Elements of transmission motorcycle Yamaha YZF-R1 Y(C) (2009-2014)

Removing the drive sprocket and drive chain
Order Job/Parts to remove Quantity Remarks Drive chain Refer to " Adjusting the drive chain slack ". 1 Locknut 2 2 Shift rod 1 3 Shift arm 1 4 Shift pedal 1 5 Drive sprocket cover 1 6 Drive sprocket nut 1 7 Washer 1 8 Drive chain guide (drive...

Removing the drive chain
1. Stand the vehicle on a level surface. Warning: Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: Drive chain Cut the drive chain with...

Checking the drive chain
1. Measure: Measure the dimension between 15-links on the inner side "a" and outer side "b" of the roller and calculate the dimension between pin centers. Dimension "c" between pin centers = (Inner dimension "a" + Outer dimension "b")/2. 15-link...

Checking the drive sprocket
1. Check: Drive sprocket More than 1/4 tooth "a" wear → Replace the drive chain sprockets as a set. Bent teeth → Replace the drive chain sprockets as a set. b. Correct; 1. Drive chain roller; 2. Drive chain sprocket

Installing the drive chain
1. Install: Drive chain Notice: Be sure to put on safety goggles when working. Drive chain cut & rivet tool 90890-01550 YM-01550. a. When press fitting the connecting plate "1", make sure the space "a" between the end of the connecting pin "2" and...

Checking the sprocket and chain
1. Check: Oil/water pump assembly drive sprocket. Cracks/damage/wear → Replace. 2. Check: Oil/water pump assembly drive chain. Damage/stiffness → Replace the oil/ water pump assembly drive chain and oil/ water pump assembly drive sprocket as a set.

Removing the clutch cover
Order Job/Parts to remove Quantity Remarks Engine oil Drain. 1 Pull lever cover 1 2 Clutch cable 1 Disconnect. 3 Clutch cover 1 4 Clutch cover gasket 1 5 Dowel pin 3 6 Oil filler cap 1 For installation, reverse the removal procedure.

Removing the pull lever shaft
Order Job/Parts to remove Quantity Remarks 1 Circlip 1 2 Pull lever 1 3 Pull lever spring 1 4 Circlip 1 5 Pull lever shaft 1 6 Oil seal 1 7 Bearing 1 8 Bearing 1 For installation, reverse the removal procedure.

Removing the clutch
Order Job/Parts to remove Quantity Remarks 1 Compression spring 6 2 Pressure plate 1 1 3 Pull rod 1 4 Bearing 1 5 Friction plate 1 1 6 Clutch plate 1 1 7 Friction plate 2 7 8 Clutch plate 2 1 9 Clutch plate 3 6 10 Friction plate 1 1 11 Clutch boss...

Removing clutch
1. Remove: Pull lever cover "1" Clutch cover "2" Gasket 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. 2. Remove: Compression spring bolts "1" Compression...

Checking the friction plates
The following procedure applies to all of the friction plates. 1. Check: Friction plate Damage/wear → Replace the friction plates as a set. 2. Measure: Friction plate thickness Out of specification → Replace the friction plates as a set. Measure the...

Checking the clutch plates
The following procedure applies to all of the clutch plates. 1. Check: Clutch plate Damage → Replace the clutch plates as a set. 2. Measure: Clutch plate warpage (with a surface plate and thickness gauge "1"). Out of specification → Replace the...

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" Out of specification → Replace the clutch springs as a set. Clutch spring...

Checking the clutch housing
1. Check: Clutch housing dogs. Damage/pitting/wear → Deburr the clutch housing dogs or replace the clutch housing. Pitting on the clutch housing dogs will cause erratic clutch operation. 2. Check: Bearing Damage/wear → Replace the bearing and clutch...

Checking the clutch boss
1. Check: Clutch boss splines. Damage/pitting/wear → Replace the clutch boss. Pitting on the clutch boss splines will cause erratic clutch operation.

Checking the pressure plate
1. Check: Pressure plate 1 "1" Pressure plate 2 "2". Cracks/damage → Replace. Bearing "3" Damage/wear → Replace.

Checking the primary drive gear
1. Check: Primary drive gear Damage/wear → Replace the crankshaft and clutch housing as a set. Excessive noise during operation → Replace the crankshaft and clutch housing as a set.

