YAMAHA YZF-R1 2003 Manual PDF
Manufacturer: YAMAHA, Model Year: 2003, Model line: YZF-R1, Model: YAMAHA YZF-R1 2003Pages: 120, PDF Size: 5.46 MB
Page 71 of 120
PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6 5. Remove the air filter case cover by
removing the screws and bolt.6. Pull the air filter element out.
7. Insert a new air filter element into
the air filter case.
EC000082*
CAUTION:_
Make sure that the air filter ele-
ment is properly seated in the
air filter case.
The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
pistons and/or cylinders may
become excessively worn.
_8. Install the air filter case cover by
installing the screws and bolt.
1. Bolt
2. Screw (× 8)
3. Air filter case cover
1. Air filter element
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Page 72 of 120
PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
69. Connect the fuel tank breather
hose and the fuel tank overflow
hose, place the fuel tank in the
original position, and then install
the bolt.
EWA00067
WARNING
_
Before installing the fuel tank,
make sure that the fuel hoses
are not damaged. If any fuel
hose is damaged, do not start
the engine but have a Yamaha
dealer replace the hose, other-
wise fuel may leak.
Make sure that the fuel hoses
are properly connected and
routed, and not pinched.
Be sure to place the fuel tank
breather hose and the fuel tank
overflow hose in the original po-
sition.
_10. Install the rider seat.
EAU04578
Adjusting the engine idling
speed The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
The engine should be warm before
making this adjustment.NOTE:_ The engine is warm when it quickly re-
sponds to the throttle. _
1. Fuel tank breather hose
2. Fuel tank overflow hose
1. Fuel tank breather hose
2. Fuel tank overflow hose
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6 Check the engine idling speed and, if
necessary, adjust it to specification by
turning the throttle stop screw. To in-
crease the engine idling speed, turn the
screw in direction
a. To decrease the
engine idling speed, turn the screw in
direction
b.
NOTE:_ If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment. _
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.
1. Throttle stop screw
Engine idling speed:
1,000–1,100 r/min
a. Throttle cable free play
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Page 74 of 120
PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
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.
_
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 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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6 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. _
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.
1. Sidewall
a. Tire tread depthMinimum tire tread depth
(front and rear)1.6 mm
1. Tire air valve
2. Tire air valve core
3. Tire air valve cap with seal
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
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.
_
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.
_
FRONT
Manufacturer Size Model
Michelin
120/70 ZR17 M/C (58W)
Pilot SPORT E
Dunlop
120/70 ZR17 M/C (58W)
D208FL
REAR
Manufacturer Size Model
Michelin
190/50 ZR17 M/C (73W)
Pilot SPORT
Dunlop
190/50 ZR17 M/C (73W)
D208L
FRONT & REAR
Tire air valve TR412
Valve core #9000A (original)
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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
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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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PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU00713
Adjusting the rear brake light
switch The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction
a. To
make the brake light come on later,
turn the adjusting nut in direction
b.
EAU00721
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU00725
Front brake pads
Each front brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator groove. If a brake
pad has worn to the point that the wear
indicator groove has almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
1. Rear brake light switch
2. Rear brake light switch adjusting nut
1. Brake pad wear indicator grooveFront
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
EAU04396
Rear brake pads
Each rear brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
Check the brake pad wear as follows.
1. Remove the brake caliper bolt,
and then tilt the caliper forward to
inspect the wear indicator groove.
If a brake pad has worn to the
point that the wear indicator
groove has almost disappeared,
have a Yamaha dealer replace the
brake pads as a set.2. Install the brake caliper bolt, and
then tighten it to the specified
torque.
EAU04856
Checking the brake fluid level Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake flu-
id level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
1. Brake caliper bolt Rear
1. Brake pad wear indicator groove
Tightening torque:
Brake caliper bolt:
27 Nm (2.7 m·kgf)
1. Minimum level markFront
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