Yamaha YZF-R1 2007 Manuals

Yamaha YZF-R1 2007 Manuals

Manuals and User Guides for Yamaha YZF-R1 2007. We have 1 Yamaha YZF-R1 2007 manual available for free PDF download: Service Manual

Yamaha YZF-R1 2007 Service Manual

Yamaha YZF-R1 2007 Service Manual (442 pages)

Brand: Yamaha | Category: Motorcycle | Size: 29.78 MB

Table of Contents

Table of Contents

7
- How to Use this Manual
  4
- 1 General Information
  9
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    Fi System
    12
    
    YCC-T (Yamaha Chip Controlled Throttle) YCC-I (Yamaha Chip Controlled Intake)
    13
  - Important Information
    21
    
    Preparation for Removal and Disassembly
    21
    
    Replacement Parts
    21
    
    Gaskets, Oil Seals and O-Rings
    21
    
    Lock Washers/Plates and Cotter Pins
    21
    
    Bearings and Oil Seals
    22
    
    Circlips
    22
  - Checking the Connections
    23
  - Special Tools
    28
Specifications

31
- General Specifications
  32
- Engine Specifications
  33
- Chassis Specifications
  40
- Electrical Specifications
  42
- Tightening Torques
  44
- Lubrication Points and Lubricant Types
  52
  - Engine
    52
  - Chassis
    53
- Lubrication System Chart and Diagrams
  54
  - Engine Oil Lubrication Chart
    54
  - Lubrication Diagrams
    56
- Cooling System Diagrams
  66
- Cable Routing
  70
Periodic Checks and Adjustments

85
- Periodic Maintenance
  
  88
  - Introduction
    88
  - Periodic Maintenance and Lubrication Chart
    88
- Engine
  
  91
  - Adjusting the Valve Clearance
    91
  - Synchronizing the Throttle Bodies
    94
  - Adjusting the Exhaust Gas Volume
    95
  - Adjusting the Throttle Cable Free Play
    96
  - Checking the Spark Plugs
    97
  - Measuring the Compression Pressure
    98
  - Checking the Engine Oil Level
    99
  - Changing the Engine Oil
    99
  - Measuring the Engine Oil Pressure
    100
  - Adjusting the Clutch Cable Free Play
    101
  - Replacing the Air Filter Element
    102
  - Checking the Throttle Body Joints
    103
  - Checking the Fuel Line
    103
  - Checking the Crankcase Breather Hose
    104
  - Checking the Exhaust System
    104
  - Adjusting the Exup Cables
    105
  - Checking the Exup Servo Motor
    106
  - Checking the Coolant Level
    106
  - Checking the Cooling System
    107
  - Changing the Coolant
    107
- Chassis
  
  110
  - Adjusting the Front Disc Brake
    110
    
    Adjusting the Rear Disc Brake
    110
    
    Checking the Brake Fluid Level
    111
    
    Checking the Front Brake Pads
    111
    
    Checking the Rear Brake Pads
    112
    
    Checking the Front Brake Hoses
    112
    
    Checking the Rear Brake Hose
    112
    
    Adjusting the Rear Brake Light Switch
    112
    
    Bleeding the Hydraulic Brake System
    113
    
    Adjusting the Shift Pedal
    114
    
    Adjusting the Drive Chain Slack
    114
    
    Lubricating the Drive Chain
    115
    
    Checking and Adjusting the Steering Head
    115
    
    Checking the Front Fork
    117
    
    Adjusting the Front Fork Legs
    117
    
    Adjusting the Rear Shock Absorber Assembly
    119
    
    Checking the Tires
    120
    
    Checking the Wheels
    122
    
    Checking and Lubricating the Cables
    122
    
    Lubricating the Levers
    122
    
    Lubricating the Pedal
    123
    
    Lubricating the Sidestand
    123
Chassis

127
- General Chassis
  
  136
  - Removing the Cover
    136
  - Installing the Cover
    136
- Front Wheel
  
  137
  - Removing the Front Wheel
    139
  - Checking the Front Wheel
    139
  - Adjusting the Front Wheel Static Balance
    140
  - Installing the Front Wheel
    141
- Rear Wheel
  
  143
  - Removing the Rear Wheel
    146
  - Checking the Rear Wheel
    146
  - Checking the Rear Wheel Drive Hub
    147
  - Checking and Replacing the Rear Wheel Sprocket
    147
  - Adjusting the Rear Wheel Static Balance
    147
  - Installing the Rear Wheel
    147
- Front Brake
  
