clutch YAMAHA YZF-R1 2003 User Guide
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Page 55 of 120
PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_CP-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel lineCheck fuel hoses for cracks or damage.√√√√ √
2*Spark plugsCheck condition.
Clean and regap.√√
Replace.√√
3*ValvesCheck valve clearance.
Adjust.Every 40,000 km
4 Air filter elementReplace.√
5ClutchCheck operation.
Adjust.√√√√√
6*Front brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
8*Brake hosesCheck for cracks or damage.√√√√ √
Replace. (See NOTE on page 6-4.) Every 4 years
9*WheelsCheck runout and for damage.√√√√
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Page 65 of 120
PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6
ECA00133
CAUTION:_
In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
Make sure that no foreign mate-
rial enters the crankcase.
_10. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.NOTE:_ After the engine is started, the engine
oil level warning light should go off if the
oil level is sufficient. _
EC000067
CAUTION:_ If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha deal-
er check the vehicle. _11. Turn the engine off, and then
check the oil level and correct it if
necessary.
12. Install the cowling.
U5PWE1.book Page 12 Monday, July 8, 2002 10:28 AM
Page 68 of 120
PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
64. Remove the clutch cable holder
from the coolant reservoir as
shown.
5. Remove the coolant reservoir by
removing the bolts.
6. Remove the coolant reservoir cap,
and then turn the coolant reservoir
upside down to empty it.
7. Install the coolant reservoir by in-
stalling the bolts, and then install
the clutch cable holder.8. Remove the radiator cap.
EW000067
WARNING
_ Never attempt to remove the radia-
tor cap when the engine is hot. _
9. Remove the coolant drain bolt to
drain the cooling system.
10. Loosen the radiator hose clamp
screw located at the left side of the
engine, and then pull off the hose
to drain the radiator.
1. Bolt (× 2)
2. Radiator cap
3. Coolant reservoir cap
4. Coolant reservoir
5. Clutch cable holder
1. Coolant drain bolt
2. Clamp screw
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Page 77 of 120
PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6
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.
EAU01356
Adjusting the clutch lever free
play The clutch lever free play should mea-
sure 10–15 mm as shown. Periodically
check the clutch lever free play and, if
necessary, adjust it as follows.
To increase the clutch lever free play,
turn the adjusting bolt at the clutch le-
ver in direction
a. To decrease the
clutch lever free play, turn the adjusting
bolt in direction
b.
NOTE:_ If the specified clutch lever free play
cannot be obtained as described
above, proceed as follows. _1. Fully turn the adjusting bolt at the
clutch lever in direction
a to loos-
en the clutch cable.
1. Clutch lever free play adjusting bolt
c. Clutch lever free play
U5PWE1.book Page 24 Monday, July 8, 2002 10:28 AM
Page 78 of 120
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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Page 84 of 120
PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6
EAU02962
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
EW000112
WARNING
_ Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions. _
EAU04034
Checking and lubricating the
throttle grip and cable The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated or
replaced at the intervals specified in
the periodic maintenance chart.
EAU03164
Checking and lubricating the
brake and clutch levers The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary. Recommended lubricant:
Engine oil
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
U5PWE1.book Page 31 Monday, July 8, 2002 10:28 AM
Page 108 of 120
8-1
8
EAU01038
8-SPECIFICATIONSSpecifications CS-01E
Model YZF-R1
Dimensions
Overall length 2,040 mm
Overall width 705 mm
Overall height 1,105 mm
Seat height 820 mm
Wheelbase 1,395 mm
Ground clearance 140 mm
Minimum turning radius 3,900 mm
Basic weight (with oil and full
fuel tank)
193 kg
Engine
Engine type Liquid-cooled 4-stroke, DOHC
Cylinder arrangement Forward-inclined parallel
4-cylinder
Displacement 998 cm
3
Bore × stroke 74 × 58 mm
Compression ratio 11.8:1
Starting system Electric starter
Lubrication system Wet sumpEngine oil
Ty p e
Recommended engine oil
classification API Service SE, SF, SG or
higher
Quantity
Without oil filter cartridge
replacement 2.9 L
With oil filter car tridge
replacement 3.1 L
Total amount (dry engine) 3.8 L
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40
CAUTION:In order to prevent clutch slippage (since the engine oil also
lubricates the clutch), do not mix any chemical additives. Do
not use oils with a diesel specification of “CD” or oils of a
higher quality than specified. In addition, do not use oils la-
beled “ENERGY CONSERVING II” or higher.
U5PWE1.book Page 1 Monday, July 8, 2002 10:28 AM
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)
Manufacturer/
model Michelin / Pilot SPORT E
Dunlop / D208FL
Rear
Model Tubeless tire
Size 190/50 ZR17 M/C (73W)
Manufacturer/
model Michelin / Pilot SPORT
Dunlop / D208L
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Page 116 of 120
INDEXAAir filter element, replacing ..................... 6-17
Anti-theft alarm ...................................... 3-11BBattery ................................................... 6-34
Brake and clutch levers, checking and
lubricating ............................................ 6-31
Brake fluid, changing ............................. 6-28
Brake fluid level, checking...................... 6-27
Brake lever............................................. 3-13
Brake light switch (rear), adjusting ......... 6-26
Brake pads, checking............................. 6-26
Brake pedal............................................ 3-14
Brake pedal, lubricating.......................... 6-32
Brake pedal position, adjusting .............. 6-25CCables, checking and lubricating............ 6-31
Care.........................................................7-1
Catalytic converter ................................. 3-16
Clutch lever ............................................ 3-13
Clutch lever free play, adjusting ............. 6-24
Conversion table ......................................8-5
Coolant .................................................. 6-13
Changing .......................................... 6-14
Checking .......................................... 6-13
Coolant temperature warning light............3-4
Cowlings and panels, removing and
installing ................................................6-5
DDimmer switch ....................................... 3-11
Drive chain, lubricating .......................... 6-30
Drive chain slack ................................... 6-29
Adjusting .......................................... 6-29
Checking .......................................... 6-29EEngine break-in ....................................... 5-3
Engine idling speed ............................... 6-19
Engine oil and oil filter cartridge ............... 6-9
Engine speed indicator light..................... 3-4
Engine stop switch................................. 3-12
Engine trouble warning light .................... 3-4
EXUP system ........................................ 3-24FFront fork, adjusting ............................... 3-19
Front fork, checking ............................... 6-33
Fuel ....................................................... 3-15
Fuel consumption, tips for reducing ......... 5-3
Fuel level warning light ............................ 3-3
Fuel tank breather hose ......................... 3-16
Fuel tank cap ......................................... 3-14
Fuses, replacing .................................... 6-36HHandlebar switches ............................... 3-11
Hazard switch ........................................ 3-12
Headlight bulb, replacing ....................... 6-37
Helmet holders ...................................... 3-18
High beam indicator light ......................... 3-4
Horn switch ........................................... 3-12
IIdentification numbers ..............................9-1
Ignition circuit cut-off system ..................3-25
Indicator and warning lights......................3-2KKey identification number .........................9-1LLicense plate light bulb, replacing...........6-39
Luggage strap holders ...........................3-23MMain switch/steering lock .........................3-1
Model label ..............................................9-2
Multi-function display................................3-6NNeutral indicator light ...............................3-4OOil level warning light ...............................3-3PParking.....................................................5-4
Part locations ...........................................2-1
Pass switch ............................................3-11
Periodic maintenance and
lubrication chart .....................................6-2
Pre-operation check list ............................4-1
U5PWE1.book Page 1 Monday, July 8, 2002 10:28 AM