Yamaha Yzf R1 2007 Manual

							CRANKSHAFT
5-81
d. Put a piece of Plastigauge® “2” on each 
crankshaft journal.
NOTE:
Do not put the Plastigauge® over the oil hole in 
the crankshaft journal.
e. Install the crankshaft journal lower bear-
ings “1” into the lower crankcase and 
assemble the crankcase halves.
NOTE:
 Align the projections “a” of the crankshaft 
journal lower bearings with the notches “b” in 
the lower crankcase.
 Do not move the crankshaft until the clear-
ance measurement has been completed.
f. Tighten the bolts to specification 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.
NOTE:
Lubricate the crankcase bolt threads with 
engine oil.
Refer to CRANKCASE on page 5-65.
g. Remove the lower crankcase and the 
crankshaft journal lower bearings.
h. Measure the compressed Plastigauge® 
width “c” on each crankshaft journal.
If the crankshaft-journal-to-crankshaft-jour-
nal bearing clearance is out of specifica-
tion, select replacement crankshaft journal 
bearings.
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 (2.4m·kg, 17 ft·lb)
Bolt “17”–“26”
 10 Nm (1.0m·kg, 7.2 ft·lb) 
						

							CRANKSHAFT
5-82
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2. Select:
 Crankshaft journal bearings (J1–J5)
NOTE:
 The numbers “A” stamped into the crank-
shaft web and the numbers “1” stamped into 
the lower crankcase are used to determine 
the replacement crankshaft journal bearing 
sizes.
 “J1–J5” refer to the bearings shown in the 
crankshaft illustration.
 If “J1–J5” are the same, use the same size 
for all of the bearings.
 If the size is the same for all “J
1 to J5” one 
digit for that size is indicated. (Crankcase 
side only)
For example, if the crankcase “J
1” and 
crankshaft web “J
1” numbers are “6” and 
“2” respectively, then the bearing size for 
“J
1” is:
EAS26200
INSTALLING THE CRANKSHAFT
1. Install:
 Crankshaft journal upper bearings “1”
(into the upper crankcase)
2. Lubricate:
 Crankshaft journal upper bearings
(with the recommended lubricant) “J
1” (crankcase) – “J1”
(crankshaft web) – 1 =
6 – 2 – 1 = 3 (brown)
CRANKSHAFT JOURNAL BEARING 
COLOR CODE
0 White
1Blue
2Black
3Brown
4 Green
Recommended lubricant
Engine oil 
						

							CRANKSHAFT
5-83
NOTE:
 Align the projections “a” on the crankshaft 
journal upper bearings with the notches “b” in 
the upper crankcase.
 Be sure to install each crankshaft journal 
upper bearing in its original place.
3. Install:
 Crankshaft
4. Install:
 Crankcase (lower)
Refer to CRANKCASE on page 5-65.
5. Install:
Pin
 Pickup rotor “1”
 Drive sprocket “2”
Drive sprocket bolt
60 Nm (6.0 m·kg, 43 ft·lb) 
						

							TRANSMISSION
5-84
EAS26240
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
Order Job/Parts to remove Q’ty Remarks
Lower crankcaseSeparate.
Refer to CRANKCASE on page 5-65.
1 Drive axle assembly 1
2 Circlip 1
3 Oil seal 1
4 Bearing 1
5 Washer 1
6 Shift fork guide bar retainer 2
7Spring 2
8 Shift fork guide bar 2
9 Shift fork-L 1
10 Shift fork-R 1
11 Shift drum assembly 1
12 Shift fork-C 1
13 Main axle retainer 1
14 Main axle assembly 1
15 Oil pipe 1
16 O-ring 2
17 Oil baffle plate 1 
						

							TRANSMISSION
5-85
For installation, reverse the removal proce-
dure.
Removing the transmission, shift drum assembly, and shift forks
Order Job/Parts to remove Q’ty Remarks 
						

							TRANSMISSION
5-86
Disassembling the main axle assembly
Order Job/Parts to remove Q’ty Remarks
1 2nd pinion gear 1
2 Toothed lock washer 1
3 Toothed lock washer retainer 1
4 6th pinion gear 1
5 Collar 1
6 Washer 1
7 Circlip 1
8 3rd pinion gear 1
9 Circlip 1
10 Washer 1
11 5th pinion gear 1
12 Collar 1
13 Main axle 1
14 Bearing housing 1
15 Bearing 1
For assembly, reverse the disassembly pro-
cedure. 
						

							TRANSMISSION
5-87
Disassembling the drive axle assembly
Order Job/Parts to remove Q’ty Remarks
1 Washer 1
2 1st wheel gear 1
3 Collar 1
4 5th wheel gear 1
5 Circlip 1
6 Washer 1
7 3rd wheel gear 1
8 Collar 1
9 Toothed lock washer 1
10 Toothed lock washer retainer 1
11 4th wheel gear 1
12 Collar 1
13 Washer 1
14 Circlip 1
15 6th wheel gear 1
16 Circlip 1
17 Washer 1
18 Collar 1
19 2nd wheel gear 1
20 Collar 1
21 Oil seal 1
22 Bearing 1
23 Drive axle 1 
						

							TRANSMISSION
5-88
For assembly, reverse the disassembly pro-
cedure.
Disassembling the drive axle assembly
Order Job/Parts to remove Q’ty Remarks 
						

							TRANSMISSION
5-89
EAS26250
REMOVING THE TRANSMISSION
1. Remove:
 Drive axle assembly “1”
 Shift drum retainers “2”
 Shift fork guide bars
 Shift fork “L” and “R”
 Shift drum assembly
 Shift fork “C”
2. Remove:
 Bearing housing “1”
 Main axle assembly “2”
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a. Insert two bolts “3” of the proper size, as 
shown in the illustration, into the main axle 
assembly bearing housing.
b. Tighten the bolts until they contact the 
crankcase surface.
c. Continue tightening the bolts until the main 
axle assembly comes free from the upper 
crankcase.
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3. Remove:
Oil pipe “1”
 Bearing “2”
EAS26260
CHECKING THE SHIFT FORKS
The following procedure applies to all of the 
shift forks.
1. Check:
 Shift fork cam follower “1”
 Shift fork pawl “2”
Bends/damage/scoring/wear → Replace 
the shift fork.
2. Check:
 Shift fork guide bar
Roll the shift fork guide bar on a flat sur-
face.
Bends → Replace.
WARNING
EWA12840
Do not attempt to straighten a bent shift 
fork guide bar. 
						

							TRANSMISSION
5-90
3. Check:
 Shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift 
forks and shift fork guide bar as a set.
EAS26270
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
 Shift drum groove
Damage/scratches/wear → Replace the 
shift drum assembly.
 Shift drum segment “1”
Damage/wear → Replace the shift drum 
assembly.
 Shift drum bearing “2”
Damage/pitting → Replace the shift drum 
assembly.
EAS26300
CHECKING THE TRANSMISSION
1. Measure:
 Main axle runout
(with a centering device and dial gauge “1”)
Out of specification → Replace the main 
axle.2. Measure:
 Drive axle runout
(with a centering device and dial gauge “1”)
Out of specification → Replace the drive 
axle.
3. Check:
 Transmission gears
Blue discoloration/pitting/wear → Replace 
the defective gear(s).
 Transmission gear dogs
Cracks/damage/rounded edges → Replace 
the defective gear(s).
Main axle runout limit
0.08 mm (0.0032 in)
Drive axle runout limit
0.08 mm (0.0032 in)