Yamaha YZF- R1RC Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-30

6

EAU00721

Checking the front and rear
brake pads

The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.

EAU00725

Front brake pads

Each front brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator groove. If a brake
pad has worn to the point that the wear
indicator groove has almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.

EAU04396

Rear brake pads

Each rear brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
Check the brake pad wear as follows.

1. Remove the brake caliper bolt,

and then tilt the caliper forward to
inspect the wear indicator groove.
If a brake pad has worn to the
point that the wear indicator
groove has almost disappeared,
have a Yamaha dealer replace the
brake pads as a set.

1. Brake pad wear indicator groove

Front

1. Brake caliper bolt

Rear

U5PW11.book Page 30 Tuesday, August 20, 2002 1:46 PM

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Summary of Contents for YZF- R1RC

Page 1: ...PRINTED IN JAPAN 2002 09 4 1 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 5PW 28199 11 LIT 11626 16 40 YZF R1R YZF R1RC OWNER S MANUAL ...

Page 2: ...EAU03438 ...

Page 3: ...torcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emis sions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle To maintain these hig...

Page 4: ...e taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE _ This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product informat...

Page 5: ...T TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE AT TAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELI ABILITY OF THIS MOTORCYCLE _ U5PW11 book Page 2 Tuesday August 20 2002 1 46 PM ...

Page 6: ...L 2002 by Yamaha Motor Corporation U S A 1st edition July 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 16 40 U5PW11 book Page 3 Tuesday August 20 2002 1 46 PM ...

Page 7: ...ND CONTROL FUNCTIONS 3 4 PRE OPERATION CHECKS 4 5 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 MOTORCYCLE CARE AND STORAGE 7 8 SPECIFICATIONS 8 9 CONSUMER INFORMATION 9 INDEX EAU00009 U5PW11 book Page 1 Tuesday August 20 2002 1 46 PM ...

Page 8: ...NFORMATION 1 Safe riding 1 1 Protective apparel 1 3 Modifications 1 3 Loading and accessories 1 3 Gasoline and exhaust gas 1 5 Location of important labels 1 7 U5PW11 book Page 1 Tuesday August 20 2002 1 46 PM ...

Page 9: ...ANICAL CONDITIONS Safe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle ...

Page 10: ...rnering insufficient lean angle for the speed a Always obey the speed limit and never travel faster than warranted by road and traffic conditions b Always signal before turning or changing lanes Make sure that other motorists can see you 6 The posture of the operator and passenger is important for proper control a The operator should keep both hands on the handlebar and both feet on the operator f...

Page 11: ...ation They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 A passenger should also observe the above precautions Modifications Modifications made to this motorcycle not approved by Yamaha or the removal of original equipment may render the motorcycle unsafe for use and may cause severe personal injury Modifications may also make your moto...

Page 12: ...ese items in cluding such cargo as sleeping bags duffel bags or tents can create unstable handling or a slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories that may be available you must personally be responsible for the proper selection installation and use of non Yamaha accessories...

Page 13: ...ty therefore such accessories are not recommended 2 Use caution when adding electrical accessories If electrical accessories exceed the capacity of the motorcycle s electrical system an electric failure could result which could cause a dangerous loss of lights or engine power Gasoline and exhaust gas 1 GASOLINE IS HIGHLY FLAMMABLE a Always turn the engine off when refueling b Take care not to spil...

Page 14: ...eater or near an open flame otherwise it could catch fire 4 When transporting the motorcycle in another vehicle make sure that it is kept upright If the motor cycle should lean over gasoline may leak out of the fuel tank 5 If you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get into your eyes see your doctor immediately If any gasoline spills on your skin or clot...

Page 15: ...SAFETY INFORMATION 1 1 7 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle U5PW11 book Page 7 Tuesday August 20 2002 1 46 PM ...

Page 16: ...or acid cleaner gasoline or solvent will damage windshield Use neutral detergent 5JW 2835Y 00 1 California only 6 3 7 4 5 2 PREMIUM UNLEADED GASOLINE ONLY 91 Min Pump Octane R M 2 5PW 2415E 10 California only U5PW11 book Page 8 Tuesday August 20 2002 1 46 PM ...

Page 17: ...SAFETY INFORMATION 1 1 9 8 California only 9 10 U5PW11 book Page 9 Tuesday August 20 2002 1 46 PM ...

Page 18: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 U5PW11 book Page 1 Tuesday August 20 2002 1 46 PM ...

