maintenance YAMAHA YZF-R1 2000 Owners Manual

TABLE OF CONTENTS
1 GIVE SAFETY THE RIGHT OF WAY
1
2 DESCRIPTION
2
3 INSTRUMENT AND CONTROL FUNCTIONS
3
4 PRE-OPERATION CHECKS
4
5 OPERATION AND IMPORTANT RIDING POINTS
5
6 PERIODIC MAINTENANCE AND MINOR REPAIR
6
7 MOTORCYCLE CARE AND STORAGE
7
8 SPECIFICATIONS
8
9 CONSUMER INFORMATION
9
INDEX
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1
1-1
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1-GIVE SAFETY THE RIGHT OF WAY
Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and
freedom. However, they also impose certain limits, which you must accept; even the best motorcycle
does not ignore the laws of physics.
Regular care and maintenance are essential for preserving value and operating condition of your
motorcycle. Moreover, what is true for the motorcycle is also true for the rider: good performance
depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of
course, out of the question. Motorcycle riders—more than car drivers—must always be at their mental
and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take
dangerous risks.
Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and
passengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant
synthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet.
Optimum protective wear, however, should not encourage carelessness. Although full-coverage
helmets and suits, in particular, create an illusion of total safety and protection, motorcyclists will
always be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt to
take chances. This is even more dangerous in wet weather. The good motorcyclist rides safely,
predictably and defensively—avoiding all dangers, including those caused by others.
Enjoy your ride!
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6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit ..................................................... 6-1
Periodic maintenance and lubrication chart.......... 6-2
Removing and installing cowlings and panels ..... 6-5
Checking the spark plugs .................................... 6-7
Engine oil and oil filter cartridge ........................... 6-8
Coolant .............................................................. 6-11
Cleaning the air filter element ............................ 6-15
Adjusting the carburetors ................................... 6-17
Adjusting the engine idling speed ...................... 6-17
Adjusting the throttle cable free play .................. 6-18
Adjusting the valve clearance ............................ 6-18
Tires .................................................................... 6-19
Wheels ................................................................ 6-22
Adjusting the clutch lever free play .................... 6-22
Adjusting the brake pedal position ..................... 6-23
Adjusting the rear brake light switch .................. 6-24
Checking the front and rear brake pads ............. 6-24
Checking the brake fluid level ............................ 6-25
Changing the brake fluid .................................... 6-26
Drive chain slack................................................. 6-27
Lubricating the drive chain ................................. 6-28Checking and lubricating the cables ................. 6-29
Checking and lubricating the throttle grip
and cable ........................................................ 6-29
Lubricating the brake pedal ............................... 6-30
Checking and lubricating the brake
and clutch levers ............................................. 6-30
Checking and lubricating the sidestand ............ 6-30
Lubricating the rear suspension ........................ 6-31
Checking the front fork ...................................... 6-31
Checking the steering ....................................... 6-32
Checking the wheel bearings ............................ 6-32
Battery ............................................................... 6-33
Replacing the fuses .......................................... 6-34
Replacing the headlight bulb ............................. 6-35
Replacing the tail/brake light bulb ..................... 6-37
Replacing a turn signal light bulb ...................... 6-37
Supporting the motorcycle ................................ 6-38
Front wheel ........................................................ 6-39
Rear wheel ......................................................... 6-41
Troubleshooting .................................................. 6-42
Troubleshooting charts ....................................... 6-43
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6-1
6
EAU00462
6-PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00464
Safety is an obligation of the owner.
Periodic inspection, adjustment and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
EW000060
WARNING
@ If you are not familiar with motor-
cycle maintenance work, have a
Yamaha dealer do it for you. @
EAU01575
Owner’s tool kitThe tool kit is located inside the storage
compartment under the passenger
seat. (See page 3-14 for passenger
seat removal procedures.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
NOTE:@ If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you. @
EW000063
WARNING
@ Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any
changes. @
1. Owner’s tool kit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
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Periodic maintenance and lubrication chart
CP-02ENO. ITEM CHECKS AND MAINTENANCE JOBSInitial
1,000 kmEvery Every
Annual
check
10,000 km 20,000 km
1
*Fuel line• Check fuel hoses and vacuum hose for cracks or damage.
• Replace if necessary.ÖÖ
2*Fuel filter• Check condition.
• Replace if necessary.Ö
3 Spark plugs• Check condition.
• Clean, regap or replace if necessary.Ö
4*Valves• Check valve clearance.
• Adjust if necessary.Every 40,000 km
5 Air filter• Clean or replace if necessary.Ö
6Clutch• Check operation.
• Adjust or replace cable.ÖÖ
7*Front brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)
• Correct accordingly.
• Replace brake pads if necessary.ÖÖ Ö
8*Rear brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)
• Correct accordingly.
