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Yamaha_YZFR1P_YZFR1PC_2002_Service_Manual &_YZF-R1P(C)_Assembly_Manual & user Guide
Yamaha_YZFR1P_YZFR1PC_2002_Service_Manual
Pages 439
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER -MODEL LABEL -
FEATURES
OUTLINE OF FI SYSTEM -FI SYSTEM -COMPONENTS -FUEL INJECTION SYSTEM -THREE-WAY CATALYTIC CONVERTER SYSTEM -INSTRUMENT FUNCTION -
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY -REPLACEMENT PARTS -GASKETS, OIL SEALS AND O-RINGS -LOCK WASHERS/PLATES AND COTTER PINS -BEARINGS AND OIL SEALS -CIRCLIPS -
CHECKING THE CONNECTIONS -SPECIAL TOOLS
CHAPTER 1
SPECIFICATIONS
GENERAL SPECIFICATIONS -ENGINE SPECIFICATIONS -CHASSIS SPECIFICATIONS -ELECTRICAL SPECIFICATIONS -CONVERSION TABLE -TIGHTENING TORQUES -GENERAL TIGHTENING TORQUE SPECIFICATIONS -ENGINE TIGHTENING TORQUES -CHASSIS TIGHTENING TORQUES -LUBRICATION POINTS AND LUBRICANT TYPES ENGINE -CHASSIS -COOLING SYSTEM DIAGRAMS -ENGINE OIL LUBRICATION CHART -LUBRICATION DIAGRAMS -CABLE ROUTING
CHAPTER 2
PERIODIC CHECKS AND ADJUSTMENTS-INTRODUCTION -PERIODIC MAINTENANCE CHART
FOR THE EMISSION CONTROL SYSTEM -GENERAL MAINTENANCE AND LUBRICATION CHART -
SEATS -FUEL TANK -
REMOVING THE FUEL TANK -REMOVING THE FUEL PUMP -INSTALLING THE FUEL PUMP -INSTALLING THE FUEL HOSE -COWLINGS -AIR FILTER CASE -ENGINE -ADJUSTING THE VALVE CLEARANCE -SYNCHRONIZING THE THROTTLE BODIES -ADJUSTING THE ENGINE IDLING SPEED -ADJUSTING THE THROTTLE CABLE FREE PLAY -CHECKING THE SPARK PLUGS -MEASURING THE COMPRESSION PRESSURE -CHECKING THE ENGINE OIL LEVEL -CHANGING THE ENGINE OIL -ADJUSTING THE CLUTCH CABLE FREE PLAY -REPLACING THE AIR FILTER ELEMENT -CHECKING THE FUEL AND BREATHER HOSES -CHECKING THE CRANKCASE BREATHER HOSE -CHECKING THE EXHAUST SYSTEM -ADJUSTING THE EXUP CABLES -CHECKING THE COOLANT LEVEL -CHECKING THE COOLING SYSTEM -CHANGING THE COOLANT -
CHASSIS -ADJUSTING THE FRONT BRAKE -ADJUSTING THE REAR BRAKE -CHECKING THE BRAKE FLUID LEVEL -CHECKING THE FRONT AND REAR BRAKE PADS -ADJUSTING THE REAR BRAKE LIGHT SWITCH -
CHECKING THE FRONT AND REAR BRAKE HOSES -BLEEDING THE HYDRAULIC BRAKE SYSTEM -DJUSTING THE SHIFT PEDAL -ADJUSTING THE DRIVE CHAIN SLACK -LUBRICATING THE DRIVE CHAIN -CHECKING AND ADJUSTING THE STEERING HEAD -CHECKING THE FRONT FORK -ADJUSTING THE FRONT FORK LEGS -ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY -CHECKING THE TIRES -CHECKING THE WHEELS -CHECKING AND LUBRICATING THE CABLES -LUBRICATING THE LEVERS AND PEDALS -
