Yamaha YZF-R1 2003 Manual

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the

YZF-R1 (R) 2003. For complete service information procedures it is necessary to use this Supplemen-

tary Service Manual together with the following manual.

YZF-R1 (P) 2002 SERVICE MANUAL: 5PW1-AE1

YZF-R1 (R) 2003

SUPPLEMENTARY

SERVICE MANUAL

E2002 by Yamaha Motor Co., Ltd.

First Edition, August 2002

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

NOTE:

WARNING

CAUTION:

EAS00002

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers

and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu-

al. 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 ve-

hicle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi-

cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and

will appear in future editions of this manual where applicable.

Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT 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 motorcycle operator, a bystander or a person checking or repairing the mo-

torcycle.

A CAUTION indicates special precautions that must be taken to avoid damage

to the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

EAS00007

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.

1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each

page indicate the current chapter.

Refer to “SYMBOLS”.

2Each chapter is divided into sections. The current section title is shown at the top of each page,

except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s) ap-

pears.

3Sub-section titles appear in smaller print than the section title.

4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a

disassembly step.

6Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

8Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

24 25

2321

19 2018

16 1715

1413

11 12

GEN

INFO SPEC

ENG

FI ELEC

COOL

CHK

ADJ

TRBL

SHTG

CHAS

EAS00008

SYMBOLS

The following symbols are not relevant to every

vehicle.

Symbols 1to 9indicate the subject of each

chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Chassis

5Engine

6Cooling system

7Fuel injection system

8Electrical system

9Troubleshooting

Symbols 10 to 17 indicate the following.

10 Serviceable with engine mounted

11 Filling fluid

12 Lubricant

13 Special tool

14 Tightening torque

15 Wear limit, clearance

16 Engine speed

17 Electrical data

Symbols 18 to 23 in the exploded diagrams indi-

cate the types of lubricants and lubrication

points.

18 Engine oil

19 Gear oil

20 Molybdenum-disulfide oil

21 Wheel-bearing grease

22 Lithium-soap- based grease

23 Molybdenum-disulfide grease

Symbols 24 to 25 in the exploded diagrams indi-

cate the following.

24 Apply locking agent (LOCTITE)

25 Replace the part

CONTENTS

SPECIFICATIONS

GENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL

CHECKING THE SWITCHES 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIGHTING SYSTEM 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCUIT DIAGRAM 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SIGNALING SYSTEM 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCUIT DIAGRAM 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE SIGNALING SYSTEM 19. . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING

FAULTY LIGHTING OR SIGNALING SYSTEM 21. . . . . . . . . . . . . . . . . . . .

HEADLIGHT DOES NOT COME ON 21. . . . . . . . . . . . . . . . . . . . . . . . . .

HEADLIGHT BULB BURNT OUT 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

YZF-R1 (R) 2003 WIRING DIAGRAM (EUR)

YZF-R1 (R) 2003 WIRING DIAGRAM (OCE)

–1–

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard Limit

Model code 5PW7 (A) (B) (CH) (D) (E) (GB) (GR) (I)

(NL) (P) (S) (ZA)

5PW8 (F)

5PW9 (OCE)

5PWG (OCE)

SSS

ENGINE SPECIFICATIONS

Item Standard Limit

Fuel

Recommended fuel

Fuel tank capacity

Total (including reserve)

Reserve only

Premium unleaded gasoline only

17 L

3.3 L

SSS

ELECTRICAL SPECIFICATIONS

Item Standard Limit

Electric starting system

System type

Starter motor

Model (manufacturer)

Power output

Brushes

Overall length

Spring force

Armature coil resistance

Commutator diameter

Mica undercut

Constant mesh

5PW (YAMAHA)

0.9 kW

10.8 mm

5.28 X7.92 N (528 X792 g)

0.009 X0.011 Ωat 20_C

24. 5 mm

1.5 mm

SSS

3.65 mm

SSS

23.5 mm

SSS

Fuses (amperage quantity)

Main fuse

Fuel injection system fuse

Headlight fuse

Signaling system fuse

Ignition fuse

Radiator fan motor fuse

Backup fuse (odometer and clock)

Turn fuse

Reserve fuse

50 A 1

15 A 1

20 A 1

10 A 1

15 A 1

10 A 1

20 A, 15 A, 10 A 1

SSS

–2–

CABLE ROUTING SPEC

I Insert the headlight relay to the

rib of the headlight body. (No

special order is specified for right

and left.)

J Route the headlight lead behind

the cap of headlight breather

hole. (It can be routed below, but

should not be in front of the cap.)

K To the auxiliary light lead.

L To meter assembly

M To headlight relay

E Secure the inner side of the junc-

tion part of the head light sub

wire harness (including the head

light lead and auxiliary light lead)

behind the pawl of the head light

body with the clamp.

F To turn signal light.

G To main harness.

H Route the junction of the head-

light, position lamp and turn sig-

nal light leads through the pawl

on the headlight body. (Pay

attention to the direction.)

1 Headlight drain plug

A Make sure to securely insert the

coupler and boot.

B The headlight lead can be routed

by either of the headlight or the

boss. Do not catch the headlight

lead when assembling the front

cowling.

C Do not make the lead stretch too

much.

D Secure the junction of the cord

headlight at the place of white

tape.

CABLE ROUTING

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