YAMAHA YZF-R1 2003 Workshop Manual

OPERATION AND IMPORTANT RIDING POINTS
5-4
5
EAU03172*
0–1,000 km
Avoid prolonged operation above
6,000 r/min.
1,000–1,600 km
Avoid prolonged operation above
7,000 r/min.
EC000052*
CAUTION:_ After 1,000 km of operation, the en-
gine oil must be changed and the oil
filter cartridge replaced. _1,600 km and beyond
The vehicle can now be operated nor-
mally.
EC000053
CAUTION:_

Keep the engine speed out of
the tachometer red zone.


If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehi-
cle.
_
NOTE:_ During and after the engine break-in
period, the exhaust heat may cause
discoloration of the exhaust pipe, but
this is normal. _
EAU00461
Parking When parking, stop the engine, and
then remove the key from the main
switch.
EW000058
WARNING
_

Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.


Do not park on a slope or on
soft ground, otherwise the
motorcycle may overturn.
_
EC000062
CAUTION:_ Never park in an area where there
are fire hazards such as grass or
other flammable materials. _
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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 .................................... 6-8
Engine oil and oil filter cartridge .......................... 6-9
Coolant .............................................................. 6-13
Replacing the air filter element .......................... 6-17
Adjusting the engine idling speed ...................... 6-19
Adjusting the throttle cable free play .................. 6-20
Adjusting the valve clearance ............................ 6-20
Tires ................................................................... 6-21
Cast wheels ....................................................... 6-24
Adjusting the clutch lever free play .................... 6-24
Adjusting the brake pedal position ..................... 6-25
Adjusting the rear brake light switch .................. 6-26
Checking the front and rear brake pads ............. 6-26
Checking the brake fluid level ............................ 6-27
Changing the brake fluid .................................... 6-28
Drive chain slack ................................................ 6-29
Lubricating the drive chain ................................. 6-30
Checking and lubricating the cables .................. 6-31Checking and lubricating the throttle grip and
cable ............................................................... 6-31
Checking and lubricating the brake and
clutch levers .................................................... 6-31
Lubricating the brake pedal ............................... 6-32
Checking and lubricating the sidestand ............ 6-32
Checking the front fork ...................................... 6-33
Checking the steering ....................................... 6-33
Checking the wheel bearings ............................ 6-34
Battery ............................................................... 6-34
Replacing the fuses .......................................... 6-36
Replacing a headlight bulb ................................ 6-37
Tail/brake light ................................................... 6-38
Replacing a turn signal light bulb ...................... 6-39
Replacing the license plate light bulb ................ 6-39
Supporting the motorcycle ................................ 6-40
Front wheel ....................................................... 6-41
Rear wheel ........................................................ 6-43
Troubleshooting ................................................. 6-45
Troubleshooting charts ...................................... 6-46
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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. _
EAU04223
Owner’s tool kit The owner’s tool kit is located inside
the storage compartment under the
passenger seat. (See page 3-17 for
passenger seat removal and installa-
tion 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 chang-
es. _
1. Owner’s tool kit
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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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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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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU04522
NOTE:_

Air filter
This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with com-
pressed air to avoid damaging it.
The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.


Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.
Replace the brake hoses every four years and if cracked or damaged.
_24
*Cooling systemCheck coolant level and vehicle for coolant leakage.√√√√ √
Change. Every 3 years
25*Front and rear brake
switchesCheck operation.√√√√√ √
26 Moving parts and cablesLubricate.√√√√ √
27*Throttle grip housing
and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√√ √
28*Air induction systemCheck the air cut-off valve, reed valve, and hose for
damage.
Replace any damaged parts if necessary.√√√√ √
29*Muffler and exhaust pipeCheck the screw clamp for looseness.√√√√√
30*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
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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.
EAU04544
Cowling A
To remove the cowling1. Remove the quick fasteners at the
front of the cowling.
1. Panel A
2. Cowling A
3. Cowling B
1. Panel B
2. Cowling B
1. Quick fastener (× 4)
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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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