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YZFR1W 2007
Yamaha YZFR1W 2007 User Manual
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SHIFT SHAFT
5-54
EAS25410
SHIFT SHAFT
Removing the
shift shaft and stopper le
ver
Order
Job/Parts to remove
Q’ty
Remarks
Shift ar
m
Refer
to "ENGINE REMO
V
AL" on
page 5-1
Clutch assembly
Ref
er to "CLUTCH" on page 5-44.
1
Circlip
1
2
W
asher
1
3
Shift shaft
1
4
Collar
1
5
Shift shaft spr
ing
1
6
W
asher
1
7
Stopper screw
1
8
Stopper lev
er
1
9
W
asher
1
10
Oil seal
1
11
Be
aring
1
12
Be
aring
1
13
Stop
per le
ver spring
1
F
or installation, re
verse the remo
val proce-
dure.
253
255
Table of Contents
General Information
6
Default Chapter
4
How to Use this Manual
4
Table of Contents
6
Identification
7
Vehicle Identification Number
7
Model Label
7
Features
8
Outline of the Fi System
8
Fi System
9
Important Information
18
Preparation for Removal and Disassembly
18
Replacement Parts
18
Gaskets, Oil Seals and O-Rings
18
Lock Washers/Plates and Cotter Pins
18
Bearings and Oil Seals
19
Circlips
19
Checking the Connections
20
Special Tools
21
Specifications
28
General Specifications
29
Specifications
29
Engine Specifications
30
Chassis Specifications
36
Electrical Specifications
38
Tightening Torques
40
General Tightening Torque Specifications
40
Engine Tightening Torques
41
Chassis Tightening Torques
45
Lubrication Points and Lubricant Types
48
Engine
48
Chassis
48
Lubrication System Chart and Diagrams
51
Engine Oil Lubrication Chart
51
Lubrication Diagrams
53
Cooling System Diagrams
63
Cable Routing
67
Periodic Checks and Adjustments
82
Periodic Maintenance
84
Introduction
84
Periodic Maintenance Chart for the Emission Control System
84
General Maintenance and Lubrication Chart
84
Engine
87
Adjusting the Valve Clearance
87
Synchronizing the Throttle Bodies
90
Carburetor Synchronizer YU
90
Adjusting the Throttle Cable Free Play
91
Checking the Spark Plugs
92
Measuring the Compression Pressure
93
Engine Compression Tester YU
93
Checking the Engine Oil Level
94
Changing the Engine Oil
94
Measuring the Engine Oil Pressure
96
Adjusting the Clutch Cable Free Play
97
Replacing the Air Filter Element
97
Checking the Throttle Body Joints
98
Checking the Fuel Line
98
Checking the Crankcase Breather Hose
99
Checking the Exhaust System
99
Adjusting the Exup Cables
100
Checking the Exup Servo Motor
101
Checking the Coolant Level
101
Checking the Cooling System
102
Changing the Coolant
102
Chassis
105
Adjusting the Front Disc Brake
105
Adjusting the Rear Disc Brake
105
Checking the Brake Fluid Level
106
Checking the Front Brake Pads
106
Checking the Rear Brake Pads
107
Checking the Front Brake Hoses
107
Checking the Rear Brake Hose
107
Adjusting the Rear Brake Light Switch
107
Bleeding the Hydraulic Brake System
108
Adjusting the Shift Pedal
109
Adjusting the Drive Chain Slack
109
Lubricating the Drive Chain
110
Checking and Adjusting the Steering Head
110
Checking the Front Fork
112
Adjusting the Front Fork Legs
112
Adjusting the Rear Shock Absorber Assembly
114
Checking the Tires
115
Checking the Wheels
117
Checking and Lubricating the Cables
117
Lubricating the Levers
117
Lubricating the Pedal
118
Electrical System
119
Chassis
121
General Chassis
127
Checking the Intake Funnel
127
Checking the Intake Funnel Operation
127
Removing the Cover
129
Installing the Cover
129
Front Wheel
130
Removing the Front Wheel
132
Checking the Front Wheel
132
Adjusting the Front Wheel Static Balance
133
Installing the Front Wheel
134
Rear Wheel
136
Removing the Rear Wheel
139
Checking the Rear Wheel
139
Checking the Rear Wheel Drive Hub
140
Checking and Replacing the Rear Wheel Sprocket
140
Adjusting the Rear Wheel Static Balance
140
Installing the Rear Wheel
140
Front Brake
142
Introduction
147
Checking the Front Brake Discs
147
Replacing the Front Brake Pads
148
Removing the Front Brake Calipers
149
Disassembling the Front Brake Calipers
150
Checking the Front Brake Calipers
150
Assembling the Front Brake Calipers
150
Installing the Front Brake Calipers
151
Removing the Front Brake Master Cylinder
152
Checking the Front Brake Master Cylinder
152
Assembling the Front Brake Master Cylinder
153
Installing the Front Brake Master Cylinder
153
Rear Brake
155
Rear Brake
157
Rear Brake
158
Introduction
160
Checking the Rear Brake Disc
160
Replacing the Rear Brake Pads
160
Removing the Rear Brake Caliper
162
Disassembling the Rear Brake Caliper
162
Checking the Rear Brake Caliper
162
Assembling the Rear Brake Caliper
163
Installing the Rear Brake Caliper
163
Removing the Rear Brake Master Cylinder
164
Checking the Rear Brake Master Cylinder
164
Assembling the Rear Brake Master Cylinder
165
Installing the Rear Brake Master Cylinder
165
Handlebars
169
Removing the Handlebar
169
Checking the Handlebars
169
Installing the Handlebars
169
Checking the Steering Damper