Checking the primary driven gear
1. Check: Primary driven gear "1". Damage/wear → Replace the clutch housing and crankshaft as a set. Excessive noise during operation → Replace the clutch housing and crankshaft as a set.

Checking the pull lever shaft and pull rod
1. Check: Pull lever shaft pinion gear teeth "1" Pull rod teeth "2" Damage/wear → Replace the pull rod and pull lever shaft as a set. 2. Check: Pull rod bearing. Damage/wear → Replace.

Installing the clutch
1. Install: Washer Bearing Clutch housing assembly "1" Thrust washer Conical spring washer Notice: Make sure to fit the projections "a" of the oil pump drive sprocket to the concave "b" of the clutch housing assembly. When installing the clutch...

Removing the shift shaft and stopper lever
Order Job/Parts to remove Quantity Remarks Shift arm Refer to " Chain drive ". Clutch assembly Refer to " Clutch ". 1 Circlip 1 2 Washer 1 3 Shift shaft 1 4 Washer 1 5 Circlip 1 6 Washer 1 7 Stopper lever 1 8 Stopper lever spring 1 9 Collar 1 10...

Checking the shift shaft
1. Check: Shift shaft "1" Bends/damage/wear → Replace. Shift shaft spring "2" Collar Damage/wear → Replace.

Checking the stopper lever
1. Check: Stopper lever Bends/damage → Replace. Roller turns roughly → Replace the stopper lever.

Installing the shift shaft
1. Install: Shift shaft spring stopper "1" Shift shaft assembly Stopper lever spring "2" Shift shaft spring stopper 22 Nm (2.2 m·kgf, 16 ft·lbf) LOCTITE®. Lubricate the oil seal lips with lithium-soapbased grease. Hook the end of the shift shaft...

Removing the transmission, shift drum assembly, and shift forks
Order Job/Parts to remove Quantity Remarks Lower crankcase Separate. Refer to " Crankcase ". 1 Drive axle assembly 1 2 Oil seal 1 3 Circlip 1 4 Bearing 1 5 Circlip 1 6 Shift drum retainer 2 7 Spring 2 8 Shift fork guide bar 2 9 Shift fork-L 1 10...

Disassembling the main axle assembly
Order Job/Parts to remove Quantity Remarks 1 2nd pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Collar 1 6 Washer 1 7 Circlip 1 8 3rd/4th pinion gear 1 9 Circlip 1 10 Washer 1 11 5th pinion gear 1 12...

Disassembling the drive axle assembly
Order Job/Parts to remove Quantity Remarks 1 Washer 1 2 1st wheel gear 1 3 Collar 1 4 5th wheel gear 1 5 Circlip 1 6 Washer 1 7 3rd wheel gear 1 8 Collar 1 9 Toothed lock washer 1 10 Toothed lock washer retainer 1 11 4th wheel gear 1 12 Collar 1 13...

Removing the transmission
1. Remove: Drive axle assembly "1" Shift drum retainers "2" Shift fork guide bars Shift fork "L" and "R" Shift drum assembly Shift fork "C" 2. Remove: Main axle assembly "1" a. Insert two bolts "2" of the proper size, as shown in the illustration,...

Checking the shift forks
The following procedure applies to all of the shift forks. 1. Check: Shift fork cam follower "1" Shift fork pawl "2" Bends/damage/scoring/wear → Replace the shift fork. 2. Check: Shift fork guide bar Roll the shift fork guide bar on a flat surface....

Checking the transmission
1. Measure: Main axle runout (with a centering device and dial gauge "1") Out of specification → Replace the main axle. Main axle runout limit 0.08 mm (0.0032 in). 2. Measure: Drive axle runout (with a centering device and dial gauge "1") Out of...

Checking the shift drum assembly
1. Check: Shift drum groove. Damage/scratches/wear → Replace the shift drum assembly. Shift drum segment "1". Damage/wear → Replace the shift drum assembly. Shift drum bearing "2". Damage/pitting → Replace the shift drum assembly.

Assembling the main axle and drive axle
1. Install: Toothed washer "1" Circlip "2" New Be sure the circlip sharp-edged corner "a" is positioned opposite side to the toothed washer and gear. Align the opening between the ends "b" of the circlip with a projection "c" of the spline in the...

Installing the transmission
1. Install: Bearing "1" Oil delivery pipe 2 "2" O-rings New Oil delivery pipe 2 bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE®. Face the seal side of the bearing to the outside and install it close to the right side end of the crankcase. 2. Install:...