Yamaha YZF-R1 2002, Service Information

Page 1: ...Yamaha Motor Co Ltd 2002 YZF R1 P 5PW1 SE1 SERVICE INFORMATION ...

Page 2: ...ormation has been prepared to introduce new service and data for the YZF R1 P 2002 For complete service information procedures it is necessary to use this Service Information together with the following manual YZF R1 P 2002 SERVICE MANUAL 5PW1 ME1 ...

Page 3: ...mprove all of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable Designs and specifications are subject to change without notice EAS00004 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following ...

Page 4: ...trical system 9 Troubleshooting Symbols 10 to 17 indicate the following 10 Serviceable with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Tightening torque 15 Wear limit clearance 16 Engine speed 17 Electrical data Symbols 18 to 23 in the exploded diagrams indi cate the types of lubricants and lubrication points 18 Engine oil 19 Gear oil 20 Molybdenum disulfide oil 21 Wheel beari...

Page 5: ...ATIONS 12 ELECTRICAL SPECIFICATIONS 16 CONVERSION TABLE 18 TIGHTENING TORQUES 18 GENERAL TIGHTINING TORQUES SPECIFICATIONS 18 ENGINE TIGHTENING TORQUES 19 CHASSIS TIGHTENING TORQUES 22 LUBRICATION POINTS AND LUBRICANT TYPES 24 ENGINE 24 CHASSIS 25 CABLE ROUTING 26 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION 36 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS 36 YZF R1 WIRING DIAGRAM ...

Page 6: ...ORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS00018 MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts 1 ...

Page 7: ...A 5PW2 F 5PW3 AUS SSS SSS SSS Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2 040 mm 705 mm 1 105 mm 820 mm 1 395 mm 140 mm 3 900 mm SSS SSS SSS SSS SSS SSS SSS Weight Wet with oil and a full fuel tank Maximum load except motorcycle 193 kg 202 kg SSS SSS 2 ...

Page 8: ... kPa 190 mmHg 1 450 kPa 14 5 kg cm2 at 400 r min SSS SSS SSS SSS SSS SSS SSS SSS Fuel Recommended fuel Fuel tank capacity Total including reserve Reserve only Premium unleaded gasoline only 17 L 3 5 L SSS SSS SSS Engine oil Lubrication system Recommended oil Quantity Total amount Without oil filter cartridge replacement With oil filter cartridge replacement Oil pressure hot Relief valve opening pr...

Page 9: ...g pressure Radiator core Width Height Depth Coolant reservoir Capacity Water pump Water pump type Reduction ratio Max impeller shaft tilt 2 45 L 95 X 125 kPa 0 95 X 1 25 kg cm2 340 mm 295 8 mm 27 mm 0 24 L Single suction centrifugal pump 68 43 28 28 1 581 SSS SSS SSS SSS SSS SSS SSS SSS 0 15 mm Starting system type Electric starter Electric fuel injection Type Manufacturer INP 731 4 NIPPON INJECTO...

Page 10: ... cap clearance Intake camshaft lobe dimensions Measurement A Measurement B Exhaust camshaft lobe dimensions Measurement A Measurement B Max camshaft runout Chain drive right 24 500 X 24 521 mm 24 459 X 24 472 mm 0 028 X 0 062 mm 32 5 X 32 6 mm 24 95 X 25 05 mm 32 95 X 33 05 mm 24 95 X 25 05 mm SSS SSS SSS SSS SSS 32 4 mm 24 85 mm 32 85 mm 24 85 mm 0 03 mm 5 ...

Page 11: ...eat width C Intake Exhaust Valve margin thickness D Intake Exhaust Valve stem diameter Intake Exhaust Valve guide inside diameter Intake Exhaust Valve stem to valve guide clearance Intake Exhaust Valve stem runout Valve seat width Intake Exhaust 22 9 X 23 1 mm 24 4 X 24 6 mm 1 76 X 2 90 mm 1 76 X 2 90 mm 0 9 X 1 1 mm 0 9 X 1 1 mm 0 5 X 0 9 mm 0 5 X 0 9 mm 3 975 X 3 990 mm 4 465 X 4 480 mm 4 000 X ...

Page 12: ...nding direction top view Intake Exhaust 38 9 mm 40 67 mm 34 5 mm 35 mm 82 X 96 N 8 2 X 9 6 kg 110 X 126 N 11 0 X 12 6 kg SSS SSS Clockwise Clockwise 37 0 mm 38 6 mm SSS SSS SSS SSS 2 5_ 1 7 mm 2 5_ 1 8 mm SSS SSS Cylinders Cylinder arrangement Bore stroke Compression ratio Bore Max taper Max out of round Forward inclined parallel 4 cylinder 74 58 mm 11 8 1 74 00 X 74 01 mm SSS SSS SSS SSS SSS SSS ...

