Yamaha Yzf R1 2007 Manual
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ENGINE 3-8 NOTE: If more than one throttle body has a bypass air screw with a white paint mark, use the one with the lowest vacuum pressure as the standard. After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again. If an air screw was removed, turn the screw 3/4 turn in and be sure to synchronize the throttle body. NOTE: The difference in vacuum pressure between two throttle bodies should not exceed 1.33 kPa (10 mmHg). If you are unable to adjust the throttle body synchronization using this procedure, use the following procedure instead. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Alternate procedure NOTE: Use this alternate procedure if you are unable to adjust the throttle body synchronization using the 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 all of the bypass air screws in fully. c. Using the throttle body with the lowest vac- uum pressure as the standard, turn out the bypass air screws of the other throttle bod- ies to adjust them. NOTE: Do not turn out the bypass air screw of the throttle body with the lowest vacuum pres- sure. After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again. If an air screw was removed, turn the screw 3/4 turn in and be sure to synchronize the throttle body. NOTE: The difference in vacuum pressure between two throttle bodies should not exceed 1.33 kPa (10 mmHg). ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 9. Stop the engine and remove the measuring equipment. 10. Adjust: Throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3-8. 11. Install: Fuel tank Fuel tank side cover Refer to FUEL TANK on page 7-1. Rider seat Refer to GENERAL CHASSIS on page 4- 1. EAS20630 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the carburetor synchronization should be adjusted properly. 1. Check: Throttle cable free play “a” Out of specification → Adjust. Intake vacuum 22.0 kPa (6.5 inHg) (165 mmHg) Engine idling speed 1150–1250 r/min Intake vacuum 22.0 kPa (6.5 inHg) (165 mmHg) Throttle cable free play 3.0–5.0 mm (0.12–0.20 in)
ENGINE 3-9 2. Adjust: Throttle cable free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Handlebar side a. Loosen the locknut “1”. b. Turn the adjusting nut “2” in direction “a” or “b” until the specified throttle cable free play is obtained. c. Tighten the locknut “1”. WARNING EWA4C81006 After adjusting the throttle cable free play, start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS20680 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: Side cowlings Lower cowlings Refer to GENERAL CHASSIS on page 4- 1. 2. Remove: Radiator upper bolts Radiator lower bolt Refer to RADIATOR on page 6-1. 3. Disconnect: Ignition coils4. Remove: Spark plugs CAUTION: ECA13320 Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders. 5. Check: Spark plug type Incorrect → Change. 6. Check: Electrode “1” Damage/wear → Replace the spark plug. Insulator “2” Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 7. Clean: Spark plugs (with a spark plug cleaner or wire brush) 8. Measure: Spark plug gap “a” (with a wire thickness gauge) Out of specification → Regap. 9. Install: Spark plugs Ignition coils NOTE: Before installing the spark plug, clean the spark plug and gasket surface. Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) Direction “a” Throttle cable free play is increased. Direction “b” Throttle cable free play is decreased.Manufacturer/model NGK/CR9EK Spark plug gap 0.6–0.7 mm (0.024–0.028 in) Spark plug 13 Nm (1.3 m·kg, 9.4 ft·lb)
ENGINE 3-10 10. Install: Radiator upper bolts Radiator lower bolt Refer to RADIATOR on page 6-1. 11. Install: Side cowlings Lower cowlings Refer to GENERAL CHASSIS on page 4- 1. EAS20710 MEASURING THE COMPRESSION PRES- SURE The following procedure applies to all of the cylinders. NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: Valve clearance Out of specification → Adjust. Refer to ADJUSTING THE VALVE CLEARANCE on page 3-4. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Disconnect: Ignition coils 4. Remove: Ignition coils Spark plugs CAUTION: ECA13340 Before removing the spark plugs, use com- pressed air to blow away any dirt accumu- lated in the spark plug wells to prevent it from falling into the cylinders. 5. Install: Compression gauge “1” Extension6. Measure: Compression pressure Out of specification → Refer to steps (c) and (d). ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compres- sion gauge stabilizes. WARNING EWA4C81007 To prevent sparking, ground all speak plug leads before cranking the engine. NOTE: The difference in compression pressure between cylinders should not exceed 100 kPa (1 kg/cm², 14 psi). c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces and piston crown for carbon deposits. Carbon deposits → Eliminate. d. If the compression pressure is below the minimum specification, pour a teaspoonful of engine oil into the spark plug bore and measure again. Refer to the following table. Compression gauge 90890-03081 Engine compression tester YU-33223 Extension 90890-04136 Standard compression pres- sure (at sea level) 1480 kPa/350 r/min (210.5 psi/ 350 r/min) (14.8 kgf/cm²/350 r/ min) Minimum–Maximum 1290–1660 kPa (183.5–236.1 psi) (12.9–16.6 kgf/cm²)
