Yamaha Yzf R1 2007 Manual

							VALVES AND VALVE SPRINGS
5-21
EAS24270
VALVES AND VALVE SPRINGS
Removing the valves and valve springs
Order Job/Parts to remove Q’ty Remarks
Cylinder head Refer to CYLINDER HEAD on page 5-18.
1 Intake valve lifter 8
2 Intake valve pad 8
3 Intake valve cotter 16
4 Intake valve upper spring seat 8
5 Intake valve spring 8
6 Intake valve oil seal 8
7 Intake valve lower spring seat 8
8 Intake valve 8
9 Intake valve guide 8
10 Exhaust valve lifter 8
11 Exhaust valve pad 8
12 Exhaust valve cotter 16
13 Exhaust valve upper spring seat 8
14 Exhaust valve spring 8
15 Exhaust valve oil seal 8
16 Exhaust valve lower spring seat 8
17 Exhaust valve 8
18 Exhaust valve guide 8 
						

							VALVES AND VALVE SPRINGS
5-22
For installation, reverse the removal proce-
dure.
Removing the valves and valve springs
Order Job/Parts to remove Q’ty Remarks 
						

							VALVES AND VALVE SPRINGS
5-23
EAS24280
REMOVING THE VALVES
The following procedure applies to all of the 
valves and related components.
NOTE:
Before removing the internal parts of the cylin-
der head (e.g., valves, valve springs, valve 
seats), make sure the valves properly seal.
1. Remove:
 Valve lifter “1”
 Valve pad “2”
NOTE:
Make a note of the position of each valve lifter 
and valve pad so that they can be reinstalled in 
their original place.
2. Check:
 Valve sealing
Leakage at the valve seat → Check the 
valve face, valve seat, and valve seat width.
Refer to CHECKING THE VALVE SEATS 
on page 5-25.
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a. Pour a clean solvent “a” into the intake and 
exhaust ports.
b. Check that the valves properly seal.
NOTE:
There should be no leakage at the valve seat 
“1”.
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3. Remove: Valve cotters “1”
NOTE:
Remove the valve cotters by compressing the 
valve spring with the valve spring compressor 
“2” and the valve spring compressor attach-
ment “3”.
4. Remove:
 Upper spring seat “1”
 Valve spring “2”
 Valve stem seal “3”
 Lower spring seat “4”
Valve “5”
NOTE:
Identify the position of each part very carefully 
so that it can be reinstalled in its original place.
EAS24290
CHECKING THE VALVES AND VALVE 
GUIDES
The following procedure applies to all of the 
valves and valve guides.
1. Measure:
Valve spring compressor
90890-04019
YM-04019
Valve spring compressor 
attachment
90890-04108
Valve spring compressor 
adapter 22 mm
YM-04108 
						

							VALVES AND VALVE SPRINGS
5-24
 Valve-stem-to-valve-guide clearance
Out of specification → Replace the valve 
guide.
2. Replace:
 Valve guide
NOTE:
To ease valve guide removal and installation, 
and to maintain the correct fit, heat the cylinder 
head to 100°C (212°F) in an oven.
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a. Remove the valve guide with the valve 
guide remover “1”.b. Install the new valve guide with the valve 
guide installer “2” and valve guide remover 
“1”.
c. After installing the valve guide, bore the 
valve guide with the valve guide reamer “3” 
to obtain the proper valve-stem-to-valve-
guide clearance.
NOTE:
After replacing the valve guide, reface the 
valve seat.  Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” -
Valve stem diameter “b”
Valve-stem-to-valve-guide clear-
ance
Valve-stem-to-valve-guide clear-
ance (intake)
0.010–0.037 mm (0.0004–
0.0015 in)
Limit
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear-
ance (exhaust)
0.025–0.052 mm (0.0010–
0.0020 in)
Limit
0.100 mm (0.0039 in) 
						

							VALVES AND VALVE SPRINGS
5-25
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3. Eliminate:
 Carbon deposits
(from the valve face and valve seat)
4. Check:
Valve face
Pitting/wear → Grind the valve face.
 Valve stem end
Mushroom shape or diameter larger than 
the body of the valve stem → Replace the 
valve.
5. Measure:
 Valve margin thickness “a”
Out of specification → Replace the valve.6. Measure:
 Valve stem runout
Out of specification → Replace the valve.
NOTE:
 When installing a new valve, always replace 
the valve guide.
 If the valve is removed or replaced, always 
replace the oil seal.
EAS24300
CHECKING THE VALVE SEATS
The following procedure applies to all of the 
valves and valve seats.
1. Eliminate:
 Carbon deposits
(from the valve face and valve seat)
2. Check:
Valve seat
Pitting/wear → Replace the cylinder head.
3. Measure:
 Valve seat width “a”
Out of specification → Replace the cylinder 
head.
Valve guide remover (ø4.5)
90890-04116
Valve guide remover (4.5 mm)
YM-04116
Valve guide remover (ø5)
90890-04097
Valve guide remover (5.0 mm)
YM-04097
Valve guide installer (ø4.5)
90890-04117
Valve guide installer (4.5 mm)
YM-04117
Valve guide installer (ø5)
90890-04098
Valve guide installer (5.0 mm)
YM-04098
Valve guide reamer (ø4.5)
90890-04118
Valve guide reamer (4.5 mm)
YM-04118
Valve guide reamer (ø5)
90890-04099
Valve guide reamer (5.0 mm)
YM-04099
Valve margin thickness
Valve margin thickness D
(intake)
1.10–1.50 mm (0.0433–0.0591
in)
Valve margin thickness D
(exhaust)
0.50–0.90 mm (0.0197–0.0354
in)
Valve stem runout
0.010 mm (0.0004 in) 
						

