Yamaha Yzf R1 2007 Manual

							CAMSHAFTS
5-11
EAS23810
REMOVING THE CAMSHAFTS
1. Remove:
 Pickup rotor cover
Refer to CRANKSHAFT POSITION SEN-
SOR on page 5-37.
2. Align:
 “T” mark “a” on the pickup rotor
(with the crankcase mating surface “b”)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise.
b. When piston #1 is at TDC on the compres-
sion stroke, align the “T” mark “a” on the 
pickup rotor with the crankcase mating sur-
face “b”.
NOTE:
TDC on the compression stroke can be found 
when the camshaft lobes are turned away from 
each other.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Loosen:
 Camshaft sprocket bolts “1”
4. Remove:
 Timing chain tensioner “1”
Gasket5. Remove:
 Camshaft caps “1”
 Dowel pins
CAUTION:
ECA13720
To prevent damage to the cylinder head, 
camshafts or camshaft caps, loosen the 
camshaft cap bolts in stages and in a criss-
cross pattern, working from the outside in.
6. Remove:
 Intake camshaft “1”
 Exhaust camshaft “2”
NOTE:
To prevent the timing chain from falling into the 
crankcase, fasten it with a wire “3”.
Camshaft wrench
90890-04143
YM-04143 
						

							CAMSHAFTS
5-12
EAS23850
CHECKING THE CAMSHAFTS
1. Check:
 Camshaft lobes
Blue discoloration/pitting/scratches → 
Replace the camshaft.
2. Measure:
 Camshaft lobe dimensions “a” and “b”
Out of specification → Replace the cam-
shaft.3. Measure:
 Camshaft runout
Out of specification → Replace.
4. Measure:
 Camshaft-journal-to-camshaft-cap clear-
ance
Out of specification → Measure the cam-
shaft journal diameter.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the camshaft into the cylinder head 
(without the dowel pins and camshaft 
caps).
b. Position “a” strip of Plastigauge® “1” onto 
the camshaft journal as shown.
c. Install the dowel pins and camshaft caps.
NOTE:
 Tighten the camshaft cap bolts in stages and 
in a crisscross pattern, working from the 
inner caps out.
 Do not turn the camshaft when measuring 
the camshaft journal-to-camshaft cap clear-
ance with the Plastigauge®.
d. Remove the camshaft caps and then mea-
sure the width of the Plastigauge® “2”.
Camshaft lobe dimension limit
Intake A
34.450–34.550 mm (1.3563–
1.3602 in)
Limit
34.350 mm (1.3524 in)
Intake B
25.170–25.270 mm (0.9909–
0.9949 in)
Limit
25.070 mm (0.9870 in)
Exhaust A
33.550–33.650 mm (1.3209–
1.3248 in)
Limit
33.450 mm (1.3169 in)
Exhaust B
25.192–25.292 mm (0.9918–
0.9957 in)
Limit
25.092 mm (0.9879 in)
Camshaft runout limit
0.030 mm (0.0012 in)
Camshaft-journal-to-camshaft-
cap clearance
0.028–0.062 mm (0.0011–
0.0024 in)
Camshaft cap bolt
10 Nm (1.0 m·kg, 7.2 ft·lb) 
						

							CAMSHAFTS
5-13
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure:
 Camshaft journal diameter “a”
Out of specification → Replace the cam-
shaft.
Within specification → Replace the cylinder 
head and the camshaft caps as a set.
EAS23870
CHECKING THE TIMING CHAIN AND CAM-
SHAFT SPROCKET
1. Check:
 Timing chain “1”
Damage/stiffness → Replace the timing 
chain and camshaft and camshaft sprocket 
as a set.2. Check:
 Camshaft sprocket
More than 1/4 tooth wear “a” → Replace 
the camshaft sprocket and the timing chain 
as a set.
EAS23950
CHECKING THE TIMING CHAIN GUIDES
The following procedure applies to all of the 
camshaft sprockets and timing chain guides.
1. Check:
 Timing chain guide (exhaust side) “1”
 Timing chain guide (intake side) “2”
 Timing chain guide (top side) “3”
Damage/wear → Replace the defective 
part(s).
EAS23960
CHECKING THE TIMING CHAIN TEN-
SIONER
1. Remove:
 Timing chain tensioner housing “1”
 Timing chain tensioner rod “2”
 Timing chain tensioner spring “3”
Camshaft journal diameter
24.459–24.472 mm (0.9630–
0.9635 in)
a. 1/4 tooth
b. Correct
1. Timing chain roller
2. Camshaft sprocket 
						

