Yamaha Yzf R1 2007 Manual
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SWINGARM 4-69 NOTE: Loosen the swingarm pivot shaft with the damper rod holder (22 mm) “2”. EAS23360 CHECKING THE SWINGARM 1. Check: Swingarm Bends/cracks/damage → Replace. 2. Check: Pivot shaft Roll the pivot shaft on a flat surface. Bends → Replace. WARNING EWA13770 Do not attempt to straighten a bent pivot shaft. 3. Wash: Pivot shaft Dust covers SpacerWashers Bearings 4. Check: Dust covers “1” Spacer “2” Washer “3” Damage/wear → Replace. Bearings “4” Damage/pitting → Replace. EAS23380 INSTALLING THE SWINGARM 1. Lubricate: Bearings Spacers Dust covers Pivot shaft 2. Install: Bearing “1” Bearing “2” Washer “3” Damper rod holder (22 mm) 90890-01365 Recommended cleaning solvent Kerosene Recommended lubricant Molybdenum disulfide grease Installed depth of bearing “a” 0–1.0 mm (0–0.04 in) 4. Dust cover
SWINGARM 4-70 3. Install: Pivot shaft “1” NOTE: Tighten the pivot shaft with the damper rod holder (22 mm) “2”. 4. Install: Pivot shaft ring nut “1” NOTE: Lubricate the pivot ring nut threads and mat- ing surfaces with lithium-soap-based grease. Tighten the pivot shaft ring nut with the ring nut wrench “2”.5. Install: Pivot shaft nut “1” NOTE: Lubricant the pivot shaft nut threads and mat- ing surfaces with lithium-soap-based grease. 6. Adjust: Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3-26. 5. Swingarm 6. Pivot shaft A. Left side B. Right side Pivot shaft 7 Nm (0.7 m·kg, 5.1 ft·lb) Damper rod holder (22 mm) 90890-01365 Pivot shaft ring nut 65 Nm (6.5 m·kg, 47 ft·lb) Ring nut wrench 90890-01507 YM-01507 Pivot shaft nut 105 Nm (10.5 m·kg, 76 ft·lb) Drive chain slack 30.0–40.0 mm (1.18–1.57 in)
CHAIN DRIVE 4-71 EAS23400 CHAIN DRIVE Removing the drive chain Order Job/Parts to remove Q’ty Remarks Swingarm Refer to SWINGARM on page 4-66. 1 Drive chain guard 1 2Drive chain 1 For installation, reverse the removal proce- dure.
CHAIN DRIVE 4-72 EAS23410 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: Drive chain (with the drive chain cutter) EAS23440 CHECKING THE DRIVE CHAIN 1. Measure: Measure the dimension between 15-links on the inner side “a” and outer side “b” of the roller and calculate the dimension between pin centers. Dimension “c” between pin centers = (Inner dimension “a” + Outer dimension “b”)/2 15-link section “c” of the drive chain Out of specification → Replace the drive chain, front drive sprocket and rear drive sprocket as a set. NOTE: While measuring the 15-link section, push down on the drive chain to increase its ten- sion. Perform this measurement at two or three dif- ferent places.2. Check: Drive chain Stiffness → Clean and lubricate or replace. 3. Clean: Drive chain ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wipe the drive chain with a clean cloth. b. Put the drive chain in kerosene and remove any remaining dirt. c. Remove the drive chain from the kerosene and completely dry it. CAUTION: ECA4C81003 This vehicle has a drive chain with small rubber O-rings “1” between the drive chain side plates. Never use high-pres- sure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain. High-pressure methods could force dirt or water into the drive chain’s internals, and solvents will deteriorate the O-rings. A coarse brush can also damage the O-rings. Therefore, use only kerosene to clean the drive chain. Do not soak the drive chain in kerosene for more than ten minutes, otherwise the O-rings can be damaged. 15-link length limit 239.3 mm (9.42 in)
CHAIN DRIVE 4-73 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: O-rings “1” Damage → Replace the drive chain. Drive chain rollers “2” Damage/wear → Replace the drive chain. Drive chain side plates “3” Damage/wear/cracks → Replace the drive chain. 5. Lubricate: Drive chain 6. Check: Drive sprocket Rear wheel sprocket More than 1/4 tooth “a” wear → Replace the drive chain sprockets as a set. Bent teeth → Replace the drive chain sprockets as a set. EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4-18 EAS23480 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4-18 EAS23490 INSTALLING THE DRIVE CHAIN 1. Lubricate: Drive chain 2. Install: Drive chain “1” Drive sprocket “2” Washer Drive sprocket nut “3” NOTE: While applying the rear brake, tighten the drive sprocket nut. Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains b. Correct 1. Drive chain roller 2. Drive chain sprocket Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains Drive sprocket nut 100 Nm (10 m·kg, 72 ft·lb)
CHAIN DRIVE 4-74 CAUTION: ECA14300 Never install a new drive chain onto worn drive chain sprockets; this will dramatically shorten the drive chain’s life. 3. Adjust: Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3-26 CAUTION: ECA13550 A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the speci- fied limits. Drive chain slack 30.0–40.0 mm (1.18–1.57 in)
ENGINE ENGINE REMOVAL...................................................................................... 5-1 INSTALLING THE ENGINE .................................................................... 5-7 CAMSHAFTS ................................................................................................ 5-9 REMOVING THE CAMSHAFTS ........................................................... 5-11 CHECKING THE CAMSHAFTS ........................................................... 5-12 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET ....... 5-13 CHECKING THE TIMING CHAIN GUIDES .......................................... 5-13 CHECKING THE TIMING CHAIN TENSIONER ................................... 5-13 INSTALLING THE CAMSHAFTS .......................................................... 5-15 CYLINDER HEAD ....................................................................................... 5-18 REMOVING THE CYLINDER HEAD .................................................... 5-19 CHECKING THE CYLINDER HEAD .................................................... 5-19 INSTALLING THE CYLINDER HEAD ................................................... 5-19 VALVES AND VALVE SPRINGS ................................................................ 