							VALVES AND VALVE SPRINGS
5-26
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a. Apply Mechanic’s blueing dye (Dykem) “b” 
onto the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide 
and onto the valve seat to make a clear 
impression.
d. Measure the valve seat width.
NOTE:
Where the valve seat and valve face contacted 
one another, the blueing will have been 
removed.
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4. Lap:
Valve face
 Valve seat
NOTE:
After replacing the cylinder head or replacing 
the valve and valve guide, the valve seat and 
valve face should be lapped.
CAUTION:
ECA4C81012
This model uses titanium intake valves. 
Titanium valves that have been used to lap 
the valve seats must not be used. Always 
replace lapped valves with new valves.
NOTE:
 When replacing the cylinder head, replace 
the valves without lapping the valve seats 
and valve faces.
 When replacing the valves or valves guides, 
use new valves to lap the valve seats, and 
then replace them with new valves.
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a. Apply a coarse lapping compound “a” to 
the valve face.
CAUTION:
ECA13790
Do not let the lapping compound enter the 
gap between the valve stem and the valve 
guide.
b. Apply molybdenum disulfide oil onto the 
valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve 
seat are evenly polished, then clean off all 
of the lapping compound.
NOTE:
For the best lapping results, lightly tap the 
valve seat while rotating the valve back and 
forth between your hands.
Valve seat width
Valve seat width C (intake)
0.90–1.10 mm (0.0354–0.0433
in)
Valve seat width C (exhaust)
0.90–1.10 mm (0.0354–0.0433
in) 
						

							VALVES AND VALVE SPRINGS
5-27
e. Apply a fine lapping compound to the valve 
face and repeat the above steps.
f. After every lapping procedure, be sure to 
clean off all of the lapping compound from 
the valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) “b” 
onto the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide 
and onto the valve seat to make a clear 
impression.
j. Measure the valve seat width “c” again. If 
the valve seat width is out of specification, 
reface and lap the valve seat.
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EAS24310
CHECKING THE VALVE SPRINGS
The following procedure applies to all of the 
valve springs.
1. Measure:
 Valve spring free length “a”
Out of specification → Replace the valve 
spring.2. Measure:
 Compressed valve spring force “a”
Out of specification → Replace the valve 
spring.
3. Measure:
 Valve spring tilt “a”
Out of specification → Replace the valve 
spring.
Valve spring free length
Free length (intake)
39.79 mm (1.57 in)
Limit
37.80 mm (1.49 in)
Free length (exhaust)
38.42 mm (1.51 in)
Limit
36.50 mm (1.44 in)
Installed compression spring
force (intake)
171–197 N (38.44–44.29 lbf)
(17.44–20.09 kgf) at 35.50 mm
(1.398 in)
Installed compression spring
force (exhaust)
202–232 N (45.41–52.15 lbf)
(20.60–23.66 kgf) at 33.00 mm
(1.299 in)
b. Installed length 
						

							VALVES AND VALVE SPRINGS
5-28
EAS24320
CHECKING THE VALVE LIFTERS
The following procedure applies to all of the 
valve lifters.
1. Check:
 Valve lifter
Damage/scratches → Replace the valve 
lifters and cylinder head.
EAS24340
INSTALLING THE VALVES
The following procedure applies to all of the 
valves and related components.
1. Deburr:
 Valve stem end
(with an oil stone)
2. Lubricate:
 Valve stem “1” Valve stem seal “2”
(with the recommended lubricant)
3. Install:
Valve “1”
 Lower spring seat “2”
 Valve stem seal “3”
 Valve spring “4”
 Upper spring seat “5”
(into the cylinder head)
NOTE:
 Make sure each valve is installed in its origi-
nal place. Refer to the following embossed 
marks.
Intake valve: Pink paint mark
Exhaust valve: “4C8”
 Install the valve springs with the larger pitch 
“a” facing up.
4. Install:
 Valve cotters “1”
NOTE:
Install the valve cotters by compressing the 
valve spring with the valve spring compressor 
“2” and the valve spring compressor attach-
ment “3”.
Spring tilt limit
Spring tilt (intake)
2.5 °/1.7 mm
Spring tilt (exhaust)
2.5 °/1.7 mm
Recommended lubricant
Molybdenum disulfide oil
b. Smaller pitch 
						

							VALVES AND VALVE SPRINGS
5-29
5. To secure the valve cotters “1” onto the 
valve stem, lightly tap the valve tip with a 
soft-face hammer.
CAUTION:
ECA13800
Hitting the valve tip with excessive force 
could damage the valve.
6. Lubricate:
 Valve pad “1”
 Valve lifter “2”
(with the recommended lubricant)
7. Install:
 Valve pad
 Valve lifter
NOTE:
 The valve lifter must move smoothly when 
rotated with a finger.
 Each valve lifter and valve pad must be rein-
stalled in its original position.
Valve spring compressor
90890-04019
YM-04019
Valve spring compressor 
attachment
90890-04108
Valve spring compressor 
adapter 22 mm
YM-04108
Recommended lubricant
Molybdenum disulfide oil 
						

							GENERATOR
5-30
EAS24480
GENERATOR
Removing the generator
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.
Side cowlings Refer to GENERAL CHASSIS on page 4-1.
Lower cowlings Refer to GENERAL CHASSIS on page 4-1.
Engine oilDrain.
Refer to CHANGING THE ENGINE OIL on 
page 3-11.
1 Stator coil assembly coupler 1 Disconnect.
2Plug 1
3 Generator rotor cover 1
4Gasket 1
5Dowel pin 2
6 Generator rotor assembly 1
7 Stator coil assembly 1
8Dowel pin 2
9 Bearing housing 1
10 Collar 1
11 Bearing 1