lock YAMAHA YZF-R1 2003 User Guide

INSTRUMENT AND CONTROL FUNCTIONS
3-18
3
To install the passenger seat
1. Insert the projections on the rear
of the passenger seat into the seat
holder as shown, and then push
the front of the seat down to lock it
in place.
2. Remove the key.NOTE:_ Make sure that the seats are properly
secured before riding. _
EAU04489
Helmet holders The helmet holders are located on the
bottom of the passenger seat.
To secure a helmet to a helmet
holder
1. Remove the passenger seat. (See
page 3-17 for passenger seat re-
moval and installation proce-
dures.)
2. Attach the helmet to a helmet
holder, and then securely install
the passenger seat.
EWA00015
WARNING
_ Never ride with a helmet attached to
a helmet holder, since the helmet
may hit objects, causing loss of
control and possibly an accident. _
ECA00128
CAUTION:_ Some helmets may contact the muf-
fler when secured to the right side
helmet holder because of their size
or shape. Be sure that your helmet
does not contact the muffler when it
is secured to the helmet holder. _To release a helmet from a helmet
holder
Remove the passenger seat, remove
the helmet from the helmet holder, and
then install the seat.
1. Projection (× 2)
2. Seat holder
1. Helmet holder (× 2)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6 2. Remove the bolts and screw, and
then loosen the quick fastener
screws 1/4 turn counterclockwise.
3. Slide the cowling backward at the
area shown.4. Disconnect the turn signal light
lead coupler.
5. Remove the screws, and then take
the cowling off.
To install the cowling
1. Install the screws.
2. Connect the turn signal light lead
coupler.
3. Place the cowling in the original
position.
4. Install the screw and the bolts,
tighten the quick fastener screws,
and then install the quick fasteners.
NOTE:_ To install the quick fastener, push the
center pin out so that it will protrude
from the fastener head, insert the fas-
tener into the cowling, and then push
the protruding pin in until it is flush with
the fastener head. _
1. Quick fastener screw (× 6)
2. Screw
3. Bolt (× 2)
1. Turn signal light lead coupler
2. Screw (× 2)
1. Quick fastenerAfter removal
Before installation
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6
EAU04555
Cowling B
To remove the cowlingRemove the bolts, loosen the quick fas-
tener screws 1/4 turn counterclock-
wise, and then take the cowling off.To install the cowling
Place the cowling in the original posi-
tion, and then tighten the quick fastener
screws and install the bolts.
EAU04531
Panels A and B
To remove one of the panelsLoosen the quick fastener screws 1/4
turn counterclockwise, remove the
screw, and then take the panel off.
To install the panelPlace the panel in the original position,
tighten the quick fastener screws, and
then install the screw.
1. Quick fastener screw (× 4)
2. Cowling B
3. Bolt Right side
1. Bolt
2. Quick fastener screw (× 3)
3. Cowling BLeft side
1. Quick fastener screw (× 2)
2. Screw
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
62. Remove cowling B. (See page 6-7
for cowling removal and installa-
tion procedures.)
3. Loosen the locknut at the crank-
case.
4. To increase the clutch lever free
play, turn the adjusting nut in di-
rection
a. To decrease the clutch
lever free play, turn the adjusting
nut in direction
b.
5. Tighten the locknut.
6. Install the cowling.
EAU01357
Adjusting the brake pedal
position The top of the brake pedal should be
positioned approximately 38–42 mm
below the bottom of the footrest brack-
et as shown. Periodically check the
brake pedal position and, if necessary,
have a Yamaha dealer adjust it.
EW000109
WARNING
_ A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the hydraulic system. If there
is air in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the motorcycle. Air in
the hydraulic system will diminish
the braking performance, which
may result in loss of control and an
accident. _
1. Locknut
2. Clutch lever free play adjusting nut
(crankcase)
a. Distance between brake pedal and footrest
bracket
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6 Observe these precautions:


When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.


Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.


Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.


