2007-2008 Yamaha R1 YZFR1 Service & Repair Manual

2007 MOTORCYCLE SERVICE MANUAL Model : YZFR1W 4C8281972000 *4C8281972000*

EAS20040 YZFR1W SERVICE MANUAL ©2006 by Yamaha Motor Co., Ltd. First edition, October 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.

EAS20070 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives. Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal- ers and will appear in future editions of this manual where applicable. NOTE: • This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully. • Designs and specifications are subject to change without notice. EAS20080 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the vehicle operator, a bystander or a person checking or repairing the vehicle. A CAUTION indicates special precautions that must be taken to avoid damage to the vehicle. A NOTE provides key information to make procedures easier or clearer. WARNING CAUTION: NOTE:

EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. • The manual is divided into chapters and each chapter is divided into sections. The current section title is shown at the top of each page “1”. • Sub-section titles appear in smaller print than the section title “2”. • To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section “3”. • Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disassembly step “4”. • Symbols indicate parts to be lubricated or replaced “5”. Refer to “SYMBOLS”. • A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc “6”. • Jobs requiring more information (such as special tools and technical data) are described sequen- tially “7”.

EAS20100 SYMBOLS The following symbols are used in this manual for easier understanding. NOTE: The following symbols are not relevant to every vehicle. 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening torque 6. Wear limit, clearance 7. Engine speed 8. Electrical data 9. Engine oil 10.Gear oil 11.Molybdenum-disulfide oil 12.Wheel-bearing grease 13.Lithium-soap-based grease 14.Molybdenum-disulfide grease 15.Apply locking agent (LOCTITE®) G M E B LS M 9 10 11 12 13 14 15 16 LT New T R . . 1 2 3 4 5 6 7 8 16.Replace the part

GENERAL INFORMATION IDENTIFICATION .......................................................................................... 1-1 VEHICLE IDENTIFICATION NUMBER................................................... 1-1 MODEL LABEL ....................................................................................... 1-1 FEATURES ................................................................................................... 1-2 FI SYSTEM ............................................................................................. 1-3 IMPORTANT INFORMATION ..................................................................... 1-12 PREPARATION FOR REMOVAL AND DISASSEMBLY ........................ 1-12 REPLACEMENT PARTS....................................................................... 1-12 GASKETS, OIL SEALS AND O-RINGS................................................ 1-12 LOCK WASHERS/PLATES AND COTTER PINS ................................. 1-12 BEARINGS AND OIL SEALS ............................................................... 1-13 CIRCLIPS ............................................................................................. 1-13 CHECKING THE CONNECTIONS ............................................................. 1-14 SPECIAL TOOLS........................................................................................ 1-15

IDENTIFICATION 1-1 EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.

FEATURES 1-2 EAS20170 FEATURES OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor. Despite the same volume of intake air, the fuel volume requirement varies by the engine operating conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter the fuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine. As the requirements for the engine to deliver more performance and cleaner exhaust gases increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned man- ner. To accommodate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions detected by various sensors. The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response, better fuel economy, and reduced exhaust emissions. 1. Intake air temperature sensor 2. Engine trouble warning light 3. Air induction system solenoid 4. Atmospheric pressure sensor 5. Throttle position sensor (for throttle cable pulley) 6. Throttle servo motor 7. Throttle position sensor (for throttle valves) 8. Intake funnel servo motor 9. Injector 10.Intake air pressure sensor 11.Fuel pump 12.Lean angle sensor 13.ECU (engine control unit) 14.Starting circuit cut-off relay 15.Speed sensor 16.EXUP servo motor 17.O 2 sensor 18.Crankshaft position sensor 19.Coolant temperature sensor 20.Spark plug 21.Ignition coil 22.Cylinder identification sensor

FEATURES 1-3 EAS4C81010 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm 2 , 46.1 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, caus- ing the fuel to be injected into the intake manifold only during the time the passage remain open. Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized (injection duration), the lesser the volume of fuel that is supplied. The injection duration and the injection timing are controlled by the ECU. Signals that are input from the throttle position sensor (for throttle valves), throttle position sensor (for throttle cable pulley), crankshaft position sensor, intake air pressure sensor, intake air temperature sensor, coolant temperature sensor, atmospheric pressure sensor, cylinder identification sensor, lean angle sensor, speed sensor and O 2 sensor enable the ECU to determine the injection duration. The injection timing is determined through the signals from the crankshaft position sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times in accordance with the driving conditions. 1. Fuel pump 2. Injector 3. Cylinder identification sensor 4. ECU (engine control unit) 5. Throttle position sensor (for throttle valves) 6. Throttle position sensor (for throttle cable pulley) 7. Speed sensor 8. Intake air temperature sensor 9. Lean angle sensor 10.O 2 sensor 11.Catalytic converter 12.Coolant temperature sensor 13.Crankshaft position sensor 14.Intake air pressure sensor 15.Throttle servo motor 16.Throttle body 17.Atmospheric pressure sensor 18.Air filter case 19.Intake funnel servo motor A. Fuel system B. Air system C. Control system

FEATURES 1-4 EAS4C81011 YCC-T (Yamaha Chip Controlled Throttle) YCC-I (Yamaha Chip Controlled Intake) Mechanism characteristics Yamaha developed the YCC-T and YCC-I system employing the most advanced electronic control technologies. Electronic control throttle systems have been used on automobiles, but Yamaha has developed a faster, more compact system specifically for the needs of a sports motorcycle. The Yamaha-developed system has a high-speed calculating capacity that produces computations of running conditions every 1/1000th of a second. The YCC-T system is designed to respond to the throttle action of the rider by having the ECU instantaneously calculate the ideal throttle valve opening and generate signals to operate the motor- driven throttle valves and thus actively control the intake air volume. The ECU contains three CPUs with a capacity about five times that of conventional units, making it possible for the system to respond extremely quickly to the slightest adjustments made by the rider. In particular, optimized control of the throttle valve opening provides the optimum volume of intake air for easy-to-use torque, even in a high-revving engine. The YCC-I system calculates the value from the engine revolution number and throttle opening rate, activates the intake air funnel with the electronic control motor drive to control the intake pipe length in order to gain the high power output in all revolution ranges from low speeds to high speeds. Aims and advantages of using YCC-T system • Increased engine power By shortening the air intake path, higher engine speed is possible → Increased engine power. • Improved driveability Air intake volume is controlled according to the operating conditions → Improved throttle response to meet engine requirement. Driving force is controlled at the optimal level according to the transmission gear position and engine speed → Improved throttle control. • Engine braking control Due to the throttle control, optimal engine braking is made possible. • Simplified idle speed control (ISC) mechanism The bypass mechanism and ISC actuator are eliminated → A simple mechanism is used to main- tain a steady idle speed. • Reduced weight Compared to using a sub-throttle mechanism, weight is reduced. 1. Throttle position sensor (for throttle cable pulley) 2. Throttle servo motor 3. Throttle position sensor (for throttle valves) 4. Throttle valves 5. Throttle cable pulley with linkage guard A. To throttle grip

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2007-2008 Yamaha R1 YZFR1 Service & Repair Manual

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