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YZFR7P
Yamaha YZFR7P User Manual
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7 - 56
CHAS
EB703002
Order
Job/Part
Q’ty
Remarks
Disassembling the front fork legs
Remove the parts in the order listed.
The following procedure applies to
both of the front fork legs.
1
Cap
bolt/O-ring
1/1
2
Straight
key
1
3
Washer
1
4
Damper adjusting rod
1
5
Nut
1
6
Spring
seat
1
7
Spacer
1
8
Fork spring
1
9
Outer
tube
1
0
Dust seal
1
A
Oil seal clip
1
B
Oil
seal
1
C
Washer
1
FRONT FORK
305
307
Table of Contents
Default Chapter
3
Introduction
3
Finding the Required Page
5
General
5
Particularly Important Information
5
How to Read Descriptions
6
Manual Format
6
Chassis
7
Cooling System
7
Electronic Fuel
7
Overhauling
7
Specifications
7
Symbols
7
Index
9
Table of Contents
10
CHAPTER 1 General Information
13
Give Safety the Right of Way
13
Description
14
Left View
14
Right View
14
Controls/Instruments
15
Instrument and Control Functions
16
Main Switch/Steering Lock
16
Indicator Lights
16
Fuel Indicator Light
16
Warning Light
17
Warning Light Circuit Check
18
Fuel Indicator Light Circuit Check
19
Selecting a Mode
19
Odometer and Trip Meter Modes
19
Resetting a Meter
19
Digital Speedometer
19
Clock Mode
20
Tachometer
20
To Set the Clock
20
Diagnosis Device
20
Lights Switch
21
Dimmer Switch
21
Handlebar Switches
21
Turn Signal Switch
21
Clutch Lever
21
Shift Pedal
22
Front Brake Lever
22
Rear Brake Pedal
22
Fuel Tank Cap
22
Starter (Choke)
23
Sidestand/Clutch Switch
23
Operation and Important Riding Points
24
Starting the Engine
24
Starting a Warm Engine
25
Engine Break-In
26
Parking
26
Included Accessories
26
Tool Kit
26
Motorcycle Care and Storage
27
Before Cleaning
27
After Normal Use
27
After Cleaning
28
Storage
28
Short-Term
28
Long-Term
28
Consumer Information
29
Identification Numbers Record
29
Key Identification Number
29
Vehicle Identification Number
29
Model Label
30
Troubleshooting Chart
30
Engine Overheating
31
Troubleshooting Chart
31
Important Information
32
Preparation for Removal and Disassembly
32
Replacement Parts
32
Gaskets, Oil Seals and O-Rings
32
Using a Dynamometer
33
Lock Washers/Plates and Cotter Pins
33
Bearings and Oil Seals
33
Circlips
33
Checking the Connections
34
Special Tools
35
General Specifications
39
Dimensions
39
Weight
39
Engine Specifications
40
Oil Filter
41
Oil Pump
41
Spark Plugs
41
Cylinder Head
41
Camshafts
42
Valves, Valve Seats, Valve Guides
43
Timing Chain
43
Valve Dimensions
43
Valve Springs
44
Valve Stem Runout
44
Connecting Rods
47
Crankshaft
47
Clutch
47
Transmission
48
Shifting Mechanism
48
Fuel Pump
48
Chassis Specifications
49
Rear Tire
50
Front Brakes
50
Rear Brake
50
Front Suspension
51
Electrical Specifications
53
Tightening Torques
55
General Tightening Torques
55
Engine Tightening Torques
56
Crankcase Tightening Sequence
58
Chassis Tightening Torques
59
Lubrication Points and Lubricant Types
60
Engine Lubrication Points and Lubricant Types
60
Chassis Lubrication Points and Lubricant Types
61
Oil Flow Chart
62
Coolant Flow Chart
63
Cable Routing
64
CHAPTER 3 Periodic Checks and Adjustments
70
Periodic Maintenance and Lubrication Intervals
70
Introduction
70
Periodic Maintenance and Lubrication
71
Fuel Tank and Air Filter
73
Removing the Fuel Tank and Air Filter
73
Cowlings
75
Removing the Front Cowling
75
Removing the Rear Cowling
76
Adjusting the Valve Clearance
