Yamaha Yzf R1 2007 Manual

							OIL PUMP
5-61
3. Check:
 Oil pump operation
Rough movement → Repeat steps (1) and 
(2) or replace the defective part(s).
EAS24970
CHECKING THE RELIEF VALVE
1. Check:
 Relief valve body “1”
 Relief valve “2”
 Spring “3”
 O-ring “4”
Damage/wear → Replace the defective 
part(s).
EAS24980
CHECKING THE OIL DELIVERY PIPES
The following procedure applies to all of the oil 
delivery pipes.
1. Check:
 Oil delivery pipe “1”
 Oil pipe “2”
Damage → Replace.
Obstruction → Wash and blow out with 
compressed air.
EAS24990
CHECKING THE OIL STRAINER
1. Check:
 Oil strainer “1”
Damage → Replace.
Contaminants → Clean with solvent.
EAS4C81013
CHECKING THE OIL NOZZLES
The following procedure applies to all of the oil 
nozzles.
1. Check:
 Oil nozzle “1”
Damage/wear → Replace the oil nozzles.
1. Inner rotor
2. Outer rotor
3. Oil pump housing 
						

							OIL PUMP
5-62
 O-ring “2”
Damage/wear → Replace.
 Oil nozzle passage
Obstruction → Blow out with compressed 
air.
EAS25010
ASSEMBLING THE OIL PUMP
1. Lubricate:
 Inner rotor
 Outer rotor
 Oil pump shaft
(with the recommended lubricant)
2. Install:
Pin “1”
 Inner rotor “2”
 Outer rotor “3”
 Oil pump housing “4”
NOTE:
When installing the inner rotor, align the pin “1” 
in the oil pump shaft with the groove “a” in the 
inner rotor “2”.
3. Install:
 Oil/water pump driven sprocket “1”
NOTE:
5VY mark of the oil/water pump driven gear is 
installed at oil pump side.
4. Check:
 Oil pump operation
Refer to CHECKING THE OIL PUMP on 
page 5-60.
EAS25030
INSTALLING THE OIL/WATER PUMP 
ASSEMBLY
1. Install:
Oil ring 
 Oil/water pump assembly “1”
Dowel pin
 Bolts “2”
2. Install:
Washer
 Oil/water pump assembly drive chain “1”
 Oil/water pump assembly drive sprocket “2”
Collar
Recommended lubricant
Engine oil
Oil pump housing bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE®
Oil/water pump driven sprocket 
bolt
15 Nm (1.5 m·kg, 11 ft·lb)
LOCTITE®
Oil/water pump assembly bolt
12 Nm (1.2 m·kg, 8.7 ft·lb)
LOCTITE®
New 
						

							OIL PUMP
5-63
NOTE:
Install the oil/water pump assembly drive chain 
“1” onto the oil/water pump assembly drive 
sprocket “2”.
CAUTION:
ECA4C81007
After installing the oil/water pump assem-
bly drive chain and drive sprocket, make 
sure the oil/water pump turns smoothly.
3. Install:
 Oil/water pump assembly drive chain guide 
“1”
NOTE:
“UP” mark of the oil/water pump assembly 
drive chain guide is upward.
4. Install:
 Oil delivery pipe “1”5. Install:
 Relief valve “1”
 O-ring 
 Oil strainer “2”
 O-ring 
 Oil pipe “3”
 O-ring 
Drain pipe “4”
 O-ring 
EAS25050
INSTALLING THE OIL PAN
1. Install:
 Dowel pins
Gasket 
 Oil pan “1”
 Oil level switch “2”
Oil/water pump assembly drive 
chain guide bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE®
Oil delivery pipe bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE®
Oil strainer bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE®
Oil pan bolt
12 Nm (1.2 m·kg, 8.7 ft·lb)
Oil level switch bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
New
New
New
New
New 
						

							OIL PUMP
5-64
 Engine oil drain bolt
WARNING
EWA12820
Always use new copper washers.
NOTE:
 Tighten the oil pan bolts in stages and in a 
crisscross pattern.
 Lubricate the oil level switch O-ring with 
engine oil.
Engine oil drain bolt
43 Nm (4.3 m·kg, 31 ft·lb) 
						

							CRANKCASE
5-65
EAS25540
CRANKCASE
Separating the crankcase
Order Job/Parts to remove Q’ty Remarks
Air filter case Refer to GENERAL CHASSIS on page 4-1.
Throttle body assembly Refer to THROTTLE BODIES on page 7-4.
Engine Refer to ENGINE REMOVAL on page 5-1
Cylinder head Refer to CYLINDER HEAD on page 5-18.
Generator Refer to GENERATOR on page 5-30.
Starter clutch Refer to STARTER CLUTCH on page 5-34.
Shift shaft Refer to SHIFT SHAFT on page 5-54.
Crankshaft position sensorRefer to CRANKSHAFT POSITION SEN-
SOR on page 5-37.
Clutch Refer to CLUTCH on page 5-44.
Oil pump Refer to OIL PUMP on page 5-57.
Starter motorRefer to ELECTRIC STARTER on page 5-
39.
1 Timing chain 1
2 Timing chain guide (intake side) 1
3Pin 2
4 Timing chain guide (exhaust side) 1
5 Left side cover 1
6O-ring 1 
						

							CRANKCASE
5-66
7 Lower crankcase 1
8Dowel pin 3
9 Damper 1
For installation, reverse the removal proce-
dure.
Separating the crankcase
Order Job/Parts to remove Q’ty Remarks 
						

