Yamaha 2002 Yzfr1 Servicemanual
Yamaha 2002 Yzfr1 Servicemanual
Yamaha 2002 Yzfr1 Servicemanual
This is the cut pages sample. Download all 439 page(s) at: ManualPlace.com
YZF-R1P
YZF-R1PC
SERVICE MANUAL
LIT-11616-15-47 5PW-28197-10
EAS00000
YZF-R1P/YZF-R1PC
SERVICE MANUAL
©2001 by Yamaha Motor Corporation, U.S.A.
First edition, December 2001
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-15-47
EAS00003
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-
ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in
one manual. 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 vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard
to performance and emissions. Proper service with the correct tools is necessary to ensure that the
vehicle will operate as designed. If there is any question about a service procedure, it is imperative
that you contact a Yamaha dealer for any service information changes that apply to this model. This
policy is intended to provide the customer with the most satisfaction from his vehicle and to conform
to federal environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-
ers and will appear in future editions of this manual where applicable.
NOTE:
_
• This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
• Designs and specifications are subject to change without notice.
EAS00004
6 2 1
3
4
7
EAS00008
1 2 SYMBOLS
The following symbols are not relevant to
GEN
INFO SPEC every vehicle.
Symbols 1 to 9 indicate the subject of each
3 4 chapter.
1 General information
CHK CHAS 2 Specifications
ADJ 3 Periodic checks and adjustments
4 Chassis
5 6
5 Engine
6 Cooling system
ENG 7 Fuel injection system
COOL 8 Electrical system
9 Troubleshooting
7 8
– +
FI ELEC
9 0 Symbols 0 to G indicate the following.
0 Serviceable with engine mounted
TRBL A Filling fluid
SHTG B Lubricant
C Special tool
A B D Tightening torque
E Wear limit, clearance
F Engine speed
G Electrical data
C D
T.
R.
E F G
TABLE OF CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC 2
PERIODIC CHECKS AND
CHK
ADJUSTMENTS ADJ 3
CHASSIS CHAS 4
ENGINE ENG 5
COOLING SYSTEM COOL 6
FUEL INJECTION SYSTEM FI 7
– +
FEATURES .....................................................................................................1-2
OUTLINE OF FI SYSTEM ........................................................................1-2
FI SYSTEM ...............................................................................................1-3
COMPONENTS ........................................................................................1-5
FUEL INJECTION SYSTEM ...................................................................1-16
THREE-WAY CATALYTIC CONVERTER SYSTEM ..............................1-19
INSTRUMENT FUNCTION .....................................................................1-20
CHAPTER 2
SPECIFICATIONS
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION .............................................................................................3-1
SEATS ............................................................................................................3-3
COWLINGS .....................................................................................................3-7
CHASSIS ......................................................................................................3-37
ADJUSTING THE FRONT BRAKE .........................................................3-37
ADJUSTING THE REAR BRAKE ...........................................................3-38
CHECKING THE BRAKE FLUID LEVEL ................................................3-39
CHECKING THE FRONT AND REAR BRAKE PADS ............................3-40
ADJUSTING THE REAR BRAKE LIGHT SWITCH ................................3-40
CHECKING THE FRONT AND REAR BRAKE HOSES .........................3-41
BLEEDING THE HYDRAULIC BRAKE SYSTEM ...................................3-41
ADJUSTING THE SHIFT PEDAL ...........................................................3-43
ADJUSTING THE DRIVE CHAIN SLACK ..............................................3-43
LUBRICATING THE DRIVE CHAIN .......................................................3-45
CHECKING AND ADJUSTING THE STEERING HEAD ........................3-45
CHECKING THE FRONT FORK ............................................................3-48
ADJUSTING THE FRONT FORK LEGS ................................................3-49
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY .................3-51
CHECKING THE TIRES .........................................................................3-53
CHECKING THE WHEELS ....................................................................3-56
CHECKING AND LUBRICATING THE CABLES ....................................3-57
LUBRICATING THE LEVERS AND PEDALS ........................................3-57
LUBRICATING THE SIDESTAND ..........................................................3-57
LUBRICATING THE REAR SUSPENSION ............................................3-57
CHAPTER 5
OVERHAULING THE ENGINE
ENGINE ...........................................................................................................5-1
DRIVE SPROCKET ..................................................................................5-1
EXHAUST PIPE ........................................................................................5-2
LEADS AND HOSES ................................................................................5-4
ENGINE ....................................................................................................5-6
INSTALLING THE ENGINE ......................................................................5-7
