Yamaha Yzf R1 2007 Manual
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PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE......................................................................... 3-1 INTRODUCTION ........................... ......................................................... 3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM............................................................................... 3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ..................... 3-1 ENGINE ......................................................................................................... 3-4 ADJUSTING THE VALVE CLEARANCE ................................................ 3-4 SYNCHRONIZING THE THROTTLE BODIES ....................................... 3-7 ADJUSTING THE THROTTLE CABLE FREE PLAY .............................. 3-8 CHECKING THE SPARK PLUGS ........................................................... 3-9 MEASURING THE COMPRESSION PRESSURE ............................... 3-10 CHECKING THE ENGINE OI L LEVEL ................................................. 3-11 CHANGING THE ENGINE OIL............................................................. 3-11 MEASURING THE ENGINE OI L PRESSURE ..................................... 3-13 ADJUSTING THE CLUTCH CABLE FREE PLAY ................................ 3-14 REPLACING THE AIR FILTER ELEMENT ........................................... 3-14 CHECKING THE THROTTLE BODY JOINTS ...................................... 3-15 CHECKING THE FUEL LINE ............................................................... 3-15 CHECKING THE CRANKCASE BREATHER HOSE ............................ 3-16 CHECKING THE EXHAUST SYSTEM ................................................. 3-16 ADJUSTING THE EXUP CABLES ....................................................... 3-17 CHECKING THE EXUP SERVO MOTOR............................................. 3-18 CHECKING THE COOLANT LEVEL .................................................... 3-18 CHECKING THE COOLING SYSTEM ................................................. 3-19 CHANGING THE COOLANT ................................................................ 3-19 CHASSIS .................................................................................................... 3-22 ADJUSTING THE FRONT DISC BRAKE ............................................. 3-22 ADJUSTING THE REAR DISC BRAKE ............................................... 3-22 CHECKING THE BRAKE FLUID LEVEL .............................................. 3-23 CHECKING THE FRONT BRAKE PADS .............................................. 3-23 CHECKING THE REAR BRAKE PADS ................................................ 3-24 CHECKING THE FRONT BRAKE HOSES........................................... 3-24 CHECKING THE REAR BRAKE HOSE ............................................... 3-24 ADJUSTING THE REAR BRAKE LIGHT SWITCH .............................. 3-24 BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................. 3-25 ADJUSTING THE SHIFT PEDAL ......................................................... 3-26 ADJUSTING THE DRIVE CHAIN SLACK ............................................ 3-26 LUBRICATING THE DRIVE CHAIN ...................................................... 3-27 CHECKING AND ADJUSTING THE STEERING HEAD ...................... 3-27 CHECKING THE FRONT FORK .......................................................... 3-29 ADJUSTING THE FRONT FORK LEGS .............................................. 3-29 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY................ 3-31 CHECKING THE TIRES ....................................................................... 3-32 CHECKING THE WHEELS .................................................................. 3-34 CHECKING AND LUBRICATING THE CABLES .................................. 3-34 LUBRICATING THE LEVER S ............................................................... 3-34 LUBRICATING THE PEDAL ................................................................. 3-35
LUBRICATING THE SIDESTAND ......................................................... 3-35 LUBRICATING THE REAR SUSPENSION .......................................... 3-35 ELECTRICAL SYSTEM.............................................................................. 3-36 CHECKING AND CHARGING THE BATTERY ..................................... 3-36 CHECKING THE FUSES...................................................................... 3-36 REPLACING THE HEADLIGHT BULBS............................................... 3-36 ADJUSTING THE HEADLIGHT BEAMS .............................................. 3-37
