Yamaha Yzf R1 2007 Manual

							TIGHTENING TORQUES
2-13
EAS20340
ENGINE TIGHTENING TORQUES
ItemThrea
d sizeQ’ty Tightening torque Remarks
Spark plugs M10 4 13 Nm (1.3 m·kg, 9.4 ft·lb)
Cylinder head nut (2pieces) M10 2 See NOTE
Cylinder head nut (8pieces) M10 8 See NOTE
Cylinder head bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb)
Camshaft cap bolt M6 20 10 Nm (1.0 m·kg, 7.2 ft·lb)
Cylinder head cover bolt M6 6 12 Nm (1.2 m·kg, 8.7 ft·lb)
Cylinder head stud bolt (exhaust 
pipe)M8 8 15 Nm (1.5 m·kg, 11 ft·lb)
Air induction system cap bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)
Camshaft sprocket bolt M7 4 24 Nm (2.4 m·kg, 17 ft·lb)
Cylinder head and throttle body 
clampM6 7 10 Nm (1.0 m·kg, 7.2 ft·lb)
Connecting rod cap bolt (1st) M8 8 20 Nm (2.0 m·kg, 14 ft·lb)
Connecting rod cap bolt (final) M8 8 specified angle 150°
Generator rotor bolt M10 1 60 Nm (6.0 m·kg, 43 ft·lb)
Timing chain tensioner bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Water pump outlet pipe bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Water pump inlet pipe bolt (water 
pump side)M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Water pump inlet pipe bolt (front 
side)M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil/water pump drive sprocket 
boltM6 1 15 Nm (1.5 m·kg, 11 ft·lb)
Water pump bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb)
Thermostat cover nut M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Thermostat inlet pipe bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil cooler bolt M20 1 63 Nm (6.3 m·kg, 46 ft·lb)
Engine oil drain bolt M14 1 43 Nm (4.3 m·kg, 31 ft·lb)
Oil pipe bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil strainer bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil delivery pipe bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil filter union bolt M20 1 70 Nm (7.0 m·kg, 51 ft·lb)
Oil filter M20 1 17 Nm (1.7 m·kg, 12 ft·lb)
Oil pan bolt M6 14 12 Nm (1.2 m·kg, 8.7 ft·lb)
Air filter case screw M5 9 2.0 Nm (0.2 m·kg, 1.4 ft·lb)
Air filter case and funnel screw M5 2 2.5 Nm (0.25 m·kg, 1.8 ft·lb)
Throttle body and throttle body 
joint clampM5 4 3.0 Nm (0.3 m·kg, 2.2 ft·lb)
Throttle body and funnel bolt M6 6 6.0 Nm (0.6 m·kg, 4.3 ft·lb)
Throttle cable adjusting bolt M5 2 4.0 Nm (0.4 m·kg, 2.9 ft·lb)
Cylinder head and exhaust pipe 
nutM8 8 20 Nm (2.0 m·kg, 14 ft·lb)
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							TIGHTENING TORQUES
2-14
Exhaust pipe and muffler bolt M8 2 20 Nm (2.0 m·kg, 14 ft·lb)
Exhaust pipe and EXUP valve 
boltM6 5 12 Nm (1.2 m·kg, 8.7 ft·lb)
Exhaust valve pipe bracket bolt M8 1 20 Nm (2.0 m·kg, 14 ft·lb)
EXUP pulley and shaft arm nut M6 1 6.5 Nm (0.65 m·kg, 4.7 ft·lb)
EXUP valve pulley cover bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
EXUP valve and EXUP valve pipe 
bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
EXUP cable bracket bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
EXUP cable nut  M6 2 6 Nm (0.6 m·kg, 4.3
 ft·lb)

EXUP servo motor cover bolt M5 2 2 Nm (0.2 m·kg, 1.4 ft·lb)
EXUP servo motor bolt M6 2 6.0 Nm (0.6 m·kg, 4.3 ft·lb)
Catalyst pipe bracket and rear 
frame M8 1 20 Nm (2.0 m·kg, 14 ft·lb)
Catalyst pipe and EXUP valve 
pipe bolt M8 1 20 Nm (2.0 m·kg, 14 ft·lb)
Catalyst pipe and catalyst pipe 
bracket bolt M8 1 20 Nm (2.0 m·kg, 14 ft·lb)
Catalyst pipe protector M6 4 6.5 Nm (0.65 m·kg, 4.7 ft·lb)
Muffler and rear frame bolt M8 2 23 Nm (2.3 m·kg, 17 ft·lb)
Muffler protector bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)
Crankcase stud bolt M10 10 8.0 Nm (0.8 m·kg, 5.8 ft·lb)
Crankcase bolt (main journal) M9 10 See NOTE
