Yamaha Yzf R1 2007 Manual
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CABLE ROUTING 2-44 1. Wire harness 2. Crankshaft position sensor lead 3. Bracket 4. Ignition coil lead 5. Right handlebar switch lead 6. Radiator fan motor lead 7. Heat protector 8. Right radiator fan motor lead 9. Coolant reservoir tank 10.Coolant reservoir drain hose 11.Hose clamp 12.O 2 sensor lead 13.Rear brake light switch 14.Protector 15.Right intake air duct 16.Right air outlet grille 17.Cover 18.Water hose 19.Clutch cable 20.Radiator stay guide 21.Radiator A. Clamp it after passing between the frame and radiator stay. Align the clamp position with the taping sections of right handlebar switch lead. Point the tip of the clamp (excessive part) to the front side of the vehicle. Fasten the right handlebar switch lead with a clamp. B. Pass the clutch cable through inside of the water hose. Route the radiator fan motor lead by the outside of the clutch cable after routing it by the inner side of the water hose. C. Route the coolant reservoir drain hose by the outside of the water hose after routing it by the inner side of the radiator cap mounting section. D. Check that the radiator fan motor lead is fixed with the guide of the radiator stay. E. Clamp so that the clamp top end is set along with the bottom end of the hose clamp. Point the tip of the clamp (excessive part) to the front side of the vehicle. Fasten the clutch cable with a clamp. F. Clamp so that the coolant reservoir drain hose is positioned at the front side of the vehicle by aligning the protector end part of the coolant reservoir drain hose with the radiator bottom end. Fasten the clutch cable and coolant reser- voir drain hose with a clamp. G. To the engine H. Clamp the coolant reservoir drain hose to the lower side of the vehicle. Fasten the clutch cable and coolant reser- voir drain hose with a clamp. I. 80 to 100 mm (3.15 to 3.94 in)J. Cut the clamp tip leaving 2 to 4 mm (0.08 to 0.16 in). K. Route the rear brake light switch lead by the outer side of the vehicle than the O 2 sensor lead and push it into the mating sur- face section of the clutch cover. L. Point the tip of the clamp (excessive part) to the lower front side of the vehicle. Fasten the right handlebar switch lead, radiator fan motor lead and ignition coil lead with a clamp. M. Point the tip of the clamp (excessive part) to the upper side of the vehicle. Fasten the right handlebar switch lead, radiator fan motor lead and ignition coil lead with a clamp. N. Pass the right handlebar switch lead and radiator fan motor lead between the frame and heat protector. O. Clamp so that there is no slack at the left side of the vehicle. Fasten the air induction system solenoid lead, cylinder identification sensor lead, ignition coil lead and air induction system solenoid hose with a clamp. P. The coupler for the air induction system solenoid lead and cylinder identification sensor lead should be connected above the ignition coil sub wire harness and it should not drop on the cylinder head cover behind the ignition coil. Q. Clamp the clutch cable so that it is within this specified clamp (90°). R. Route the lead to be positioned by the inner side of the vehicle than the tip of the clamp (excessive part.) S. It should not enter the inner side of the vehicle than the radiator stay guide.
