Yamaha Yzf R1 2007 Manual
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THERMOSTAT 6-7 EAS26450 CHECKING THE THERMOSTAT 1. Check: Thermostat Does not open at 71–85°C (160–185°F) → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Suspend the thermostat “1” in a container “2” filled with water. b. Slowly heat the water “3”. c. Place a thermometer “4” in the water.d. While stirring the water, observe the ther- mostat and thermometer’s indicated tem- perature. Disassembling the thermostat assembly Order Job/Parts to remove Q’ty Remarks 1 Thermostat housing cover 1 2 Thermostat 1 3 Thermostat housing 1 4O-ring 1 For assembly, reverse the disassembly pro- cedure.
THERMOSTAT 6-8 NOTE: If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause seri- ous overheating or over cooling. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: Thermostat housing cover “1” Thermostat housing “2” Cracks/damage → Replace. EAS26460 ASSEMBLING THE THERMOSTAT ASSEM- BLY 1. Install: Thermostat housing “1” Thermostat “2” O-ring “3” Thermostat housing cover “4” NOTE: Install the thermostat with its breather hole “a” facing up. EAS26480 INSTALLING THE THERMOSTAT ASSEM- BLY 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. A. Fully closed B. Fully open Thermostat housing cover nut 10 Nm (1.0 m·kg, 7.2 ft·lb) New
WATER PUMP 6-9 EAS26500 WAT E R P U M P Disassembling the water pump Order Job/Parts to remove Q’ty Remarks Oil/water pump assembly Refer to OIL PUMP on page 5-57. Oil pump rotor Refer to OIL PUMP on page 5-57. 1 Water pump cover 1 2O-ring 1 3Pin 2 4 Impeller shaft (along with the impeller) 1 5 Water pump seal 1 6 Oil seal 1 7 Bearing 1 8O-ring 1 For installation, reverse the removal proce- dure.
WATER PUMP 6-10 EAS26520 DISASSEMBLING THE WATER PUMP 1. Remove: Water pump seal “1” Water pump housing “2” NOTE: Tap out the bearing and oil seal from the out- side of the water pump housing. 2. Remove: Oil seal “1” Bearing “2” Water pump housing “3” NOTE: Tap out the bearing and oil seal from the out- side of the water pump housing. 3. Remove: Rubber damper holder “1” Rubber damper “2” (from the impeller, with a thin, flat-head screwdriver) NOTE: Do not scratch the impeller shaft. EAS26540 CHECKING THE WATER PUMP 1. Check: Water pump housing cover “1” Water pump housing “2” Impeller shaft “3” Rubber damper “4” Rubber damper holder “5” Water pump seals Oil seal Cracks/damage/wear → Replace. 2. Check: Bearing Rough movement → Replace. 3. Check: Water pump outlet pipe Radiator outlet hose Cracks/damage/wear → Replace. EAS26560 ASSEMBLING THE WATER PUMP 1. Install: Oil seal “1” (into the water pump housing “2”) NOTE: Before installing the oil seal, apply tap water or coolant onto its out surface. Install the oil seal with a socket that matches its outside diameter. New
WATER PUMP 6-11 2. Install: Water pump seal “1” CAUTION: ECA14080 Never lubricate the water pump seal sur- face with oil or grease. NOTE: Install the water pump seal with the special tools. Before installing the water pump seal, apply Yamaha bond No. 1215 (Three bond No. 1215®) “2” to the water pump housing “3”.3. Install: Rubber damper holder “1” Rubber damper “2” NOTE: Before installing the rubber damper, apply tap water or coolant onto its outer surface. 4. Measure: Impeller shaft tilt Out of specification → Repeat steps (3) and (4). CAUTION: ECA14090 Make sure the rubber damper and rubber damper holder are flush with the impeller. a. 17.2 mm (0.68 in) Mechanical seal installer 90890-04078 Water pump seal installer YM-33221-A Middle driven shaft bearing driver 90890-04058 Bearing driver 40 mm YM-04058 Yamaha bond No. 1215 (Three bond No. 1215®) 90890-85505 A. Push down 4. Mechanical seal installer 5. Middle driven shaft bearing driver New Impeller shaft tilt limit 0.15 mm (0.006 in) 1. Straightedge 2. Impeller New New
FUEL SYSTEM FUEL TANK.................................................................................................. 7-1 REMOVING THE FUEL TANK ................................................................ 7-2 REMOVING THE FUEL PUMP............................................................... 7-2 CHECKING THE FUEL PUMP BODY .................................................... 7-2 CHECKING THE FUEL PUMP OPERATION ......................................... 7-2 INSTALLING THE FUEL PUMP.............................................................. 7-2 INSTALLING THE FUEL TANK ............................................................... 7-3 THROTTLE BODIES ..................................................................................... 7-4 CHECKING THE INJECTORS ............................................................... 7-6 CHECKING THE THROTTLE BODIES .................................................. 7-6 CHECKING THE FUEL PRESSURE ...................................................... 7-6 ADJUSTING THE THROTTLE POSITION SENSOR (FOR THROTTLE VALVES) .................................................................... 7-6 ADJUSTING THE THROTTLE POSITION SENSOR (FOR THROTTLE CABLE PULLEY)....................................................... 7-7 AIR INDUCTION SYSTEM ........................................................................... 7-9 CHECKING THE AIR INDUCTION SYSTEM ....................................... 7-10
FUEL TANK 7-1 EAS26620 FUEL TANK Removing the fuel tank 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. 1 Fuel tank side cover 2 2 Fuel sender coupler 1 3 Fuel pump coupler 1 4 Fuel tank drain hose 1 5 Fuel tank breather hose 1 6 Fuel hose connector 1 7 Fuel hose 1 8Fuel tank 1 9 Fuel tank top cover 1 10 Fuel pump 1 For installation, reverse the removal proce- dure.
