ECU YAMAHA YZF-R1 2002 Owners Manual

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)
U5PWE0.book Page 18 Friday, December 7, 2001 5:14 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
CE-01E
CE-07E
EWA00012
WARNING
_ Because loading has an enormous
impact on the handling, braking,
performance and safety characteris-
tics of your motorcycle, you should
keep the following precautions in
mind.

NEVER OVERLOAD THE
MOTORCYCLE! Operation of an
overloaded motorcycle may re-
sult in tire damage, loss of con-
trol, or severe injury. Make surethat the total weight of rider,
passenger, cargo, and accesso-
ries does not exceed the speci-
fied maximum load for the
vehicle.


Do not carry along loosely
packed items, which can shift
during a ride.


Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.


Adjust the suspension and tire
air pressure with regard to the
load.


Check the tire condition and air
pressure before each ride.
_
Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail
or glass fragments in it, or if the side-
wall is cracked, have a Yamaha dealer
replace the tire immediately.CE-08ENOTE:_ The tire tread depth limits may differ
from country to country. Always comply
with the local regulations. _
Tire air pressure
(measured on cold tires)
Load* Front Rear
Up to 90 kg250 kPa
(2.50 kgf/cm
2,
2.50 bar)250 kPa
(2.50 kgf/cm
2,
2.50 bar)
90 kg–maximum250 kPa
(2.50 kgf/cm
2,
2.50 bar)290 kPa
(2.90 kgf/cm
2,
2.90 bar)
High-speed riding250 kPa
(2.50 kgf/cm
2,
2.50 bar)250 kPa
(2.50 kgf/cm
2,
2.50 bar)
Maximum load* 202 kg
* Total weight of rider, passenger, cargo and
accessories
1. Sidewall
a. Tire tread depthMinimum tire tread depth
(front and rear)1.6 mm
U5PWE0.book Page 20 Friday, December 7, 2001 5:14 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
EW000079
WARNING
_

Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta-
bility and can lead to loss of
control.


The replacement of all wheel
and brake related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
_
Tire information
This motorcycle is equipped with cast
wheels and tubeless tires with valves.
EW000080
WARNING
_

The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the motor-
cycle cannot be guaranteed.


After extensive tests, only the
tires listed below have been ap-
proved for this model by
Yamaha Motor Co., Ltd.


Always make sure that the valve
caps are securely installed to
prevent air pressure leakage.


Use only the tire valves and
valve cores listed below to
avoid tire deflation during a
high-speed ride.
_
1. Tire air valve
2. Tire air valve core
3. Tire air valve cap with seal
U5PWE0.book Page 21 Friday, December 7, 2001 5:14 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6
EAU03163
Lubricating the brake pedal The operation of the brake pedal
should be checked before each ride,
and the pedal pivot should be lubricat-
ed if necessary.
EAU03165
Checking and lubricating the
sidestand The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
EW000113
WARNING
_ If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. _
EAU02939
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
EW000115
WARNING
_ Securely support the motorcycle so
that there is no danger of it falling
over. _Check the inner tubes for scratches,
damage and excessive oil leakage.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
U5PWE0.book Page 31 Friday, December 7, 2001 5:14 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6 To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
EC000098
CAUTION:_ If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it. _
EAU00794
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
EW000115
WARNING
_ Securely support the motorcycle so
that there is no danger of it falling
over. _
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steer-
ing.
U5PWE0.book Page 32 Friday, December 7, 2001 5:14 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
6
EAU04503
Replacing a headlight bulb This motorcycle is equipped with
quartz bulb headlights. If a headlight
bulb burns out, replace it as follows.
1. Disconnect the headlight coupler,
and then remove the bulb cover.2. Unhook the headlight bulb holder,
and then remove the defective
bulb.
EW000119
WARNING
_ Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down. _3. Place a new headlight bulb into
position, and then secure it with
the bulb holder.
1. Headlight bulb cover
2. Headlight coupler
1. Headlight bulb holder
1. Do not touch the glass part of the bulb.
U5PWE0.book Page 36 Friday, December 7, 2001 5:14 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-39
6
EAU01579
Supporting the motorcycle Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other mainte-
nance requiring the motorcycle to
stand upright. Check that the motor-
cycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed un-
der the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un-
der the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placing
a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
EAU04532
Front wheel To remove the front 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 bolt, the wheel
axle pinch bolts, and then the
brake caliper bolts.1. Front wheel axle pinch bolt (× 4)
U5PWE0.book Page 39 Friday, December 7, 2001 5:14 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-41
6
EAU04661
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle.
3. Lower the front wheel so that it is
on the ground.
4. Install the brake calipers by install-
ing the bolts, and then tightening
them to the specified torque.NOTE:_ Make sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brake
discs. _5. Install the brake hose holders by
installing the bolts and nuts.6. Secure the wheel axle by installing
the axle bolt, and then tightening it
to the specified torque.
NOTE:_ While tightening the axle bolt, hold the
wheel axle with a 19-mm hexagon
wrench to keep it from turning. _7. Tighten wheel axle pinch bolts A
and B to the specified torque.8. Tap the outer side of the right fork
leg with a rubber mallet to align it
with the end of the wheel axle.
9. Tighten wheel axle pinch bolts C
and D to the specified torque.
10. While applying the front brake,
push down hard on the handlebar
several times to check for proper
fork operation. Tightening torque:
Brake caliper bolt:
40 Nm (4.0 m·kgf)1. Front wheel axle pinch bolt A
2. Front wheel axle pinch bolt B
3. Front wheel axle pinch bolt C
4. Front wheel axle pinch bolt D
Tightening torque:
Axle bolt:
91 Nm (9.1 m·kgf)
Tightening torque:
Wheel axle pinch bolt:
18 Nm (1.8 m·kgf)
Tightening torque:
Wheel axle pinch bolt:
18 Nm (1.8 m·kgf)
E_5pw_Periodic.fm Page 41 Friday, January 18, 2002 8:46 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-42
6
EAU04533
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 6-39.3. Remove the axle nut, and then re-
move the brake caliper by remov-
ing the bolts.
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
U5PWE0.book Page 42 Friday, December 7, 2001 5:14 PM