tires YAMAHA YZF-R1 2002 Owners Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2002, Model line: YZF-R1, Model: YAMAHA YZF-R1 2002Pages: 120, PDF Size: 5.39 MB
Page 45 of 120
PRE-OPERATION CHECKS
4-2
4
NOTE:_ Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved. _
EWA00033
WARNING
_ If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle. _Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-29
Drive chainCheck chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.6-27–6-28
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-19–6-22
Brake and shift pedalsMake sure that operation is smooth.
Lubricate the brake pedal pivoting point if necessary.6-31
Brake and clutch leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-30
SidestandMake sure that operation is smooth.
Lubricate pivot if necessary.6-31
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switchesCheck operation.
Correct if necessary.—
Sidestand switchCheck operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.3-26 ITEM CHECKS PAGE
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Page 53 of 120
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 .................................... 6-8
Engine oil and oil filter cartridge .......................... 6-9
Coolant .............................................................. 6-12
Replacing the air filter element .......................... 6-16
Adjusting the engine idling speed ...................... 6-18
Adjusting the throttle cable free play .................. 6-19
Adjusting the valve clearance ............................ 6-19
Tires ................................................................... 6-19
Cast wheels ....................................................... 6-22
Adjusting the clutch lever free play .................... 6-23
Adjusting the brake pedal position ..................... 6-24
Adjusting the rear brake light switch .................. 6-24
Checking the front and rear brake pads ............. 6-25
Checking the brake fluid level ............................ 6-26
Changing the brake fluid .................................... 6-27
Drive chain slack ................................................ 6-27
Lubricating the drive chain ................................. 6-29
Checking and lubricating the cables .................. 6-29Checking and lubricating the throttle grip and
cable ............................................................... 6-30
Checking and lubricating the brake and clutch
levers ............................................................... 6-30
Lubricating the brake pedal ............................... 6-31
Checking and lubricating the sidestand ............ 6-31
Checking the front fork ...................................... 6-31
Checking the steering ....................................... 6-32
Checking the wheel bearings ............................ 6-33
Battery ............................................................... 6-33
Replacing the fuses .......................................... 6-35
Replacing a headlight bulb ................................ 6-36
Tail/brake light ................................................... 6-37
Replacing a turn signal light bulb ...................... 6-37
Replacing the license plate light bulb ................ 6-38
Supporting the motorcycle ................................ 6-39
Front wheel ....................................................... 6-39
Rear wheel ........................................................ 6-42
Troubleshooting ................................................. 6-44
Troubleshooting charts ...................................... 6-45
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Page 56 of 120
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 50,000 km
13 Drive chainCheck chain slack.
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
14*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20,000 km
15*Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.√√√√ √
16 SidestandCheck operation.
Lubricate.√√√√ √
17*Sidestand switchCheck operation.√√√√√ √
18*Front forkCheck operation and for oil leakage.√√√√
19*Shock absorber
assemblyCheck operation and shock absorber for oil leakage.√√√√
20*Rear suspension relay
arm and connecting arm
pivoting pointsCheck operation.√√√√
21*Electronic fuel injectionAdjust engine idling speed and synchronization.√√√√√ √
22 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
23 Engine oil filter cartridgeReplace.√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
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Page 72 of 120
PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6
EAU00635
Adjusting the throttle cable
free play The throttle cable free play should
measure 3–5 mm at the throttle grip.
Periodically check the throttle cable
free play and, if necessary, have a
Yamaha dealer adjust it.
EAU00637
Adjusting the valve clearance The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
EAU00658
Tires To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
EW000082
WARNING
_
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
The tire air pressure must be
adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approved
for this model.
_
a. Throttle cable free playU5PWE0.book Page 19 Friday, December 7, 2001 5:14 PM
Page 73 of 120
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
Page 74 of 120
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
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Page 75 of 120
PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
CE-10E
CE-14EEAU00684
WARNING
_ This motorcycle is fitted with super-
high-speed tires. Note the following
points in order to make the most ef-
ficient use of these tires.
Use only the specified replace-
ment tires. Other tires may run
the danger of bursting at super
high speeds.
Brand-new tires can have a rela-
tively poor grip on certain road
surfaces until they have been
“broken in”. Therefore, it is ad-
visable before doing any high-
speed riding to ride conserva-
tively for approximately 100 km
after installing a new tire.
The tires must be warmed up
before a high-speed run.
Always adjust the tire air pres-
sure according to the operating
conditions.