							CAMSHAFTS
5-14
NOTE:
Squeeze the timing chain tensioner clip, and 
then remove the timing chain tensioner spring 
and timing chain tensioner rod.
2. Check:
 Timing chain tensioner housing
 Timing chain tensioner rod
 Timing chain tensioner spring
Damage/wear → Replace.
3. Install:
 Timing chain tensioner spring
 Timing chain tensioner rod “1”
NOTE:
Prior to installing the timing chain tensioner 
rod, drain the engine oil from the timing chain 
tensioner housing.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the timing chain tensioner spring and 
timing chain tensioner rod “1”.
b. Squeeze the timing chain tensioner clip “2” 
and push the timing chain tensioner rod “3”.
NOTE:
When the timing chain tensioner rod “3” is 
pushed while holding the grip of the timing 
chain tensioner clip “2”, make sure not to 
release the timing chain tensioner rod “3” 
before releasing the timing chain tensioner clip 
“2”. (Otherwise, the timing chain tensioner rod 
“3” may run off.)
c. Hook the clip “4” to the timing chain ten-
sioner rod “3”.
NOTE:
Hook the timing chain tensioner rod pin “5” to 
the center of the clip “4”. After the installation, 
check that the clip “4” can come off by its own 
weight by pushing the timing chain tensioner 
rod “3” at the position of installation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 
						

							CAMSHAFTS
5-15
EAS24000
INSTALLING THE CAMSHAFTS
1. Align:
 “T” mark “a” on the pickup rotor
(with the crankcase mating surface “b”)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
b. When position #1 is at TDC, align the “T” 
mark “a” with the crankcase mating surface 
“b”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
 Intake camshaft sprocket “1”
 Exhaust camshaft sprocket “2”
(with the camshaft sprockets temporarily 
tightened)
NOTE:
Install the camshaft sprockets as a illustration.
3. Install:
 Exhaust camshaft “1”
 Intake camshafts “2”
(with the camshaft sprockets temporarily 
tightened)
NOTE:
Make sure the punch mark “a” on each cam-
shaft faces up.4. Install:
 Dowel pins
 Intake camshaft caps
 Exhaust camshaft caps
NOTE:
 Make sure each camshaft cap is installed in 
its original place. Refer to the identification 
marks as follows:
“I”: Intake side camshaft cap mark
“E”: Exhaust side camshaft cap mark
“IL”: Intake left side camshaft cap mark
“IR”: Intake right side camshaft cap mark
“EL”: Exhaust left side camshaft cap mark
“ER”: Exhaust right side camshaft cap mark
 Make sure the arrow mark “a” on each cam-
shaft points towards the right side of the 
engine.
5. Install:
 Camshaft cap bolts
NOTE:
Tighten the camshaft cap bolts in stages and 
in a crisscross pattern, working from the inner 
caps out.
Camshaft cap bolt
10 Nm (1.0 m·kg, 7.2 ft·lb) 
						

							CAMSHAFTS
5-16
CAUTION:
ECA4C81004
 Lubricate the camshaft cap bolts with the 
engine oil.
 The camshaft cap bolts must be tightened 
evenly or damage to the cylinder head, 
camshaft caps, and camshafts will result.
 Do not turn the crankshaft when installing 
the camshaft to avoid damage or 
improper valve timing.
6. Tighten:
 Camshaft sprocket bolts “1”
CAUTION:
ECA4C81005
Be sure to tighten the camshaft sprocket 
bolts to the specified torque to avoid the 
possibility of the bolts coming loose and 
damaging the engine.
7. Align:
 Camshaft punch mark “a”
Align the camshaft punch mark “a” and the 
camshaft cap arrow mark “b”.8. Install:
Gasket 
 Timing chain tensioner “1”
 Timing chain tensioner bolts “2”
CAUTION:
ECA4C81006
The arrow mark “a” on the timing chain ten-
sioner should face up.
WARNING
EWA4C81004
Always use a new gasket.
9. Turn:
 Crankshaft
(several turns clockwise)
10. Check:
“T” mark “a”
Make sure the “T” mark on the pickup rotor 
is aligned with the crankcase mating sur-
face “b”.
 Camshaft punch mark “c”
Make sure the punch mark “c” on the cam-
shaft is aligned with the camshaft cap 
arrow mark “d”.
Out of alignment → Adjust.
Refer to the installation steps above.
Camshaft sprocket bolt
24 Nm (2.4 m·kg, 17 ft·lb)
Camshaft wrench
90890-04143
YM-04143
Camshaft wrench
90890-04143
YM-04143
Timing chain tensioner bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
New 
						

							CAMSHAFTS
5-17
11. Measure:
 Valve clearance
Out of specification → Adjust.
Refer to ADJUSTING THE VALVE 
CLEARANCE on page 3-4.
12. Install:
 Pickup coil rotor cover
CRANKSHAFT POSITION SENSOR on 
page 5-37. 
						