78
Engine
78
Valve Pad Selection Table
82
Intake
82
Exhaust
82
Adjusting the Valve Clearance
82
Synchronizing the Throttle Bodies
83
Adjusting the Engine Idling Speed
85
Adjusting the Throttle Cable Free Play
86
Checking the Spark Plugs
88
Handlebar Side
88
Measuring the Compression Pressure
89
Measuring the Compression Pressure
91
Checking the Engine Oil Level
92
Changing the Engine Oil
93
Checking the Clutch Fluid Level
95
Bleeding the Hydraulic Clutch System
96
Cleaning the Air Filter Element
97
Checking the Fuel Hoses
98
Checking the Crankcase Breather Hose
98
Checking the Exhaust System
99
Checking the Coolant Level
100
Checking the Cooling System
101
Changing the Coolant
102
Adjusting the Rear Brake
105
Chassis
105
Checking the Brake Fluid Level
106
Checking the Brake Pads
107
Checking the Brake Hoses
108
Bleeding the Hydraulic Brake System
108
Adjusting the Shift Pedal
110
Adjusting the Drive Chain Slack
110
Lubricating the Drive Chain
112
Checking and Adjusting the Steering Head
112
Recommended Lubricant
112
Lower Ring Nut
114
Steering Head Tension
115
Checking the Front Fork
115
Adjusting the Front Fork Legs
116
Spring Preload
116
Rebound Damping
117
Compression Damping
117
Adjusting Positions
117
Adjusting the Front Fork Legs
117
Adjusting the Rear Shock Absorber Assembly
118
Minimum Tire Tread Depth
121
Front Tire
121
Checking the Tires
122
Checking the Wheels
122
Checking and Lubricating the Cables
123
Lubricating the Levers and Pedals
123
Lubricating the Sidestand
123
Lubricating the Rear Suspension
123
Electrical System
124
Checking and Charging the Battery
124
Charging Method Using a Variable-Voltage Charger
127
Charging Method Using a Constant-Voltage Charger
128
Checking the Fuses
129
Replacing the Headlight Bulbs
131
Adjusting the Headlight Beams
132
CHAPTER 4 Overhauling the Engine
133
Removing the Drive Sprocket
133
Removing the Exhaust Assembly
135
Disconnecting the Leads and Hoses
136
Installing the Engine
139
Removing the Cylinder Head Cover
140
Camshafts
140
Removing the Camshafts
141
Installing the Camshafts
147
Removing the Cylinder Head
150
Checking the Cylinder Head
151
Installing the Cylinder Head
152
Valves and Valve Springs
153
Removing the Valves and Valve Springs
153
Removing the Valves
155
Checking the Valves and Valve Guides
156
Checking the Valve Springs
160
Valve Spring Free Length
160
Inner Spring
160
Compressed Spring Force
161
Maximum Spring Tilt
161
Checking the Valve Lifters
161
Installing the Valves
162
Generator
164
Removing the Stator Coil Assembly
164
Removing the Generator
165
Installing the Generator
165
Pickup Coil
167
Removing the Pickup Coil and Pickup Coil Rotor
167
Removing the Pickup Coil Rotor
169
Installing the Pickup Coil Rotor
169
Removing the Clutch Cover
171
Removing the Clutch
172
Checking the Friction Plates
174
Checking the Clutch Plates
175
Checking the Clutch Spring Plate
175
Checking the Clutch Housing
175
Checking the Clutch Boss
176
Checking the Pressure Plate
176
Checking the Push Rods and Ball
176
Checking the Back Torque Limiter
176
Checking the Starter Clutch
177
Installing the Clutch
178
Shift Shaft
180
Removing the Shift Shaft and Stopper Lever
180
Checking the Shift Shaft
181
Checking the Stopper Lever
181
Installing the Shift Shaft
181
Oil Pan and Oil Pump
182
Removing the Oil Pan and Oil Pump
182
Removing the Oil Pan
185
Removing the Oil Pump
185