Page 13: ...talled Ring side clearance 2nd ring Ring type Dimensions B T End gap installed Ring side clearance Oil ring Dimensions B T End gap installed 0 010 X 0 035 mm 73 975 X 73 990 mm 5 mm 17 002 X 17 013 mm 0 5 mm Intake side 16 991 X 17 000 mm 0 002 X 0 022 mm Barrel 0 90 2 75 mm 0 32 X 0 44 mm 0 030 X 0 065 mm Taper 0 8 2 8 mm 0 43 X 0 58 mm 0 020 X 0 055 mm 1 5 2 6 mm 0 10 X 0 35 mm 0 12 mm SSS SSS m...

Page 14: ...S 0 160 X 0 262 mm 0 029 X 0 053 mm 1 Violet 0 White 1 Blue 2 Black 3 Brown SS SSS 0 03 mm SSS SSS SSS Clutch Clutch type Clutch release method Clutch release method operation Operation Clutch cable free play at the end of the clutch lever Friction plates Thickness Plate quantity Clutch plates Thickness Plate quantity Max warpage Clutch springs Free length Spring quantity Wet multiple disc Outer p...

Page 15: ...axle runout Constant mesh 6 speed Spur gear 68 43 1 581 Chain drive 43 16 2 688 Left foot operation 35 14 2 500 35 19 1 842 30 20 1 500 28 21 1 333 30 25 1 200 29 26 1 115 SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS 0 08 mm 0 08 mm Shifting mechanism Shift mechanism type Max shift fork guide bar bending Guide bar SSS SSS 0 1 mm Air filter type Wet element SSS Fuel pump Pump type Model ...

Page 16: ...eter Throttle bodies Model manufacturer quantity Intake vacuum pressure Throttle cable free play at the flange of the throttle grip 40EIS MIKUNI 4 25 3 kPa 190 mmHg 3 X 5 mm SSS SSS SSS of the throttle gri ID mark Throttle valve size 5PW1 00 GB S D NL B E P I CH A GR 5PW2 10 F 100 SSS SSS Max EXUP cable free play at the EXUP valve pulley 1 5 mm SSS 11 ...

Page 17: ... SSS 1 mm 0 5 mm Rear wheel Wheel type Rim Size Material Wheel travel Wheel runout Max radial wheel runout Max lateral wheel runout Cast wheel 17 M C MT6 00 Aluminum 130 mm SSS SSS SSS SSS SSS SSS 1 mm 0 5 mm Front tire Tire type Size Model manufacturer Tire pressure cold 0 X 90 kg 90 X 202 kg High speed riding Min tire tread depth Tubeless 120 70 ZR17 M C 58W Pilot SPORT E MICHELIN D208FL DUNLOP ...

Page 18: ...ess Master cylinder inside diameter Caliper cylinder inside diameter Dual disc brake Right hand operation DOT 4 2 3 X 11 5 mm 298 5 mm SSS SSS 4 5 mm 14 mm 30 1 mm and 27 mm SSS SSS SSS SSS SSS 4 5 mm 0 1 mm 0 5 mm SSS SSS Rear brake Brake type Operation Brake pedal position from the top of the brake pedal to the bottom of the rider footrest bracket Recommended fluid Brake pedal freeplay Brake dis...

Page 19: ...ube with the inner tube fully compressed and without the fork spring Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum Standard Maximum Compression damping adjusting positions Minimum Standard Maximum from the fully turned in position Telescopic fork Coil spring oil damper 120 mm 251 mm 74 mm 244 mm 8 34 N mm 0 83 kg mm 0 X 120 mm 43 mm SSS No ...

Page 20: ...bound damping adjusting positions Minimum Standard Maximum Compression damping adjusting positions Minimum Standard Maximum from the fully turned in position Swingarm link suspension Coil spring gas oil damper 65 mm 176 5 mm 162 5 mm 88 3 N mm 8 83 kg mm 0 X 65 mm No 1 200 kPa 12 kg cm2 1 4 9 20 15 1 20 15 1 SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS Swingarm Free play...

Page 21: ...0_C SSS SSS SSS SSS Charging system System type Model manufacturer Normal output Stator coil resistance color AC magneto F4T471 MITSUBISHI 14 V 32 A at 5 000 r min 0 19 X 0 23 Ω at 20_C W W SSS SSS SSS SSS Rectifier regulator Regulator type Model manufacture Semi conductor short circuit FH001 SHINDENGEN SSS SSS No load regulated voltage Rectifier capacity Withstand voltage 14 1 X 14 9 V 35 A 200 V...