Page 19: ...bolt page 3 18 5 Front brake fluid reservoir page 6 31 6 Shock absorber assembly spring preload adjusting ring page 3 20 7 Shock absorber assembly compression damping force adjusting screw page 3 21 8 Owner s tool kit page 6 1 9 Shock absorber assembly rebound damping force adjusting screw page 3 21 10 Engine oil drain bolt page 6 14 11 Engine oil filter cartridge page 6 15 U5PW11 book Page 1 Tues...

Page 20: ... Electronic fuel injection fuse page 6 40 16 Battery page 6 39 17 Rear brake fluid reservoir page 6 31 18 Air filter element page 6 22 19 Radiator cap page 6 19 20 Coolant reservoir page 6 17 21 Engine oil level check window page 6 14 22 Engine oil filler cap page 6 14 U5PW11 book Page 2 Tuesday August 20 2002 1 46 PM ...

Page 21: ...2 2 Left handlebar switches page 3 11 3 Multi function display page 3 6 4 Main switch steering lock page 3 1 5 Tachometer page 3 11 6 Right handlebar switches page 3 12 7 Throttle grip page 6 23 8 Brake lever page 3 13 U5PW11 book Page 3 Tuesday August 20 2002 1 46 PM ...

Page 22: ...12 Shift pedal 3 12 Brake lever 3 13 Brake pedal 3 13 Fuel tank cap 3 13 Fuel 3 14 Catalytic converter 3 15 Seats 3 15 Helmet holders 3 17 Storage compartment 3 17 Adjusting the front fork 3 18 Adjusting the shock absorber assembly 3 20 Luggage strap holders 3 23 EXUP system 3 23 Sidestand 3 23 Ignition circuit cut off system 3 24 U5PW11 book Page 1 Tuesday August 20 2002 1 46 PM ...

Page 23: ...annot be re moved NOTE _ The headlights come on automatically when the engine is started and stay on until the key is turned to OFF even if the engine stalls _ EAU00038 OFF All electrical systems are off The key can be removed EAU00040 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the...

Page 24: ...as soon as possible The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical cir cuit NOTE _ This model is also equipped with a self diagnosis device for the fuel level de tection circuit If the fuel level detection circuit is defective the following cycle will b...

Page 25: ...curs have a Yamaha dealer check the motor cycle _ EAU00061 Neutral indicator light This indicator light comes on when the transmission is in the neutral position EAU04896 Engine trouble warning light This warning light comes on or flashes when an electrical circuit monitoring the engine is defective When this oc curs have a Yamaha dealer check the self diagnosis system See page 3 7 for an explanat...

Page 26: ...it EAU04923 Coolant temperature warning light This warning light comes on when the engine overheats When this occurs stop the engine immediately and allow the engine to cool The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical cir cuit EC000002 CAUTION _ Do n...

Page 27: ... flashes Warning light comes on Stop the motorcycle and allow it to idle until the coolant temperature goes down If the temperature does not go down stop the engine See the Engine overheating section on page 6 51 for further instructions Above 140 C 284 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See the Engine overheating sec tion on page 6 51 for further in s...

Page 28: ...meter and odometer tripmeter displays be tween kilometers and miles press the SELECT button and RESET button together for at least two seconds _ Odometer and tripmeter modes Pushing the SELECT button switches the display between the odometer mode ODO and the tripmeter modes TRIP 1 and TRIP 2 in the following order ODO TRIP 1 TRIP 2 ODO If the fuel level warning light comes on see page 3 2 the odom...

Page 29: ...start flashing push the RESET button to set the hours 3 Push the SELECT button and the minute digits will start flashing 4 Push the RESET button to set the minutes 5 Push the SELECT button and then release it to start the clock Self diagnosis device This model is equipped with a self di agnosis device for various electrical cir cuits If any of those circuits are defective the engine trouble warnin...

Page 30: ...which the indicator light will be activated 4 Engine speed indicator light deac tivation This function allows you to select the engine speed at which the indicator light will be de activated 5 Engine speed indicator light brightness This function allows you to adjust the brightness of the indicator light to suit your prefer ence NOTE _ To make any settings in this mode you have to cycle through al...

Page 31: ...tor light will flash when activated This setting is selected when the indicator light flashes four times per second c The indicator light is deactivated in other words it will not come on or flash This setting is selected when the indicator light flashes once every two seconds 2 Push the SELECT button to con firm the selected indicator light ac tivity The control mode changes to the engine speed i...

Page 32: ...1 Push the RESET button to select the desired engine speed for de activating the indicator light 2 Push the SELECT button to con firm the selected engine speed The control mode changes to the engine speed indicator light bright ness function To adjust the engine speed indicator light brightness 1 Push the RESET button to select the desired indicator light bright ness level 2 Push the SELECT button...