  149
- Rear Brake
  
  162
  - Introduction
    167
  - Checking the Rear Brake Disc
    167
  - Replacing the Rear Brake Pads
    167
  - Removing the Rear Brake Caliper
    169
  - Disassembling the Rear Brake Caliper
    169
  - Checking the Rear Brake Caliper
    169
  - Assembling the Rear Brake Caliper
    170
  - Installing the Rear Brake Caliper
    170
  - Removing the Rear Brake Master Cylinder
    171
  - Checking the Rear Brake Master Cylinder
    171
  - Assembling the Rear Brake Master Cylinder
    172
  - Installing the Rear Brake Master Cylinder
    172
- Handlebars
  
  176
  - Removing the Handlebar
    176
  - Checking the Handlebars
    176
  - Installing the Handlebars
    176
  - Checking the Steering Damper
    177
- Front Fork
  
  179
  - Removing the Front Fork Legs
    181
  - Disassembling the Front Fork Legs
    181
  - Checking the Front Fork Legs
    182
  - Assembling the Front Fork Legs
    183
  - Installing the Front Fork Legs
    187
- Steering Head
  
  188
  - Removing the Lower Bracket
    190
  - Checking the Steering Head
    190
  - Installing the Steering Head
    190
- Rear Shock Absorber Assembly
  
  192
- Swingarm
  
  195
  - Removing the Swingarm
    197
  - Checking the Swingarm
    198
  - Installing the Swingarm
    198
- Chain Drive
  
  200
  - Removing the Drive Chain
    201
  - Checking the Drive Chain
    201
  - Checking the Rear Wheel Sprocket
    202
  - Checking the Rear Wheel Drive Hub
    202
  - Installing the Drive Chain
    202
Engine

205
- Engine Removal
  
  208
  - Installing the Engine
    214
- Camshafts
  
  216
  - Removing the Camshafts
    218
  - Checking the Camshafts
    219
  - Checking the Timing Chain and Camshaft Sprocket
    220
  - Checking the Timing Chain Guides
    220
  - Checking the Timing Chain Tensioner
    220
  - Installing the Camshafts
    222
- Cylinder Head
  
  225
  - Removing the Cylinder Head
    226
  - Checking the Cylinder Head
    226
  - Installing the Cylinder Head
    226
- Valves and Valve Springs
  
  229
  - Removing the Valves
    230
  - Checking the Valves and Valve Guides
    230
  - Checking the Valve Seats
    232
  - Checking the Valve Springs
    234
  - Checking the Valve Lifters
    235
  - Installing the Valves
    235
- Generator
  
  237
  - Removing the Generator
    239
  - Installing the Generator
    239
- Starter Clutch
  
  241
  - Removing the Starter Clutch
    242
  - Checking the Damper
    242
  - Checking the Starter Clutch
    242
  - Installing the Starter Clutch
    243
- Crankshaft Position Sensor
  
  244
  - Removing the Crankshaft Position Sensor
    245
  - Installing the Crankshaft Position Sensor
    245
- Electric Starter
  
  246
  - Checking the Starter Motor
    248
  - Assembling the Starter Motor
    249
  - Installing the Starter Motor
    250
- Clutch
  
  251
  - Removing the Clutch
    254
  - Checking the Friction Plates
    255
  - Checking the Clutch Plates
    255
  - Checking the Clutch Springs
    256
  - Checking the Clutch Housing
    256
  - Checking the Clutch Boss
    256
  - Checking the Pressur Plate 2
    257
  - Checking the Pressure Plate 1
    257
  - Checking the Push Lever Shaft and Push Rod
    257
  - Installing the Clutch
    257
- Shift Shaft
  
  261
  - Removing the Shift Shaft
    262
  - Checking the Shift Shaft
    262
  - Checking the Stopper Lever
    262
  - Installing the Shift Shaft
    262
- Oil Pump
  
  264
  - Removing the Oil Pan
    267
  - Checking the Sprocket and Chain
    267
  - Checking the Oil Pump
    267
  - Checking the Relief Valve
    268
  - Checking the Oil Delivery Pipes
    268
  - Checking the Oil Strainer
    268
  - Checking the Oil Nozzles
    268
  - Assembling the Oil Pump
    269
  - Installing the Oil/Water Pump Assembly
    269
  - Installing the Oil Pan
    270
- Crankcase
  