Page 22: ...elay Model manufacturer Amperage Coil resistance 2768079 A JIDECO 180 A 4 18 X 4 62 Ω at 20_C SSS SSS SSS Horn Horn type Model manufacturer quantity Max amperage Performance Coil resistance Plain YF 12 NIKKO 1 3 A 105 X 113 db 2 mm 1 15 X 1 25 Ω at 20_C SSS SSS SSS SSS SSS EXUP servo motor Type manufacturer 5PW YAMAHA SSS Turn signal relay Relay type Model manufacturer Self cancelling device built...

Page 23: ... tightening torques 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm Nm mSkg 6 15 30 55 85 130 0 6 1 5 3 0 5 5 8 5 13 0 EAS00028 CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS Use this table to convert METRIC unit data to IMPERIAL unit data Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in CONVERSION TABLE METRIC TO IMPE...

Page 24: ...ion check bolt EXUP pulley cover EXUP cable bracket Exhaust pipe and exhaust valve Exhaust valve and housing EXUP pulley and arm shaft Exhaust joint Exhaust valve pipe Air induction system pipe Crankcase cylinder head Nut Nut Cap nut Bolt Bolt Bolt Stud bolt Nut Screw Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Screw Bolt Clamp Nut Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt ...

Page 25: ...entification sensor Atmospheric pressure sensor Speed sensor Stator coil clamp Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Nut Bolt Nut Screw Bolt Screw Nut Nut Bolt Bolt Screw Screw Bolt Screw Bolt Screw Bolt Bolt M6 M6 M8 M6 M6 M6 M6 M6 M6 M6 M6 M8 M6 M6 M20 M6 M22 M6 M6 M8 M6 M6 M6 M6 M6 M6 M10 M6 M12 M5 M12 M6 M5 M6 M6 2 14 2 9 2 1 1 8 8 5 5 1 1 3 1 6 1 3 2 1 1 1 1 1 ...

Page 26: ...2 20 TIGHTENING TORQUES SPEC Crankcase tightening sequence 21 ...

Page 27: ...rear frame Throttle cable adjuster lock nut engine side Pivot shaft nut Pivot shaft adjust bolt Connecting arm and frame Relay arm and connecting rod Relay arm and swingarm Rear shock absorber and relay arm Rear shock absorber and frame Drive chain guard Fuel tank and fuel pump Fuel tank stay and fram front Fuel tank and stay rear Fuel tank and fuel tank side cover Rider seat and frame Coolant res...

Page 28: ... M8 M8 M6 M10 M10 M14 2 28 28 18 30 63 90 0 2 2 8 2 8 1 8 3 0 6 3 9 0 Front wheel axle and bolt Rear wheel axle nut Front brake caliper and front fork Brake disc and wheel Rear wheel sprocket and rear wheel drive hub Brake caliper and bleed screw Pinch bolt front wheel axle M14 M24 M10 M6 M10 M8 M8 90 150 40 18 100 6 18 9 0 15 0 4 0 1 8 10 0 6 1 8 1 First tighten the ring nut to approximately 50 N...

Page 29: ...and outer Oil pump housing Oil strainer Clutch pull rod Oil water pump drive sprocket and washer Clutch thrust plate Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Transmission gears wheel and pinion Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Cylinder head cover mating surface Yamaha bond No 1215 Crankc...

Page 30: ...l Rear wheel drive hub mating surface Rear brake pedal shaft Sidestand pivoting point and metal to metal moving parts Throttle grip inner surface Brake lever pivoting point and metal to metal moving parts Clutch lever pivoting point and metal to metal moving parts Relay arm connecting rod and rear shock absorber collar Pivot shaft Swing arm pivot bush Swing arm head pipe end and oil seal Oil seal ...

Page 31: ...eads at the place of white tape with the clamp behind the pawl of head light body F To turn signal light G To main harness H Route the junction of the head light position lamp and turn sig nal light leads through the pawl on the headlight body Pay attention to the direction 1 Headlight drain plug A Make sure to securely insert the coupler and boot B The headlight lead can be routed by either of th...

Page 32: ...gneto lead 8 Speed sensor lead 9 lead 10 Rear brake switch lead 11 EXUP servo motor lead 12 ACmagneto lead 13 AI system lead 14 Oil level switch lead 15 Sidestand switch lead 16 Wire harness assembly 17 Injector sub lead 1 18 Starter lead 19 lead 20 lead 21 Cover 1 22 Injector sub lead 23 AI system lead 24 Oil level switch lead 25 Sidestand switch lead 27 ...

Page 33: ...tion sensor lead under the throttle body J Wiring section K Connect the leads behind the clamp without crankshaft posi tion sensor lead Fasten the wire harness speed sensor neutral switch rear brake switch pick up coil and starter leads with the clamp in serted to the frame L EXUP servo motor M To rectifier regulator 3 N Fasten the wire harness lead AC magneto lead and recti fier regulator lead ju...