Page 33: ...et this switch to for the high beam and to for the low beam EAU03889 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When released the switch returns to the cen ter position To cancel the turn signal lights push the switch in after it has re turned to the center position EAU00129 Horn switch Press this switch to sound the horn 1 Tac...

Page 34: ...disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the ignition circuit cut off system See page 3 24 for an explanation of the ignition circuit cut off system EAU00157 Shift pedal The shift pedal is ...

Page 35: ...w mark on the brake lever EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal EAU02935 Fuel tank cap To open the fuel tank cap Open the fuel tank cap lock cover in sert the key into the lock and then turn it 1 4 turn clockwise The lock will be re leased and the fuel tank cap can be opened To close the fuel tank cap 1 Pus...

Page 36: ...fuel tank oth erwise it may overflow when the fuel warms up and expands Avoid spilling fuel on the hot engine _ EAU00185 CAUTION _ Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts _ EAU04917 ECA00104 CAUTION _ Use only unleaded gasoline The use of leaded gasoline will cause se vere damage to internal engine parts such as th...

Page 37: ...performance problems EAU01084 Catalytic converter This motorcycle is equipped with a cat alytic converter in the exhaust cham ber EW000128 WARNING _ The exhaust system is hot after op eration Make sure that the exhaust system has cooled down before do ing any maintenance work _ EC000114 CAUTION _ The following precautions must be observed to prevent a fire hazard or other damages Use only unleaded...

Page 38: ...unterclockwise 2 While holding the key in that posi tion lift the front of the passenger seat and pull it forward To install the passenger seat 1 Insert the projections on the rear of the passenger seat into the seat holder as shown and then push the front of the seat down to lock it in place 2 Remove the key NOTE _ Make sure that the seats are properly secured before riding _ 1 Projection 2 Seat ...

Page 39: ... the muf fler when secured to the right side helmet holder because of their size or shape Be sure that your helmet does not contact the muffler when it is secured to the helmet holder _ To release a helmet from a helmet holder Remove the passenger seat remove the helmet from the helmet holder and then install the seat EAU01242 Storage compartment The storage compartment is located under the passen...

Page 40: ...Spring preload To increase the spring preload and thereby harden the suspension turn the adjusting bolt on each fork leg in di rection a To decrease the spring pre load and thereby soften the suspension turn the adjusting bolt on each fork leg in direction b NOTE _ Align the appropriate groove on the ad justing mechanism with the top of the front fork cap bolt _ CI 10E 1 Spring preload adjusting b...

Page 41: ...ism beyond the maximum or minimum settings _ NOTE _ Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above spec ifications due to small differences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the num ber of clicks of each damping force ad just...

Page 42: ... spring preload and thereby harden the suspension turn the adjusting ring in direction a To de crease the spring preload and thereby soften the suspension turn the adjust ing ring in direction b NOTE _ Align the appropriate notch in the adjusting ring with the position in dicator on the shock absorber Use the special wrench included in the owner s tool kit to make the ad justment _ CI 10E 1 Spring...

Page 43: ...s of a damping force adjusting mechanism may not exactly match the above spec ifications due to small differences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the num ber of clicks of each damping force ad justing mechanism and to modify the specifications as necessary _ 1 Rebound damping force ...

Page 44: ...r property damage or personal injury that may result from improper handling Do not tamper with or attempt to open the gas cylinder Do not subject the shock ab sorber to an open flame or other high heat sources otherwise it may explode due to excessive gas pressure Do not deform or damage the gas cylinder in any way as this will result in poor damping per formance Always have a Yamaha dealer servic...

Page 45: ...usted in accordance with the engine speed by a computer controlled servomotor EC000027 CAUTION _ The EXUP system has been set and extensively tested at the Yamaha factory Changing these settings without sufficient technical knowledge may result in poor performance of or dam age to the engine If the EXUP system does not op erate have a Yamaha dealer check it _ EAU00330 Sidestand The sidestand is lo...

Page 46: ...unction properly _ EAU03720 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the trans mission is in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch lever is pulled but the ...

Page 47: ...he clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle shou...

Page 48: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 U5PW11 book Page 1 Tuesday August 20 2002 1 46 PM ...

Page 49: ...evel in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 6 17 6 18 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 30 6 32 Rear brake Check operation If soft or spongy have Yamaha de...