  272
  - Disassembling the Crankcase
    274
  - Checking the Crankcase
    274
  - Checking the Bearing and Oil Seals
    274
  - Assembling the Crankcase
    274
- Crankshaft
  
  276
  - Removing the Connecting Rods and Pistons
    278
  - Removing the Crankshaft Assembly
    278
  - Checking the Cylinder and Piston
    279
  - Checking the Piston Rings
    279
  - Checking the Piston Pin
    280
  - Checking the Big End Bearings
    281
  - Installing the Connecting Rod and Piston
    284
  - Checking the Crankshaft
    287
  - Checking the Crankshaft Drive Sprocket
    287
  - Checking the Crankshaft Journal Bearings
    287
  - Installing the Crankshaft
    289
- Transmission
  
  291
  - Removing the Transmission
    296
  - Checking the Shift Forks
    296
  - Checking the Shift Drum Assembly
    297
Cooling System

301
- Radiator
  
  304
  - Checking the Radiator
    304
  - Installing the Radiator
    304
- Oil Cooler
  
  305
  - Checking the Oil Cooler
    306
  - Installing the Oil Cooler
    306
- Thermostat
  
  307
- Water Pump
  
  310
  - Disassembling the Water Pump
    311
  - Checking the Water Pump
    311
  - Assembling the Water Pump
    311
Fuel System

313
- Fuel Tank
  
  315
  - Checking the Fuel Pump Body
    315
  - Checking the Fuel Pump Operation
    315
  - Installing the Fuel Pump
    315
  - Removing the Fuel Pump
    315
  - Removing the Fuel Tank
    315
  - Installing the Fuel Tank
    316
- Throttle Bodies
  
  318
- Air Induction System
  
  323
  - Checking the Air Induction System
    323
Electrical System

325
- General Information
  325
- Ignition System
  
  328
  - Circuit Diagram
    328
  - Troubleshooting
    330
- Electric Starting System
  
  332
  - Circuit Diagram
    332
  - Starting Circuit Cut-Off System Operation
    334
  - Troubleshooting
    336
- Charging System
  
  338
  - Circuit Diagram
    338
  - Troubleshooting
    340
- Lighting System
  
  342
  - Circuit Diagram
    342
  - Troubleshooting
    344
- Signaling System
  
  346
  - Circuit Diagram
    346
  - Troubleshooting
    348
- Cooling System
  
  352
  - Circuit Diagram
    352
  - Troubleshooting
    354
- Fuel Injection System
  
  356
  - Circuit Diagram
    356
  - Ecu Self-Diagnostic Function
    358
  - Fail-Safe Actions (Substitute Characteristics Operation Control)
    360
  - Troubleshooting Method
    363
  - Diagnostic Mode
    364
  - Troubleshooting Details
    372
- Fuel Pump System
  
  394
  - Circuit Diagram
    394
  - Troubleshooting
    396
- Immobilizer System
  
  398
  - Circuit Diagram
    398
  - General Information
    400
  - Part Replacement and Key Code Registration Requirements
    401
  - Troubleshooting
    404
  - Self-Diagnosis Fault Code Indication
    405
- Electrical Components
  
  408
  - Checking the Switches
    412
  - Checking the Bulbs and Bulb Sockets
    415
  - Checking the Fuses
    416
  - Checking and Charging the Battery
    416
  - Checking the Relays
    419
  - Checking the Turn Signal/Hazard Relay
    420
  - Checking the Relay Unit (Diode)
    421
  - Checking the Ignition Coils
    422
  - Checking the Crankshaft Position Sensor
    423
  - Checking the Lean Angle Sensor
    423
  - Checking the Starter Motor Operation
    424
  - Checking the Stator Coil
    424
  - Checking the Rectifier/Regulator
    424
  - Checking the Horn
    425
  - Checking the Oil Level Switch
    425
  - Checking the Fuel Sender
    426
  - Checking the Speed Sensor
    426
  - Checking the Radiator Fan Motors
    427
  - Checking the Coolant Temperature Sensor
    427
  - Checking the Throttle Position Sensor (for Throttle Cable Pulley)
    428
  - Checking the Throttle Position Sensor (for Throttle Valves)
    428
  - Checking the Air Induction System Solenoid
    429
  - Checking the Atmospheric Pressure Sensor
    429
  - Checking the Cylinder Identification Sensor
    429
    
    Checking the Intake Air Pressure Sensor
    430
    
    Checking the Intake Air Temperature Sensor
    430
  - Specifications
    430
  - Troubleshooting
    433
    
    Wiring Diagram
    438

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