CAMSHAFT ....................................................................................................5-8
CYLINDER HEAD COVERS ...................................................................5-8
CAMSHAFTS ............................................................................................5-9
REMOVING THE CAMSHAFTS .............................................................5-11
CHECKING THE CAMSHAFTS .............................................................5-12
CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS,
AND TIMING CHAIN GUIDES ...............................................................5-14
CHECKING THE TIMING CHAIN TENSIONER .....................................5-15
INSTALLING THE CAMSHAFTS ...........................................................5-15
CYLINDER HEAD ........................................................................................5-19
REMOVING THE CYLINDER HEAD ......................................................5-20
CHECKING THE CYLINDER HEAD ......................................................5-20
INSTALLING THE CYLINDER HEAD ....................................................5-21
GENERATOR ..............................................................................................5-32
REMOVING THE GENERATOR ............................................................5-33
INSTALLING THE GENERATOR ...........................................................5-33
CLUTCH ........................................................................................................5-40
CLUTCH COVER ..................................................................................5-40
PULL LEVER SHAFT .............................................................................5-41
CLUTCH .................................................................................................5-42
REMOVING THE CLUTCH ....................................................................5-44
CHECKING THE FRICTION PLATES ....................................................5-44
CHECKING THE CLUTCH PLATES ......................................................5-45
CHECKING THE CLUTCH HOUSING ...................................................5-45
CHECKING THE CLUTCH BOSS ..........................................................5-45
CHECKING THE PRESSURE PLATE ...................................................5-46
CHECKING THE PULL LEVER SHAFT AND PULL ROD ......................5-46
CHECKING THE STARTER CLUTCH ...................................................5-46
INSTALLING THE CLUTCH ...................................................................5-47
CRANKCASE ...............................................................................................5-58
DISASSEMBLING THE CRANKCASE ...................................................5-60
CHECKING THE CRANKCASE .............................................................5-61
CHECKING THE BEARINGS AND OIL SEALS .....................................5-61
CHECKING THE SPROCKET AND CHAINS .........................................5-61
ASSEMBLING THE CRANKCASE .........................................................5-62
CRANKSHAFT .............................................................................................5-76
CHECKING THE CRANKSHAFT ...........................................................5-77
CHECKING THE CRANKSHAFT JOURNAL BEARINGS ......................5-77
INSTALLING THE CRANKSHAFT .........................................................5-80
TRANSMISSION ...........................................................................................5-81
REMOVING THE TRANSMISSION ........................................................5-87
CHECKING THE SHIFT FORKS ............................................................5-87
CHECKING THE SHIFT DRUM ASSEMBLY .........................................5-88
CHECKING THE TRANSMISSION ........................................................5-88
INSTALLING THE TRANSMISSION ......................................................5-89
CHAPTER 6
COOLING SYSTEM
RADIATOR .....................................................................................................6-1
CHECKING THE RADIATOR ...................................................................6-3
INSTALLING THE RADIATOR .................................................................6-4
THERMOSTAT ...............................................................................................6-7
CHECKING THE THERMOSTAT ...........................................................6-10
ASSEMBLING THE THERMOSTAT ASSEMBLY ..................................6-11
INSTALLING THE THERMOSTAT ASSEMBLY ....................................6-11
CHAPTER 7
FUEL INJECTION SYSTEM
CHAPTER 8
ELECTRICAL
CHAPTER 9
TROUBLESHOOTING
OVERHEATING ..............................................................................................9-4
ENGINE ....................................................................................................9-4
COOLING SYSTEM .................................................................................9-4
FUEL SYSTEM .........................................................................................9-4
CHASSIS ..................................................................................................9-4
ELECTRICAL SYSTEMS .........................................................................9-4
OVERCOOLING .............................................................................................9-4
COOLING SYSTEM .................................................................................9-4
This is the cut pages sample. Download all 439 page(s) at: ManualPlace.com