Checking the Oil Pump
185
Checking the Relief Valve
186
Checking the Oil Strainer
186
Assembling the Oil Pump
186
Installing the Oil Pump
187
Installing the Oil Strainer
187
Installing the Oil Pan
187
Crankcase
188
Separating the Crankcase
188
Removing the Oil Baffle Plates and Oil Filter Bolt
190
Disassembling the Crankcase
191
Checking the Crankcase
192
Checking the Bearings and Oil Seals
192
Checking the Sprockets and Chains
192
Assembling the Crankcase
193
Connecting Rods and Pistons
195
Removing the Connecting Rods and Pistons
195
Checking the Cylinders and Pistons
197
Checking the Piston Rings
198
Checking the Piston Pins
199
Checking the Big End Bearings
200
Installing the Pistons and Connecting Rods
202
Big End Bearing Color Code
202
Removing the Crankshaft Assembly
206
Removing the Crankshaft
207
Checking the Crankshaft
207
Checking the Crankshaft Journal Bearings
207
Transmission
211
Removing the Transmission
217
Checking the Shift Forks
217
Checking the Shift Drum Assembly
218
Checking the Transmission
218
Transmission Gears
218
Transmission Gear Dogs
218
Installing the Transmission
219
CHAPTER 5 Cooling System
220
Radiator and Thermostat
220
Removing the Radiator
220
Removing the Thermostat Assembly
222
Radiator and Thermostat
222
Disassembling the Thermostat Assembly
224
Checking the Radiator
225
Radiator Cap Opening Pressure
225
Radiator Cap Tester
225
Assembling the Thermostat Assembly
226
Installing the Thermostat Assembly and Radiator
227
Oil Cooler
228
Removing the Oil Cooler
228
Checking the Oil Cooler
229
Installing the Oil Cooler
229
Water Pump
231
Removing the Impeller Shaft
231
Disassembling the Water Pump
233
Checking the Water Pump
233
Assembling the Water Pump
234
CHAPTER 6 Electronic Fuel Injection
236
Removing the Injector 2 Assembly and Air Filter Case
236
Removing the Injector 2
238
Electronic Fuel Injection Efi
238
Removing the Throttle Body Assembly
240
Removing the Injector 1 and Throttle Body
242
Checking the Injector
244
Checking the Throttle Body
244
Electronic Fuel Injection Efi
244
Checking the Pressure Regulator
245
Checking and Adjusting the Throttle Position Sensor
245
Checking the Fuel Pump and Pressure Regulator Operation
249
Front Wheel and Brake Discs
251
Removing the Front Wheel and Brake Discs
251
Chapter 7 Chassis
251
Disassembling the Front Wheel
252
Removing the Front Wheel
253
Checking the Front Wheel
253
Checking the Brake Discs
255
Installing the Front Wheel
256
Adjusting the Front Wheel Static Balance
257
Rear Wheel, Brake Disc, and Rear Wheel Sprocket
259
Removing the Rear Wheel
259
Removing the Brake Disc and Rear Wheel Sprocket
260
Disassembling the Rear Wheel
261
Checking the Rear Wheel
262
Checking the Rear Wheel Drive Hub
263
Checking and Replacing the Rear Wheel Sprocket
263
Installing the Rear Wheel
264
Adjusting the Rear Wheel Static Balance
264
Front and Rear Brakes
265
Removing the Front Brake Pads
265
Removing the Rear Brake Pads
266
Replacing the Front Brake Pads
267
Replacing the Rear Brake Pads
269
Removing the Front Brake Calipers
272
Disassembling the Front Brake Calipers
273
Removing the Rear Brake Caliper
274
Disassembling the Rear Brake Caliper
275
Checking the Front and Rear Brake Calipers
278
Recommended Brake Component Replacement Schedule
278
Assembling and Installing the Front Brake Calipers
279
Assembling and Installing the Rear Brake Caliper
281
Recommended Brake Fluid
282