170
Front Fork
172
Removing the Front Fork Legs
174
Disassembling the Front Fork Legs
174
Checking the Front Fork Legs
175
Assembling the Front Fork Legs
176
Installing the Front Fork Legs
180
Steering Head
181
Removing the Lower Bracket
183
Checking the Steering Head
183
Installing the Steering Head
183
Rear Shock Absorber Assembly
185
Handling the Rear Shock Absorber
186
Disposing of a Rear Shock Absorber
186
Removing the Rear Shock Absorber Assembly
186
Checking the Rear Shock Absorber Assembly
186
Checking the Connecting Arm and Relay Arm
187
Installing the Relay Arm
187
Installing the Rear Shock Absorber Assembly
187
Swingarm
188
Removing the Swingarm
190
Checking the Swingarm
191
Installing the Swingarm
191
Chain Drive
193
Removing the Drive Chain
194
Checking the Drive Chain
194
Checking the Rear Wheel Sprocket
195
Checking the Rear Wheel Drive Hub
195
Installing the Drive Chain
195
Engine
198
Engine Removal
207
Installing the Engine
207
Camshafts
209
Removing the Camshafts
211
Checking the Camshafts
212
Checking the Timing Chain and Camshaft Sprocket
213
Checking the Timing Chain Guides
213
Checking the Timing Chain Tensioner
213
Installing the Camshafts
215
Cylinder Head
218
Removing the Cylinder Head
219
Checking the Cylinder Head
219
Installing the Cylinder Head
219
Valves and Valve Springs
222
Removing the Valves
223
Checking the Valves and Valve Guides
223
Checking the Valve Seats
225
Valve Guide Remover (Ø4.5)
225
Checking the Valve Springs
227
Checking the Valve Lifters
228
Installing the Valves
228
Generator
230
Removing the Generator
232
Installing the Generator
232
Starter Clutch
234
Removing the Starter Clutch
235
Checking the Damper
235
Checking the Starter Clutch
235
Installing the Starter Clutch
236
Crankshaft Position Sensor
237
Removing the Crankshaft Position Sensor
238
Installing the Crankshaft Position Sensor
238
Electric Starter
239
Checking the Starter Motor
241
Assembling the Starter Motor
242
Installing the Starter Motor
243
Clutch
244
Removing the Clutch
247
Checking the Friction Plates
248
Checking the Clutch Plates
248
Checking the Clutch Springs
249
Checking the Clutch Housing
249
Checking the Clutch Boss
249
Checking the Pressur Plate 2
250
Checking the Pressure Plate 1
250
Checking the Push Lever Shaft and Push Rod
250
Installing the Clutch
250
Shift Shaft
254
Removing the Shift Shaft
255
Checking the Shift Shaft
255
Checking the Stopper Lever
255
Installing the Shift Shaft
255
Oil Pump
257
Removing the Oil Pan
260
Checking the Sprocket and Chain
260
Checking the Oil Pump
260
Checking the Relief Valve
261
Checking the Oil Delivery Pipes
261
Checking the Oil Strainer
261
Checking the Oil Nozzles
261
Assembling the Oil Pump
262
Installing the Oil/Water Pump Assembly
262
Installing the Oil Pan
263
Crankcase
265
Disassembling the Crankcase
267
Checking the Crankcase
267
Checking the Bearing and Oil Seals
267
Assembling the Crankcase
267
Three Bond no
267
Crankshaft
269
Removing the Connecting Rods and Pistons
271
Removing the Crankshaft Assembly
271
Checking the Cylinder and Piston
272
Checking the Piston Rings
272
Checking the Piston Pin
273
Checking the Big End Bearings
274
Installing the Connecting Rod and Piston
277
Checking the Crankshaft
280
Checking the Crankshaft Drive Sprocket
280
Checking the Crankshaft Journal Bearings
280
Installing the Crankshaft
282
Transmission
284
Removing the Transmission
289
Checking the Shift Forks
289
Checking the Shift Drum Assembly
290
Cooling System
294
Radiator
297
Checking the Radiator
297
Installing the Radiator
297
Cooling System
297
Oil Cooler
298
Checking the Oil Cooler
299
Installing the Oil Cooler
299
Thermostat
300
Checking the Thermostat
301
Assembling the Thermostat Assembly
302
Installing the Thermostat Assembly
302
Water Pump
303
Disassembling the Water Pump
304
Checking the Water Pump
304
Assembling the Water Pump
304
Fuel System
306
Fuel Tank
308
Removing the Fuel Tank
308
Removing the Fuel Pump
308
Checking the Fuel Pump Body
308
Checking the Fuel Pump Operation
308
Installing the Fuel Pump
308
Installing the Fuel Tank
309
Throttle Bodies
310
Checking the Injectors
312
Checking the Throttle Bodies
312
Checking the Fuel Pressure
312
Adjusting the Throttle Position Sensor (for Throttle Valves)
312
Adjusting the Throttle Position Sensor (for Throttle Cable Pulley)
313
Air Induction System
315
Checking the Air Induction System
316
Ignition System
320
Electric Starting System
324
Charging System
330
Lighting System
334
Signaling System
338
Fuel Injection System
348
Fuel Pump System
384
Immobilizer System
388
Electrical Components
400
Troubleshooting
422
Wiring Diagram
426
5
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Yamaha YZFR1W 2007 Specifications
General
Brand
Yamaha
Model
YZFR1W 2007
Category
Motorcycle
Language
English
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