FUEL TANK 7-2 EAS26630 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: Fuel hose connector cover Fuel hose Fuel sender coupler Fuel pump coupler Fuel tank drain hose Fuel tank breather hose Fuel tank side cover CAUTION: ECA4C81002 Be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools. Although the fuel has been removed from the fuel tank be careful when removing the fuel hoses, since there may be fuel remaining in it. NOTE: To remove the fuel hose from the fuel injec- tion pipe, slide the cover “a” on the end of the hose in the direction of the arrow shown and then remove the hose. Before removing the hoses, place a few rags in the area under where it will be removed. 3. Remove: Fuel tank NOTE: Do not set the fuel tank down so that the instal- lation surface of the fuel pump is directly under the tank. Be sure to lean the fuel tank in an upright position. EAS26640 REMOVING THE FUEL PUMP 1. Remove: Fuel pump CAUTION: ECA14720 Do not drop the fuel pump or give it a strong shock. Do not touch the base section of the fuel sender. EAS26670 CHECKING THE FUEL PUMP BODY 1. Check: Fuel pump body Obstruction → Clean. Cracks/damage → Replace the fuel pump assembly. 2. Check: Diaphragms and gaskets Turn/fatigue/cracks → Replace the fuel pump assembly. EAS26690 CHECKING THE FUEL PUMP OPERATION 1. Check: Fuel pump operation Refer to CHECKING THE FUEL PRES- SURE on page 7-6. EAS26710 INSTALLING THE FUEL PUMP 1. Install: Fuel pump NOTE: Do not damage the installation surface of the fuel tank when installing the fuel pump. Always use a new fuel pump gasket. Install the fuel pump as shown in the illustra- tion. Align the projection “a” on the fuel pump with the slot in the fuel pump bracket. Tighten the fuel pump bolts in stages in a crisscross pattern and to the specified torque. Fuel pump bolt 4 Nm (0.4 m·kg, 2.9 ft·lb)
FUEL TANK 7-3 EAS4C81002 INSTALLING THE FUEL TANK 1. Install: Fuel hose Fuel hose connector cover CAUTION: ECA14740 When installing the fuel hose, make sure that it is securely connected, and that the fuel hose holders are in the correct posi- tion, otherwise the fuel hose will not be properly installed. NOTE: Install the fuel hose connector securely onto the fuel tank until a distinct “click” is heard, and then make sure that it does not come loose. To install the fuel hose from the fuel injection hose, slide the cover “a” on the end of the hose in the direction of arrow shown. 2. Install: Fuel sender coupler Fuel pump coupler Fuel tank breather hose Fuel tank drain hose Fuel tank side cover NOTE: There is white paint mark on the fuel tank breather hose. Refer to CABLE ROUTING on page 2-39.
THROTTLE BODIES 7-4 EAS26970 THROTTLE BODIES Removing the throttle bodies 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. 1 Sub-wire harness coupler 1 Disconnect. 2 Coolant temperature sensor coupler 1 Disconnect. 3 Throttle servo motor coupler 1 Disconnect. 4Throttle position sensor (for throttle valves) cou- pler1 Disconnect. 5Throttle position sensor (for throttle cable pulley) coupler1 Disconnect. 6 Throttle body joint clamp 4 Loosen. 7 Throttle cables 2 Disconnect. 8 Throttle bodies 1 9 Throttle body joint 3 10 Engine ground 2 11 Heat protector 1 12 Fuel hose 1 For installation, reverse the removal proce- dure.