Yamaha Yzf R1 2007 Manual

HANDLEBARS
4-49 

FRONT FORK
4-50
EAS22950
FRONT FORK
Removing the front fork legs
Order Job/Parts to remove Q’ty Remarks
Front wheel Refer to FRONT WHEEL on page 4-8.
Front brake caliper Refer to FRONT BRAKE on page 4-20.
Side cowling Refer to GENERAL CHASSIS on page 4-1.
1 Front fender 1
2 Handlebar pinch bolt 1 Loosen.
3 Upper bracket pinch bolt 1 Loosen.
4 Cap bolt 1 Loosen.
5 Lower bracket pinch bolt 1 Loosen.
6Front fork leg 1
For installation, reverse the removal proce-
dure. 

FRONT FORK
4-51
Disassembling the front fork legs
Order Job/Parts to remove Q’ty Remarks
1 Cap bolt 1
2O-ring 1
3 Damper adjusting rod 1
4 Damper adjusting rod locknut 1
5 Washer 1
6Spacer 1
7 Fork spring 1
8 Dust seal 1
9 Oil seal clip 1
10 Oil seal 1
11 Washer 1
12 Damper rod assembly bolt 1
13 Copper washer 1
14 Damper rod assembly 1
15 Inner tube 1
16 Outer tube 1
For assembly, reverse the disassembly pro-
cedure. 

FRONT FORK
4-52
EAS22970
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there 
is no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that 
the front wheel is elevated.
2. Remove:
 Front wheel
Refer to FRONT WHEEL on page 4-8.
 Front brake caliper
Refer to FRONT BRAKE on page 4-20.
 Side cowlings
Refer to GENERAL CHASSIS on page 4-
1.
3....

FRONT FORK
4-53
3. Remove:
 Dust seal
 Oil seal clip “1”
(with a flat-head screwdriver)
Oil seal
 Washer
4. Remove:
 Damper rod assembly bolt
 Damper rod assembly
NOTE:
While holding the damper rod with the damper 
rod holder “1”, loosen the damper rod assem-
bly bolt.
EAS23010
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.1. Check:
 Inner tube “1”
 Outer tube “2”
Bends/damage/scratches → Replace.
WARNING
EWA13650
Do not attempt to straighten a bent...

FRONT FORK
4-54
4. Check:
 Cap bolt O-ring “1”
Damage/wear → Replace.
EAS23040
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
WARNING
EWA13660
 Make sure the oil levels in both front fork 
legs are equal.
 Uneven oil levels can result in poor han-
dling and a loss of stability.
NOTE:
 When assembling the front fork leg, be sure 
to replace the following parts:
- Outer tube bushing
-Oil seal
- Dust seal
 Before assembling the front fork leg, make 
sure...

FRONT FORK
4-55
4. Install:
 Dust seal “1”
 Oil seal clip “2”
Oil seal “3”
 Washer “4”
CAUTION:
ECA14220
Make sure the numbered side of the oil seal 
faces up.
NOTE:
 Before installing the oil seal, lubricate its lips 
with lithium-soap-based grease.
 Lubricate the outer surface of the inner tube 
with fork oil.
 Before installing the oil seal, cover the top of 
the front fork leg with a plastic bag to protect 
the oil seal during installation.
5. Install:
 Washer
Oil seal “1”
(with the fork...

FRONT FORK
4-56
9. Fill:
 Front fork leg
(with the specified amount of the recom-
mended fork oil)
CAUTION:
ECA14230
 Be sure to use the recommended fork oil. 
Other oils may have an adverse effect on 
front fork performance.
 When disassembling and assembling the 
front fork leg, do not allow any foreign 
material to enter the front fork.
10. After filling the front fork leg, slowly stroke 
the damper rod “1” up and down (at least 
ten times) to distribute the fork oil.
NOTE:
Be sure to stroke the...

FRONT FORK
4-57
a. Remove the rod puller attachment.
b. Install the nut.
c. Install the fork spring and spacer.
NOTE:
Install the spring with the smaller pitch “a” fac-
ing up “A”.
d. Reinstall the rod puller attachment
e. Press down in the spacer with the fork 
spring compressor “1”
f. Pull up the rod puller and install the rod 
holder “2” between the damper adjusting 
rod locknut “3” and the spacer “4”.
NOTE:
Use the side of the rod holder that is marked 
“A”.g. Remove the rod puller and the rod puller...

FRONT FORK
4-58
WARNING
EWA4C81003
 The fork spring is compressed.
 Always use a new cap bolt O-ring.
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EAS23050
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
1. Install:
 Front fork leg
Temporarily tighten the upper and lower 
bracket pinch bolts.
2. Tighten:
 Lower bracket pinch bolt “1”
 Cap bolt “2”
 Handlebar pinch bolt “3”
 Upper bracket pinch bolt “4”
WARNING
EWA13680
Make sure the brake hoses are routed prop-...