2007 YAMAHA YZF-R1 Shock absorber

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Immobilizer system .........................3-1
Main switch/steering lock ................3-2
Indicator and warning lights ............3-3
Multi-function meter unit .................3-7
Anti-theft alarm (optional) .............3-13
Handlebar switches ......................3-14
Clutch lever ...................................3-15
Shift pedal .....................................3-15
Brake lever ...................................3-16
Brake pedal ..................................3-16
Fuel tank cap ................................3-17
Fuel ...............................................3-17
Fuel tank breather/
overflow hose ............................3-18
Catalytic converter ........................3-19
Seats ............................................3-19
Helmet holders .............................3-20
Adjusting the front fork ..................3-21
Adjusting the shock absorber
assembly ...................................3-22
Luggage strap holders ..................3-25
EXUP system ...............................3-25Sidestand ..................................... 3-25
Ignition circuit cut-off system ........ 3-26
PRE-OPERATION CHECKS............. 4-1
Pre-operation check list .................. 4-2
OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting the engine ......................... 5-1
Shifting ........................................... 5-2
Tips for reducing fuel
consumption ............................... 5-3
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
Owner’s tool kit ............................... 6-1
Periodic maintenance and
lubrication chart .......................... 6-2
Removing and installing cowlings
and panels .................................. 6-6
Checking the spark plugs ............... 6-9
Engine oil and oil filter cartridge ... 6-10
Coolant ......................................... 6-13
Replacing the air filter element ..... 6-16
Checking the throttle cable
free play .................................... 6-18
Valve clearance ............................ 6-18
Tires ............................................. 6-18
Cast wheels .................................. 6-21Adjusting the clutch lever
free play .................................... 6-21
Adjusting the rear brake
light switch ................................ 6-22
Checking the front and rear
brake pads ................................ 6-22
Checking the brake fluid level ...... 6-23
Changing the brake fluid .............. 6-24
Drive chain slack .......................... 6-24
Cleaning and lubricating
the drive chain .......................... 6-26
Checking and lubricating
the cables ................................. 6-26
Checking and lubricating
the throttle grip and cable ......... 6-27
Checking and lubricating
the brake and clutch levers ...... 6-27
Checking and lubricating
the shift pedal ........................... 6-28
Checking and lubricating
the sidestand ............................ 6-28
Lubricating the swingarm
pivots ........................................ 6-28
Checking the front fork ................. 6-29
Checking the steering .................. 6-29
Checking the wheel bearings ....... 6-30
Battery ......................................... 6-30
Replacing the fuses ..................... 6-32
Replacing a headlight bulb .......... 6-34
Tail/brake light ............................. 6-37U4C8E0E0.book Page 1 Friday, September 15, 2006 3:21 PM

DESCRIPTION
2-1
2
EAU10410
Left view1. Fuse box (page 6-32)
2. Front fork rebound damping force adjusting screw (page 3-21)
3. Front fork spring preload adjusting bolt (page 3-21)
4. Fuel injection system fuse (page 6-32)
5. Main fuse (page 6-32)
6. Shock absorber assembly compression damping force adjusting bolt
(for fast compression damping) (page 3-22)
7. Shock absorber assembly compression damping force adjusting bolt
(for slow compression damping) (page 3-22)8. Shock absorber assembly rebound damping force adjusting screw
(page 3-22)
9. Shock absorber assembly spring preload adjusting ring (page 3-22)
10.Engine oil drain bolt (page 6-10)
11.Coolant drain bolt (page 6-14)
12.Engine oil filter cartridge (page 6-10)
13.Front fork compression damping force adjusting screw (page 3-21)U4C8E0E0.book Page 1 Friday, September 15, 2006 3:21 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-22
3Compression damping force
To increase the compression damping
force and thereby harden the compres-
sion damping, turn the adjusting screw
on each fork leg in direction (a). To de-
crease the compression damping force
and thereby soften the compression
damping, turn the adjusting screw on
each fork leg in direction (b).
CAUTION:
ECA10100
Never attempt to turn an adjusting
mechanism beyond the maximum orminimum settings.NOTE:Although the total number of clicks of a
damping force adjusting mechanism
may not exactly match the above spec-
ifications due to small differences in
production, the actual number of clicks
always represents the entire adjusting
range. To obtain a precise adjustment,
it would be advisable to check the num-
ber of clicks of each damping force ad-
justing mechanism and to modify thespecifications as necessary.
EAU42940
Adjusting the shock absorber
assembly This shock absorber assembly is
equipped with a spring preload adjust-
ing ring, a rebound damping force ad-
justing screw, a compression damping
force adjusting bolt (for fast compres-
sion damping) and a compression
damping force adjusting bolt (for slow
compression damping).CAUTION:
ECA10100
Never attempt to turn an adjusting
mechanism beyond the maximum orminimum settings.
1. Compression damping force adjusting screwCompression damping setting:
Minimum (soft):
25 click(s) in direction (b)*
Standard:
10 click(s) in direction (b)*
Maximum (hard):
1 click(s) in direction (b)*
* With the adjusting screw fully turned
in direction (a)
U4C8E0E0.book Page 22 Friday, September 15, 2006 3:21 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-23
3 Spring preload
To increase the spring preload and
thereby harden the suspension, turn
the adjusting ring in direction (a). To de-
crease the spring preload and thereby
soften the suspension, turn the adjust-
ing ring in direction (b).
NOTE:

Align the appropriate notch in the
adjusting ring with the position in-
dicator on the shock absorber.