							CRANKCASE
5-67
EAS25550
DISASSEMBLING THE CRANKCASE
1. Place the engine upside down.
2. Remove:
 Crankcase bolts
NOTE:
 Loosen each bolt 1/4 of a turn at a time, in 
stages and in a crisscross pattern. After all of 
the bolts are fully loosened, remove them.
 Loosen the bolts in decreasing numerical 
order (refer to the numbers in the illustration).
 The numbers embossed on the crankcase 
indicate the crankcase tightening sequence.
M6 × 50 mm (2.0 in) bolts: “1”, “7”
M6 × 60 mm (2.4 in) bolts: “2”, “3”
M6 × 70 mm (2.8 in) bolts: “4”, “6”, “8”
M6 × 60 mm (2.4 in) bolt and washer: “5”
M6 × 65 mm (2.5 in) bolts: “9”, “10”
M8 × 60 mm (2.4 in) bolts: “11”, “15”
M8 × 50 mm (2.0 in) bolts: “12” – “14”
M8 × 60 mm (2.4 in) bolt: “16” LOCTITE®
M9 × 105 mm (4.1 in) bolts: “17” – “26”
3. Remove:
 Lower crankcase
CAUTION:
ECA13900
Tap on one side of the crankcase with a 
soft-face hammer. Tap only on reinforced 
portions of the crankcase, not on the 
crankcase mating surfaces. Work slowly 
and carefully and make sure the crankcase 
halves separate evenly.
4. Remove:
 Dowel pins
5. Remove:
 Crankshaft journal lower bearing
(from the lower crankcase)
NOTE:
Identify the position of each crankshaft journal 
lower bearing so that it can be reinstalled in its 
original place.
EAS25580
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a 
mild solvent.
2. Thoroughly clean all the gasket surfaces 
and crankcase mating surfaces.
3. Check:
 Crankcase
Cracks/damage → Replace.
 Oil delivery passages
Obstruction → Blow out with compressed 
air.
EAS4C81014
CHECKING THE BEARING AND OIL SEALS
1. Check:
 Bearings
Clean and lubricate the bearings, then 
rotate the inner race with your finger.
Rough movement → Replace.
2. Check:
 Oil seals
Damage/wear → Replace.
EAS25650
ASSEMBLING THE CRANKCASE
1. Lubricate:
 Crankshaft journal bearings
(with the recommended lubricant)
2. Apply:
 Sealant
NOTE:
Do not allow any sealant to come into contact 
with the oil gallery or crankshaft journal bear-
ings. Do not apply sealant to within 2–3 mm 
(0.08–0.12 in) of the crankshaft journal bear-
ings.
Recommended lubricant
Engine oil
Yamaha bond No. 1215
(Three bond No. 1215®)
90890-85505 
						

							CRANKCASE
5-68
3. Install:
Dowel pin
4. Set the shift drum assembly and transmis-
sion gears in the neutral position.
5. Install:
 Lower crankcase “1”
(onto the upper crankcase “2”)
CAUTION:
ECA13980
Before tightening the crankcase bolts, 
make sure the transmission gears shift cor-
rectly when the shift drum assembly is 
turned by hand.
6. Install:
 Crankcase bolts
NOTE:
 Lubricate the bolt threads with engine oil.
 Install a washer on bolts “1” – “10” and “22”.
 Seal bolt “18”
 Tighten the bolts in the tightening sequence 
cast on the crankcase.
M9 × 105 mm (4.1 in) bolts: “1” – “10”
M8 × 60 mm (2.4 in) bolt: “11” LOCTITE®
M8 × 60 mm (2.4 in) bolts: “12”, “16”
M8 × 50 mm (2.0 in) bolts: “13” – “15”
M6 × 65 mm (2.5 in) bolts: “17”, “18”
M6 × 70 mm (2.8 in) bolts: “19”, “21”, “23”
M6 × 50 mm (2.0 in) bolts: “20”, “26”
M6 × 60 mm (2.4 in) bolt and washer: “22”
M6 × 60 mm (2.4 in) bolts: “24”, “25”*Following the tightening order, loosen the 
bolt one by one and then retighten it to the 
specific torque.
Crankcase bolt
Bolt “1”–“10”
1st: 20 Nm (2.0 m·kg, 14 ft·lb)
2nd*: 20 Nm (2.0 m·kg, 14 ft·lb)
3rd: +60°
Bolt “11”–“16”
24 Nm (2.4 m·kg, 17 ft·lb)
Bolt “17”–“26”
10 Nm (1.0 m·kg, 7.2 ft·lb) 
						

							CRANKSHAFT
5-69
EAS25960
CRANKSHAFT
Removing the connecting rods and pistons
Order Job/Parts to remove Q’ty Remarks
Lower crankcase Refer to CRANKCASE on page 5-65.
1 Connecting rod cap 4
2 Big end lower bearing 4
3 Big end upper bearing 4
4 Piston pin clip 8
5 Piston pin 4
6Piston 4
7 Connecting rod 4
8 Top ring 4
9 2nd ring 4
10 Oil ring 4
11 Cylinder 1
12 Cylinder gasket 1
For installation, reverse the removal proce-
dure. 
						

							CRANKSHAFT
5-70
Removing the crankshaft
Order Job/Parts to remove Q’ty Remarks
Lower crankcase Refer to CRANKCASE on page 5-65.
Connecting rod and connecting rod capsRefer to REMOVING THE CONNECTING 
RODS AND PISTONS on page 5-71.
1Crankshaft 1
2 Crankshaft journal lower bearing 5
3 Crankshaft journal upper bearing 5
4 Washer 1
5 Crankshaft drive gear 1
6Pin 1
7Pickup rotor 1
For installation, reverse the removal proce-
dure.