							CYLINDER HEAD
5-18
EAS24100
CYLINDER HEAD
Removing the cylinder head
Order Job/Parts to remove Q’ty Remarks
Engine Refer to ENGINE REMOVAL on page 5-1.
Intake camshaft Refer to CAMSHAFTS on page 5-9.
Exhaust camshaft Refer to CAMSHAFTS on page 5-9.
1 Cylinder head 1
2 Cylinder head gasket 1
3Dowel pin 2
4 Coolant pipe 1
5O-ring 1
6 Water pump breather hose 1
For installation, reverse the removal proce-
dure. 
						

							CYLINDER HEAD
5-19
EAS24120
REMOVING THE CYLINDER HEAD
1. Remove:
 Intake camshaft
 Exhaust camshaft
Refer to REMOVING THE CAMSHAFTS 
on page 5-11.
2. Remove:
 Cylinder head nuts
 Cylinder head bolts
NOTE:
 Loosen the nuts in the proper sequence as 
shown.
 Loosen each nut 1/2 of a turn at a time. After 
all of the nuts are fully loosened, remove 
them.
EAS24160
CHECKING THE CYLINDER HEAD
1. Eliminate:
 Combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damag-
ing or scratching:
 Spark plug bore threads
Valve seats
2. Check:
 Cylinder head
Damage/scratches → Replace.
NOTE:
Replace the titanium valves with the cylinder 
head.
Refer to CHECKING THE VALVE SEATS 
on page 5-25.
 Cylinder head water jacket
Mineral deposits/rust → Eliminate.
3. Measure:
 Cylinder head warpage
Out of specification → Resurface the cylin-
der head.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge “1” and a thickness 
gauge “2” across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylin-
der head as follows.
d. Place a 400–600 grit wet sandpaper on the 
surface plate and resurface the cylinder 
head using a figure-eight sanding pattern.
NOTE:
To ensure an even surface, rotate the cylinder 
head several times.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24240
INSTALLING THE CYLINDER HEAD
1. Check:
 Cylinder head bolts “1”
NOTE:
Retighten the cylinder head bolts to specifica-
tion, before installing the cylinder head.
Warpage limit
0.10 mm (0.0039 in)
Cylinder head bolt
8 Nm (0.8 m·kg, 5.8 ft·lb) 
						

							CYLINDER HEAD
5-20
2. Install:
 Gasket “1” 
 Dowel pins
3. Install:
 Cylinder head
NOTE:
Pass the timing chain through the timing chain 
cavity.
4. Tighten:
 Cylinder head nuts “1” – “10”
 Cylinder head nuts “7” “10”
 Cylinder head bolts “11” “12”
NOTE:
 First, tighten the nuts “1” – “10” to approxi-
mately 10 Nm (1.0 m·kg, 7.2 ft·lb) with a 
torque wrench, and then tighten the 25 Nm 
(2.5 m·kg, 18 ft·lb).
 Retighten the nuts “1” – “10” to 40 Nm (4.0 
m·kg, 29 ft·lb) with a torque wrench.
 Final, tighten the nuts “7”, “10” to 55 Nm (5.5 
m·kg, 40 ft·lb) with a torque wrench.
 Lubricate the cylinder head nuts with engine 
oil.
 Tighten the cylinder head nuts in the proper 
tightening sequence as shown and torque 
them in four stages.
5. Install:
 Exhaust camshaft
 Intake camshaft
Refer to INSTALLING THE CAMSHAFTS 
on page 5-15.
Cylinder head nut (1st)
10 Nm (1.0 m·kg, 7.2 ft·lb)
Cylinder head nut (2nd)
25 Nm (2.5 m·kg, 18 ft·lb)
Cylinder head nut (3rd)
40 Nm (4.0 m·kg, 29 ft·lb)
Cylinder head nut (final)
55 Nm (5.5 m·kg, 40 ft·lb)
Cylinder head bolt
12 Nm (1.2 m·kg, 8.7 ft·lb)
New