torque YAMAHA YZF-R1 2003 Owners Manual

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
U5PWE1.book Page 1 Monday, July 8, 2002 10:28 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
NOTE:_ If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible. _
EAU04913
Engine oil and oil filter
cartridge The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:_ Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. _
2. Start the engine, warm it up for
several minutes, and then turn it off.
3. Wait a few minutes until the oil set-
tles, and then check the oil level
through the check window located
at the bottom-right side of the
crankcase.NOTE:_ The engine oil should be between the
minimum and maximum level marks. _4. If the engine oil is at or below the
minimum level mark, add sufficient
oil of the recommended type to
raise it to the correct level. Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf)1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
4. Engine oil filler cap
U5PWE1.book Page 9 Monday, July 8, 2002 10:28 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
66. Apply a thin coat of engine oil to
the O-ring of the new oil filter car-
tridge.
NOTE:_ Make sure that the O-ring is properly
seated. _
7. Install the new oil filter cartridge,
and then tighten it to the specified
torque with a torque wrench.
8. Install the engine oil drain bolt, and
then tighten it to the specified
torque.NOTE:_ Check the washer for damage and re-
place it if necessary. _
9. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
1. O-ring
1. Torque wrench
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge
replacement:
2.9 L
With oil filter cartridge
replacement:
3.1 L
Total amount (dry engine):
3.8 L
U5PWE1.book Page 11 Monday, July 8, 2002 10:28 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6 11. After the coolant is completely
drained, thoroughly flush the cool-
ing system with clean tap water.
12. Install the coolant drain bolt, and
then tighten it to the specified
torque.
NOTE:_ Check the washer for damage and re-
place it if necessary. _13. Connect the radiator hose, and
then tighten the clamp screw.14. Pour the specified amount of rec-
ommended coolant into the radia-
tor and reservoir.
EC000080
CAUTION:_

If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.


If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the cool-
ing system will not be protected
against frost and corrosion.


If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
_
Tightening torque:
Coolant drain bolt:
10 Nm (1.0 m·kgf)
Antifreeze/water mixture ratio:
1:1
Recommended antifreeze:
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Coolant quantity:
Total amount:
2.45 L
Coolant reservoir capacity
(up to the maximum level mark):
0.24 L
U5PWE1.book Page 16 Monday, July 8, 2002 10:28 AM

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
U5PWE1.book Page 27 Monday, July 8, 2002 10:28 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6
NOTE:_ Using the alignment marks on each
side of the swingarm, make sure that
both chain pullers are in the same posi-
tion for proper wheel alignment. _
EC000096
CAUTION:_ Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits. _3. Tighten the locknuts, and then
tighten the axle nut to the specified
torque.
EAU03006
Lubricating the drive chain The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.
EC000097
CAUTION:_ The drive chain must be lubricated
after washing the motorcycle or
riding in the rain. _1. Clean the drive chain with kero-
sene and a small soft brush.
ECA00053
CAUTION:_ To prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents. _
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
ECA00052
CAUTION:_ Do not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings. _
Tightening torque:
Axle nut:
150 Nm (15.0 m·kgf)
U5PWE1.book Page 30 Monday, July 8, 2002 10:28 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-42
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 DTightening 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)
U5PWE1.book Page 42 Monday, July 8, 2002 10:28 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-44
6 7. While supporting the brake caliper
bracket, pull the wheel axle out.
8. Remove the wheel.
EAU04921
To install the rear wheel
1. Install the wheel and the brake cal-
iper bracket by inserting the wheel
axle from the left-hand side.
2. Install the drive chain onto the rear
sprocket, and then adjust the drive
chain slack. (See page 6-29 for
drive chain slack adjustment pro-
cedures.)
3. Install the axle nut, and then lower
the rear wheel so that it is on the
ground.
4. Install the brake caliper by install-
ing the bolts.NOTE:_ Make sure that there is enough space
between the brake caliper pistons and
brake caliper pad before installing the
brake caliper. _5. Tighten the axle nut and the brake
caliper bolts to the specified
torques.
1. Wheel axle
Tightening torques:
Axle nut:
150 Nm (15.0 m·kgf)
Brake caliper bolt:
27 Nm (2.7 m·kgf)
U5PWE1.book Page 44 Monday, July 8, 2002 10:28 AM

SPECIFICATIONS
8-5
8
EAU04513
Conversion table CS-04EAll specification data in this manual are listed in SI and
METRIC UNITS.
Use this table to convert METRIC unit values to IMPERIAL
unit values.
Example:METRIC VALUE CONVERSION
FACTORIMPERIAL VALUE
2 mm× 0.03937 = 0.08 in
Conversion table
METRIC SYSTEM TO IMPERIAL SYSTEM
Metric unit Conversion factor Imperial unit
Torquem·kgf
m·kgf
cm·kgf
cm·kgf
× 7.233× 86.794× 0.0723× 0.8679ft·lbf
in·lbf
ft·lbf
in·lbf
Weightkg
g× 2.205× 0.03527lb
oz
Speed km/h× 0.6214 mi/h
Distancekm
m
m
cm
mm× 0.6214× 3.281× 1.094× 0.3937× 0.03937mi
ft
yd
in
in
Volume,
Capacitycc (cm
3)
cc (cm3)
L (liter)
L (liter)
× 0.03527× 0.06102× 0.8799× 0.2199oz (IMP liq.)
cu·in
qt (IMP liq.)
gal (IMP liq.)
Miscellaneouskg/mm
kgf/cm
2
°
C
× 55.997× 14.2234× 1.8 + 32 lb/in
psi (lbf/in
2)
°
F
U5PWE1.book Page 5 Monday, July 8, 2002 10:28 AM