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. Loosen:
 Handlebar pinch bolt “1”
 Upper bracket pinch bolts “2”
 Cap bolt “3”
 Lower bracket pinch bolts “4”
WARNING
EWA13640
Before loosening the upper and lower 
bracket pinch bolts, support the front fork 
leg.
4. Remove: Front fork leg
EAS22990
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
1. Remove:
 Cap bolt “1”
(from the damper adjusting rod)
 Spacers “2”
Nut “3”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Press down on the spacer with the fork 
spring compressor “4”.
b. Install the rod holder “5” between the nut 
“3” and the spacer “2”.
NOTE:
Use the side of the rod holder that is marked 
“A”.
c. Hold the spring preload adjusting bolt “6” 
and loosen the nut “3”.
d. Remove the cap bolt.
e. Remove the rod holder and fork spring 
compressor.
f. Remove the spacer and nut.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Drain:
 Fork oil
NOTE:
Stroke the damper rod “1” several times while 
draining the fork oil.
Fork spring compressor
90890-01441
YM-01441
Rod holder
90890-01434
Damper rod holder double 
ended
YM-01434 
						

							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 inner 
tube as this may dangerously weaken it.
2. Measure:
 Spring free length “a”
Out of specification → Replace.
3. Check:
 Damper rod assembly “1”
Damage/wear → Replace.
Obstruction → Blow out all of the oil pas-
sages with compressed air.
 Damper adjusting rod
Bends/damage → Replace.
CAUTION:
ECA14200
 The front fork leg has a built-in damper 
adjusting rod and a very sophisticated 
internal construction, which are particu-
larly sensitive to foreign material.
 When disassembling and assembling the 
front fork leg, do not allow any foreign 
material to enter the front fork.
Damper rod holder
90890-01423
Damping rod holder
YM-01423
Fork spring free length
237.5 mm (9.35 in)
Limit
232.8 mm (9.17 in) 
						

							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 all of the components are clean.
1. Install:
 Damper rod assembly “1”
 Inner tube “2”
 Damper rod assembly bolt
 Cooper washer 
WARNING
EWA4C81002
Always use new copper washer.
CAUTION:
ECA14210
Allow the damper rod assembly to slide 
slowly down the inner tube “2” until it pro-
trudes from the bottom of the inner tube. 
Be careful not to damage the inner tube.2. Lubricate:
 Inner tube’s outer surface
3. Tighten:
 Damper rod assembly bolt “1”
NOTE:
While holding the damper rod assembly with 
the damper rod holder “2”, tighten the damper 
rod assembly bolt.
New
Recommended oil
Suspension oil 01 or equiva-
lent
Damper rod assembly bolt
23 Nm (2.3 m·kg, 17 ft·lb)
LOCTITE®
Damper rod holder
90890-01423
Damping rod holder
YM-01423 
						

							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 seal driver “2”)6. Install:
 Oil seal clip “1”
NOTE:
Adjust the oil seal clip so that it fits into the 
outer tube’s groove.
7. Install:
 Dust seal “1”
(with the fork seal driver “2”)
8. Install:
 Rod puller “1”
 Rod puller attachment “2”
(onto the damper rod “3”)
Fork seal driver
90890-01442
Adjustable fork seal driver (36–
46 mm)
YM-01442
Fork seal driver
90890-01442
Adjustable fork seal driver (36–
46 mm)
YM-01442 
						

							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 damper rod slowly 
because the fork oil may spurt out.11. Before measuring the fork oil level, wait ten 
minutes until the oil has settled and the air 
bubbles have dispersed.
NOTE:
Be sure to bleed the front fork leg of any resid-
ual air.
12. Measure:
 Front fork leg oil level “a”
Out of specification → Correct.
13. Install:
 Damper adjusting rod locknut “1”
 Fork spring “2”
 Spacer “3”
 Damper adjusting rod “4”
 Cap bolt “5”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Rod puller
90890-01437
Universal damping rod bleeding 
tool set
YM-A8703
Rod puller attachment (M12)
90890-01435
Universal damping rod bleeding 
tool set
YM-A8703
Quantity
513.0 cm³ (17.34 US oz) (18.09
Imp.oz)
Recommended oil
Suspension oil 01
Level
101.0 mm (3.98 in) 
						

							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 
attachment.
h. Install the nut “1” and position it as speci-
fied “b”.
i. Set the cap bolt distance “c” to specifica-
tion.
j. Install the damper adjusting rod and cap 
bolt, and then finger tighten the cap bolt.
k. Hold the cap bolt and tighten the damper 
adjusting rod locknut to specification.
l. Remove the rod holder and fork spring 
compressor.
Rod puller
90890-01437
Universal damping rod bleeding 
tool set
YM-A8703
Rod puller attachment (M12)
90890-01435
Universal damping rod bleeding 
tool set
YM-A8703
Fork spring compressor
90890-01441
YM-01441
Rod holder
90890-01434
Damper rod holder double 
ended
YM-01434
Distance “b”
11 mm (0.43 in)
Distance “c”
13 mm (0.51 in)
Damper adjusting rod locknut
29 Nm (2.9 m·kg, 21 ft·lb) 
						

							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-
erly.3. Adjust:
 Spring preload
 Rebound damping
 Compression damping
Refer to ADJUSTING THE FRONT FORK 
LEGS on page 3-29.
Lower bracket pinch bolt
23 Nm (2.3 m·kg, 17 ft·lb)
Cap bolt
23 Nm (2.3 m·kg, 17 ft·lb)
Handlebar pinch bolt
17 Nm (1.7 m·kg, 12 ft·lb)
Upper bracket pinch bolt
26 Nm (2.6 m·kg, 19 ft·lb)