• Replace brake pads if necessary.ÖÖ Ö
9*Brake hose• Check for cracks or damage.
• Replace if necessary.ÖÖ
10*Wheels• Check balance, runout and for damage.
• Rebalance or replace if necessary.Ö
11*Tires• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.Ö
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
12
*Wheel bearings• Check bearings for looseness or damage.
• Replace if necessary. Ö
13*Swingarm• Check swingarm pivoting point for play.
• Correct if necessary.
• Lubricate with lithium-soap-based grease.Ö
14 Drive chain• Check chain slack.
• Adjust if necessary. Make sure that the rear wheel is properly
aligned.
• Clean and lubricate.Every 1,000 km and after washing the
motorcycle or riding in the rain
15*Steering bearings• Check bearing play and steering for roughness.
• Correct accordingly. ÖÖ
• Lubricate with lithium-soap-based grease. Every 24,000 km
16*Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.ÖÖ
17 Sidestand• Check operation.
• Lubricate and repair if necessary.ÖÖ
18*Sidestand switch• Check operation.
• Replace if necessary.ÖÖ Ö
19*Front fork• Check operation and for oil leakage.
• Correct accordingly.Ö
20*Rear shock absorber
assembly• Check operation and shock absorber for oil leakage.
• Replace shock absorber assembly if necessary. Ö
21*Rear suspension relay
arm and connecting arm
pivoting points• Check operation.
• Correct if necessary.Ö
22*Carburetors• Check engine idling speed, synchronization and starter operation.
• Adjust if necessary.ÖÖ Ö
23 Engine oil• Check oil level and vehicle for oil leakage.
• Correct if necessary.
• Change. (Warm engine before draining.)ÖÖ Ö NO. ITEM CHECKS AND MAINTENANCE JOBSInitial
1,000 kmEvery Every
Annual
check
10,000 km 20,000 km
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
EAU03126
NOTE:@ l
The annual checks must be performed once a year, regardless of the mileage traveled.
l
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
l
Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
@24 Engine oil filter cartridge• Replace.ÖÖ
25
*Cooling system• Check coolant level and vehicle for coolant leakage.
• Correct if necessary.ÖÖ
• Change coolant.Ö
26*Front and rear brake
switches• Check operation.
• Correct accordingly.ÖÖ Ö
27 Moving parts and cables• Lubricate if necessary.ÖÖ
28*Air induction system• Check the air cut valve and reed valve for damage.
• Replace the entire air induction system if necessary.Ö
29*Muffler and exhaust pipe• Check the screw clamp for looseness.
• Tighten if necessary.ÖÖ
30*Lights, signals and
switches• Check operation.
• Correct if necessary.
• Adjust headlight beam if necessary.ÖÖ Ö NO. ITEM CHECKS AND MAINTENANCE JOBSInitial
1,000 kmEvery Every
Annual
check
10,000 km 20,000 km
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU01139
Removing and installing
cowlings and panels The cowlings and panels shown above
need to be removed to perform some
of the maintenance jobs described in
this chapter. Refer to this section each
time a cowling or panel needs to be re-
moved and installed.
EAU01254
Cowling A
To remove the cowlingLoosen the quick fastener screws and
remove the screws, 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 screws.
1. Cowling A
2. Cowling B
3. Panel A
1. Quick fastener screw (´ 4)
2. Screw
1. Quick fastener screw (´ 4)
2. Screw
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6
EAU01255
Panel A
To remove the panelLoosen the quick fastener screw and
remove the screw, and then take the
panel off.
To install the panelPlace the panel in the original position,
and then tighten the quick fastener
screw and install the screw.
EAU01259
Cowling B
To remove the cowling1. Remove cowling A and panel A.
2. Disconnect the turn signal light
lead connectors.
3. Remove the screw, loosen the
quick fastener screws, remove the
quick fastener at the front of the
cowling, and then take the cowling
off.
NOTE:@ The quick fastener is removed by push-
ing the center pin in with a screwdriver,
then pulling the fastener out. @
1. Screw
2. Quick fastener screwRight side
1. Lead connector (´ 2)
2. Quick fastener screw (´ 2)
3. Screw
1. Quick fastener
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6To install the cowling
1. Connect the turn signal light lead
connectors.
2. Place the cowling in the original
position.
3. Install the screw, tighten the quick
fastener screws, and then install
the quick fastener.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. @4. Install the cowling and the panel.
EAU01880
Checking the spark plugs The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal col-
or when the motorcycle is ridden nor-
mally), and all spark plugs installed inthe engine should have the same color.
If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.
Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
After removal
Before installation
a. Spark plug gap
Specified spark plug:
CR9E (NGK) or
U27ESR-N (DENSO)
Spark plug gap:
0.7–0.8 mm
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