Yamaha YZF-R1 2003 Supplementary Service Manual Download Page 3

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FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the
YZF-R1 (R) 2003. For complete service information procedures it is necessary to use this Supplemen-
tary Service Manual together with the following manual.

YZF-R1 (P) 2002 SERVICE MANUAL: 5PW1-AE1

YZF-R1 (R) 2003

SUPPLEMENTARY

SERVICE MANUAL

2002 by Yamaha Motor Co., Ltd.

First Edition, August 2002

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

Summary of Contents for YZF-R1 2003

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Page 3: ...it is necessary to use this Supplemen tary Service Manual together with the following manual YZF R1 P 2002 SERVICE MANUAL 5PW1 AE1 YZF R1 R 2003 SUPPLEMENTARY SERVICE MANUAL E2002 by Yamaha Motor Co Ltd First Edition August 2002 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ... 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 5: ...he top of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s ap pears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number i...

Page 6: ...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 7: ...HECKING THE SWITCHES 12 LIGHTING SYSTEM 13 CIRCUIT DIAGRAM 13 TROUBLESHOOTING 15 SIGNALING SYSTEM 17 CIRCUIT DIAGRAM 17 CHECKING THE SIGNALING SYSTEM 19 TROUBLESHOOTING FAULTY LIGHTING OR SIGNALING SYSTEM 21 HEADLIGHT DOES NOT COME ON 21 HEADLIGHT BULB BURNT OUT 21 YZF R1 R 2003 WIRING DIAGRAM EUR YZF R1 R 2003 WIRING DIAGRAM OCE ...

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Page 9: ...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 10: ...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 11: ...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 12: ... 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 13: ...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 14: ...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 15: ... 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 16: ...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 17: ...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 18: ...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 19: ...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 20: ...itch 6 Turn signal switch 7 Hazard switch 8 Sidestand switch 9 Engine stop switch 10 Start switch EAS00731 ELECTRICAL CHECKING THE SWITCHES Check each switch for damage or wear proper connections and also for continuity between the termi nals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace Improperly connected Properly connect Incorrect continuity reading Replace the switch ...

Page 21: ... 13 LIGHTING SYSTEM ELEC EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM ...

Page 22: ...y 13 ECU 35 Hi beam indicator light 38 Meter light 44 Pass switch 45 Dimmer switch 54 Headlight 55 License light 56 Tail brake light 64 Fuse turn 66 Fuse headlight 68 Headlight relay on off 69 Headlight relay dimmer LIGHTING SYSTEM ELEC EA ...

Page 23: ...G SYSTEM ELEC NOTE YES NO 1 Main signal headlight and turn fuses SCheck the main signal headlight and turn fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main signal headlight and turn fuses OK Replace the fuse s 2 Battery SCheck the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 EAS00739 EAS00781 TROUBLESHOOTING Any of the following fail ...

Page 24: ...he pocket tester Ω 1 and bat tery 12 V to the headlight relay dimmer coupler as shown SDoes the headlight relay dimmer have continuity NO YES Replace the head light relay dimmer 1 2 Hi beam Positive battery lead yellow Negative battery lead black Positive tester probe black blue Negative tester probe black yellow 3 4 1 2 Low beam Positive tester probe black blue Negative tester probe black green E...

Page 25: ... 17 SIGNALING SYSTEM ELEC EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM ...

Page 26: ... function meter 34 Coolant temperature indicator light 36 Turn signal indicator light L 37 Turn signal indicator light R 40 Oil level gauge 41 Turn signal relay 43 Hazard switch 46 Horn switch 48 Turn signal switch 49 Rear turn signal light R 50 Rear turn signal light L 51 Front turn signal light R 52 Front turn signal light L 53 Horn 56 Tail brake light 57 Rear brake light switch 59 Front brake l...

Page 27: ...2 V on brown at the turn signal relay coupler wire harness side SIs the voltage within specification 1 YES NO The wiring circuit from the main switch to the turn signal relay coupler is faulty and must be re paired YES NO 5 Voltage SConnect the pocket tester DC 20 V to the turn signal relay coupler wire harness side as shown The turn signal relay is faulty and must be replaced Positive tester prob...

Page 28: ...ester probe chocolate Negative tester probe ground Right turn signal light Positive tester probe dark green Negative tester probe ground 1 2 SSet the main switch to ON SSet the turn signal switch to or SMeasure the voltage DC 12 V of the choco late or dark green at the turn signal light connector wire harness side SIs the voltage within specification 1 2 This circuit is OK A B C ...

Page 29: ...ncorrect connection SImproperly grounded circuit SPoor contacts main or dimmer switch SBurnt out headlight bulb SHeadlight relay on off SHeadlight relay dimmer HEADLIGHT BULB BURNT OUT SWrong headlight bulb SFaulty battery SFaulty rectifier regulator SImproperly grounded circuit SFaulty main switch SFaulty dimmer switch SFaulty headlight relay on off SFaulty headlight relay dimmer SHeadlight bulb ...

Page 30: ...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 31: ...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...

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Page 35: ...YZF R1 R 2003 WIRING DIAGRAM EUR ...

Page 36: ...YZF R1 R 2003 WIRING DIAGRAM OCE ...

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