Yamaha YZF-R1(P) 2002 Bedienungs- und Montageanleitung

Yamaha Motor Co., Ltd.

2002

YZF-R1(P)

5PW1-SE1

SERVICE

INFORMATION

Yamaha Motor Co., Ltd.

FOREWORD

This service information 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

NOTE:

WARNING

CAUTION:

EAS00003

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers

and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu-

al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles

should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-

hicle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve 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.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to

the motorcycle operator, a bystander or a person checking or repairing the mo-

torcycle.

A CAUTION indicates special precautions that must be taken to avoid damage

to the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

24 25

2321

19 2018

16 1715

1413

11 12

GEN

INFO SPEC

ENG

FI ELEC

COOL

CHK

ADJ

TRBL

SHTG

CHAS

EAS00008

SYMBOLS

The following symbols are not relevant to every

vehicle.

Symbols 1to 9indicate the subject of each

chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Chassis

5Engine

6Cooling system

7Fuel injection system

8Electrical system

9Troubleshooting

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-bearing grease

22 Lithium-soap- based grease

23 Molybdenum-disulfide grease

Symbols 24 to 25 in the exploded diagrams indi-

cate the following.

24 Apply locking agent (LOCTITE)

25 Replace the part

CONTENTS

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . 1

MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SPECIFICATIONS

GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

1-1

MOTORCYCLE IDENTIFICATION GEN

INFO

EAS00014

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

EAS00017

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1is stamped

into the right side of the steering head pipe.

EAS00018

MODEL LABEL

The model label 1is affixed to the frame. This

information will be needed to order spare parts.

2-1

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard Limit

Model code 5PW1 (A) (B) (CH) (D) (E) (GB) (GR) (I)

(NL) (P) (S) (ZA)

5PW2 (F)

5PW3 (AUS)

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

Weight

Wet (with oil and a full fuel tank)

Maximum load (except motorcycle)

193 kg

202 kg

SSS

2-2

ENGINE SPECIFICATIONS SPEC

ENGINE SPECIFICATIONS

Item Standard Limit

Engine

Engine type

Displacement

Cylinder arrangement

Bore stroke

Compression ratio

Engine idling speed

Vacuum pressure at engine idling

speed

Standard compression pressure

(at sea level)

Liquid-cooled, 4-stroke, DOHC

998 cm3

Forward-inclined parallel 4-cylinder

74 58 mm

11.8 : 1

1,000 X1,100 r/min

25.3 kPa (190 mmHg)

1,450 kPa (14.5 kg/cm2) at 400 r/min

SSS

Fuel

Recommended fuel

Fuel tank capacity

Total (including reserve)

Reserve only

Premium unleaded gasoline only

17 L

3.5 L

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 pressure

Wet sump

SAE20W40SE or SAE10W30SE

3.8 L

2.9 L

3.1 L

45 kPa at 1,100 r/min

(0.45 kg/cm2at 1,100 r/min)

480 X560 kPa (4.8 X5.6 kg/cm2)

SSS

2-3

ENGINE SPECIFICATIONS SPEC

Item Standard Limit

Oil filter

Oil filter type

Bypass valve opening pressure

Cartridge (paper)

80 X120 kPa (0.8 X1.2 kg/cm2)

SSS

Oil pump

Oil pump type

Inner-rotor-to-outer-rotor-tip

clearance

Outer-rotor-to-oil-pump-housing

clearance

Trochoid

0.01 X0.10 mm

0.09 X0.15 mm

SSS

0.18 mm

0.22 mm

Cooling system

Radiator capacity

Radiator cap opening pressure

Radiator core

Width

Height

Depth

Coolant reservoir

Capacity

Water pump

Water pump type

Reduction ratio

Max. impeller shaft tilt

2.45 L

95 X125 kPa (0.95 X1.25 kg/cm2)

340 mm

295.8 mm

27 mm

0.24 L

Single suction centrifugal pump

68/43 28/28 (1.581)

SSS

0.15 mm

Starting system type Electric starter

Electric fuel injection

Type

Manufacturer

INP-731/4

NIPPON INJECTOR

SSS

Spark plugs

Model (manufacturer) quantity

Spark plug gap

CR9EIA 9/IU27D (NGK/DENSO) 4

0.8 X0.9 mm

SSS

Cylinder head

Volume

Max. warpage

13.45 X14.05 cm3

SSS

0.1 mm

2-4

ENGINE SPECIFICATIONS SPEC

Item Standard Limit

Camshafts

Drive system

Camshaft cap inside diameter

Camshaft journal diameter

Camshaft-journal-to-camshaft-

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 X24.521 mm

24.459 X24.472 mm

0.028 X0.062 mm

32.5 X32.6 mm

24.95 X25.05 mm

32.95 X33.05 mm

24.95 X25.05 mm

SSS

32.4 mm

24.85 mm

32.85 mm

24.85 mm

0.03 mm

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