CABLE ROUTING 2-46 1. Left radiator fan motor lead 2. Heat protector 3. Immobilizer lead 4. Left handlebar switch lead 5. Main switch lead 6. Bracket 7. EXUP servo motor lead 8. Cover 9. Fuel tank drain hose and fuel tank breather hose 10.Water pipe 11.Sidestand switch lead 12.Oil level switch lead 13.AC magneto lead 14.Headlight lead 15.Fuse box stay 16.Fuse box 17.Wire harness 18.Cover 19.Left air outlet grille 20.Left intake air duct 21.Water hose 22.Stay 23.Fuel tank drain hose 24.Fuel tank breather hose 25.Chain case cover 26.Intake air temperature sensor lead 27.Headlight lead and left turn signal light lead A. Clamp the leads so that they are posi- tioned inner of the vehicle than the washer position after routing them between the frame and radiator stay. Align the clamp position with the taping sections of leads. Point the tip of the clamp (excessive part) to the lower front side of the vehicle. What the clamp fastens at this stage are the handlebar switch, main switch and immobilizer leads. B. Check that the radiator fan motor lead is fixed with the guide of the radiator stay. C. Pass the main switch lead, left handlebar switch lead and immobilizer lead between the frame and the heat protector. D. To the inside of the frame E. Point the tip of the clamp (excessive part) to the lower front side of the vehicle. Fasten the left handlebar switch lead and main switch lead with a clamp. F. Fold back the clamp and secure it after passing the lead through the clamp. G. To the EXUP servo motor H. Pass the fuel tank drain hose and fuel tank breather hose through the hole of the cover from the outside of the water pipe after passing the water hose through first. Any direction of the hose cut edge can be acceptedI. 40 to 60mm (1.57 to 2.36 in) J. Route the sidestand switch lead by the inside of the water hose and water pipe. K. Route the oil level switch lead by the inside of the water hose and water pipe. L. There should be no exposure of bared con- ductors due to the displacement of the tube. M. Route by the outside of vehicle away from the water hose. N. Point the tip of the clamp (excessive part) to the front inside of the vehicle. Fasten the wire harness and left radiator fan motor lead with a clamp. O. Align the clamp position with the taping sections of headlight lead. Point the tip of the clamp (excessive part) to the rear inside of the stay. Fasten the headlight lead, intake air tem- perature sensor lead and wire harness with a clamp. P. To the intake air temperature sensor Q. Point the tip of the clamp (excessive part) to the front inside of the vehicle. Fasten the wire harness and left radiator fan motor lead with a clamp. R. Align the clamp position with the taping sections of wire harness Point the tip of the clamp (excessive part) to the inside of the vehicle. Fasten the wire harness and left radiator fan motor lead with a clamp. S. Route the water hose so that it is placed at the outermost position finally after routing other leads and hoses in the guide. T. Align the molded part of the fuel tank drain hose and fuel tank breather hose with the stay. U. Can be routed in any order.
CABLE ROUTING 2-48 1. Throttle cables 2. Rectifier/regulator 3. Rectifier/regulator lead 4. Right air outlet grille 5. Air induction system solenoid hose 6. Intake funnel servo motor lead 7. O 2 sensor lead 8. Rear brake light switch lead 9. Crankshaft position sensor lead 10.Engine ground lead 11.Battery negative lead 12.Neutral switch lead 13.Speed sensor lead 14.Oil level switch lead 15.Sidestand switch lead 16.Fuel tank drain hose 17.AC magneto lead 18.Pulley cover rib 19.Atmospheric pressure sensor 20.Immobilizer lead 21.Left air outlet grille 22.Left radiator fan motor lead 23.Cover 2 24.Wire harness 25.Throttle position sensor (for throttle valves) lead 26.Atmospheric pressure sensor lead 27.Frame 28.Locating damper 29.Throttle body 30.Connector housing A. To the right handlebar switch lead. B. Pass it so that there is no torsion through the clamp which inserted to the cover. C. To the engine D. Pass the rectifier/regulator lead through the notch hole of the cover. E. To the throttle body F. To the intake funnel servo motor G. Intake funnel servo motor lead should be routed by the front and outer side than the air induction system solenoid hose. H. Clamp the wire harness winding in and insert it to the frame hole. I. After connecting the coupler, make sure to insert it between the delivery pipe and ther- mostat. J. For routing the fuel hoses, refer to the fuel tank section. K. To the starter motor L. To the air filter case M. Point the tip of the clamp (cut the tip of the clamp leaving 2 to 4 mm (0.08 to 0.16 in).) to the inside of the vehicle. Fasten