Page 50: ...essure Correct if necessary 6 24 6 27 Shift pedal Make sure that operation is smooth Correct if necessary Brake pedal Make sure that operation is smooth Lubricate brake pedal pivoting point if necessary 6 36 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 35 6 36 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 36...

Page 51: ...U5PW11 book Page 3 Tuesday August 20 2002 1 46 PM ...

Page 52: ...OPERATION AND IMPORTANT RIDING POINTS 5 Starting the engine 5 1 Shifting 5 3 Engine break in 5 4 Parking 5 5 U5PW11 book Page 1 Tuesday August 20 2002 1 46 PM ...

Page 53: ...le loss of control _ EAU00376 CAUTION _ Make sure not to store personal items near the air cleaner in take otherwise air intake will be blocked and performance will suffer Make sure not to put anything near the battery and its termi nals otherwise electrical failure and acid corrosion may result _ EAU04919 Starting the engine In order for the ignition circuit cut off system to enable starting one ...

Page 54: ... the transmission is in the neutral position the neutral indicator light should be on otherwise have a Yamaha dealer check the electrical cir cuit _ 3 Start the engine by pushing the start switch NOTE _ If the engine fails to start release the start switch wait a few seconds and then try again Each starting attempt should be as short as possible to pre serve the battery Do not crank the en gine mo...

Page 55: ...while changing gears to avoid dam aging the engine transmission and drive train which are not designed to withstand the shock of forced shifting _ EAU02988 To start out and accelerate 1 Pull the clutch lever to disengage the clutch 2 Shift the transmission into first gear The neutral indicator light should go out 3 Open the throttle gradually and at the same time release the clutch lever slowly 4 ...

Page 56: ... are shown in the table below CF 05E EAU01128 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1 600 km 1 000 mi For this reason you should read the following material carefully Since the engine is brand new do not put an excessive load on it for the first 1 600 km 1 000 mi The various parts in the engine wear and polish them selves to...

Page 57: ...the engine break in period immediately have a Yamaha dealer check the vehi cle _ NOTE _ During and after the engine break in period the exhaust heat may cause discoloration of the exhaust pipe but this is normal _ EAU00461 Parking When parking stop the engine and then remove the key from the main switch EW000058 WARNING _ Since the engine and exhaust system can become very hot park in a place wher...

Page 58: ...ake light switch 6 29 Checking the front and rear brake pads 6 30 Checking the brake fluid level 6 31 Changing the brake fluid 6 32 Drive chain slack 6 33 Lubricating the drive chain 6 34 Checking and lubricating the cables 6 35 Checking and lubricating the throttle grip and cable 6 35 Checking and lubricating the brake and clutch levers 6 35 Lubricating the brake pedal 6 36 Checking and lubricati...

Page 59: ...THE MAINTENANCE SERVICES RELAT ED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOWING PERIODIC MAINTE NANCE CHARTS THE SERVICES RELATED TO EMISSIONS CON TROL ARE GROUPED SEPARATE LY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIPMENT YAMAHA DEAL ERS ARE TRAINED AND EQUIPPED TO...

Page 60: ...a particular job have a Yamaha dealer perform it for you _ EW000062 WARNING _ Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes _ U5PW11 book Page 2 Tuesday August 20 2002 1 46 PM ...

Page 61: ... adjust valve clearance when engine is cold Every 26 600 mi 42 000 km 2 Spark plugs Check condition Adjust gap and clean Replace every 8 000 mi 13 000 km or 12 months Replace Replace 3 Crankcase ventilation system Check ventilation hose for cracks or damage Replace if necessary 4 Fuel line Check fuel hoses for cracks or damage Replace if necessary 5 Exhaust system Check for leakage Retighten if ne...

Page 62: ...for damage Replace if necessary 8 Air induction system Check the air cut off valve reed valve and hose for damage Replace any damaged parts if necessary No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1 000 km or 1 month 4 000mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 km or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 km or 30 months U5PW11 book Page 4...

Page 63: ...very 8 000 mi 13 000 km or 12 months 3 Air filter element Check condition Replace if necessary 4 Cooling system Check hoses for cracks or damage Replace if necessary Replace with ethylene glycol anti freeze coolant every 24 months Replace 5 Brake system Check operation pad wear and fluid leakage See NOTE on page 6 7 Correct if necessary 6 Clutch Check operation Adjust or replace cable 7 Control ca...

Page 64: ...Apply lithium soap based grease lightly 15 Drive chain Check chain slack alignment condition Adjust and lubricate chain thoroughly with a special O ring chain lubricant Every 600 mi 1 000 km or after washing the motorcycle or riding in the rain 16 Wheel bearings Check bearings for smooth operation 17 Sidestand pivot Check operation Apply lithium soap based grease lightly 18 Sidestand switch Check ...