_
EAU03773
Cast wheels To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.
The wheel rims should be checked
for cracks, bends or warpage be-
fore each ride. If any damage is
found, have a Yamaha dealer re-
place the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.
The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.
Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
FRONT
Manufacturer Size Model
Michelin
120/70 ZR17 M/C (58W)
Pilot SPORT E
120/70 ZR17 (58W)
Dunlop
120/70 ZR17 M/C (58W)
D208FL
REAR
Manufacturer Size Model
Michelin
190/50 ZR17 M/C (73W)
Pilot SPORT
190/50 ZR17 (73W)
Dunlop
190/50 ZR17 M/C (73W)
D208L
FRONT & REAR
Tire air valve TR412
Valve core #9000A (original)
U5PWE0.book Page 22 Friday, December 7, 2001 5:14 PM
Page 104 of 120
MOTORCYCLE CARE AND STORAGE
7-3
7Cleaning the titanium muffler
This model is equipped with a titanium
muffler, which requires the following
special care.
Use only a soft, clean cloth or
sponge with mild detergent and
water to clean the titanium muffler.
However, if the muffler cannot be
thoroughly cleaned with mild de-
tergent, alkaline products and a
soft brush may be used.
Never use compounds or other
special treatments to clean the ti-
tanium muffler, as they will remove
the finish on the outer surface of
the muffler.
Even the smallest amounts of oil,
such as from oily towels or finger-
prints, will leave stains on the tita-
nium muffler, which can be
removed with a mild detergent.
Note that the thermally induced
discoloring of the portion of the ex-
haust pipe leading into the titani-
um muffler is normal and cannot
be removed.After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts.
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
5. Use spray oil as a universal clean-
er to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
EWA00031
WARNING
_
Make sure that there is no oil or
wax on the brakes or tires.
If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac-
etone, and wash the tires with
warm water and a mild deter-
gent. Before riding at higher
speeds, test the motorcycle’s
braking performance and cor-
nering behavior.
_
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Page 106 of 120
MOTORCYCLE CARE AND STORAGE
7-5
7a. Remove the spark plug caps and
spark plugs.
b. Pour a teaspoonful of engine oil
into each spark plug bore.
c. Install the spark plug caps onto the
spark plugs, and then place the
spark plugs on the cylinder head
so that the electrodes are ground-
ed. (This will limit sparking during
the next step.)
d. Turn the engine over several times
with the starter. (This will coat the
cylinder walls with oil.)
e. Remove the spark plug caps from
the spark plugs, and then install
the spark plugs and the spark plug
caps.
EWA00003
WARNING
_ To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over. _
4. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
5. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
6. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
7. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place (less
than 0 °C or more than 30 °C). For
more information on storing the
battery, see page 6-34.
NOTE:_ Make any necessary repairs before
storing the motorcycle. _
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Page 109 of 120
SPECIFICATIONS
8-2
8
Cooling system capacity
(total amount)
2.45 L
Air filterOil-coated paper element
Fuel
Type PREMIUM UNLEADED
GASOLINE ONLY
Fuel tank capacity 17 L
Amount remaining when the fuel
level warning light comes on 3.3 L
Electronic fuel injection
ModelINP-731/4
Manufacturer NIPPON INJECTOR
Spark plug
Manufacturer/model NGK / CR9EIA 9 or
DENSO / IU27D
Gap 0.8–0.9 mm
Clutch typeWet, multiple-disc
Transmission
Primary reduction system Spur gear
Primary reduction ratio 1.581
Secondary reduction system Chain drive
Secondary reduction ratio 2.688
Number of drive chain
sprocket teeth (front/rear) 16/43
Transmission type Constant-mesh 6-speed
Operation Left footGear ratio
1st 2.500
2nd 1.842
3rd 1.500
4th 1.333
5th 1.200
6th 1.115
Chassis
Frame type Diamond
Caster angle 24°
Trail 103 mm
Tires
Front
Model Tubeless tire
Size 120/70 ZR17 M/C (58W)
120/70 ZR17 (58W)
Manufacturer/
model Michelin / Pilot SPORT E
Dunlop / D208FL
Rear
Model Tubeless tire
Size 190/50 ZR17 M/C (73W)
190/50 ZR17 (73W)
Manufacturer/
model Michelin / Pilot SPORT
Dunlop / D208L
U5PWE0.book Page 2 Friday, December 7, 2001 5:14 PM