PERIODIC MAINTENANCE 3-1 EAS20450 PERIODIC MAINTENANCE EAS20460 INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter. EAS4C81028 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. EAS4C81029 GENERAL MAINTENANCE AND LUBRICATION CHART NO. ITEM ROUTINEINITIAL ODOMETER READINGS 1000 km (600 mi) or 1 month7000 km (4000 mi) or 6 months13000 km (8000 mi) or 12 months19000 km (12000 mi) or 18 months25000 km (16000 mi) or 24 months31000 km (20000 mi) or 30 months 1 * Fuel line Check fuel hoses for cracks or damage. Replace if necessary.√√√√√ 2 * Spark plugs Check condition. Adjust gap and clean. Replace every 13000 km (8000 mi) or 12 months.√Replace.√Replace.√ 3 * Valve clearance Check and adjust valve clear- ance when engine is cold.Every 42000 km (26600 mi) 4*Crankcase breather system Check breather hose for cracks or damage. Replace if necessary.√√√√√ 5*Fuel injection Adjust synchronization.√√√√√ 6 * Exhaust system Check for leakage. Tighten if necessary. Replace gasket(s) if necessary. √√√√√ 7*Air induction sys- tem Check the air cut-off valve, reed valve, and hose for damage. Replace any damaged parts if necessary.√√ NO. ITEM ROUTINEINITIAL ODOMETER READINGS 1000 km (600 mi) or 1 month7000 km (4000 mi) or 6 months13000 km (8000 mi) or 12 months19000 km (12000 mi) or 18 months25000 km (16000 mi) or 24 months31000 km (20000 mi) or 30 months 1 * Air filter element Check condition and damage. Replace if necessary.√√√√√ 2*Clutch Check operation. Adjust or replace cable.√√√√√√ 3 * Front brake Check operation, fluid level, and for fluid leakage. Replace brake pads if neces- sary.√√√√√√ 4 * Rear brake Check operation, fluid level, and for fluid leakage. Replace brake pads if neces- sary.√√√√√√ 5 * Brake hoses Check for cracks or damage.√√√√√ Replace. Every 4 years
PERIODIC MAINTENANCE 3-2 6 * Wheels Check runout and for damage. Replace if necessary.√√√√√ 7*Tires Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary.√√√√√ 8 * Wheel bearings Check bearings for smooth operation. Replace if necessary.√√√√√ 9*Swingarm pivot bearings Check bearing assemblies for looseness. Moderately repack with lithium soap-based grease.√Repack. 10 Drive chain Check chain slack, alignment and condition. Adjust and lubricate chain with a special O-ring chain lubricant thoroughly.Every 800 km (500 mi) and after washing the motorcycle or riding in the rain 11 * Steering bearings Check bearing assemblies for looseness. Moderately repack with lithium soap-based grease every 16000 mi (25000 km) or 24 months.√√√√Repack.√ 12 * Steering damper Check operation and for oil leakage.√√√√√ 13 * Chassis fasteners Check all chassis fitting and fasteners. Correct if necessary.√√√√√ 14Brake and clutch lever pivot shafts Apply lithium-soap-based grease (all-purpose grease) lightly.√√√√√ 15Shift pedal rod pivots Apply lithium-soap-based grease (all-purpose grease) lightly.√√√√√ 16 Sidestand pivot Check operation. Apply lithium-soap-based grease (all-purpose grease) lightly.√√√√√ 17 * Sidestand switch Check operation and replace if necessary.√√√√√√ 18 * Front fork Check operation and for oil leakage. Replace if necessary.√√√√√ 19 *Shock absorber assembly Check operation and for oil leakage. Replace if necessary.√√√√√ 20 *Rear suspension link pivots Check operation. Correct if necessary.√√ 21 Engine oil Change (warm engine before draining).√√√√√√ 22 *Engine oil filter cartridge Replace.√√√ 23 * Cooling system Check hoses for cracks or damage. Replace if necessary.√√√√√ Change with ethylene glycol antifreeze coolant every 24 months.Change. NO. ITEM ROUTINEINITIAL ODOMETER READINGS 1000 km (600 mi) or 1 month7000 km (4000 mi) or 6 months13000 km (8000 mi) or 12 months19000 km (12000 mi) or 18 months25000 km (16000 mi) or 24 months31000 km (20000 mi) or 30 months
PERIODIC MAINTENANCE 3-3 * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 37000 km (24000 mi) or 36 months, repeat the maintenance intervals starting from 13000 km (8000 mi) or 12 months. NOTE: Air filter This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas. Hydraulic brake service After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required. Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. Replace the brake hoses every four years and if cracked or damaged. 24 * EXUP system Check operation, cable free play and pulley position.√Every 19000 km (12000 mi) 25 *Front and rear brake switches Check operation.√√√√√√ 26 * Control cables Apply Yamaha chain and cable lube or engine oil SAE 10W-30 thoroughly.√√√√√√ 27 *Throttle grip hous- ing and cable Check operation and free play. Adjust the throttle cable free play if necessary. Lubricate the throttle grip housing and cable.√√√√√ 28 *Lights, signals and switches Check operation. Adjust headlight beam.√√√√√√ NO. ITEM ROUTINEINITIAL ODOMETER READINGS 1000 km (600 mi) or 1 month7000 km (4000 mi) or 6 months13000 km (8000 mi) or 12 months19000 km (12000 mi) or 18 months25000 km (16000 mi) or 24 months31000 km (20000 mi) or 30 months