Page 65: ... or dusty areas Hydraulic brake service After disassembling the brake master cylinders and calipers always change the fluid Regularly check the brake fluid levels and fill the reservoirs as required Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged _ 19 Chassis fas...

Page 66: ...lings and panels shown above need to be removed to perform some of the maintenance jobs described in this chapter Refer to this section each time a cowling or panel needs to be re moved and installed 1 Panel A 2 Cowling A 3 Cowling B 1 Panel B 2 Cowling B U5PW11 book Page 8 Tuesday August 20 2002 1 46 PM ...

Page 67: ...Disconnect the turn signal light lead coupler 5 Remove the screws and then take the cowling off To install the cowling 1 Install the screws 2 Connect the turn signal light lead coupler 3 Place the cowling in the original position 4 Install the screw and the bolts tighten the quick fastener screws and then install the quick fasten ers 1 Quick fastener 4 1 Quick fastener screw 6 2 Screw 3 Bolt 2 1 T...

Page 68: ...Cowling B To remove the cowling Remove the bolts loosen the quick fas tener screws 1 4 turn counterclock wise and then take the cowling off To install the cowling Place the cowling in the original posi tion and then tighten the quick fastener screws and install the bolts 1 Quick fastener After removal Before installation 1 Quick fastener screw 4 2 Cowling B 3 Bolt Right side 1 Bolt 2 Quick fastene...

Page 69: ... the periodic mainte nance and lubrication chart In addition the condition of the spark plugs can re veal the condition of the engine The porcelain insulator around the cen ter electrode of each spark plug should be a medium to light tan the ideal col or when the motorcycle is ridden nor mally and all spark plugs installed in the engine should have the same color If any spark plug shows a distinct...

Page 70: ...nd then wipe off any grime from the spark plug threads NOTE _ If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the speci fied torque as soon as possible _ a Spark plug gap Spark plug gap 0 8 0 9 mm 0 03 0 04 in Tightening torque Spark plug 12 5 Nm 1 25 m kgf 9 0 ft ...

Page 71: ...cked and if nec essary clean it EAU04913 Engine oil and oil filter cartridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter car tridge replaced at the intervals speci fied in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the motorcycle on a level surface and hold it in an upright position NOTE _ ...

Page 72: ...aise it to the correct level To change the engine oil with or without oil filter cartridge replace ment 1 Remove cowling B See page 6 10 for cowling removal and installation procedures 2 Start the engine warm it up for several minutes and then turn it off 3 Place an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcas...

Page 73: ...at the O ring is properly seated _ 7 Install the new oil filter cartridge and then tighten it to the specified torque with a torque wrench 8 Install the engine oil drain bolt and then tighten it to the specified torque NOTE _ Check the washer for damage and re place it if necessary _ 1 Oil filter wrench 2 Oil filter cartridge 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 ...

Page 74: ...e If oil is leaking immediately turn the engine off and check for the cause NOTE _ After the engine is started the engine oil level warning light should go off if the oil level is sufficient _ EC000067 CAUTION _ If the oil level warning light flickers or remains on immediately turn the engine off and have a Yamaha deal er check the vehicle _ 11 Turn the engine off and then check the oil level and ...

Page 75: ...tioned straight up when checking the coolant level A slight tilt to the side can result in a false reading _ 2 Check the coolant level in the coolant reservoir NOTE _ The coolant should be between the minimum and maximum level marks _ 3 If the coolant is at or below the minimum level mark remove panel A See page 6 11 for panel removal and installation proce dures remove the reservoir cap add coola...

Page 76: ...tent of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced _ EW000067 WARNING _ Never attempt to remove the radia tor cap when the engine is hot _ NOTE _ The radiator fan is automatically switched on or off according to the coolant temperature in the radia tor If the engine overheats see page 6 51 for further instructions _ EAU04925 To change the coolant 1 P...

Page 77: ...s and then install the clutch cable holder 8 Remove the radiator cap EW000067 WARNING _ Never attempt to remove the radia tor cap when the engine is hot _ 9 Remove the coolant drain bolt to drain the cooling system 10 Loosen the radiator hose clamp screw located at the left side of the engine and then pull off the hose to drain the radiator 1 Bolt 2 2 Radiator cap 3 Coolant reservoir cap 4 Coolant...