LUBRICATING THE SIDESTAND -LUBRICATING THE REAR SUSPENSION
ELECTRICAL SYSTEM -
CHECKING AND CHARGING THE BATTERY -CHECKING THE FUSES -REPLACING THE HEADLIGHT BULBS -
ADJUSTING THE HEADLIGHT BEAM
CHAPTER 3
CHASSIS
FRONT WHEEL AND BRAKE DISCS -
FRONT WHEEL -REMOVING THE FRONT WHEEL -CHECKING THE FRONT WHEEL -CHECKING THE BRAKE DISCS -INSTALLING THE FRONT WHEEL -ADJUSTING THE FRONT WHEEL STATIC BALANCE -
REAR WHEEL AND BRAKE DISC -
REAR WHEEL -REMOVING THE REAR WHEEL -CHECKING THE REAR WHEEL -CHECKING THE REAR WHEEL DRIVE HUB -CHECKING AND REPLACING THE REAR WHEEL SPROCKET -INSTALLING THE REAR WHEEL -
ADJUSTING THE REAR WHEEL STATIC BALANCE -
FRONT AND REAR BRAKES -
FRONT BRAKE PADS -REAR BRAKE PADS -REPLACING THE FRONT BRAKE PADS -REPLACING THE REAR BRAKE PADS -FRONT BRAKE MASTER CYLINDER -REAR BRAKE MASTER CYLINDER -DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER -DISASSEMBLING THE REAR BRAKE MASTER CYLINDER -CHECKING THE FRONT-AND REAR BRAKE MASTER CYLINDERS -ASSEMBLING AND INSTALLING-THE FRONT BRAKE MASTER CYLINDER -ASSEMBLING THE REAR BRAKE MASTER CYLINDER -FRONT BRAKE CALIPERS -
REAR BRAKE CALIPER -DISASSEMBLING THE FRONT BRAKE CALIPERS -DISASSEMBLING THE REAR BRAKE CALIPER -CHECKING THE FRONT AND REAR BRAKE CALIPERS -ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS -ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER -
FRONT FORK -
REMOVING THE FRONT FORK LEGS -DISASSEMBLING THE FRONT FORK LEGS -CHECKING THE FRONT FORK LEGS -ASSEMBLING THE FRONT FORK LEGS -INSTALLING THE FRONT FORK LEGS -
HANDLEBARS -
REMOVING THE HANDLEBARS -CHECKING THE HANDLEBARS -INSTALLING THE HANDLEBARS -
STEERING HEAD -
REMOVING THE LOWER BRACKET -CHECKING THE STEERING HEAD -INSTALLING THE STEERING HEAD -
REAR SHOCK ABSORBER ASSEMBLY -
HANDLING THE REAR SHOCK ABSORBER-AND GAS CYLINDER -DISPOSING OF A REAR SHOCK ABSORBER
AND GAS CYLINDER -REMOVING THE REAR SHOCK ABSORBER ASSEMBLY -CHECKING THE REAR SHOCK ABSORBER ASSEMBLY -INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY -
SWINGARM AND DRIVE CHAIN
REMOVING THE SWINGARM -REMOVING THE DRIVE CHAIN -CHECKING THE SWINGARM -CHECKING THE DRIVE CHAIN -INSTALLING THE SWINGARM -
CHAPTER 4
OVERHAULING THE ENGINE
ENGINE -
DRIVE SPROCKET -EXHAUST PIPE -LEADS AND HOSES -ENGINE -INSTALLING THE ENGINE -
CAMSHAFT -
CYLINDER HEAD COVERS -CAMSHAFTS -REMOVING THE CAMSHAFTS -CHECKING THE CAMSHAFTS -
CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS,-AND TIMING CHAIN GUIDES -CHECKING THE TIMING CHAIN TENSIONER -INSTALLING THE CAMSHAFTS
CYLINDER HEAD -
REMOVING THE CYLINDER HEAD -CHECKING THE CYLINDER HEAD -INSTALLING THE CYLINDER HEAD -
VALVES AND VALVE SPRINGS -
REMOVING THE VALVES -CHECKING THE VALVES AND VALVE GUIDES -CHECKING THE VALVE SEATS -
CHECKING THE VALVE SPRINGS -CHECKING THE VALVE LIFTERS -INSTALLING THE VALVES -
GENERATOR -
REMOVING THE GENERATOR -INSTALLING THE GENERATOR -
PICKUP COIL -
REMOVING THE PICKUP COIL ROTOR -INSTALLING THE PICKUP COIL ROTOR -
CLUTCH -
CLUTCH COVER -PULL LEVER SHAFT -CLUTCH -REMOVING THE CLUTCH -CHECKING THE FRICTION PLATES -CHECKING THE CLUTCH PLATES -CHECKING THE CLUTCH HOUSING -CHECKING THE CLUTCH BOSS -CHECKING THE PRESSURE PLATE -CHECKING THE PULL LEVER SHAFT AND PULL ROD -
CHECKING THE STARTER CLUTCH -INSTALLING THE CLUTCH -
SHIFT SHAFT -SHIFT SHAFT AND STOPPER LEVER -CHECKING THE SHIFT SHAFT -CHECKING THE STOPPER LEVER -INSTALLING THE SHIFT SHAFT
OIL PAN AND OIL PUMP -
OIL PUMP -REMOVING THE OIL PAN -CHECKING THE OIL PUMP -CHECKING THE RELIEF VALVE -
CHECKING THE OIL DELIVERY PIPES -CHECKING THE OIL STRAINER -ASSEMBLING THE OIL PUMP -
INSTALLING THE OIL PUMP -INSTALLING THE OIL STRAINER -INSTALLING THE OIL PAN -
CRANKCASE -DISASSEMBLING THE CRANKCASE -CHECKING THE CRANKCASE -CHECKING THE BEARINGS AND OIL SEALS -CHECKING THE SPROCKET AND CHAINS -ASSEMBLING THE CRANKCASE -
CONNECTING RODS AND PISTONS -
REMOVING THE CONNECTING RODS AND PISTONS -REMOVING THE CRANKSHAFT ASSEMBLY -CHECKING THE CYLINDER AND PISTONS -CHECKING THE PISTON RINGS -CHECKING THE PISTON PINS -CHECKING THE BIG END BEARINGS -INSTALLING THE CONNECTING ROD AND PISTON -
CRANKSHAFT -
CHECKING THE CRANKSHAFT -CHECKING THE CRANKSHAFT JOURNAL BEARINGS -INSTALLING THE CRANKSHAFT -
TRANSMISSION -
REMOVING THE TRANSMISSION -CHECKING THE SHIFT FORKS -CHECKING THE SHIFT DRUM ASSEMBLY -
CHECKING THE TRANSMISSION -INSTALLING THE TRANSMISSION
CHAPTER 5
COOLING SYSTEM
RADIATOR -
CHECKING THE RADIATOR -INSTALLING THE RADIATOR -
OIL COOLER -
CHECKING THE OIL COOLER -INSTALLING THE OIL COOLER -
THERMOSTAT -
CHECKING THE THERMOSTAT -ASSEMBLING THE THERMOSTAT ASSEMBLY -INSTALLING THE THERMOSTAT ASSEMBLY -
WATER PUMP -
DISASSEMBLING THE WATER PUMP -CHECKING THE WATER PUMP -ASSEMBLING THE WATER PUMP -
CHAPTER 6
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM -
