Yamaha Yzf R1 2007 Manual

							ENGINE
3-18
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6. Install:
 EXUP valve pulley cover
7. Install:
 Lower cowlings
Refer to GENERAL CHASSIS on page 4-
1.
EAS28360
CHECKING THE EXUP SERVO MOTOR
1. Check:
 EXUP servo motor operation
Out of specification → Replace.
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a. Check whether or not the EXUP valve is 
seized.
 Disconnect the EXUP cable and check that 
the EXUP valve is moved smoothly by 
hand.
 When the valve is not moved smoothly, 
repair or replace it.
Refer to ADJUSTING THE EXUP 
CABLES on page 3-17.
b. When the EXUP valve is moved smoothly, 
replace the EXUP servo motor.
c. Perform the self-diagnosis mode and check 
the operation of EXUP valve by visual 
inspection (Code No: 53).
The operation should be carried out as 3-
second drive in the full open direction, 2-
second stop and 3-second drive in the full 
close direction.
d. Check that the EXUP servo motor pulley 
rotates several times.
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EAS21110
CHECKING THE COOLANT LEVEL
1. Stand the vehicle on a level surface.
NOTE:
 Place the vehicle on a suitable stand.
 Make sure the vehicle is upright.
2. Remove:
 Lower cowlings
 Right side cowling
Refer to GENERAL CHASSIS on page 4-
1.
3. Check:
 Coolant level
The coolant level should be between the 
maximum level mark “a” and minimum level 
mark “b”.
Below the minimum level mark → Add the 
recommended coolant to the proper level.
CAUTION:
ECA13470
 Adding water instead of coolant lowers 
the antifreeze content of the coolant. If 
water is used instead of coolant check, 
and if necessary, correct the antifreeze 
concentration of the coolant.
 Use only distilled water. However, if dis-
tilled water is not available, soft water 
may be used.
4. Start the engine, warm it up for several 
minutes, and then turn it off.
5. Check:
 Coolant level
NOTE:
Before checking the coolant level, wait a few 
minutes until it settles.
6. Install:
 Right side cowling
 Lower cowlings
Refer to GENERAL CHASSIS on page 4-
1.
EXUP valve pulley cover bolt
10 Nm (1.0 m·kg, 7.2 ft·lb) 
						

							ENGINE
3-19
EAS21120
CHECKING THE COOLING SYSTEM
1. Remove:
 Lower cowlings
 Side cowling
Refer to GENERAL CHASSIS on page 4-
1.
2. Check:
 Radiator “1”
 Radiator inlet hose “2”
 Radiator outlet hose “3”
Oil cooler “4”
 Oil cooler inlet hose “5”
 Oil cooler outlet hose “6”
 Water jacket joint “7”
 Water jacket joint inlet hose “8”
 Water pump inlet pipe “9” 
 Water pump outlet pipe “10”
Cracks/damage → Replace.
Refer to RADIATOR on page 6-1 and 
OIL COOLER on page 6-4.
3. Install: Side cowlings
 Lower cowlings
Refer to GENERAL CHASSIS on page 4-
1.
EAS21130
CHANGING THE COOLANT
1. Remove:
 Lower cowlings
 Side cowlings
Refer to GENERAL CHASSIS on page 4-
1.
2. Remove:
 Coolant reservoir
 Coolant reservoir hose
3. Disconnect:
 Coolant reservoir cap “1”
4. Drain:
 Coolant
(from the coolant reservoir)
5. Remove:
 Radiator cap “2”
WARNING
EWA13030
A hot radiator is under pressure. Therefore, 
do not remove the radiator cap when the 
engine is hot. Scalding hot fluid and steam 
may be blown out, which could cause seri-
ous injury. When the engine has cooled, 
open the radiator cap as follows:
Place a thick rag or a towel over the radia-
tor cap and slowly turn the radiator cap 
counterclockwise toward the detent to 
allow any residual pressure to escape. 
When the hissing sound has stopped, 
press down on the radiator cap and turn it 
counterclockwise to remove.
The following procedure applies to all of the 
coolant drain bolts and copper washers.
6. Remove:
 Coolant drain bolt (engine) “1”
(along with the copper washer) 
						