Crankcase bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Crankcase bolt M6 8 10 Nm (1.0 m·kg, 7.2 ft·lb)
Crankcase bolt M8 1 24 Nm (2.4 m·kg, 17 ft·lb)
Crankcase bolt M8 5 24 Nm (2.4 m·kg, 17 ft·lb)
Generator rotor cover bolt M6 4 12 Nm (1.2 m·kg, 8.7 ft·lb)
Generator rotor cover bolt M8 3 22 Nm (2.2 m·kg, 16 ft·lb)
Drive sprocket cover bolt M6 3 12 Nm (1.2 m·kg, 8.7 ft·lb)
Crankcase cover bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Clutch cover bolt M6 7 12 Nm (1.2 m·kg, 8.7 ft·lb)
Clutch cover bolt M6 1 12 Nm (1.2 m·kg, 8.7 ft·lb)
Pickup rotor cover bolt M6 6 12 Nm (1.2 m·kg, 8.7 ft·lb)
Breather cover bolt M6 4 12 Nm (1.2 m·kg, 8.7 ft·lb)
Breather plate bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Plate bolt M6 1 12 Nm (1.2 m·kg, 8.7 ft·lb)
Plate bolt M6 1 12 Nm (1.2 m·kg, 8.7 ft·lb)
Pickup rotor cover blind bolt M8 1 15 Nm (1.5 m·kg, 11 ft·lb)
Oil level plug M20 1 1.5 Nm (0.15 m·kg, 1.1 ft·lb)
Generator rotor cover plug M20 1 8.0 Nm (0.8 m·kg, 5.8 ft·lb)
Main gallery plug (oil return) M16 3 8.0 Nm (0.8 m·kg, 5.8 ft·lb)
Main gallery plug  M20 1 8.0  Nm (0.8 m·kg, 5.8 ft·lb)
Item
Threa
d size Q’ty Tightening torque Remarks
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							TIGHTENING TORQUES
2-15
NOTE:
 Cylinder head nut (2 pieces)
1. First, tighten the bolts to 10 Nm (1.0 m·kg, 7.2 ft·lb) with a torque wrench following the tighten-
ing order.
2. Second, tighten the bolts to 25 Nm (2.5 m·kg, 18 ft·lb) with a torque wrench following the tight-
ening order.
3. Third, tighten the bolts to 40 Nm (4.0 m·kg, 29 ft·lb) with a torque wrench following the tighten-
ing order.
4. Final, tighten the bolts to 55 Nm (5.5 m·kg, 40 ft·lb) with a torque wrench following the tighten-
ing order.
 Cylinder head nut (8 pieces)
1. First, tighten the bolts to 10 Nm (1.0 m·kg, 7.2 ft·lb) with a torque wrench following the tighten-
ing order.
2. Second, tighten the bolts to 25 Nm (2.5 m·kg, 18 ft·lb) with a torque wrench following the tight-
ening order. Oil return pipe bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil return plug M12 2 24 Nm (2.4 m·kg, 17 ft·lb)
AC magneto lead bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Stator coil screw M6 3 14 Nm (1.4 m·kg, 10 ft·lb)
Generator rotor cover screw M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Thermostat assembly stay bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Starter clutch idler gear bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Clutch boss nut M20 1 115 Nm (11.5 m·kg, 83 ft·lb)
Use a lock 
washer
Clutch spring bolt M6 6 10 Nm (1.0 m·kg, 7.2 ft·lb)
Drive sprocket nut M22 1 85 Nm (8.5 m·kg, 61 ft·lb)
Use a lock 
washer
Bearing plate bolt M6 3 12 Nm (1.2 m·kg, 8.7 ft·lb)
Shift bar stopper plate bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Stopper screw M8 1 22 Nm (2.2 m·kg, 16 ft·lb)
Shift rod nut M6 1 6.5 Nm (0.65 m·kg, 4.7 ft·lb)Left 
thread
Shift rod nut M6 1 6.5 Nm (0.65 m·kg, 4.7 ft·lb)
Joint rod bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Shift arm bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Neutral switch M10 1 20 Nm (2.0 m·kg, 14 ft·lb)
Coolant temperature sensor  M12 1 18 Nm (1.8 m·kg, 13 ft·lb)
Cylinder identification sensor bolt M6 1 8.0 Nm (0.8 m·kg, 5.8 ft·lb)
Atmospheric pressure sensor 
screwM5 2 7.0 Nm (0.7 m·kg, 5.0 ft·lb)
Crankshaft position sensor bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil level switch bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)ItemThrea
d sizeQ’ty Tightening torque Remarks
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							TIGHTENING TORQUES
2-16
3. Final, tighten the bolts to 40 Nm (4.0 m·kg, 29 ft·lb) with a torque wrench following the tighten-
ing order.