WIRING DIAGRAM -ECU‘S SELF-DIAGNOSTIC FUNCTION -SUBSTITUTE CHARACTERISTICS OPERATION CONTROL-(FAIL-SAFE ACTION) -FAIL-SAFE ACTIONS TABLE -TROUBLESHOORING CHART -
DIAGNOSTIC MODE -TROUBLESHOOTING DETAILS -
THROTTLE BODIES -
CHECKING THE INJECTOR -CHECKING THE THROTTLE BODY -CHECKING THE PRESSURE REGULATOR -
CHECKING THE FUEL PUMP-AND PRESSURE REGULATOR OPERATION -CHECKING AND ADJUSTING
THE THROTTLE POSITION SENSOR -
AIR INDUCTION SYSTEM
AIR INDUCTION -AIR CUT-OFF VALVE -AIR INDUCTION SYSTEM DIAGRAMS -CHECKING THE AIR INDUCTION SYSTEM -
CHAPTER 7
ELECTRICAL
ELECTRICAL COMPONENTS -
CHECKING SWITCH CONTINUITY -
CHECKING THE SWITCHES -
CHECKING THE BULBS AND BULB SOCKETS -
TYPES OF BULBS -CHECKING THE CONDITION OF THE BULBS -CHECKING THE CONDITION OF THE BULB SOCKETS -CHECKING THE LEDS -
IGNITION SYSTEM -
CIRCUIT DIAGRAM -TROUBLESHOOTING -
ELECTRIC STARTING SYSTEM -
CIRCUIT DIAGRAM -STARTING CIRCUIT CUT-OFF SYSTEM OPERATION -TROUBLESHOOTING -
STARTER MOTOR -CHECKING THE STARTER MOTOR -ASSEMBLING THE STARTER MOTOR -
CHARGING SYSTEM -
CIRCUIT DIAGRAM -TROUBLESHOOTING -
LIGHTING SYSTEM -
CIRCUIT DIAGRAM -TROUBLESHOOTING -CHECKING THE LIGHTING SYSTEM -
SIGNALING SYSTEM -
CIRCUIT DIAGRAM -TROUBLESHOOTING -CHECKING THE SIGNALING SYSTEM
COOLING SYSTEM -
CIRCUIT DIAGRAM -TROUBLESHOOTING -
FUEL PUMP SYSTEM -
CIRCUIT DIAGRAM -FUEL PUMP SYSTEM -TROUBLESHOOTING -CHECKING THE FUEL PUMP -
CHAPTER 8
TROUBLESHOOTING
STARTING FAILURES -
ENGINE -FUEL SYSTEM -ELECTRICAL SYSTEMS -
INCORRECT ENGINE IDLING SPEED -
ENGINE -FUEL SYSTEM -ELECTRICAL SYSTEMS -
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE -
ENGINE -FUEL SYSTEM -
FAULTY GEAR SHIFTING -
SHIFTING IS DIFFICULT -SHIFT PEDAL DOES NOT MOVE -JUMPS OUT OF GEAR -
FAULTY CLUTCH -
CLUTCH SLIPS -CLUTCH DRAGS -
OVERHEATING -
ENGINE -COOLING SYSTEM -FUEL SYSTEM -CHASSIS -ELECTRICAL SYSTEMS -
OVERCOOLING -
COOLING SYSTEM -
POOR BRAKING PERFORMANCE -
FAULTY FRONT FORK LEGS -
LEAKING OIL -MALFUNCTION -
UNSTABLE HANDLING -
FAULTY LIGHTING OR SIGNALING SYSTEM -
HEADLIGHT DOES NOT COME ON -HEADLIGHT BULB BURNT OUT -TAIL/BRAKE LIGHT DOES NOT COME ON TAIL/BRAKE LIGHT BULB BURNT OUT -TURN SIGNAL DOES NOT COME ON -TURN SIGNAL BLINKS SLOWLY
TURN SIGNAL REMAINS LIT -TURN SIGNAL BLINKS QUICKLY -HORN DOES NOT SOUND -
CONSUMER INFORMATION
Yamaha_YZF-R1P(C)_Assembly_Manual
Pages 135
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
IDENTIFICATION NUMBERS -
KEY IDENTIFICATION NUMBER -
VEHICLE IDENTIFICATION NUMBER -
MODEL LABEL -
REPORTING SAFETY DEFECTS -