							ENGINE
3-20
7. Drain:
 Coolant
(from the engine and radiator)
8. Check:
 Copper washer “1”   (coolant drain 
bolt “2”)
9. Install:
 Coolant drain bolt (with the copper washer)
10. Connect:
 Coolant reservoir hose
11. Install:
 Coolant reservoir
12. Fill:
 Cooling system
(with the specified amount of the recom-
mended coolant)Handling notes for coolant
Coolant is potentially harmful and should 
be handled with special care.
WARNING
EWA13040
 If coolant splashes in your eyes, thor-
oughly wash them with water and consult 
a doctor.
 If coolant splashes on your clothes, 
quickly wash it away with water and then 
with soap and water.
 If coolant is swallowed, induce vomiting 
and get immediate medical attention.
CAUTION:
ECA13480
 Adding water instead of coolant lowers 
the antifreeze content of the coolant. If 
water is used instead of coolant check, 
and if necessary, correct the antifreeze 
concentration of the coolant.
 Use only distilled water. However, if dis-
tilled water is not available, soft water 
may be used.
 If coolant comes into contact with painted 
surfaces, immediately wash them with 
water.
 Do not mix different types of antifreeze.
13. Install:
Radiator cap
14. Fill:
 Coolant reservoir
(with the recommended coolant to the max-
imum level mark “a”)
Coolant drain bolt
7 Nm (0.7 m·Kg, 5.1 ft·lb)
New
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Radiator capacity (including all
routes)
2.76 L (2.92 US qt) (2.43
Imp.qt)
Coolant reservoir capacity (up
to the maximum level mark)
0.25 L (0.26 US qt) (0.22
Imp.qt) 
						

							ENGINE
3-21
15. Install:
 Coolant reservoir cap
16. Start the engine, warm it up for several 
minutes, and then stop it.
17. Check:
 Coolant level
Refer to CHECKING THE COOLANT 
LEVEL on page 3-18.
NOTE:
Before checking the coolant level, wait a few 
minutes until the coolant has settled.
18. Install:
 Side cowlings
 Lower cowlings
Refer to GENERAL CHASSIS on page 4-
1. 
						

							CHASSIS
3-22
EAS21140
CHASSIS
EAS21160
ADJUSTING THE FRONT DISC BRAKE
1. Adjust:
 Brake lever position
(distance “a” from the throttle grip to the 
brake lever)
NOTE:
While pushing the brake lever forward, turn the 
adjusting dial “1” until the brake lever is in the 
desired position.
WARNING
EWA13060
 After adjusting the brake lever position, 
make sure the pin on the brake lever 
holder is firmly inserted in the hole in the 
adjusting dial.
 A soft or spongy feeling in the brake lever 
can indicate the presence of air in the 
brake system. Before the vehicle is oper-
ated, the air must be removed by bleeding 
the brake system. Air in the brake system 
will considerably reduce in loss of control 
and possibly an accident. Therefore, 
check and if necessary, bleed the brake 
system.
CAUTION:
ECA13490
After adjusting the brake lever position, 
make sure there is no brake drag.
EAS21190
ADJUSTING THE REAR DISC BRAKE
1. Check:
 Brake pedal position(distance “a” from the center of the footrest 
bracket bolt to the center of the brake 
pedal)
Out of specification → Adjust.
2. Adjust:
 Brake pedal position
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a. Loosen the locknut “1”.
b. Turn the adjusting bolt “2” in direction “a” or 
“b” until the specified brake pedal position 
is obtained.
WARNING
EWA13070
After adjusting the brake pedal position, 
check that the end of the adjusting bolt “c” 
is visible through the hole “d”.
c. Tighten the locknut “1” to specification.
Direction “b”
Distance “a” is the largest.
Direction “c”
Distance “a” is the smallest.
Brake pedal position
25.2 mm (0.99 in)
Direction “a”
Brake pedal is raised.
Direction “b”
Brake pedal is lowered.
Locknut
18 Nm (1.8 m·kg, 13 ft·lb) 
						

