Yamaha Yzf R1 2007 Manual
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CHASSIS 3-28 c. Loosen the lower ring nut “4” completely, then tighten it to specification. WARNING EWA13140 Do not overtighten the lower ring nut. d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings. Refer to STEERING HEAD on page 4-59. e. Install the rubber washer “3”. f. Install the upper ring nut “2”. g. Finger tighten the upper ring nut “2”, then align the slots of both ring nuts. If neces- sary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned. h. Install the lock washer “1”. NOTE: Make sure the lock washer tabs “a” sit correctly in the ring nut slots “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: Upper bracket Refer to STEERING HEAD on page 4-59. 6. Measure: Steering head tension ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ NOTE: Make sure all of the cables and wires are prop- erly routed. a. Point the front wheel straight ahead. b. Install a plastic locking tie “1” loosely around the end of the handlebar as shown. c. Hook a spring gauge “2” onto the plastic locking tie. d. Hold the spring gauge at a 90° angle from the handlebar, pull the spring gauge, and then record the measurement when the handlebar starts to run. Steering nut wrench 90890-01403 Spanner wrench YU-33975 Lower ring nut (initial tightening torque) 52 Nm (5.2 m·kg, 38 ft·lb) Lower ring nut (final tightening torque) 18 Nm (1.8 m·kg, 13 ft·lb) Steering head tension 200–500 g
CHASSIS 3-29 e. Repeat the above procedure on the oppo- site handlebar. f. If the steering head tension is out of specifi- cation (both handlebars should be within specification), remove the upper bracket and loosen or tighten the upper ring nut. g. Reinstall the upper bracket and measure the steering head tension again as described above. h. Repeat the above procedure until the steer- ing head tension is within specification. i. Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness → Adjust the steering head. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21530 CHECKING THE FRONT FORK 1. Stand the vehicle on a level surface. WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over. 2. Check: Inner tube “1” Damage/scratches → Replace. Oil seal “2” Oil leakage → Replace. 3. Hold the vehicle upright and apply the front brake.4. Check: Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement → Repair. Refer to FRONT FORK on page 4-50. EAS21580 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING EWA13150 Always adjust both front fork legs evenly. Uneven adjustment can result in poor handling and loss of stability. Securely support the vehicle so that there is no danger of it falling over. Spring preload CAUTION: ECA13570 Grooves are provided to indicate the adjustment position. Never go beyond the maximum or mini- mum adjustment positions. 1. Adjust: Spring preload ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting bolt “1” in direction “a” or “b”. Direction “a” Spring preload is increased (suspension is harder). Direction “b” Spring preload is decreased (suspension is softer).
CHASSIS 3-30 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Rebound damping CAUTION: ECA13590 Never go beyond the maximum or minimum adjustment positions. 1. Adjust: Rebound damping ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Compression damping CAUTION: ECA13590 Never go beyond the maximum or minimum adjustment positions. 1. Adjust: Compression damping ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. Spring preload adjusting posi- tions Minimum 8 Standard 5 Maximum 0 Direction “a” Rebound damping is increased (suspension is harder). Direction “b” Rebound damping is decreased (suspension is softer). Rebound damping adjust posi- tions Minimum 26 click(s) out* Standard 10 click(s) out* Maximum 1 click(s) out* * With the adjusting screw fully turned in. Direction “a” Compression damping is increased (suspension is harder). Direction “b” Compression damping is decreased (suspension is softer). Compression damping adjust points Minimum 25 click(s) out* Standard 10 click(s) out* Maximum 1 click(s) out* * With the adjusting screw fully turned in.
CHASSIS 3-31 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21610 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over. Spring preload CAUTION: ECA13590 Never go beyond the maximum or minimum adjustment positions. 1. Adjust: Spring preload ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Adjust the spring preload with the special wrench and extension bar included in the owner’s tool kit. b. Turn the adjusting ring “1” in direction “a” or “b”. c. Align the desired position on the adjusting ring with the stopper “2”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Rebound damping CAUTION: ECA13590 Never go beyond the maximum or minimum adjustment positions. 1. Adjust: Rebound damping ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting knob “1” in direction “a” or “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Direction “a” Spring preload is increased (suspension is harder). Direction “b” Spring preload is decreased (suspension is softer). Spring preload adjusting posi- tions Minimum 1 Standard 5 Maximum 9 Direction “a” Rebound damping is increased (suspension is harder). Direction “b” Rebound damping is decreased (suspension is softer). Rebound damping adjust posi- tions Minimum 20 click(s) out* Standard 12 click(s) out* Maximum 3 click(s) out* * With the adjusting screw fully turned in.
CHASSIS 3-32 Compression damping (fast compression damping) CAUTION: ECA13590 Never go beyond the maximum or minimum adjustment positions. 1. Adjust: Compression damping (fast compression damping) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Compression damping (slow compression damping) CAUTION: ECA13590 Never go beyond the maximum or minimum adjustment positions. 1. Adjust: Compression damping (slow compression damping) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting knob “1” in direction “a” or “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21650 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: Tire pressure Out of specification → Regulate. Direction “a” Compression damping is increased (suspension is harder). Direction “b” Compression damping is decreased (suspension is softer). Compression damping (fast com- pression damping) adjusting positions Minimum 4 turn(s) out* Standard 3 turn(s) out* Maximum 0 turn(s) out* * With the adjusting screw fully turned in. Direction “a” Compression damping is increased (suspension is harder). Direction “b” Compression damping is decreased (suspension is softer). Compression damping (slow compression damping) adjusting positions Minimum 20 click(s) out* Standard 12 click(s) out* Maximum 1 click(s) out* * With the adjusting screw fully turned in.