Be careful that water does not en-
ter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU03976
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the master cylin-
ders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.

Oil seals: Replace every two
years.


Brake hoses: Replace every four
years.
1. Minimum level mark
Recommended brake fluid: DOT 4RearRear
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6
EAU00744
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
To check the drive chain slack
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:_ When checking and adjusting the drive
chain slack, the motorcycle should be
positioned straight up and there should
be no weight on it. _
2. Shift the transmission into the neu-
tral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain
slack as shown.
4. If the drive chain slack is incorrect,
adjust it as follows.
EAU03608
To adjust the drive chain slack
1. Loosen the axle nut and the lock-
nut on each side of the swingarm.
2. To tighten the drive chain, turn the
adjusting bolt on each side of the
swingarm in direction
a. To loos-
en the drive chain, turn the adjust-
ing bolt on each side of the
swingarm in direction
b, and then
push the rear wheel forward.
a. Drive chain slack
Drive chain slack:
40–50 mm
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6
NOTE:_ Using the alignment marks on each
side of the swingarm, make sure that
both chain pullers are in the same posi-
tion for proper wheel alignment. _
EC000096
CAUTION:_ Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits. _3. Tighten the locknuts, and then
tighten the axle nut to the specified
torque.
EAU03006
Lubricating the drive chain The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.
EC000097
CAUTION:_ The drive chain must be lubricated
after washing the motorcycle or
riding in the rain. _1. Clean the drive chain with kero-
sene and a small soft brush.
ECA00053
CAUTION:_ To prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents. _
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
ECA00052
CAUTION:_ Do not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings. _
Tightening torque:
Axle nut:
150 Nm (15.0 m·kgf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
6
EAU04876*
Replacing the fuses The main fuse and the electronic fuel
injection fuse are located under the rid-
er seat. (See page 3-17 for rider seat
removal and installation procedures.)
The fuse box, which contains the fuses
for the individual circuits, is located un-
der panel B. (See page 6-7 for panel
removal and installation procedures.)
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
EC000103
CAUTION:_ Do not use a fuse of a higher amper-
age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire. _3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
1. Headlight fuse
2. Signaling system fuse
3. Ignition fuse
4. Radiator fan fuse
5. Odometer and clock fuse (backup fuse)
6. Turn signal lights and hazard fuse
7. Spare fuse (× 3)
1. Main fuse
2. Electronic fuel injection fuse
3. Electronic fuel injection spare fuse
Specified fuses:
Main fuse: 50 A
Headlight fuse: 20 A
Signaling system fuse: 10 A
Radiator fan fuse: 15 A
Ignition fuse: 15 A
Electronic fuel injection
fuse: 15 A
Turn signal lights and
hazard fuse: 10 A
Odometer and clock fuse
(backup fuse): 10 A
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-39
6
EAU03497
Replacing a turn signal light
bulb 1. Remove the turn signal light lens
by removing the screw.
2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw.
ECA00065
CAUTION:_ Do not overtighten the screw, other-
wise the lens may break. _
EAU04574
Replacing the license plate
light bulb 1. Remove the license plate light unit
by removing the screws.
1. Screw
1. Screw (× 2)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-43
6
EAU04915
Rear wheel To remove the rear wheel
EW000122
WARNING
_

It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no danger
of it falling over.
_1. Loosen the axle nut and the brake
caliper bolts.
2. Lift the rear wheel off the ground
according to the procedure on
page 6-40.3. Remove the axle nut, and then re-
move the brake caliper by remov-
ing the bolts.
ECA00146
CAUTION:_ Do not apply the brake after the
brake caliper has been removed,
otherwise the brake caliper pistons
will be forced out. _4. Loosen the locknut on each side of
the swingarm.
5. Turn the drive chain slack adjust-
ing bolts fully in direction
a.6. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:_ The drive chain does not need to be
disassembled in order to remove and
install the rear wheel. _
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
1. Bolt (× 2)
2. Brake caliper
3. Brake caliper bracket
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