Yamaha Yzf R1 2007 Manual
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CHASSIS GENERAL CHASSIS.................................................................................... 4-1 CHECKING THE INTAKE FUNNEL ........................................................ 4-5 CHECKING THE INTAKE FUNNEL ........................................................ 4-5 CHECKING THE INTAKE FUNNEL OPERATION .................................. 4-5 REMOVING THE COVER....................................................................... 4-7 INSTALLING THE COVER ..................................................................... 4-7 FRONT WHEEL ............................................................................................ 4-8 REMOVING THE FRONT WHEEL ....................................................... 4-10 CHECKING THE FRONT WHEEL........................................................ 4-10 ADJUSTING THE FRONT WHEEL STATIC BALANCE ....................... 4-11 INSTALLING THE FRONT WHEEL ...................................................... 4-12 REAR WHEEL ............................................................................................ 4-14 REMOVING THE REAR WHEEL ......................................................... 4-17 CHECKING THE REAR WHEEL .......................................................... 4-17 CHECKING THE REAR WHEEL DRIVE HUB ..................................... 4-18 CHECKING AND REPLACING THE REAR WHEEL SPROCKET ....... 4-18 ADJUSTING THE REAR WHEEL STATIC BALANCE .......................... 4-18 INSTALLING THE REAR WHEEL ........................................................ 4-18 FRONT BRAKE .......................................................................................... 4-20 INTRODUCTION ........................... ....................................................... 4-25 CHECKING THE FRONT BRAKE DISCS ............................................ 4-25 REPLACING THE FRONT BR AKE PADS ............................................ 4-26 REMOVING THE FRONT BRAKE CALIPERS ..................................... 4-27 DISASSEMBLING THE FRONT BRAKE CALIPERS ........................... 4-28 CHECKING THE FRONT BRAKE CALIPERS ..................................... 4-28 ASSEMBLING THE FRONT BRAKE CALIPERS ................................. 4-28 INSTALLING THE FRONT BRAKE CALIPERS .................................... 4-29 REMOVING THE FRONT BRAKE MASTER CYLINDER..................... 4-30 CHECKING THE FRONT BRAKE MASTER CYLINDER ..................... 4-30 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER................. 4-31 INSTALLING THE FRONT BRAKE MASTER CYLINDER ................... 4-31 REAR BRAKE ............................................................................................ 4-33 INTRODUCTION ........................... ....................................................... 4-38 CHECKING THE REAR BRAKE DISC ................................................. 4-38 REPLACING THE REAR BRAKE PADS .............................................. 4-38 REMOVING THE REAR BR AKE CALIPER.......................................... 4-40 DISASSEMBLING THE REAR BRAKE CALIPER ................................ 4-40 CHECKING THE REAR BRAKE CALIPER .......................................... 4-40 ASSEMBLING THE REAR BRAK E CALIPER ...................................... 4-41 INSTALLING THE REAR BRAKE CALIPER......................................... 4-41 REMOVING THE REAR BRAKE MASTER CYLINDER ....................... 4-42 CHECKING THE REAR BRAKE MASTER CYLINDER ....................... 4-42 ASSEMBLING THE REAR BRAKE MASTER CYLINDER ................... 4-43 INSTALLING THE REAR BRAKE MASTER CYLINDER ...................... 4-43
HANDLEBARS........................................................................................... 4-45 REMOVING THE HANDLEBAR ........................................................... 4-47 CHECKING THE HANDLEBARS ......................................................... 4-47 INSTALLING THE HANDLEBARS ........................................................ 4-47 CHECKING THE STEERING DAMPER ............................................... 4-48 FRONT FORK............................................................................................. 4-50 REMOVING THE FRONT FORK LEGS ............................................... 4-52 DISASSEMBLING THE FRONT FORK LEGS ..................................... 4-52 CHECKING THE FRONT FORK LEGS ................................................ 4-53 ASSEMBLING THE FRONT FORK LEGS ........................................... 4-54 INSTALLING THE FRONT FORK LEGS .............................................. 4-58 STEERING HEAD....................................................................................... 4-59 REMOVING THE LOWER BRACKET .................................................. 4-61 CHECKING THE STEERING HEAD .................................................... 4-61 INSTALLING THE STEERING HEAD ................................................... 4-61 REAR SHOCK ABSORBER ASSEMBLY.................................................. 4-63 HANDLING THE REAR SHOCK ABSORBER ..................................... 4-64 DISPOSING OF A REAR SHOCK ABSORBER ................................... 4-64 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY................. 4-64 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................. 4-64 CHECKING THE CONNECTING ARM AND RELAY ARM .................. 4-65 INSTALLING THE RELAY ARM............................................................ 4-65 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ............... 4-65 SWINGARM................................................................................................ 4-66 REMOVING THE SWINGARM ............................................................. 4-68 CHECKING THE SWINGARM ............................................................. 4-69 INSTALLING THE SWINGARM ............................................................ 4-69 CHAIN DRIVE............................................................................................. 4-71 REMOVING THE DRIVE CHAIN .......................................................... 4-72 CHECKING THE DRIVE CHAIN .......................................................... 4-72 CHECKING THE REAR WHEEL SPROCKET ..................................... 4-73 CHECKING THE REAR WHEEL DRIVE HUB ..................................... 4-73 INSTALLING THE DRIVE CHAIN ......................................................... 4-73
GENERAL CHASSIS 4-1 EAS21830 GENERAL CHASSIS Removing the seat and battery Order Job/Parts to remove Q’ty Remarks 1 Rider seat 2 Passenger seat 1 3 Battery negative lead 1 4 Battery positive lead 1 5 ECU (engine control unit) 1 6 ECU lead coupler 1 Disconnect. 7ECU cover 1 8 Battery band 1 9Battery 1 10 Battery seat 1 For installation, reverse the removal proce- dure.
