Yamaha YZF-R1P 2001-2003, Assembly Manual

Page 1: ... 1 5PW 28107 10 LIT 11666 15 47 YZF R1P YZF R1PC ASSEMBLY MANUAL ...

Page 2: ...er NOTICE The service specifications given in this assembly manual are based on the model as manufactured Modifications and significant changes in specifications and or procedures will be forwarded to Authorized Yamaha Dealers The procedures below are described in the order that the procedures are carried out correctly and completely Failure to do so can result in poor performance and possible har...

Page 3: ...ctacles or safety goggles when using compressed air when grinding or when doing any operation which may cause particles to fly off Product hands and feet by wearing safety gloves or doing SYMBOLS USED ON CRATE CARTON Contents of the transport package are fragile therefore it shall be handled with care Indicates correct upright position of the transport package Transport package shall be kept away ...

Page 4: ...issors 2 Remove the bolts 2 upper bracket 3 Remove the bolt 3 front tire 4 Remove the packing frames 4 upward and sideways NOTE Remove the bolts while holding frame NOTE Before starting the assembly check for damaged or missing parts The parts are contained in the cartan and the motorcycle for damage scratches and other defects ...

Page 5: ... 2 PARTS LOCATION 1 Carton box ...

Page 6: ...asher and special nuts windscreen Bolt front master cylinder Bolt handle crown and handlebar Nut rear view mirror Nut front reflector Front reflector Vinyl bag 1 Plugs handle crown Owner s manual Rear view mirrors Windscreen ...

Page 7: ... 4 SETUP PROCEDURES 5 2 6 1 3 4 ...

Page 8: ...olt to specified torque Tightening torque 13 Nm 1 3 m kg 9 4 ft lb C Tighten the bolt to specified torque Tightening torque 13 Nm 1 3 m kg 9 4 ft lb A Tighten the screws to specified torque Tightening torque 40 Nm 4 0 m kg 29 ft lb 1 2 3 4 5 2 2 2 4 4 Reflector bracket Reflector Nut Washer Caliper bolt V V d 5 0 20 d 10 0 39 d 10 0 39 r 30 1 18 3 Clutch cable 1 Clutch cable 1 A Check the clutch le...

Page 9: ...n Special nut Washer Screw C V V V d 5 0 20 d 5 5 0 22 d 5 0 20 r 15 0 59 A Before installing the battery charge the battery NOTE Refer to ADJUSTMENTS AND PREDELIVERY SERVICE B First connect the lead Red color lead to the terminal C Connect the lead Black color lead to the terminal NOTE Refer to CABLE ROUTING 1 2 3 4 5 6 1 2 1 1 2 2 Battery Bolt Band Front seat Collar Bolt d 6 0 24 r 12 0 47 d 6 0...

Page 10: ...hrottle cable in front of the brake hose ı Pass the clutch cable behind the front fork Ç In this area the handlebar switch lead right side should not be in front of the throttle cable It should not cross the throttle cable around the guide air Î In this area pass the handlebar switch right side lead behind of the throttle cable ...

Page 11: ... 8 1 lead 2 lead ...

Page 12: ... 9 ADJUSTMENTS AND PREDELIVERY SERVICE J L Q A E P B N M B K N H C J I L G J D I F O ...

Page 13: ...Check Using a digital voltmeter the state of a discharged MF battery can be checked by measuring open circuit voltage the voltage measured with the positive and negative terminals being disconnected Open circuit Charging time voltage 12 8 V or Charging is not necessary higher EAA00128 B CHECKING THE TIRE PRESSURE 1 Measure tire pressure Out of specification Adjust WARNING Tire inflation pressure s...

Page 14: ...coolant level should be between the maximum level marks a and minimum level marks b Below the minimum level mark Add the recommended coolant to the proper level CAUTION Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and correct the antifreeze concentration of the coolant Use only distilled water Soft water may be used if disti...

Page 15: ...d Direction a Throttle cable free play is increased Direction b Throttle cable free play is decreased c Tighten the locknut WARNING After adjusting the throttle cable free play turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change EAA00142 G ADJUSTING THE FRONT BRAKE 1 Adjust brake lever position distance a from the throttle grip to th...

