1"
• Pressure plate 2 "2"
Cracks/damage → Replace.
• Bearing "3"
Damage/wear → Replace.
5-58