 Crankcase bolt (main journal)
1. First, tighten the bolts to approximately 20 Nm (2.0 m·kg, 14 ft·lb) with a torque wrench follow-
ing the tightening order.
2. Loosen all the bolts one by one following the tightening order and then tighten them to 20 Nm 
(2.7 m·kg, 14 ft·lb) again.
3. Retighten the bolts further to reach the specified angle (56-61°).
Cylinder head tightening sequence:
Crankcase tightening sequence: 
						

							TIGHTENING TORQUES
2-17
EAS20350
CHASSIS TIGHTENING TORQUES
ItemThrea
d sizeQ’ty Tightening torque Remarks
Upper bracket pinch bolt M8 2 26 Nm (2.6 m·kg, 19 ft·lb)
Steering stem nut M28 1 113 Nm (11.3 m·kg, 82 ft·lb)
Handlebar pinch bolt M8 2 17 Nm (1.7m·kg, 12 ft·lb)
Handlebar bolt M6 2 13 Nm (1.3 m·kg, 9.4 ft·lb)
Cap bolt M46 2 23 Nm (2.3 m·kg, 17 ft·lb)
Lower ring nut M30 2 See NOTE
Lower bracket pinch bolt M8 4 23 Nm (2.3 m·kg, 17 ft·lb)
Brake master cylinder reservoir 
cap screwM4 1 1.2 Nm (0.12 m·kg, 0.9 ft·lb)
Front brake hose union bolt M10 3 30 Nm (3.0 m·kg, 22 ft·lb)
Front brake master cylinder 
holder boltM6 2 13 Nm (1.3 m·kg, 9.4 ft·lb)
Meter assembly and cowling stay 
screw– 3 1.3 Nm (0.13 m·kg, 0.9 ft·lb)
Headlight and cowling stay screw – 6 0.8 Nm (0.08 m·kg, 0.6 ft·lb)
Front cowling and headlight screw – 5 1.5 Nm (0.15 m·kg, 1.1 ft·lb)
Side cowling bracket and frame 
boltM6 2 5.0 Nm (0.5 m·kg, 3.6 ft·lb)
Under cowling and engine bolt M6 3 5.0 Nm (0.5 m·kg, 3.6 ft·lb)
Rear view mirror nut M6 4 7.0 Nm (0.7 m·kg, 5.1 ft·lb)
Front cowling and intake air duct 
panel screwM5 2 1.3 Nm (0.13 m·kg, 0.9 ft·lb)
Grip end bolt M6 2 4.0 Nm (0.4 m·kg, 2.9 ft·lb)
Horn bracket bolt M6 2 11 Nm (1.1 m·kg, 8.0 ft·lb)
Coolant reservoir bolt M6 2 5.0 Nm (0.5 m·kg, 3.6 ft·lb)
Left front engine mounting bolt M10 1 45 Nm (4.5 m·kg, 33 ft·lb)
Right front engine mounting bolt M10 1 45 Nm (4.5 m·kg, 33 ft·lb)
Engine mount self locking nut 
(upper)M10 1 51 Nm (5.1 m·kg, 37 ft·lb)See 
NOTE
Engine mount self locking nut 
(lower)M10 1 51 Nm (5.1 m·kg, 37 ft·lb)See 
NOTE
Engine mounting adjust bolt 
(upper)M16 1 7.0 Nm (0.7 m·kg, 5.1 ft·lb)See 
NOTE
Engine mounting adjust bolt 
(lower)M16 1 7.0 Nm (0.7 m·kg, 5.1 ft·lb)See 
NOTE
Clutch cable locknut (engine side) M8 1 7.0 Nm (0.7 m·kg, 5.1 ft·lb)
Main frame and rear frame boltM10 4 50 Nm (5.0 m·kg, 36 ft·lb)See 
NOTE
Pivot shaft M30 1 7.0 Nm (0.7 m·kg, 5.1 ft·lb)
Pivot shaft ring nut M30 1 65 Nm (6.5 m·kg, 47 ft·lb)
Pivot shaft nut M20 1 105 Nm (10.5 m·kg, 76 ft·lb)
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							TIGHTENING TORQUES
2-18
NOTE:
 Lower ring nut
1. First, tighten the lower ring nut approximately 52 Nm (5.2 m·kg, 38 ft·lb) by using the torque 
wrench, then loosen the ring nut completely.