ENGINE 3-11 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Install: Spark plugs Ignition coils 8. Connect: Ignition coils EAS20730 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle on a level surface. NOTE: Place the vehicle on a suitable stand. Make sure the vehicle is upright. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Check: Engine oil level The engine oil level should be between the minimum level mark “a” and maximum level mark “b”. Below the minimum level mark → Add the recommended engine oil to the proper level. CAUTION: ECA13360 Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives. Do not allow foreign materials to enter the crankcase. 4. Start the engine, warm it up for several minutes, and then turn it off. 5. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. EAS20790 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: Lower cowlings Refer to GENERAL CHASSIS on page 4- 1. 4. Remove: Engine oil filler cap “1” Engine oil drain bolt “2” (along with the gasket) Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without oilPiston ring(s) wear or damage → Repair. Same as without oil Piston, valves, cylin- der head gasket or piston possibly defec- tive → Repair. Spark plug 13 Nm (1.3 m·kg, 9.4 ft·lb) Ty p e YAMALUBE 4, SAE 10W30 or SAE 20W40 Recommended engine oil grade API service, SG type or higher, JASO standard MA
ENGINE 3-12 5. Drain: Engine oil (completely from the crankcase) 6. If the oil filter cartridge is also to be replaced, perform the following procedure. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the oil filter cartridge “1” with an oil filter wrench “2”. b. Lubricate the O-ring “3” of the new oil filter cartridge with a thin coat of engine oil. CAUTION: ECA13390 Make sure the O-ring “3” is positioned cor- rectly in the groove of the oil filter car- tridge.c. Tighten the new oil filter cartridge to speci- fication with an oil filter wrench. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Check: Engine oil drain bolt gasket 8. Install: Engine oil drain bolt (along with the gasket) 9. Fill: Crankcase (with the specified amount of the recom- mended engine oil) 10. Install: Engine oil filler cap Lower cowlings Refer to GENERAL CHASSIS on page 4- 1. 11. Start the engine, warm it up for several minutes, and then turn it off. 12. Check: Engine (for engine oil leaks) Oil filter wrench 90890-01426 YU-38411 Oil filter cartridge 17 Nm (1.7 m·kg, 12 ft·lb) Engine oil drain bolt 43 Nm (4.3 m·kg, 31 ft·lb) Engine oil quantity Total amount 3.83 L (4.05 US qt) (3.37 Imp.qt) Without oil filter cartridge replacement 2.90 L (3.07 US qt) (2.55 Imp.qt) With oil filter cartridge replace- ment 3.10 L (3.28 US qt) (2.73 Imp.qt) New
ENGINE 3-13 13. Check: Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3-11. EAS20820 MEASURING THE ENGINE OIL PRESSURE 1. Check: Engine oil level Below the minimum level mark ”a” → Add the recommended engine oil to the proper level. 2. Start the engine, warm it up for several minutes, and then turn it off. CAUTION: ECA13410 When the engine is cold, the engine oil will have a higher viscosity, causing the engine oil pressure to increase. Therefore, be sure to measure the engine oil pressure after warming up the engine. 3. Remove: Main gallery bolt “1” WARNING EWA12980 The engine, muffler and engine oil are extremely hot. 4. Install: Oil pressure gauge “1” Adapter “2”5. Measure: Engine oil pressure (at the following conditions) Out of specification → Adjust. 6. Install: Main gallery boltCAUTION: ECA4C81014 Be careful to tighten too much. Pressure gauge 90890-03153 YU-03153 Oil pressure adapter H 90890-03139 Engine oil pressure 230 kPa (2.3 psi) (32.71 kgf/ cm²) Engine speed Approx 5000r/min Oil temperature 80.0–90.0 °C (176.00–194.00 °F) Engine oil pressure Possible causes Below specification Faulty oil pump Clogged oil filter Leaking oil passage Broken or damaged oil seal Above specification Leaking oil passage Faulty oil filter Oil viscosity too high Main gallery bolt 8 Nm (0.8 m·kg, 5.8 ft·lb)