Removing the Front Brake Master Cylinder and Brake Fluid Reservoir
283
Disassembling the Front Brake Master Cylinder
285
Removing the Rear Brake Master Cylinder and Brake Fluid Reservoir
286
Disassembling the Rear Brake Master Cylinder
287
Checking the Front and Rear Brake Master Cylinders
288
Assembling and Installing the Front Brake Master Cylinder
289
Assembling the Rear Brake Master Cylinder
291
Hydraulic Clutch
293
Removing the Clutch Master Cylinder
293
Disassembling the Clutch Master Cylinder
295
Checking the Clutch Master Cylinder
296
Assembling and Installing the Clutch Master Cylinder
297
Removing the Clutch Release Cylinder
300
Disassembling the Clutch Release Cylinder
301
Assembling and Installing the Clutch Release Cylinder
303
Front Fork
305
Removing the Front Fork Legs
305
Disassembling the Front Fork Legs
306
Checking the Front Fork Legs
310
Assembling the Front Fork Legs
311
Installing the Front Fork Legs
316
Handlebars
317
Removing the Handlebars
317
Checking the Handlebars
319
Installing the Handlebars
319
Steering Head
322
Removing the Lower Bracket
322
Checking the Steering Head
324
Installing the Steering Head
325
Rear Shock Absorber Assembly
326
Removing the Rear Shock Absorber Assembly
326
Handling the Rear Shock Absorber and Gas Cylinder
327
Disposing of a Rear Shock Absorber and Gas Cylinder
327
Checking the Rear Shock Absorber Assembly and Gas Cylinder
328
Checking the Relay Arm and Connecting Arm
329
Installing the Rear Shock Absorber Assembly
329
Swingarm and Drive Chain
330
Removing the Swingarm and Drive Chain
330
Removing the Swingarm
332
Removing the Drive Chain
333
Checking the Swingarm
333
Checking the Drive Chain
334
Installing the Swingarm
336
Electrical Components
337
Switches
338
Checking Switch Continuity
338
Checking the Switches
339
Checking the Bulbs and Bulb Sockets
340
Checking the Condition of the Bulbs
340
Checking the Condition of the Bulb Sockets
342
Checking the Leds
342
Ignition System
343
Circuit Diagram
343
Troubleshooting
344
Measuring the Ignition Spark Gap
345
Minimum Ignition Spark Gap
345
Measuring the Ignition Coil Resistance
346
Measuring the Pickup Coil Resistance
346
Checking the Diode
347
Checking the Relay Unit
347
Electric Starting System
348
The Starter Motor Fails to Turn
349
Electric Starting System
349
Checking the Starter Relay
351
Checking the Diodes
351
Charging System
352
The Battery Is Not Being Charged
353
Measuring the Charging Voltage
354
Measuring the Stator Coil Assembly Resistances
354
Lighting System
355
Signaling System
357
Checking the Oil Level Switch
359
Pocket Tester
359
Cooling System
360
Checking the Thermo Switch
362
Electronic Fuel Injection System
364
The Condition Code Is Displayed by the Tachometer
365
Electrical Control System
366
User Mode
366
Tachometer Display Sequence (Engine Not Running)
367
Condition Code List
368
Diagnosis Mode
369
CO, Diagnosis Switch Box Method
369
Operation after Entering the Diagnosis Mode
370
Test Coupler Adapter Method
371
Diagnosis Code List
372
Co Emission Adjustment Mode
375
Exhaust Attachment
375
Engine Tachometer
375
CO, Diagnosis Switch Box
375
Standard CO Concentration
377
Yzf-R7 Wiring Diagram
378
Color Code
378
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Yamaha YZFR7P Specifications
General
Brand
Yamaha
Model
YZFR7P
Category
Motorcycle
Language
English
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