2. Retighten the lower ring nut 18 Nm (1.8 m·kg, 13 ft·lb). Connecting arm nut (connecting 
arm and frame)M10 1 44 Nm (4.4 m·kg, 32 ft·lb)
Relay arm nut (relay arm and 
connecting arm)M10 1 44 Nm (4.4 m·kg, 32 ft·lb)
Relay arm nut (relay arm and 
swingarm)M10 1 44 Nm (4.4 m·kg, 32 ft·lb)
Rear shock absorber assembly 
lower nutM10 1 44 Nm (4.4 m·kg, 32 ft·lb)
Rear shock absorber upper 
bracket nutM10 1 44 Nm (4.4 m·kg, 32 ft·lb)
Rear shock absorber assembly 
upper nutM10 1 92 Nm (9.2 m·kg, 67 ft·lb)
Drive chain guard bolt M6 2 7.0 Nm (0.7 m·kg, 5.1 ft·lb)
Drive chain guide bolt M6 1 13 Nm (1.3 m·kg, 9.4 ft·lb)
Drive chain adjusting locknut M8 2 16 Nm (1.6 m·kg, 12 ft·lb)
Fuel pump bolt M5 6 4.0 Nm (0.4 m·kg, 2.9 ft·lb)
Fuel tank bolt (front) M6 1 7.0 Nm (0.7 m·kg, 5.1 ft·lb)
Fuel tank bracket bolt M6 2 7.0 Nm (0.7 m·kg, 5.1 ft·lb)
Fuel tank bolt (rear) M6 4 7.0 Nm (0.7 m·kg, 5.1 ft·lb)
Fuel tank side cover screw M5 2 4.0 Nm (0.4 m·kg, 2.9 ft·lb)
Rider seat bolt M6 2 7.0 Nm (0.7 m·kg, 5.1 ft·lb)
Seat lock assembly bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Upper tail cover bolt M5 1 4.0 Nm (0.4 m·kg, 2.9 ft·lb)
Battery box bolt M6 2 7.0 Nm (0.7 m·kg, 5.1 ft·lb)
Lean angle sensor bolt M4 2 2.0 Nm (0.2 m·kg, 1.4 ft·lb)
Footrest bracket bolt M8 4 28 Nm (2.8 m·kg, 20 ft·lb)
Rear brake master cylinder bolt M8 2 23 Nm (2.3 m·kg, 17 ft·lb)
Rear brake hose union bolt M10 230 Nm (3.0 m·kg, 22 ft·lb)
Sidestand and bracket nut M10 1 61 Nm (6.1 m·kg, 44 ft·lb)
Sidestand bracket and frame bolt M10 2 63 Nm (6.3 m·kg, 46 ft·lb)
Front wheel axle bolt M14 1 91 Nm (9.1 m·kg, 66 ft·lb)
Rear wheel axle nut M24 1 150 Nm (15.0 m·kg, 108 ft·lb)
Front brake caliper bolt M10 4 35 Nm (3.5 m·kg, 25 ft·lb)
Front brake disc bolt M6 10 18 Nm (1.8 m·kg, 13 ft·lb)
Rear brake disc bolt M8 5 30 Nm (3.0 m·kg, 22 ft·lb)
Rear wheel sprocket nut M10 6 100 Nm (10.0 m·kg, 72 ft·lb)
Brake caliper bleed screw M8 3 6.0 Nm (0.6 m·kg, 4.3 ft·lb)
Front wheel axle pinch bolt M8 4 21 Nm (2.1 m·kg, 15 ft·lb)See 
NOTE ItemThrea
d sizeQ’ty Tightening torque Remarks
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							TIGHTENING TORQUES
2-19
 Engine mounting adjust bolt and engine mount self locking nut
Refer to INSTALLING THE ENGINE on page 5-7.