ENGINE 3-14 EAS20870 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: Clutch cable free play “a” Out of specification → Adjust. 2. Adjust: Clutch cable free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Handlebar side a. Turn the adjusting bolt “1” in direction “b” or “c” until the specified clutch cable free play is obtained. b. Tighten the locknut “1”. NOTE: If the specified clutch cable free play cannot be obtained on the handlebar side of the cable, use the adjusting nut on the engine side. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Engine side a. Loosen the locknuts “1”. b. Turn the adjusting bolt “2” in direction “a” or “b” until the specified clutch cable free play is obtained.c. Tighten the locknuts “1”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS20960 REPLACING THE AIR FILTER ELEMENT 1. 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. 2. Remove: Air filter case cover “1” Refer to GENERAL CHASSIS on page 4- 1. 3. Check: Air filter element “1” Damage → Replace. NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) Direction “b” Clutch cable free play is increased. Direction “c” Clutch cable free play is decreased. Direction “a” Clutch cable free play is increased. Direction “b” Clutch cable free play is decreased. Locknut 7 Nm (0.7 m·kg, 5.1 ft·lb)
ENGINE 3-15 4. Install: Air filter element NOTE: Install a new air filter element by fitting the pro- jections 1 on the element into the slots in the air filter case. CAUTION: ECA4C81021 Make sure that the air filter element is properly seated in the air filter case. Pay attention to handling of the products so that the projections is not deformed. 5. Install: Air filter case cover CAUTION: ECA4C81015 Never operate the engine without the air fil- ter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air filter element will also affect throttle bodies synchronization, leading to poor engine performance and possible overheating. NOTE: When installing the air filter element into the air filter case cover, make sure that the sealing surfaces are aligned to prevent any air leaks. 6. Install: Fuel tank Fuel tank side covers Refer to FUEL TANK on page 7-1. Rider seat Refer to GENERAL CHASSIS on page 4- 1. EAS21010 CHECKING THE THROTTLE BODY JOINTS The following procedure applies to all of the throttle body joints and intake manifolds. 1. Remove: Throttle bodies Refer to THROTTLE BODIES on page 7- 4. 2. Check: Throttle body joints “1” Cracks/damage → Replace. 3. Install: Throttle bodies Refer to THROTTLE BODIES on page 7- 4. EAS21030 CHECKING THE FUEL LINE The following procedure applies to all of the fuel, vacuum and breather hoses. 1. 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. 2. Check: Fuel hose “1” Breather hose “2” Cracks/damage → Replace. Loose connection → Connect properly. 1. Projection 1 2. Projection 2 3. Slot
ENGINE 3-16 NOTE: Before removing the fuel hoses, place a few rags in the area under where it will be remov- ing. CAUTION: ECA14940 Make sure the fuel tank breather hose is routed correctly. 3. Install: Fuel tank Fuel tank side covers Refer to FUEL TANK on page 7-1. Rider seat Refer to GENERAL CHASSIS on page 4- 1. CAUTION: ECA4C81016 To install the fuel tank, check that the breather hose is not folded or pinched by the fuel tank. EAS21070 CHECKING THE CRANKCASE BREATHER HOSE 1. 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. 2. Check: Crankcase breather hose “1” Cracks/damage → Replace. Loose connection → Connect properly. CAUTION: ECA13450 Make sure the crankcase breather hose is routed correctly.3. Install: Fuel tank Fuel tank side covers Refer to FUEL TANK on page 7-1. Rider seat Refer to GENERAL CHASSIS on page 4- 1. CAUTION: ECA4C81016 To install the fuel tank, check that the breather hose is not folded or pinched by the fuel tank. EAS21080 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets. 1. Check: Exhaust pipe “1” Exhaust valve pipe “2” Muffler “3” Cracks/damage → Replace. Gasket “4” Exhaust gas leaks → Replace. Catalist pipe “5” Cracks/damage → Replace. 2. Check: Tightening torque Exhaust pipe nut “6” Exhaust pipe and exhaust valve pipe bolt “7” Exhaust valve pipe and catalist pipe bolt “8” Catalist pipe bolt “9” Catalist pipe and muffler bolt “10” Muffler and frame bolt “11”
ENGINE 3-17 NOTE: When installing the EXUP cables, make sure they are parallel and not twisted. Upper cable: White metal section “12” Lower cable: Black metal section “13” EAS21100 ADJUSTING THE EXUP CABLES 1. Remove: Lower cowlings Refer to GENERAL CHASSIS on page 4- 1. 2. Remove: EXUP valve pulley cover “1” 3. Check: EXUP system operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the main switch ON b. Check that the EXUP valve operates prop- erly ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: EXUP cable free play (at the EXUP valve pulley) “a” 5. Adjust: EXUP cable free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the main switch to “ON”. b. Check the EXUP pulley position. c. Projection of the EXUP pulley position is between “1” and “2” . d. Loosen the both locknuts “3” e. Turn the both adjusting nuts “4” in or out. f. Tighten the both locknuts. Exhaust pipe nut 20 Nm (2.0 m·kg, 14 ft·lb) Exhaust pipe and exhaust valve pipe bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Exhaust valve pipe and catalist pipe bolt 20 Nm (2.0 m·kg, 14 ft·lb) Catalist pipe bolt 20 Nm (2.0 m·kg, 14 ft·lb) Catalist pipe and muffler bolt 20 Nm (2.0 m·kg, 14 ft·lb) Muffler and frame bolt 23 Nm (2.3 m·kg, 17 ft·lb) Maximum EXUP cable free play (at the EXUP valve pulley) Less than 3 mm (0.12 in)