MOTORCYCLE NOISE REGULATION -
MAINTENANCE RECORD -
DESCRIPTION
LEFT VIEW -
RIGHT VIEW -
CONTROLS AND INSTRUMENTS -
INSTRUMENT AND CONTROL FUNCTIONS
MAIN SWITCH/STEERING LOCK -INDICATOR AND WARNING LIGHTS -MULTI-FUNCTION DISPLAY -TACHOMETER -HANDLEBAR SWITCHES -CLUTCH LEVER -SHIFT PEDAL -BRAKE LEVER -BRAKE PEDAL -
FUEL TANK CAP -FUEL -CATALYTIC CONVERTER -SEATS -HELMET HOLDERS -STORAGE COMPARTMENT
ADJUSTING THE FRONT FORK -ADJUSTING THE SHOCK ABSORBER ASSEMBLY -LUGGAGE STRAP HOLDERS -EXUP SYSTEM -SIDESTAND -IGNITION CIRCUIT CUT-OFF SYSTEM -
PRE-OPERATION CHECKS
PRE-OPERATION CHECK LIST -
OPERATION AND IMPORTANT RIDING POINTS
STARTING AND WARMING UP A COLD ENGINE -
SHIFTING -
ENGINE BREAK-IN -
PARKING -
PERIODIC MAINTENANCE AND MINOR REPAIR
PERIODIC MAINTENANCE -
OWNER‘S TOOL KIT -
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM -
GENERAL MAINTENANCE AND LUBRICATION CHART -
REMOVING AND INSTALLING COWLINGS AND PANELS -
CHECKING THE SPARK PLUGS -
CANISTER (FOR CALIFORNIA ONLY) -
ENGINE OIL AND OIL FILTER CARTRIDGE -
COOLANT -
REPLACING THE AIR FILTER ELEMENT -
ADJUSTING THE THROTTLE CABLE FREE PLAY -
ADJUSTING THE VALVE CLEARANCE -
TIRES -
CAST WHEELS -
ACCESSORIES AND REPLACEMENT PARTS -
ADJUSTING THE CLUTCH LEVER FREE PLAY -
ADJUSTING THE BRAKE PEDAL POSITION -
ADJUSTING THE REAR BRAKE LIGHT SWITCH -
CHECKING THE FRONT AND REAR BRAKE PADS -
CHECKING THE BRAKE FLUID LEVEL -
CHANGING THE BRAKE FLUID -
DRIVE CHAIN SLACK -
LUBRICATING THE DRIVE CHAIN -
CHECKING AND LUBRICATING THE CABLES -
CHECKING AND LUBRICATING THE THROTTLE
GRIP AND CABLE -
CHECKING AND LUBRICATING THE BRAKE AND
CLUTCH LEVERS -
LUBRICATING THE BRAKE PEDAL -
CHECKING AND LUBRICATING THE SIDESTAND -
CHECKING THE FRONT FORK -
CHECKING THE STEERING -
CHECKING THE WHEEL BEARINGS -
BATTERY -
REPLACING THE FUSES -
REPLACING A HEADLIGHT BULB -
TAIL/BRAKE LIGHT -
REPLACING A TURN SIGNAL LIGHT BULB -
REPLACING THE LICENSE PLATE LIGHT BULB -
SUPPORTING THE MOTORCYCLE -
FRONT WHEEL -
REAR WHEEL -
TROUBLESHOOTING -
TROUBLESHOOTING CHARTS -
MOTORCYCLE CARE AND STORAGE
CARE -
STORAGE -
SPECIFICATIONS
SPECIFICATIONS -
CONSUMER INFORMATION
IDENTIFICATION NUMBERS -
KEY IDENTIFICATION NUMBER -
VEHICLE IDENTIFICATION NUMBER -
MODEL LABEL -
REPORTING SAFETY DEFECTS -
MOTORCYCLE NOISE REGULATION -
MAINTENANCE RECORD -
YAMAHA MOTOR CORPORATION, USA STREET AND
ENDURO MOTORCYCLE LIMITED WARRANTY -
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