							CHASSIS
3-23
WARNING
EWA13050
A soft or spongy feeling in the brake lever 
can indicate the presence of air in the brake 
system. Before the vehicle is operated, the 
air must be removed by bleeding the brake 
system. Air in the brake system will consid-
erably reduce braking performance.
CAUTION:
ECA13510
After adjusting the brake pedal position, 
make sure there is no brake drag.
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3. Adjust:
 Rear brake light switch
Refer to ADJUSTING THE REAR BRAKE 
LIGHT SWITCH on page 3-24.
EAS21240
CHECKING THE BRAKE FLUID LEVEL
1. Stand the vehicle on a level surface.
NOTE:
 Place the vehicle on a suitable stand.
 Make sure the vehicle is upright.
2. Check:
 Brake fluid level
Below the minimum level mark “a” → Add 
the recommended brake fluid to the proper 
level.
WARNING
EWA13090
 Use only the designated brake fluid. 
Other brake fluids may cause the rubber 
seals to deteriorate, causing leakage and 
poor brake performance.
 Refill with the same type of brake fluid 
that is already in the system. Mixing brake 
fluids may result in a harmful chemical 
reaction, leading to poor brake perfor-
mance.
 When refilling, be careful that water does 
not enter the brake fluid reservoir. Water 
will significantly lower the boiling point of 
the brake fluid and could cause vapor 
lock.
CAUTION:
ECA13540
Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the 
brake fluid level, make sure the top of the 
brake fluid reservoir is horizontal.
EAS21250
CHECKING THE FRONT BRAKE PADS
The following procedure applies to all of the 
brake pads.
1. Operate the brake.
2. Check:
 Front brake pad
Wear indicators “a” almost touch the brake 
disc → Replace the brake pads as a set.
Refer to FRONT BRAKE on page 4-20.
Recommended fluid
DOT 4
A. Front brake
B. Rear brake 
						

							CHASSIS
3-24
EAS21260
CHECKING THE REAR BRAKE PADS
The following procedure applies to all of the 
brake pads.
1. Operate the brake.
2. Check:
 Rear brake pad
Wear indicators “a” almost touch the brake 
disc → Replace the brake pads as a set.
Refer to REAR BRAKE on page 4-33.
EAS21280
CHECKING THE FRONT BRAKE HOSES
The following procedure applies to all of the 
brake hoses and brake hose clamps.
1. Check:
 Brake hose “1”
Cracks/damage/wear → Replace.
2. Check:
 Brake hose clamp “2”
Loose → Tighten the clamp bolt.3. Hold the vehicle upright and apply the 
brake several times.
4. Check:
 Brake hose
Brake fluid leakage → Replace the dam-
aged hose.
Refer to FRONT BRAKE on page 4-20.
EAS21290
CHECKING THE REAR BRAKE HOSE
1. Check:
 Brake hose “1”
Cracks/damage/wear → Replace.
2. Check:
 Brake hose clamp “2”
Loose Connection → Tighten the clamp 
bolt.
3. Hold the vehicle upright and apply the front 
brake several times.
4. Check:
 Brake hose
Brake fluid leakage → Replace the dam-
aged hose.
Refer to REAR BRAKE on page 4-33.
EAS21330
ADJUSTING THE REAR BRAKE LIGHT 
SWITCH
NOTE:
The rear brake light switch is operated by 
movement of the brake pedal. The rear brake 
light switch is properly adjusted when the 
brake light comes on just before the braking 
effect starts.
1. Check:
 Rear brake light operation timing
Incorrect → Adjust.
2. Adjust:
 Rear brake light operation timing 
						

							CHASSIS
3-25
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a. Hold the main body “1” of the rear brake 
light switch so that it does not rotate and 
turn the adjusting nut “2” in direction “a” or 
“b” until the rear brake light comes on at the 
proper time.
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EAS21360
BLEEDING THE HYDRAULIC BRAKE SYS-
TEM
WARNING
EWA13100
Bleed the hydraulic brake system when-
ever:
 The system is disassembled.
 A brake hose is loosened, disconnected 
or replaced.
 The brake fluid level is very low.
 Brake operation is faulty.
NOTE:
 Be careful not to spill any brake fluid or allow 
the brake fluid reservoir to overflow.
 When bleeding the hydraulic brake system, 
make sure there is always enough brake fluid 
before applying the brake. Ignoring this pre-
caution could allow air to enter the hydraulic 
brake system, considerably lengthening the 
bleeding procedure.
 If bleeding is difficult, it may be necessary to 
let the brake fluid settle for a few hours. 
Repeat the bleeding procedure when the tiny 
bubbles in the hose have disappeared.
1. Bleed:
 Hydraulic brake system
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a. Fill the brake fluid reservoir to the proper 
level with the recommended brake fluid.
b. Install the brake fluid reservoir diaphragm.
c. Connect a clear plastic hose “1” tightly to 
the bleed screw “2”.
NOTE:
Bleeding order of the front hydraulic brake sys-
tem is the following order:
 Front brake master cylinder
 Front brake calipers
 Front brake master cylinder
d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake several times.
f. Fully pull the brake lever or fully press 
down the brake pedal and hold it in posi-
tion.
Direction “a”
Brake light comes on sooner.
Direction “b”
Brake light comes on later.
A. Front brake master cylinder
B. Front brake caliper
C. Rear brake caliper 
						

