Yamaha YZF-R1(P) 2002 Service Information Download Page 1

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Yamaha Motor Co., Ltd.

2002

YZF-R1(P)

5PW1-SE1

SERVICE

INFORMATION

Summary of Contents for YZF-R1(P) 2002

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

Page 2: ...rmation 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 followin...

Page 3: ...prove 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 wher...

Page 4: ...rical 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...

Page 5: ...TIONS 12 ELECTRICAL SPECIFICATIONS 16 CONVERSION TABLE 18 TIGHTENING TORQUES 18 GENERAL TIGHTINING TORQUES SPECIFICATIONS 18 ENGINE TIGHTENING TORQUES 19 CHASSIS TIGHTENING TORQUES 22 LUBRICATION POIN...

Page 6: ...RCYCLE 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 affi...

Page 7: ...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 m...

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...

Page 9: ...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...

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...

Page 11: ...at 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...

Page 12: ...ding 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...

Page 13: ...alled 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...

Page 14: ...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 fr...

Page 15: ...xle 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 S...

Page 16: ...ter 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...

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...

Page 18: ...ss 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...

Page 19: ...be 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...

Page 20: ...ound 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 oi...

Page 21: ...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 at 20_C W W SSS SSS SSS SS...

Page 22: ...elay Model manufacturer Amperage Coil resistance 2768079 A JIDECO 180 A 4 18 X 4 62 at 20_C SSS SSS SSS Horn Horn type Model manufacturer quantity Max amperage Performance Coil resistance Plain YF 12...

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 man...

Page 24: ...on 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 Crankca...

Page 25: ...ntification 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 Scre...

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

Page 27: ...ear 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 rela...

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...

Page 29: ...nd 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 T...

Page 30: ...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 pa...

Page 31: ...ads 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 le...

Page 32: ...neto 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 1...

Page 33: ...ion 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 sw...

Page 34: ...otor 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...

Page 35: ...e 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...

Page 36: ...pen 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 tan...

Page 37: ...nd 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...

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...

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 Ro...

Page 40: ...ass 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 rout...

Page 41: ...an and regap See page 3 24 S Replace 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 5 Clutch See page 3 31 S Check operati...

Page 42: ...ars 25 Front and rear brake switches See page 3 45 See page 8 4 S Check operation 26 Moving parts and cables See page 3 62 S Lubricate 27 Throttle grip housing and cable See page 3 22 S Check operatio...

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 id...

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

Page 45: ...itch 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 Atm...

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

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