Page 16: ...refore check and if necessary bleed the brake system CAUTION After adjusting the brake pedal position make sure that there is no brake drag EAA00151 I CHECKING THE BRAKE FLUID LEVEL 1 Stand the motorcycle on a level surface NOTE Place the motorcycle on a suitable stand Make sure that the motorcycle is upright 2 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid ...

Page 17: ...es f Fully squeeze the brake lever or fully depress the brake pedal and hold it in position g Loosen the bleed screw This will release the tension and cause the brake lever to contact the throttle grip or the brake pedal to fully extend h Tighten the bleed screw and then release the brake lever or brake pedal i Repeat steps e to h until all of the air bubbles have disappeared from the brake fluid ...

Page 18: ...osition Standard 6 Minimum 8 Maximum 1 Rebound damping CAUTION Never go beyond the maximum or minimum adjustment positions 1 Adjust rebound damping a Turn the adjusting screw 2 in direction a or b Rebound damping is Direction a increased suspension is harder Rebound damping is Direction b decreased suspension is softer Adjuster position Standard 13 clicks out Minimum 26 clicks out Maximum 1 click ...

Page 19: ...m 9 Rebound damping CAUTION Never go beyond the maximum or minimum adjustment positions 1 Adjust rebound damping a Turn the adjusting screw 3 in direction a or b Rebound damping is Direction a increased suspension is harder Rebound damping is Direction b decreased suspension is softer Adjuster position Standard 15 clicks out Minimum 20 clicks out Maximum 1 click out from the fully turned in positi...

Page 20: ... sure that there is no clearance between the wheel axle plates and the end of the adjusting bolts c Tighten the wheel axle nut to specification Wheel axle nut 150 Nm 15 m kg 108 ft lb d Tighten the locknuts to specification Locknut 16 Nm 1 6 m kg 12 ft lb EAA00181 O ADJUSTING THE REAR BRAKE LIGHT SWICTH NOTE The rear brake light switch is operated by movement of the brake pedal The rear brake ligh...

Page 21: ... mode push the SELECT button 3 1 Adjust digital clock 1 a Pushthe SELECT button3and RESET button 2 together for at least two seconds b When the hour digits start flashing push the RESET button 2 to set the hours c Push the SELECT button 3 and the minute digits will start flashing d Push the RESET button 2 to set the minutes e Push the SELECT button 3 and then release it to start the clock ...

Page 22: ...49 US gal 0 11 0 20 mm 0 0043 0 0079 in 0 21 0 27 mm 0 0083 0 0106 in 202 kg 445 lb for USA 201 kg 443 lb for California SERVICE DATA Engine idling speed Spark plug Type Gap Fuel Recommended fuel Fuel tank capacity Total Valve clearance cold IN EX Maximum load Front 250 kPa 2 5 kgf cm2 36 psi 250 kPa 2 5 kgf cm2 36 psi 250 kPa 2 5 kgf cm2 36 psi Up to 90 kg 198 lb load 90 kg 198 lb Maximum load Hi...

Page 23: ...ounting Front mounting bolts M10 45 4 5 33 Rear mounting bolts upper and lower M10 50 5 0 36 Pinch bolts front M8 24 2 4 17 Engine mount adjust bolt rear M16 7 0 7 5 1 Exhaust pipe bracket and frame M8 34 3 4 25 Clutch cable adjuster locknut engine side M8 7 0 7 5 1 Main frame and rear frame M10 40 4 0 29 Throttle cable adjuster locknut engine side M6 5 0 5 3 6 Pivot shaft nut M18 105 10 5 76 Pivo...

Page 24: ...0 2 1 4 Rider footrest bracket and frame M8 28 2 8 20 Passenger footrest bracket and frame M8 28 2 8 20 Rear master cylinder M6 18 1 8 13 Rear brake hose union bolts M10 30 3 0 22 Sidestand M10 63 6 3 46 Front wheel axle and bolt M14 90 9 0 65 Rear wheel axle nut M24 150 15 0 108 Front brake caliper and front fork M10 40 4 0 29 Brake disc and wheel M6 18 1 8 13 Rear wheel sprocket and rear wheel d...

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Page 26: ... 2 PRINTED IN U S A YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...