							CHASSIS
3-26
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release the 
pressure and cause the brake lever to contact 
the throttle grip or the brake pedal to fully 
extend.
h. Tighten the bleed screw and then release 
the brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air 
bubbles have disappeared from the brake 
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
k. Fill the brake fluid reservoir to the proper 
level with the recommended brake fluid.
Refer to CHECKING THE BRAKE FLUID 
LEVEL on page 3-23.
WARNING
EWA13110
After bleeding the hydraulic brake system, 
check the brake operation.
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EAS21380
ADJUSTING THE SHIFT PEDAL
1. Adjust:
 Shift pedal position
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a. Loosen both locknuts “1”.
b. Turn the shift rod “2” in direction “a” or “b” to 
obtain the correct shift pedal position.
c. Tighten both locknuts.
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EAS21410
ADJUSTING THE DRIVE CHAIN SLACK
NOTE:
The drive chain slack must be checked at the 
tightest point on the chain.
CAUTION:
ECA13550
A drive chain that is too tight will overload 
the engine and other vital parts, and one 
that is too loose can skip and damage the 
swingarm or cause an accident. Therefore, 
keep the drive chain slack within the speci-
fied limits.
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 rear wheel is elevated.
2. Spin the rear wheel several times and find 
the tightest position of drive chain.
3. Check:
 Drive chain slack “a”
Out of specification → Adjust.
4. Adjust:
 Drive chain slack
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a. Loosen the wheel axle nut “1”.
b. Loosen both locknuts “2”.
c. Turn both adjusting nuts “3” in direction “a” 
or “b” until the specified drive chain slack is 
obtained.
Bleed screw
6 Nm (0.6 m·kg, 4.3 ft·lb)
Direction “a”
Shift pedal is raised.
Direction “b”
Shift pedal is lowered.
Drive chain slack
30.0–40.0 mm (1.18–1.57 in) 
						

							CHASSIS
3-27
NOTE:
To maintain the proper wheel alignment, adjust 
both sides evenly.
d. Tighten both locknuts to specification.
e. Tighten the wheel axle nut to specification.
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EAS21440
LUBRICATING THE DRIVE CHAIN
The drive chain consists of many interacting 
parts. If the drive chain is not maintained prop-
erly, it will wear out quickly. Therefore, the drive 
chain should be serviced, especially when the 
vehicle is used in dusty areas.
This vehicle has a drive chain with small rub-
ber O-rings between each side plate. Steam 
cleaning, high-pressure washing, certain sol-
vents, and the use of a coarse brush can dam-
age these O-rings. Therefore, use only 
kerosene to clean the drive chain. Wipe the 
drive chain dry and thoroughly lubricate it with 
engine oil or chain lubricant that is suitable for 
O-ring chains. Do not use any other lubricants 
on the drive chain since they may contain sol-
vents that could damage the O-rings.
EAS21500
CHECKING AND ADJUSTING THE STEER-
ING HEAD
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. Check:
 Steering head
Grasp the bottom of the front fork legs and 
gently rock the front fork.
Binding/looseness → Adjust the steering 
head.
3. Remove:
 Upper bracket
Refer to HANDLEBARS on page 4-45 
and STEERING HEAD on page 4-59.
4. Adjust:
 Steering head
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a. Remove the lock washer “1”, the upper ring 
nut “2”, and the rubber washer “3”.
b. Loosen the lower ring nut “4” and then 
tighten it to specification with a steering nut 
wrench “5”.
NOTE:
Set the torque wrench at a right angle to the 
steering nut wrench.
Direction “a”
Drive chain is tightened.
Direction “b”
Drive chain is loosened.
Locknut
16 Nm (1.6 m·kg, 12 ft·lb)
Wheel axle nut
150 Nm (15 m·kg, 108 ft·lb)
Recommended lubricant
Engine oil or chain lubricant 
suitable for O-ring chains