Yamaha Yzf R1 2007 Manual

							TRANSMISSION
5-91
EAS26350
INSTALLING THE TRANSMISSION
1. Install:
 Bearing “1”
NOTE:
Make the seal side of bearing face to the out-
side and install it close to the right end face of 
the crankcase.
Oil pipe “2”
2. Install:
 Main axle assembly “1”
 Bearing housing “2”
 Shift fork “C”
 Shift drum assembly
 Shift fork guide bar
 Shift fork guide bar retainer
NOTE:
 The embossed marks on the shift forks 
should face towards the right side of the 
engine and be in the following sequence: “R”, 
“C”, “L”.
 Carefully position the shift forks so that they 
are installed correctly into the transmission 
gears.
 Install shift fork “C” into the groove in the 3rd 
and 4th pinion gear on the main axle.3. Install:
 Shift fork “L” “1” and “R” “2” 
 Drive axle assembly “3”
 Shift fork guide bar
 Shift fork guide bar retainer “4”
NOTE:
 Install shift fork “L” into the groove in the 6th 
wheel gear and shift fork “R” into the groove 
in the 5th wheel gear on the drive axle.
 Make sure that the drive axle bearing circlip 
“a” is inserted into the grooves in the upper 
crankcase.
Bearing housing bolt
12 Nm (1.2 m·kg, 8.7 ft·lb)
LOCTITE®
Shift fork guide bar retainer bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE®
Shift fork guide bar retainer bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE® 
						

							TRANSMISSION
5-92
4. Check:
Transmission
Rough movement → Repair.
NOTE:
Oil each gear, shaft, and bearing thoroughly. 
						

							TRANSMISSION
5-93 
						

							COOLING SYSTEM
RADIATOR.................................................................................................... 6-1
CHECKING THE RADIATOR.................................................................. 6-3
INSTALLING THE RADIATOR ................................................................ 6-3
OIL COOLER ................................................................................................ 6-4
CHECKING THE OIL COOLER .............................................................. 6-5
INSTALLING THE OIL COOLER ............................................................ 6-5
THERMOSTAT .............................................................................................. 6-6
CHECKING THE THERMOSTAT ............................................................ 6-7
ASSEMBLING THE THERMOSTAT ASSEMBLY ................................... 6-8
INSTALLING THE THERMOST AT ASSEMBLY ...................................... 6-8
WAT E R  P U M P .............................................................................................. 6-9
DISASSEMBLING THE WATER  PUMP................................................ 6-10
CHECKING THE WATER PUMP .......................................................... 6-10
ASSEMBLING THE WATER PU MP...................................................... 6-10 
						

							RADIATOR
6-1
EAS26380
RADIATOR
Removing the radiator
Order Job/Parts to remove Q’ty Remarks
Rider seat Refer to GENERAL CHASSIS on page 4-1.
Side cowling Refer to GENERAL CHASSIS on page 4-1.
CoolantDrain.
Refer to CHANGING THE COOLANT on 
page 3-19.
Fuel tank Refer to FUEL TANK on page 7-1.
Air filter case Refer to GENERAL CHASSIS on page 4-1.
1 Radiator fan coupler 2 Disconnect.
2 Fuse holder stay 1
3 Coolant reservoir tank 1
4 Coolant reservoir hose 1
5 Radiator inlet hose 1
6 Oil cooler outlet hose 1
7 Radiator outlet hose 1
8 Water pump inlet pipe 1
9O-ring 1
10 Radiator 1 
						

							RADIATOR
6-2
11 Radiator fan motor 2
For installation, reverse the removal proce-
dure.
Removing the radiator
Order Job/Parts to remove Q’ty Remarks 
						

							RADIATOR
6-3
EAS26390
CHECKING THE RADIATOR
1. Check:
 Radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the 
radiator.
Damage → Repair or replace.
NOTE:
Straighten any flattened fins with a thin, flat-
head screwdriver.
2. Check:
 Radiator hoses
 Radiator pipes
Cracks/damage → Replace.
3. Measure:
 Radiator cap opening pressure
Below the specified pressure → Replace 
the radiator cap.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the radiator cap tester “1” and radia-
tor cap tester adapter “2” to the radiator 
cap “3”.b. Apply the specified pressure for ten sec-
onds and make sure there is no drop in 
pressure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
Radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to RADIATOR on page 6-1.
EAS26400
INSTALLING THE RADIATOR
1. Fill:
 Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to CHANGING THE COOLANT on 
page 3-19.
2. Check:
 Cooling system
Leaks → Repair or replace any faulty part.
Radiator cap opening pressure
108–137 kPa (15.4–19.5 psi)
(1.08–1.37 kgf/cm²)
Radiator cap tester
90890-01325
Radiator pressure tester
YU-24460-01
Radiator cap tester adapter
90890-01352
YU-33984 
						

							OIL COOLER
6-4
EAS26410
OIL COOLER
Removing the oil cooler
Order Job/Parts to remove Q’ty Remarks
Engine oilDrain.
Refer to CHANGING THE ENGINE OIL on 
page 3-11.
CoolantDrain.
Refer to CHANGING THE COOLANT on 
page 3-19.
1 Oil cooler inlet hose 1
2 Oil cooler bolt 1 Loosen.
3 Washer 1 Disconnect.
4 Oil cooler 1 Disconnect.
5O-ring 1
6 Water pump outlet pipe 1
7O-ring 1
8 Water jacket joint inlet hose 1
9O-ring 1
10 Water jacket joint 1
11 Stay 1
12 O-ring 1
For installation, reverse the removal proce-
dure. 
						

							OIL COOLER
6-5
EAS26420
CHECKING THE OIL COOLER
1. Check:
Oil cooler
Cracks/damage → Replace.
2. Check:
 Oil cooler inlet hose
 Oil cooler outlet hose
Cracks/damage/wear → Replace.
EAS26430
INSTALLING THE OIL COOLER
1. Clean:
 Mating surfaces of the oil cooler and the 
crankcase
(with a cloth dampened with lacquer thin-
ner)
2. Install:
 O-ring 
Oil cooler “1”
 Washer “2” 
 Oil cooler bolt “3”
NOTE:
 Before installing the oil cooler, lubricate the 
oil cooler bolt and O-ring with a thin coat of 
engine oil.
 Make sure the O-ring is positioned properly.
 Align the projection “a” on the oil cooler with 
the slot “b” in the crankcase.3. Fill:
 Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to CHANGING THE COOLANT on 
page 3-19.
 Crankcase
(with the specified amount of the recom-
mended engine oil)
Refer to CHANGING THE ENGINE OIL 
on page 3-11.
4. Check:
 Cooling system
Leaks → Repair or replace any faulty part.
Oil cooler
63 Nm (6.3 m·kg, 46 ft·lb)
New
New 
						

							THERMOSTAT
6-6
EAS26440
THERMOSTAT
Removing the thermostat assembly
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.
Air filter case Refer to GENERAL CHASSIS on page 4-1.
CoolantRefer to CHANGING THE COOLANT on 
page 3-19.
1 Thermostat assembly outlet hose 1
2 Thermostat assembly breather hose 1
3 Thermostat assembly 1
4 Thermostat assembly inlet hose 1
5Band 1
For installation, reverse the removal proce-
dure.