CHASSIS 3-33 WARNING EWA13180 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed. Operation of an overloaded vehicle could cause tire damage, an accident or an injury. NEVER OVERLOAD THE VEHICLE. WARNING EWA13190 It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately. 2. Check: Tire surfacesDamage/wear → Replace the tire. WARNING EWA14080 Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. When using a tube tire, be sure to install the correct tube. Always replace a new tube tire and a new tube as a set. To avoid pinching the tube, make sure the wheel rim band and tube are centered in the wheel groove. Patching a punctured tube is not recom- mended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality replacement. Tire air pressure (measured on cold tires) Loading condition 0–90 kg (0–198 lb) Front 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar) Rear 290 kPa (42 psi) (2.90 kgf/cm²) (2.90 bar) Loading condition 90–195 kg (198–430 lb) Front 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar) Rear 290 kPa (42 psi) (2.90 kgf/cm²) (2.90 bar) High-speed riding Front 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar) Rear 290 kPa (42 psi) (2.90 kgf/cm²) (2.90 bar) Maximum load 195 kg (430 lb) * Total weight of rider, passenger, cargo and accessories 1. Tire tread depth 2. Side wall 3. Wear indicator Wear limit (front) 0.8 mm (0.03 in) Wear limit (rear) 0.8 mm (0.03 in) A. Tire B. Wheel Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire
CHASSIS 3-34 WARNING EWA14090 After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufac- turer and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this vehi- cle. WARNING EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. NOTE: For tires with a direction of rotation mark “1”: Install the tire with the mark pointing in the direction of wheel rotation. Align the mark “2” with the valve installation point. EAS21670 CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: Wheel Damage/out-of-round → Replace. WARNING EWA13260 Never attempt to make any repairs to the wheel. NOTE: After a tire or wheel has been changed or replaced, always balance the wheel. EAS21690 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables. WARNING EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement. Replace damaged outer cable and inner cables as soon as possible. 1. Check: Outer cable Damage → Replace. 2. Check: Cable operation Rough movement → Lubricate. NOTE: Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device. EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal-to-metal moving parts of the levers. Front tire Size 120/70 ZR17M/C (58W) Manufacturer/model PIRELLI/DIABLO CORSA E Manufacturer/model MICHELIN/Pilot POWER Rear tire Size 190/50 ZR17M/C (73W) Manufacturer/model PIRELLI/DIABLO CORSA L Manufacturer/model MICHELIN/Pilot POWER Recommended lubricant Engine oil or a suitable cable lubricant Recommended lubricant Lithium-soap-based grease
CHASSIS 3-35 EAS21710 LUBRICATING THE PEDAL Lubricate the pivoting point and metal-to-metal moving parts of the pedal. EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension. Recommended lubricant Lithium-soap-based grease Recommended lubricant Lithium-soap-based grease Recommended lubricant Molybdenum disulfide grease
ELECTRICAL SYSTEM 3-36 EAS21750 ELECTRICAL SYSTEM EAS21760 CHECKING AND CHARGING THE BATTERY Refer to ELECTRICAL COMPONENTS on page 8-77. EAS21770 CHECKING THE FUSES Refer to ELECTRICAL COMPONENTS on page 8-77. EAS21790 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Remove: Intake air duct panel Refer to GENERAL CHASSIS on page 4- 1. 2. Remove: Headlight bulb coupler (high beam) “1” Headlight bulb cover “2” 3. Disconnect: Headlight bulb coupler (low beam) “1” 4. Remove: Headlight bulb holders “3”5. Remove: Headlight bulb WARNING EWA13320 Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 6. Install: Headlight bulb Secure the new headlight bulbs with the headlight bulb holder. CAUTION: ECA13690 Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 7. Install: Headlight bulb holder 8. Connect: Headlight bulb coupler (low beam) 9. Install: Headlight bulb cover 10. Connect: A. High beam B. Low beam a. High beam b. High beam bulb socket c. Low beam New
ELECTRICAL SYSTEM 3-37 Headlight bulb coupler (high beam) 11. Install: Intake air duct panel Refer to GENERAL CHASSIS on page 4- 1. EAS21810 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights. 1. Remove: Front cowling inner panels Refer to GENERAL CHASSIS on page 4- 1. 2. Adjust: Headlight beam (vertically) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Adjust: Headlight beam (horizontally) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting knob “2” in direction “a” or “b”. Left headlight Right headlight ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Install: Front cowling inner panels Refer to GENERAL CHASSIS on page 4- 1. Direction “a” Headlight beam is raised. Direction “b” Headlight beam is lowered. Direction “a” Headlight beam moves to the right. Direction “b” Headlight beam moves to the left. Direction “a” Headlight beam moves to the left. Direction “b” Headlight beam moves to the right.