 Front wheel axle pinch bolt
1. Insert the front wheel axle from the right side and tighten it with the flange bolt from the left 
side to 91 Nm (9.1 m·kg, 65.8 ft·lb).
2. In the order from the pinch bolt “2” → pinch bolt “1” → pinch bolt “2”, tighten each bolt to 21 Nm 
(2.1 m·kg, 15 ft·lb) without performing temporary tightening.
3. Check that the end face of the axle head and the end face of the fork side are flush-mounted.
If they are out of alignment, make sure to fit them by adding the external force by hand or with 
a plastic hammer, etc.
If the end face of the axle is not parallel to the end face of the fork, align them so that one point 
of the axle circumference is positioned on the end face of the fork.
At this stage, it can be accepted if the end face of the axle becomes partially concave to the 
end face of the fork.
4. In the order from the pinch bolt “4” → pinch bolt “3” → pinch bolt “4”, tighten each bolt to 21 Nm 
(2.1 m·kg, 15 ft·lb) without performing temporary tightening.
 Main frame and rear frame bolt
1. Check the clearance between rear frame and main frame by thickness gauge “1”.
Insert adjusting shim(s) to eliminate the gap according to the chart as shown below.
Shim: 0.5 mm (0.02 in)
Thickness Shim(s)
Under 0.5 mm 
(Under 0.01969 in)NONE
0.51–1.0 mm 
(0.02008–0.03937 in)One shim on the left side
1.01–1.5 mm 
(0.03976–0.05906 in)Two shims on the left side
1.51–2.0 mm 
(0.05945–0.07874 in)Three shims on the left side
2.01–2.5 mm 
(0.07913–0.09843 in)Three shims on the left side and one shim on the right side
2.51–3.0 mm 
(0.09882–0.11811 in)Three shims on the left side and two shims on the right side 
						

							LUBRICATION POINTS AND LUBRICANT TYPES
2-20
EAS20360
LUBRICATION POINTS AND LUBRICANT TYPES
EAS20370
ENGINE
EAS20380
CHASSISLubrication point Lubricant
Oil seal lips
O-rings
Bearings
Crankshaft pins
Piston surfaces
Piston pins
Connecting rod bolts
Crankshaft journals
Camshaft lobes
Camshaft journals
Valve stems (intake and exhaust)
Valve stem ends (intake and exhaust)
Water pump impeller shaft
Oil pump rotors (inner and outer)
Oil pump housing
Oil strainer
Clutch (pull rod)
Starter clutch idle gear inner surface
Starter clutch assembly
Primary driven gear
Transmission gears (wheel and pinion)
Main axle and drive axle
Shift drum
Shift forks and shift fork guide bars
Cylinder head cover mating surfaceYamaha bond No. 
1215
Cylinder head cover semicircularYamaha bond No. 
1215
Crankcase mating surfaceYamaha bond No. 
1215
Crankcase cover mating surfaceYamaha bond No. 
1215
Generator rotor cover (stator coil assembly lead grommet)Yamaha bond No. 
1215
Lubrication point Lubricant
Steering bearings and bearing races (upper and lower)
Throttle grip inner surface
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							LUBRICATION POINTS AND LUBRICANT TYPES
2-21
Brake lever pivoting point and metal-to-metal moving parts
Clutch lever pivoting point and metal-to-metal moving parts
Engine mount bolts (rear upper and lower)
Relay arm, connecting rod and rear shock absorber collar
Pivot shaft
Swingarm pivot bearing
Swingarm head pipe end, oil seal and bush
Oil seal (relay arm, connecting arm and rear shock absorber)
Seat lock assembly moving parts
Sidestand pivoting pint and metal-to-metal moving parts
Link and sidestand switch contact point
Sidestand hook and spring
Shift shaft joint
Front wheel oil seal (right and left)
Front axle shaft
Rear wheel oil seal
Rear wheel drive hub oil seal
Rear wheel drive hub mating surfaceLubrication point LubricantLS
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							LUBRICATION POINTS AND LUBRICANT TYPES
2-22