the wire harness and crankshaft position sensor lead with a clamp.N. All hoses and leads should be routed over the vehicle’s upper side above the heat protector. O. To the fuel pump P. To the speed sensor Q. Clamp the wire harness winding in and insert it to the frame hole. R. Install the leads so that the engine ground lead is positioned lower and the battery negative lead to be upper. Install the protrusion of each lead to be above the vehicle. S. It should not be positioned on the harness. T. Route it under the wire harness, speed sensor lead, O 2 sensor lead and rear brake light switch lead. U. Point the tip of the clamp (cut the tip of the clamp leaving 2 to 4 mm (0.08 to 0.16 in).) to the inside of the vehicle. Fasten the wire harness, oil level switch lead and sidestand switch lead with a clamp. V. Align the clamp position with the taping sections Point the tip of the clamp (cut the tip of the clamp leaving 2 to 4 mm (0.08 to 0.16 in).) to the upper side of the vehicle. Fasten the AC magneto lead with a clamp. W. Route the AC magneto lead by the outside of the pulley cover rib. X. Clamp the wire harness winding in and insert it to the frame hole. Y. Pass the AC magneto lead through the notch hole of the cover 2. Z. To the throttle cable lever AA.To the radiator AB.Clamp the AC magneto lead. AC.To the throttle position sensor (for throttle valves) AD.Route each lead lower than the frame plate. Leads should be routed in random order. Clamp can be inserted in any direction. AE.Route each lead higher than the frame plate, pass it to the inside of the vehicle from the hole. Leads should be routed in random order. Clamp can be inserted in any direction. AF.Fit the immobilizer lead coupler into the connector housing with its projection posi- tioned as shown in the illustration, and then install the holder onto the cover 2.
CABLE ROUTING 2-50 1. Starter relay lead 2. Starter motor lead 3. Battery positive lead 4. Lean angle sensor 5. Turn signal relay 6. Main fuse 7. Turn signal light/license plate light lead 8. Tail/brake light lead 9. Tail/brake light bracket 10.Lower tail cover 11.Seat lock cable 12.Anti safety alarm coupler 13.Starting circuit cut-off relay 14.Battery negative lead 15.Starter relay 16.Rear frame 17.Rear arm bracket 18.Wire harness 19.Battery box 1 20.Battery 21.ECU (engine control unit) 22.Cover 23.Battery box 2 24.License plate light lead 25.Turn signal light lead 26.Mud guard A. Point the tip of the clamp (excessive part) to the inner down side of the vehicle and clamp at the junction of the wire harness. Fasten the battery negative lead, wire har- ness and starter motor lead with a clamp. B. Point the tip of the clamp (excessive part) to the inside of the vehicle. Fasten the wire harness with a clamp. C. Hold down the clamp tips after passing each lead. D. Insert the leads to the rear frame hole. E. Insert the clamp from the vehicle front to the rear side and fasten each leads, cou- pler and onionhead to the tail/brake light bracket, and then point the tip of the clamp (excessive part) to the lower front side of the vehicle. F. It should be set in the rear frame not to be caught in the sheet bottom or the covers. G. Pass the battery negative lead through inside of the battery band. H. Battery negative lead should not run on the rear arm bracket. I. All leads should be positioned lower than the tail/brake light bracket.
CABLE ROUTING 2-52 1. Fuel tank 2. O-ring 3. Fuel hose 4. Fuel tank drain hose 5. Fuel tank breather hose 6. Air filter stay 7. Clip 8. Fuel tank bracket 9. Fuel hose clamp 10.Fuel pump assembly A. Install the lip of O-ring facing upward. B. Install the part pointing the white paint part of the hose to the left side of the vehicle. C. Point the clip grip to the inside of the vehi- cle. D. Fuel piping connector attachment direc- tions. (fuel pump side) Always use hands to connect/disconnect the connector without using tool. E. Insert the connector until the click sound is heard and check that the connector does not come off. Make sure that no foreign matter is caught in the sealing section. (It is prohibited to wear the cotton work gloves or equivalent coverings.) F. After item “E” mentioned above is finished, check that the clamp is inserted from the down side “a”, “b” and “c” sections are per- fectly equipped. G. This part works as a dropout stopper. H. Fuel piping connector attachment direc- tions. (engine side) Always use hands to connect/disconnect the connector without using tool. I. After Step “H” as above is finished, check that the connector is completely attached by sliding the double lock (orange part) “d” on the connector as shown in the illustra- tion and seeing if it touches firmly or not.