ENGINE 3-4 EAS20470 ENGINE EAS20490 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: Valve clearance adjustment should be made on a cold engine, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1. Remove: 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. Lower cowlings Side cowlings Refer to GENERAL CHASSIS on page 4- 1. Throttle body assembly Refer to THROTTLE BODIES on page 7- 4. Air cut-off valve Refer to AIR INDUCTION SYSTEM on page 7-9. Radiator Radiator fan motor Refer to RADIATOR on page 6-1. 2. Remove: Ignition coils Spark plugs Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS on page 5-9. 3. Remove: Pickup rotor cover “1”4. Measure: Valve clearance Out of specification → Adjust. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the TDC mark “a” on the generator rotor with the mark “b” on the crankcase. NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. c. Measure the valve clearance with a thick- ness gauge “2”. NOTE: If the valve clearance is incorrect, record the measured reading. Measure the valve clearance in the following sequence. Valve clearance (cold) Intake 0.11–0.20 mm (0.0043–0.0079 in) Exhaust 0.26–0.30 mm (0.0102–0.0118 in)
ENGINE 3-5 d. To measure the valve clearances of the other cylinders, starting with cylinder #1 at TDC, turn the crankshaft counterclockwise as specified in the following table. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Remove: Camshafts NOTE: Refer to CAMSHAFTS on page 5-9. When removing the timing chain and cam- shafts, fasten the timing chain with a wire to retrieve it if it falls into the crankcase. 6. Adjust: Valve clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve lifter “1” and the valve pad “2” with a valve lapper “3”. NOTE: Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. Make a note of the position of each valve lifter “1” and valve pad “2” so that they can be installed in the correct place. b. Select the proper valve pad from the follow- ing table. Valve clearance measuring sequence Cylinder #1 → #2 → #4 → #3 A. Front A. Degrees that the crankshaft is turned counterclockwise B. Cylinder C. Combustion cycle Cylinder #2 180° Cylinder #4 360° Cylinder #3 540° Valve lapper 90890-04101 Valve lapping tool YM-A8998 Valve pad range Nos. 156–240 Valve pad thickness1.56–2.40 mm (0.0614–0.0945 in) Available valve pads25 thicknesses in 0.05 mm (0.002 in) increments
ENGINE 3-6 NOTE: The thickness “a” of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter. Since valve pads of various sizes are origi- nally installed, the valve pad number must be rounded in order to reach the closest equiva- lent to the original. c. Round off the original valve pad number according to the following table. EXAMPLE: Original valve pad number = 148 (thickness = 1.48 mm (0.058 in)) Rounded value = 150 d. Locate the rounded number of the original valve pad and the measured valve clear- ance in the valve pad selection table. The point where the column and row intersect is the new valve pad number. NOTE: The new valve pad number is only an approxi- mation. The valve clearance must be mea- sured again and the above steps should be repeated if the measurement is still incorrect. e. Install the new valve pad “1” and the valve lifter “2”. NOTE: Lubricate the valve pad with molybdenum disulfide grease. Lubricate the valve lifter with molybdenum disulfide oil. The valve lifter must turn smoothly when rotated by hand. Install the valve lifter and the valve pad in the correct place. f. Install the exhaust and intake camshafts, timing chain and camshaft caps. NOTE: Refer to CAMSHAFTS on page 5-9. Lubricate the camshaft bearings, camshaft lobes and camshaft journals. First, install the exhaust camshaft. Align the camshaft marks with the camshaft cap marks. Turn the crankshaft counterclockwise several full turns to seat the parts. g. Measure the valve clearance again. h. If the valve clearance is still out of specifi- cation, repeat all of the valve clearance adjustment steps until the specified clear- ance is obtained. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Install: All removed parts NOTE: For installation, reverse the removal proce- dure. Note the following points. Last digit Rounded value 0 or 2 0 55 810 Camshaft cap bolt 10 Nm (1.0 m·kg, 7.2 ft·lb)
ENGINE 3-7 EAS20570 SYNCHRONIZING THE THROTTLE BODIES NOTE: Prior to synchronizing the throttle bodies, the valve clearance should be properly adjusted and the ignition timing should be checked. 1. Stand the vehicle on a level surface. NOTE: Place the vehicle on a suitable stand. 2. Remove: Rider seat Refer to GENERAL CHASSIS on page 4- 1. Fuel tank side covers Fuel tank Refer to FUEL TANK on page 7-1. Air filter case Refer to GENERAL CHASSIS on page 4- 1. 3. Remove: Synchronizing hoses “1” 4. Install: Vacuum gauge “1” (onto the synchronizing hose)5. Install: Fuel tank Refer to FUEL TANK on page 7-1. 6. Start the engine and let it warm up for sev- eral minutes. 7. Check: Engine idling speed 8. Adjust: Throttle body synchronization ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Basic procedure a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed. b. Turn the bypass air screw “1” with a white paint mark out a little, and then turn it in fully. c. Using the throttle body that has the bypass air screw with a white paint mark as the standard, turn the bypass air screws with- out white paint marks in or out to the adjust the other throttle bodies. Vacuum gauge 90890-03094 Carburetor synchronizer YU-44456 Engine idling speed 1150–1250 r/min Engine idling speed 1150–1250 r/min