Yamaha 5PW1-SE2 Service Manual Download Page 1 | Manualshive

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Yamaha Motor Co., Ltd.

2003

YZF-R1(R)

5PW1-SE2

SERVICE

INFORMATION

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Summary of Contents for 5PW1-SE2

Page 1: ...Yamaha Motor Co Ltd 2003 YZF R1 R 5PW1 SE2 SERVICE INFORMATION ...

Page 2: ...troduce new service and data for the YZF R1 R 2003 For complete service information procedures it is necessary to use this Supplementary Service Information together with the following manual YZF R1 P R 2002 2003 SERVICE MANUAL 5PW1 ME2 YZF R1 P 2002 SERVICE INFORMATION 5PW1 SE1 ...

Page 3: ... to improve all its models Modifications and signifi cant 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 INFORMATION Particularly important information is distinguished in this manual by the following The S...

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: ...CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS 1 ENGINE SPECIFICATIONS 1 ELECTRICAL SPECIFICATIONS 1 CABLE ROUTING 2 YZF R1 R 2003 WIRING DIAGRAM EUR YZF R1 R 2003 WIRING DIAGRAM OCE ...

Page 6: ...rting system System type Starter motor Model manufacturer Power output Brushes Overall length Spring force Armature coil resistance Commutator diameter Mica undercut Constant mesh 5PW YAMAHA 0 9 kW 10 8 mm 5 28 X 7 92 N 528 X 792 g 0 009 X 0 011 Ω at 20_C 24 5 mm 1 5 mm SSS SSS SSS 3 65 mm SSS SSS 23 5 mm SSS Fuses amperage quantity Main fuse Fuel injection system fuse Headlight fuse Signaling sys...

Page 7: ...e head light lead and auxiliary light lead behind the pawl of the head light body with the clamp 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 ...

Page 8: ...gneto lead 8 Speed sensor lead 9 lead 10 Rear brake switch lead 11 EXUP servo motor lead 12 AC magneto 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 ...

Page 9: ... the throttle body J Wiring section K Wire the leads in front of the clamp excluding the brake light switch lead Secure the wire harness vehicle speed sensor lead neutral switch lead brake light switch lead pickup coil lead and starter lead with the clamp inserted to the frame Point the tip of the clamp to the downward Do not bind over the bare wire 3 L EXUP servo motor M To rectifier regulator N ...

Page 10: ...battery AA Route the starter 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 Beneat...

Page 11: ...the 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 lea...

Page 12: ... 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 outer tub...

Page 13: ...or lead between the engine and the radiator hose Make sure to push it into the deeper position so that it is not caught between the cylinder head cover 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 ...

Page 14: ...2 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 brak...

Page 15: ...l 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 t...

Page 16: ...I system hose is not regulated in the clamp P 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 clam...

Page 17: ...lay 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 22 Atmospheric pressure sensor 23 Intake air pressure sensor 24 Throttle position sensor 25 Coolant temperature sensor 26 Intake air temperature sensor 27 Crankshaft position sensor 28 Neutral ...

Page 18: ...YZF R1 R 2003 WIRING DIAGRAM EUR ...

Page 19: ...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 relay 21 Cylinder identification sensor 22 Atmospheric pressure sensor 23 Intake air pressure sensor 24 Throttle position sensor 25 Coolant temperature sensor 26 Intake air temperature sensor 27 Crankshaft position sensor 28 Neutral s...

Page 20: ...YZF R1 R 2003 WIRING DIAGRAM OCE ...

Page 21: ......

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