Use the special wrench included in
the owner’s tool kit to make the ad-justment.Rebound damping force
To increase the rebound damping force
and thereby harden the rebound damp-
ing, turn the adjusting screw in direction
(a). To decrease the rebound damping
force and thereby soften the rebound
damping, turn the adjusting screw in di-
rection (b).Compression damping force
Compression damping force (for fast
compression damping)To increase the compression damping
force and thereby harden the compres-
sion damping, turn the adjusting bolt in
1. Special wrench
2. Spring preload adjusting ring
3. Position indicator
Spring preload setting:
Minimum (soft):
1
Standard:
5
Maximum (hard):
9
1. Rebound damping force adjusting screw
Rebound damping setting:
Minimum (soft):
20 click(s) in direction (b)*
Standard:
12 click(s) in direction (b)*
Maximum (hard):
3 click(s) in direction (b)*
* With the adjusting screw fully turned
in direction (a)
1. Compression damping force adjusting bolt
(for fast compression damping)
2. Compression damping force adjusting bolt
(for slow compression damping)
U4C8E0E0.book Page 23 Friday, September 15, 2006 3:21 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-24
3direction (a). To decrease the compres-
sion damping force and thereby soften
the compression damping, turn the ad-
justing bolt in direction (b).
Compression damping force (for slow
compression damping)To increase the compression damping
force and thereby harden the compres-
sion damping, turn the adjusting bolt in
direction (a). To decrease the compres-
sion damping force and thereby soften
the compression damping, turn the ad-
justing bolt in direction (b).
NOTE:Although the total number of clicks or
turns of a damping force adjusting
mechanism may not exactly match the
specifications listed due to small differ-
ences in production, the actual number
of clicks or turns always represents the
entire adjustment range. To obtain a
precise adjustment, it would be advis-
able to check the number of clicks or
turns of each damping force adjusting
mechanism and to modify the specifi-cations as necessary.
WARNING
EWA10220
This shock absorber contains highly
pressurized nitrogen gas. For prop-
er handling, read and understandthe following information before
handling the shock absorber. The
manufacturer cannot be held re-
sponsible for property damage or
personal injury that may result from
improper handling.


Do not tamper with or attempt to
open the gas cylinder.


Do not subject the shock ab-
sorber to an open flame or other
high heat sources, otherwise it
may explode due to excessive
gas pressure.


Do not deform or damage the
gas cylinder in any way, as this
will result in poor damping per-
formance.


Always have a Yamaha dealerservice the shock absorber.
Compression damping setting (for
fast compression damping):
Minimum (soft):
4 turn(s) in direction (b)*
Standard:
3 turn(s) in direction (b)*
Maximum (hard):
0 turn(s) in direction (b)*
* With the adjusting bolt fully turned in
direction (a)
Compression damping setting (for
slow compression damping):
Minimum (soft):
20 click(s) in direction (b)*
Standard:
12 click(s) in direction (b)*
Maximum (hard):
1 click(s) in direction (b)*
* With the adjusting bolt fully turned in
direction (a)
U4C8E0E0.book Page 24 Friday, September 15, 2006 3:21 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
10*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
11*Wheel bearingsCheck bearing for looseness or damage.√√√√
12*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50000 km
13 Drive chainCheck chain slack, alignment and condition.
Adjust and lubricate chain with a special O-ring chain lu-
bricant thoroughly. Every 800 km and after washing the motorcycle or
riding in the rain
14*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20000 km
15*Steering damperCheck operation and for oil leakage.√√√√
16*Chassis fastenersMake sure that all nuts, bolts and screws are properly
tightened.√√√√ √
17 Shift pedal rod pivotsLubricate with lithium-soap-based grease.√√√√ √
18 SidestandCheck operation.
Lubricate.√√√√ √
19*Sidestand switchCheck operation.√√√√√ √
20*Front forkCheck operation and for oil leakage.√√√√
21*Shock absorber assem-
blyCheck operation and shock absorber for oil leakage.√√√√
22*Rear suspension relay
arm and connecting
arm pivoting pointsCheck operation.√√√√
23*Fuel injection systemAdjust synchronization.√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
U4C8E0E0.book Page 3 Friday, September 15, 2006 3:21 PM