GENERAL CHASSIS 4-2 Removing the front cowling and side cowlings Order Job/Parts to remove Q’ty Remarks 1 Side cowling inner panel 2 2 Side cowling 2 3 Front turn signal light lead coupler 2 Disconnect. 4 Lower cowling 2 5 Lower cowling front cover 1 6 Intake air duct panel 2 7 Intake air temperature coupler 1 Disconnect. 8 Meter assembly coupler 1 Disconnect. 9 Front cowling 1 10 Rear intake air duct 2 11 Front intake air duct 2 12 Rear view mirror 2 13 Windshield 1 For installation, reverse the removal proce- dure.
GENERAL CHASSIS 4-3 Removing the rear fender Order Job/Parts to remove Q’ty Remarks Rider seat Refer to GENERAL CHASSIS on page 4-1. Passenger seat Refer to GENERAL CHASSIS on page 4-1. Muffler Refer to ENGINE REMOVAL on page 5-1. 1 Upper tail cover 1 2 Tail/brake light lead coupler 1 Disconnect. 3 Turn signal light/licence plate light lead coupler 4 Disconnect. 4 Mud guard assembly 1 5Lower tail cover 1 6 Tail/brake light 1 For installation, reverse the removal proce- dure.
GENERAL CHASSIS 4-4 Removing the air filter case Order Job/Parts to remove Q’ty Remarks Rider seat Refer to GENERAL CHASSIS on page 4-1. Fuel tank Refer to FUEL TANK on page 7-1. 1 Air filter case cover 1 2 Air filter 1 3 Intake funnel servo motor rod assembly 1 4 Intake funnel joint 2 5 Intake funnel 2 6 Intake funnel rod 2 7 Bushing 2 5 8 Air induction system hose 1 9 Crankcase breather hose 1 10 Air filter case 1 11 Intake funnel servo motor 1 For installation, reverse the removal proce- dure.
GENERAL CHASSIS 4-5 EAS4C81025 CHECKING THE INTAKE FUNNEL 1. Check: Intake funnel Cracks/damage → Replace. Intake funnel seal rubber “1” Cracks/damage → Replace. Intake funnel rods Damage/scratches → Replace. EAS4C81026 CHECKING THE INTAKE FUNNEL 1. Install: Intake funnel rod Intake funnel NOTE: To install the intake funnel, do not mistake the front and rear directions. For Bushing 2 “a”, point the direction of notch hole as shown in the illustration. CAUTION: ECA4C81020 After assembly, make sure that the intake funnel smoothly moves to the contacting surface between upper stopper and lower seating position when it is moved by hand. Make sure that the intake funnel smoothly strokes from the upper position to the seating position by its own weight. Air filter case Intake funnel joint bolt “1” CAUTION: ECA4C81022 Do not remove the bolts from the intake funnel joint. Intake funnel joint bolt “2” Intake funnel servo motor rod assembly EAS4C81027 CHECKING THE INTAKE FUNNEL OPERA- TION 1. Check: Intake funnel operation A. Upper B. Lower Intake funnel joint bolt 6 Nm (0.6 m·kg, 4.3 ft·lb) Intake funnel joint bolt 3 Nm (0.3 m·kg, 2.2 ft·lb)
GENERAL CHASSIS 4-6 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Activate the diagnostic mode and select the diagnostic code number “34”. Refer to FUEL INJECTION SYSTEM on page 8-29. b. Set the engine stop switch to “ ”. c. Check that the intake funnel operate smoothly strokes from the upper position to the lower seating position. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
GENERAL CHASSIS 4-7 EAS21840 REMOVING THE COVER 1. Remove: Tail cover Rear fender NOTE: To remove the quick fastener, push its center with a screwdriver, then pull the fastener out. EAS21850 INSTALLING THE COVER 1. Install: Rear fender Tail cover NOTE: To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the cover and push the pin “a” in with screwdriver. Make sure that the pin is flush with the fastener’s head.
FRONT WHEEL 4-8 EAS21870 FRONT WHEEL Removing the front wheel and brake discs Order Job/Parts to remove Q’ty Remarks 1 Reflector 2 2 Reflector bracket 2 3 Left brake hose holder 1 4 Right brake hose holder 1 5 Left front brake caliper 1 6 Right front brake caliper 1 7 Front wheel axle pinch bolt 4 8 Front wheel axle bolt 1 9 Front wheel axle 1 10 Collar (left and right) 2 11 Dust cover (left and right) 2 12 Front wheel 1 13 Front brake disc (left and right) 2 For installation, reverse the removal proce- dure.