Page 78: ...ater has been used instead of coolant replace it with cool ant as soon as possible other wise the engine may not be sufficiently cooled and the cool ing system will not be protected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced _ Tight...

Page 79: ...eck the cooling system 19 Install the cowlings and the panel EAU04572 Replacing the air filter element The air filter element should be re placed at the intervals specified in the periodic maintenance and lubrication chart Replace the air filter element more frequently if you are riding in un usually wet or dusty areas 1 Remove the rider seat See page 3 15 for rider seat removal and in stallation ...

Page 80: ...ne should never be op erated without the air filter ele ment installed otherwise the pistons and or cylinders may become excessively worn _ 8 Install the air filter case cover by installing the screws and bolt 9 Connect the fuel tank breather hose and the fuel tank overflow hose place the fuel tank in the original position and then install the bolt 1 Bolt 2 Screw 8 3 Air filter case cover 1 Air fi...

Page 81: ...der seat EAU00635 Adjusting the throttle cable free play The throttle cable free play should measure 3 5 mm 0 1 0 2 in at the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it EAU00637 Adjusting the valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurri...

Page 82: ... loosely packed items that can shift Securely pack your heaviest items close to the center of the motorcycle and dis tribute the weight evenly from side to side Properly adjust the suspen sion for your load and check the condition and pressure of your tires NEVER OVERLOAD YOUR MOTOR CYCLE Make sure that the total weight of the cargo rider passen ger and accessories cowling sad dlebags etc if appro...

Page 83: ...hen a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience _ Tire information This motorcycle is equipped with cast wheels and tubeless tires with valves 1 Sidewall 2 Tire wear indicator a Tir...

Page 84: ... the most ef ficient use of these tires Use only the specified replace ment tires Other tires may run the danger of bursting at super high speeds Brand new tires can have a rela tively poor grip on certain road surfaces until they have been broken in Therefore it is ad visable before doing any high speed riding to ride conserva tively for approximately 100 km 60 mi after installing a new tire The ...

Page 85: ...develop its optimal characteris tics EAU00691 Accessories and replacement parts EW000098 WARNING _ This motorcycle is not designed to pull a trailer or to be attached to a sidecar The accessories or replace ment parts you choose for your motorcycle should be designed spe cifically for this model and they must be securely mounted to main tain the inherent stability of the orig inal design Genuine Y...

Page 86: ...r free play cannot be obtained as described above proceed as follows _ 1 Fully turn the adjusting bolt at the clutch lever in direction a to loos en the clutch cable 2 Remove cowling B See page 6 10 for cowling removal and installation procedures 3 Loosen the locknut at the crank case 4 To increase the clutch lever free play turn the adjusting nut in di rection a To decrease the clutch lever free ...

Page 87: ...hydraulic system will diminish the braking performance which may result in loss of control and an accident _ EAU00713 Adjusting the rear brake light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting nut while holding th...

Page 88: ...the point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set EAU04396 Rear brake pads Each rear brake pad is provided with a wear indicator groove which allows you to check the brake pad wear with out having to disassemble the brake Check the brake pad wear as follows 1 Remove the brake caliper bolt and then tilt the caliper forward to inspe...

Page 89: ...to check the brake pads for wear and the brake system for leakage Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only the recommended quali ty brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful che...

Page 90: ...vel to gradually go down However if the brake fluid level goes down sud denly have a Yamaha dealer check the cause EAU03976 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic mainte nance and lubrication chart In addition have the oil seals of the master cylin ders and calipers as well as the brake hoses replaced at the in...

Page 91: ... motorcycle to locate the tight est portion of the drive chain and then measure the drive chain slack as shown 4 If the drive chain slack is incorrect adjust it as follows EAU03608 To adjust the drive chain slack 1 Loosen the axle nut and the lock nut on each side of the swingarm 2 To tighten the drive chain turn the adjusting bolt on each side of the swingarm in direction a To loos en the drive c...

Page 92: ...he periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows EC000097 CAUTION _ The drive chain must be lubricated after washing the motorcycle or riding in the rain _ 1 Clean the drive chain with kero sene and a small soft brush ECA00053 CAUTION _ To prevent damaging the O rings do not clean the d...

Page 93: ...les as soon as possible to prevent unsafe conditions _ EAU04034 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart EAU03164 Checking and lubricating the brake and clutch levers The operation of the brake and clu...

Page 94: ...he operation of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary EW000113 WARNING _ If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it _ Recommended lubricant Lithium soap based grease all purpose grease Recommended lubricant Lithium soap based grease all purpose g...

Page 95: ... 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and re bounds smoothly EC000098 CAUTION _ If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it _ EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be ...