Page 34: ...motor lead through the clamp inserted to the box battery AB Clamp the lead as being in parallel along the fender Make sure to clamp three leads AC Fasten the wire harness with the clamp inserted to the hole of the box battery AD Routing position of each lead except the wire harness is not regulated in the clamp AE Branch from the main harness AF Assembling point Beneath the under bracket below the...

Page 35: ...he ALARM coupler lead AO Press the lead of the coupler for ALARM in under the cou pler of ECU AP Pay attention not to allow the lead to slack and get caught after wiring when assembling the side cover AQ Make sure to hook the har ness on the hook of battery box AR Pick up coil lead Should be wired in front of the clamp AS Neutral switch lead Should be wired in front of the clamp AT Fasten the lead...

Page 36: ...open side to the vehicle outside E Fasten the clutch cable with the clamp to the inside of the coolant reservoir tank F Fasten the sidestand switch lead behind the bracket and cut the tip G To fuel tank H Pass the throttle cable in front of the brake hose I Pass the clutch cable behind the front fork J Pass the handlebar switch lead and main switch lead between the steering stopper and front fork ...

Page 37: ...ind of the throttle cable O Route the coolant temperature sensor lead between the engine and the radiator hose P Route the clutch cable through the inside of radiator hose and fasten it with the clamp to the ra diator Q Fasten the clutch cable and cool ant reservoir tank breather hose with the clamp 32 ...

Page 38: ... 1 17 Oil level gauge lead 18 AI system hose 19 Sidestand switch lead 20 Fuel return hose 21 Fuel tank breather hose 22 Fuel feeder hose 23 Fuel tank drain hose 24 Injector sub lead 25 Wire harness 26 To throttle body 27 To air cleaner 28 To fuel tank 29 Crankcase breather hose 30 Assembling point 31 Speed sensor lead 32 EXUP servo motor 33 EXUP servo motor lead 2 34 To throttle body 35 Rear brake...

Page 39: ... gauge side stand switch lead and radiator hose in the drive sprocket cover G Do not pinch the hose H Pass the oil level gauge lead and sidestand switch lead by the in ner side of the coolant hose I Route the fuel tank breather hose and fuel tank drain hoses through the clamp and pass by the outside of the bottom cowl ing Make the end length of hoses even C Clamp the air cleaner drain hose fuel ta...

Page 40: ...Pass all the hoses under the in jector sub lead and wire harness Q Neutral switch lead Route the lead so that it surely points to the right upward R Clamp the lead making slack so that the harness routes to the coupler from the downside of the EXUP serve motor S Pay attention to the inserting direction of the relay Y Position the clamp between the clamp of oil level switch lead and the radiator co...

Page 41: ...Ǹ 3 Valves See page 3 9 S Check valve clearance S Adjust Every 40 000 km 4 Air filter element See page 3 33 S Replace See NOTE Ǹ 5 Clutch See page 3 31 S Check operation S Adjust Ǹ Ǹ Ǹ Ǹ Ǹ 6 Front brake See page 3 42 S Check operation fluid level and vehicle for fluid leakage See NOTE Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ See page 3 42 S Replace brake pads Whenever worn to the limit 7 Rear brake See page 3 43 S Check opera...

Page 42: ...Change Every 3 years 25 Front and rear brake switches See page 3 45 See page 8 4 S Check operation Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ 26 Moving parts and cables See page 3 62 S Lubricate Ǹ Ǹ Ǹ Ǹ Ǹ 27 Throttle grip housing and cable See page 3 22 S Check operation and free play S Adjust the throttle cable free play if necessary S Lubricate the throttle grip housing and cable Ǹ Ǹ Ǹ Ǹ Ǹ 28 Air induction system See page 7 3...

Page 43: ... off relay 11 Side stand switch 12 Fuel pump 13 ECU 14 Ignition coil 15 Spark plug 16 Fuel injector 17 AI system solenoid 18 EXUP servo motor 19 Speed sensor 20 Lean angle cut off switch 21 Cylinder identification sensor 22 Atmospheric pressure sensor 23 Intake air pressure sensor 24 Throttle position sensor 25 Crankshaft position sensor 26 Intake air temperature sensor 27 Coolant temperature sens...

Page 44: ...YZF R1 2002 WIRING DIAGRAM for EUR ...

Page 45: ...witch 12 Fuel pump 13 ECU 14 Ignition coil 15 Spark plug 16 Fuel injector 17 AI system solenoid 18 EXUP servo motor 19 Speed sensor 20 Lean angle cut off switch 21 Cylinder identification sensor 22 Atmospheric pressure sensor 23 Intake air pressure sensor 24 Throttle position sensor 25 Crankshaft position sensor 26 Intake air temperature sensor 27 Coolant temperature sensor 28 Neutral switch 29 Fu...

Page 46: ...YZF R1 P 2002 WIRING DIAGRAM for AUS ...

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