SPECIFICATIONS
8-2
8
Gear ratio:
1st:
38/15 (2.533)
2nd:
33/16 (2.063)
3rd:
37/21 (1.762)
4th:
35/23 (1.522)
5th:
30/22 (1.364)
6th:
33/26 (1.269)Chassis:Frame type:
Diamond
Caster angle:
24.00 °
Trail:
102.0 mm (4.02 in)Front tire:Type:
Tubeless
Size:
120/70 ZR17M/C (58W)
Manufacturer/model:
MICHELIN/Pilot POWER P
Manufacturer/model:
PIRELLI/DIABLO CORSA E (for full PS
models only)Rear tire:Type:
TubelessSize:
190/50 ZR17M/C (73W)
Manufacturer/model:
MICHELIN/ Pilot POWER
Manufacturer/model:
PIRELLI/DIABLO CORSA L (for full PS
models only)
Loading:Maximum load:
195 kg (430 lb)
(Total weight of rider, passenger, cargo and
accessories)Tire air pressure (measured on cold
tires):Loading condition:
0–90 kg (0–198 lb)
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
290 kPa (42 psi) (2.90 kgf/cm²)
Loading condition:
90–195 kg (198–430 lb)
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
290 kPa (42 psi) (2.90 kgf/cm²)
High-speed riding:
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
290 kPa (42 psi) (2.90 kgf/cm²)Front wheel:Wheel type:
Cast wheelRim size:
17M/C x MT3.50
Rear wheel:Wheel type:
Cast wheel
Rim size:
17M/C x MT6.00Front brake:Type:
Dual disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 4Rear brake:Type:
Single disc brake
Operation:
Right foot operation
Recommended fluid:
DOT 4Front suspension:Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
120.0 mm (4.72 in)Rear suspension:Type:
Swingarm (link suspension)
Spring/shock absorber type:
Coil spring/gas-oil damper
U4C8E0E0.book Page 2 Monday, October 23, 2006 1:23 PM

INDEX
AAir filter element, replacing ................... 6-16
Anti-theft alarm (optional) ..................... 3-13
Auxiliary light bulb, replacing ................ 6-38BBattery .................................................. 6-30
Brake and clutch levers, checking and
lubricating ........................................... 6-27
Brake fluid, changing ............................ 6-24
Brake fluid level, checking .................... 6-23
Brake lever ........................................... 3-16
Brake pedal .......................................... 3-16CCables, checking and lubricating .......... 6-26
Care ........................................................ 7-1
Catalytic converter ................................ 3-19
Clutch lever........................................... 3-15
Clutch lever free play, adjusting ........... 6-21
Coolant ................................................. 6-13
Coolant temperature warning light.......... 3-4
Cowlings and panels, removing and
installing ............................................... 6-6DDimmer switch ...................................... 3-14
Drive chain, cleaning and lubricating .... 6-26
Drive chain slack .................................. 6-24EEngine break-in ...................................... 5-3
Engine oil and oil filter cartridge ........... 6-10
Engine stop switch................................ 3-14
Engine trouble warning light ................... 3-7
EXUP system ....................................... 3-25FFront and rear brake pads, checking .... 6-22Front fork, adjusting .............................. 3-21
Front fork, checking...............................6-29
Fuel ....................................................... 3-17
Fuel consumption, tips for reducing ........ 5-3
Fuel level warning light............................ 3-4
Fuel tank breather/overflow hose .......... 3-18
Fuel tank cap......................................... 3-17
Fuses, replacing .................................... 6-32
HHandlebar switches ............................... 3-14
Hazard switch........................................ 3-15
Headlight bulb, replacing....................... 6-34
Helmet holders ...................................... 3-20
High beam indicator light......................... 3-4
Horn switch ........................................... 3-14IIdentification numbers ............................. 9-1
Ignition circuit cut-off system ................. 3-26
Immobilizer system .................................3-1
Immobilizer system indicator light ........... 3-7
Indicator and warning lights .................... 3-3KKey identification number ........................ 9-1LLicense plate light bulb, replacing ......... 6-37
Luggage strap holders .......................... 3-25MMain switch/steering lock ........................ 3-2
Matte color, caution .................................7-1
Model label .............................................. 9-2
Multi-function meter unit .......................... 3-7NNeutral indicator light .............................. 3-4
OOil level warning light .............................. 3-4PParking.................................................... 5-4
Part locations .......................................... 2-1
Pass switch ........................................... 3-14
Periodic maintenance and
lubrication chart .................................... 6-2
Pre-operation check list .......................... 4-2RRear brake light switch, adjusting ......... 6-22SSafety information ................................... 1-1
Seats..................................................... 3-19
Shifting .................................................... 5-2
Shift pedal ............................................. 3-15
Shift pedal, checking and lubricating .... 6-28
Shift timing indicator light ........................ 3-7
Shock absorber assembly, adjusting .... 3-22
Sidestand .............................................. 3-25
Sidestand, checking and lubricating ..... 6-28
Spark plugs, checking............................. 6-9
Specifications.......................................... 8-1
Starting the engine.................................. 5-1
Start switch ........................................... 3-14
Steering, checking ................................ 6-29
Storage ................................................... 7-4
Supporting the motorcycle .................... 6-39
Swingarm pivots, lubricating ................. 6-28TTail/brake light ...................................... 6-37
Throttle cable free play, checking ......... 6-18
Throttle grip and cable, checking and
lubricating ........................................... 6-27
U4C8E0E0.book Page 1 Friday, September 15, 2006 3:21 PM