Page 96: ...ha dealer check or repair the steer ing EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings U5PW11 book Page 38 Tuesday August 20 2002 1 46 PM ...

Page 97: ...ng FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ...

Page 98: ...The fuse box which contains the fuses for the individual circuits is located un der panel B See page 6 11 for panel removal and installation procedures If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage 1 Headlight fuse 2 Signaling system fuse 3 Ignition fuse 4 ...

Page 99: ...light bulb This motorcycle is equipped with quartz bulb headlights If a headlight bulb burns out replace it as follows 1 Disconnect the headlight coupler and then remove the bulb cover 2 Unhook the headlight bulb holder and then remove the defective bulb EW000119 WARNING _ Headlight bulbs get very hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until...

Page 100: ...b using a cloth moistened with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the head light lens Do not use a headlight bulb of a wattage higher than speci fied _ 4 Install the headlight bulb cover and then connect the coupler 5 Have a Yamaha dealer adjust the headlight beam if necessary EAU03730 Tail brake light This motorcycle is equipped with an LED type...

Page 101: ...counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screw ECA00065 CAUTION _ Do not overtighten the screw other wise the lens may break _ EAU04574 Replacing the license plate light bulb 1 Remove the license plate light unit by removing the screws 1 Screw 1 Screw 2 U5PW11 book Page 43 Tuesday August 20 2002...

Page 102: ...is in a stable and level position before starting any maintenance A strong wooden box can be placed un der the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a mo...

Page 103: ...ccording to the procedure on page 6 44 3 Remove the brake hose holder on each side by removing the bolt and nut 4 Remove the brake caliper and re flector on each side by removing the bolts 5 Remove the axle bolt pull the wheel axle out and then remove the wheel ECA00046 CAUTION _ Do not apply the brake after the brake calipers have been removed otherwise the brake pads will be forced shut _ 1 Fron...

Page 104: ...old the wheel axle with a 19 mm hexagon wrench to keep it from turning _ 7 Tighten wheel axle pinch bolts A and B to the specified torque 8 Tap the outer side of the right fork leg with a rubber mallet to align it with the end of the wheel axle 9 Tighten wheel axle pinch bolts C and D to the specified torque 10 While applying the front brake push down hard on the handlebar several times to check f...

Page 105: ...aliper by remov ing the bolts ECA00146 CAUTION _ Do not apply the brake after the brake caliper has been removed otherwise the brake caliper pistons will be forced out _ 4 Loosen the locknut on each side of the swingarm 5 Turn the drive chain slack adjust ing bolts fully in direction a 6 Push the wheel forward and then remove the drive chain from the rear sprocket NOTE _ The drive chain does not n...

Page 106: ...e 6 33 for drive chain slack adjustment pro cedures 3 Install the axle nut and then lower the rear wheel so that it is on the ground 4 Install the brake caliper by install ing the bolts NOTE _ Make sure that there is enough space between the brake caliper pistons and brake caliper pad before installing the brake caliper _ 5 Tighten the axle nut and the brake caliper bolts to the specified torques ...

Page 107: ... troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often infer...

Page 108: ... no compression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Bat...

Page 109: ...ing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap _ CT 2AE NOTE _ If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible _ Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low...

Page 110: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 U5PW11 book Page 1 Tuesday August 20 2002 1 46 PM ...

Page 111: ...ightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00056 CAUTION _ Avoid using strong acidic wheel cleaners especially on spoked wheels If such products are used on hard to r...

Page 112: ... shield is scratched use a quali ty plastic polishing compound after washing _ After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After ridi...

Page 113: ... is normal and cannot be removed After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Immediately dry the drive chain and lubricate it to prevent it from rusting 3 Use a chrome polish to shine chrome aluminum and stainless steel parts 4 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal including chrome and nickel plat ed surfaces 5 Us...

Page 114: ...CA00014 CAUTION _ Storing the motorcycle in a poorly ventilated room or cover ing it with a tarp while it is still wet will allow water and humid ity to seep in and cause rust To prevent corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemi cals are stored _ Long term Before storing your motorcycle for several months 1 Follow all the instructions in t...

Page 115: ...ing the engine over _ 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand centerstand 5 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 6 Cover the...

Page 116: ...SPECIFICATIONS 8 Specifications 8 1 U5PW11 book Page 1 Tuesday August 20 2002 1 46 PM ...