5-21 REMOVING THE VALVES .................................................................... 5-23 CHECKING THE VALVES AND VALVE GUIDES ................................. 5-23 CHECKING THE VALVE SEATS .......................................................... 5-25 CHECKING THE VALVE SPRINGS...................................................... 5-27 CHECKING THE VALVE LIFTERS ....................................................... 5-28 INSTALLING THE VALVES ................................................................... 5-28 GENERATOR .............................................................................................. 5-30 REMOVING THE GENERATOR ........................................................... 5-32 INSTALLING THE GENERATOR .......................................................... 5-32 STARTER CLUTCH .................................................................................... 5-34 REMOVING THE STARTER CLUTCH ................................................. 5-35 CHECKING THE DAMPER .................................................................. 5-35 CHECKING THE STARTER CLUTCH .................................................. 5-35 INSTALLING THE STARTER CLUTCH ................................................ 5-36 CRANKSHAFT POSITION SENSOR ......................................................... 5-37 REMOVING THE CRANKSHAFT POSITION SENSOR ...................... 5-38 INSTALLING THE CRANKSHAFT POSITION SENSOR ..................... 5-38 ELECTRIC STARTER ................................................................................. 5-39 CHECKING THE STARTER MOTOR ................................................... 5-41 ASSEMBLING THE STARTER MO TOR ............................................... 5-42 INSTALLING THE STARTER MOTOR .................................................. 5-43 CLUTCH ...................................................................................................... 5-44 REMOVING THE CLUTCH................................................................... 5-47 CHECKING THE FRICTION PLATES .................................................. 5-48
CHECKING THE CLUTCH PLATES ..................................................... 5-48 CHECKING THE CLUTCH SPRINGS .................................................. 5-49 CHECKING THE CLUTCH HOUSING ................................................. 5-49 CHECKING THE CLUTCH BOSS ........................................................ 5-49 CHECKING THE PRESSUR PLATE 2 ................................................. 5-50 CHECKING THE PRESSURE PLATE 1 ............................................... 5-50 CHECKING THE PUSH LEVER SHAFT AND PUSH ROD.................. 5-50 INSTALLING THE CLUTCH.................................................................. 5-50 SHIFT SHAFT............................................................................................. 5-54 REMOVING THE SHIFT SHAFT .......................................................... 5-55 CHECKING THE SHIFT SHAFT .......................................................... 5-55 CHECKING THE STOPPER LEVER .................................................... 5-55 INSTALLING THE SHIFT SHAFT ......................................................... 5-55 OIL PUMP................................................................................................... 5-57 REMOVING THE OIL PAN ................................................................... 5-60 CHECKING THE SPROCKET AND CHAIN ......................................... 5-60 CHECKING THE OIL PUMP ................................................................ 5-60 CHECKING THE RELIEF VALVE ......................................................... 5-61 CHECKING THE OIL DELIVERY PIPES.............................................. 5-61 CHECKING THE OIL STRAINER ......................................................... 5-61 CHECKING THE OIL NOZZLES .......................................................... 5-61 ASSEMBLING THE OIL PUMP............................................................ 5-62 INSTALLING THE OIL/WATER PUMP ASSEMBLY.............................. 5-62 INSTALLING THE OIL PAN .................................................................. 5-63 CRANKCASE............................................................................................. 5-65 DISASSEMBLING THE CRANKCASE ................................................. 5-67 CHECKING THE CRANKCASE ........................................................... 5-67 CHECKING THE BEARING AND OIL SEALS ..................................... 5-67 ASSEMBLING THE CRANKCASE ....................................................... 5-67 CRANKSHAFT........................................................................................... 5-69 REMOVING THE CONNECTING RODS AND PISTONS..................... 5-71 REMOVING THE CRANKSHAFT ASSEMBLY ..................................... 5-71 CHECKING THE CYLINDER AND PISTON......................................... 5-72 CHECKING THE PISTON RINGS ........................................................ 5-72 CHECKING THE PISTON PIN ............................................................. 5-73 CHECKING THE BIG END BEARINGS ............................................... 5-74 INSTALLING THE CONNECTING ROD AND PISTON ........................ 5-77 CHECKING THE CRANKSHAFT ......................................................... 5-80 CHECKING THE CRANKSHAFT DRIVE SPROCKET......................... 5-80 CHECKING THE CRANKSHAFT JOURNAL BEARINGS .................... 5-80 INSTALLING THE CRANKSHAFT ........................................................ 5-82 TRANSMISSION......................................................................................... 5-84 REMOVING THE TRANSMISSION ...................................................... 5-89 CHECKING THE SHIFT FORKS .......................................................... 5-89 CHECKING THE SHIFT DRUM ASSEMBLY ........................................ 5-90
CHECKING THE TRANSMISSION ...................................................... 5-90 INSTALLING THE TRANSMISSION ..................................................... 5-91