Page 117: ...stem Electric starter Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG or higher Quantity Without oil filter cartridge replacement 2 9 L 2 55 lmp qt 3 07 US qt With oil filter cartridge replacement 3 1 L 2 73 lmp qt 3 28 US qt Total amount dry engine 3 8 L 3 34 lmp qt 4 02 US qt 0 10 30 50 70 90 110 130 F YAMALUBE 4 20W 40 or SAE 20W 40 20 10 0...

Page 118: ... multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 1 581 Secondary reduction system Chain drive Secondary reduction ratio 2 688 Number of drive chain sprocket teeth front rear 16 43 Transmission type Constant mesh 6 speed Operation Left foot Gear ratio 1st 2 500 2nd 1 842 3rd 1 500 4th 1 333 5th 1 200 6th 1 115 Chassis Frame type Diamond Caster angle 24 Trail 10...

Page 119: ...e Cast wheel Size 17 M C MT 3 50 Rear Type Cast wheel Size 17 M C MT 6 00 Brakes Front Type Dual disc brake Operation Right hand Fluid DOT 4 Rear Type Single disc brake Operation Right foot Fluid DOT 4 Suspension Front Telescopic fork Rear Swingarm link suspension Spring shock absorber Front Coil spring oil damper Rear Coil spring gas oil damper Wheel travel Front 120 mm 4 72 in Rear 130 mm 5 12 i...

Page 120: ... LED Neutral indicator light LED High beam indicator light LED Turn signal indicator light LED Fuel level warning light LED Oil level warning light LED Engine trouble warning light LED Engine speed indicator light LED Fuses Main fuse 50 A Headlight fuse 20 A Signaling system fuse 15 A Radiator fan fuse 15 A Ignition fuse 15 A Odometer and clock fuse backup fuse 5 A Electronic fuel injection fuse 1...

Page 121: ...identification number 9 1 Model label 9 2 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 9 7 YAMAHA EXTENDED SERVICE Y E S 9 9 U5PW11 book Page 1 Tuesday August 20 2002 1 46 PM ...

Page 122: ... EAU01041 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE _ The vehicle identification number is used to identify y...

Page 123: ...r the passenger seat See page 3 16 for passenger seat removal and installation procedures Record the in formation on this label in the space pro vided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label U5PW11 book Page 2 Tuesday August 20 2002 1 46 PM ...

Page 124: ...stigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Tra...

Page 125: ... for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc CL 01...

Page 126: ... printed only as a reminder that maintenance work is required It is not acceptable proof of maintenance work CL 04E Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1 000 km or 1 month 4 000 mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 km or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 km or 30 months 24 000 mi...

Page 127: ...or 42 months 32 000 mi 49 000 km or 48 months 36 000 mi 55 000 km or 54 months 40 000 mi 61 000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks U5PW11 book Page 6 Tuesday August 20 2002 1 46 PM ...

Page 128: ...CONSUMER INFORMATION 9 7 9 EAU02918 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U5PW11 book Page 7 Tuesday August 20 2002 1 46 PM ...

Page 129: ...CONSUMER INFORMATION 9 8 9 U5PW11 book Page 8 Tuesday August 20 2002 1 46 PM ...

Page 130: ...vered repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency tow...

Page 131: ...backed protection even after your Yamaha Limited Warranty expires A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 1 866 YES EXTD 1 866 937 3983 U5PW11 book Page 10 Tuesday August 20 2002 1 46 PM ...

Page 132: ...e break in 5 4 Engine oil and oil filter cartridge 6 13 Engine speed indicator light 3 4 Engine stop switch 3 12 Engine trouble warning light 3 3 EXUP system 3 23 F Front fork adjusting 3 18 Front fork checking 6 37 Fuel 3 14 Fuel level warning light 3 2 Fuel tank cap 3 13 Fuses replacing 6 40 H Handlebar switches 3 11 Headlight bulb replacing 6 41 Helmet holders 3 17 High beam indicator light 3 3...

Page 133: ... 37 Storage 7 4 Storage compartment 3 17 Supporting the motorcycle 6 44 T Tachometer 3 11 Tail brake light 6 42 Throttle cable free play adjusting 6 23 Throttle grip and cable checking and lubricating 6 35 Tires 6 24 Tool kit 6 1 Troubleshooting 6 49 Troubleshooting charts 6 50 Turn signal indicator lights 3 2 Turn signal light bulb replacing 6 43 Turn signal switch 3 11 V Valve clearance adjustin...

Page 134: ...PRINTED IN JAPAN 2002 09 4 1 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 5PW 28199 11 LIT 11626 16 40 YZF R1R YZF R1RC OWNER S MANUAL ...

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