Yamaha 5PW1-SE2 User manual

Yamaha Motor Co., Ltd.
2003
YZF-R1(R)
5PW1-SE2
SERVICE
INFORMATION

Yamaha Motor Co., Ltd.
FOREWORD
This service information 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 Supplementary Service Information together with the following manual.
YZF-R1(P,R) 2002, 2003 SERVICE MANUAL: 5PW1-ME2
YZF-R1(P) 2002 SERVICE INFORMATION: 5PW1-SE1

NOTE:
WARNING
CAUTION:
EAS00002
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu-
al. 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 ve-
hicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving 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 Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person checking or repairing the mo-
torcycle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

22
1
3
5
7
9
2
4
8
6
24 25
2321
19 2018
16 1715
1413
11 12
10
GEN
INFO SPEC
ENG
FI ELEC
COOL
CHK
ADJ
TRBL
SHTG
CHAS
EAS00008
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols 1to 9indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Chassis
5Engine
6Cooling system
7Fuel injection system
8Electrical system
9Troubleshooting
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-bearing grease
22 Lithium-soap- based grease
23 Molybdenum-disulfide grease
Symbols 24 to 25 in the exploded diagrams indi-
cate the following.
24 Apply locking agent (LOCTITE)
25 Replace the part

CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
YZF-R1(R) 2003 WIRING DIAGRAM (EUR)
YZF-R1(R) 2003 WIRING DIAGRAM (OCE)

–1–
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Model code 5PW7 (A) (B) (CH) (D) (E) (GB) (GR) (I)
(NL) (P) (S) (ZA)
5PW8 (F)
5PW9 (OCE)
5PWG (OCE)
SSS
SSS
SSS
SSS
ENGINE SPECIFICATIONS
Item Standard Limit
Fuel
Recommended fuel
Fuel tank capacity
Total (including reserve)
Reserve only
Premium unleaded gasoline only
17 L
3.3 L
SSS
SSS
SSS
ELECTRICAL SPECIFICATIONS
Item Standard Limit
Electric starting 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 X7.92 N (528 X792 g)
0.009 X0.011 Ωat 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 system fuse
Ignition fuse
Radiator fan motor fuse
Backup fuse (odometer and clock)
Turn fuse
Reserve fuse
50 A 1
15 A 1
20 A 1
10 A 1
15 A 1
15 A 1
10 A 1
10 A 1
20 A, 15 A, 10 A 1
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS

–2–
CABLE ROUTING SPEC
I Insert the headlight relay to the
rib of the headlight body. (No
special order is specified for right
and left.)
J Route the headlight lead behind
the cap of headlight breather
hole. (It can be routed below, but
should not be in front of the cap.)
K To the auxiliary light lead.
L To meter assembly
M To headlight relay
E Secure the inner side of the junc-
tion part of the head light sub
wire harness (including the 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
by either of the headlight or the
boss. Do not catch the headlight
lead when assembling the front
cowling.
C Do not make the lead stretch too
much.
D Secure the junction of the cord
headlight at the place of white
tape.
CABLE ROUTING

–3–
CABLE ROUTING SPEC
1Handlebar switch (left)
2Main switch
3Throttle position sensor lead
4Guide-air
5Handlebar switch (right)
6Wiring section
7AC magneto lead
8Speed 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

–4–
CABLE ROUTING SPEC
A Route the horn lead under the rib
of bracket horn positioning the
stepped part of protector outside
the rib.
B Make the horn lead face the out-
side.
C Route the handlebar switch lead
along the groove of the guide-air.
D Handlebar switch (right) lead
coupler.
E Fasten the wire harness and
coolant temperature sensor lead
with the clamp inserted to the
frame. Point the clamp tip down-
ward.
F To starter motor.
G To pick-up coil.
H To fuel pump.
I Insert the holding clamp of the
wire harness to the frame. Route
the starter motor lead and crank-
shaft position sensor lead under
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 Fasten the wire harness, (–)
lead, AC magneto lead and recti-
fier regulator lead junction with
the clamp inserted to the box
battery.
O Fasten the wire harness, AI sys-
tem lead, AC magneto lead, oil
level gauge lead, sidestand
switch lead and injector sub lead
with the clamp inserted to the
frame.
P Pay attention to the direction of
installation.
Q Connect the leads between the
clamp and the junction.

–5–
CABLE ROUTING SPEC
R Route the (–) and AC magneto
leads under the wire harness.
S Route under the wire harness to
the assembling point .
T Insert the holding clamp of the
wire harness to the frame.
U Fasten the wire harness with the
clamp inserted to the frame.
V Route the radiator fan motor lead
above the wire harness.
W Assembling point
Beneath the under bracket
X Route the handlebar switch lead
and main switch leads along the
groove of the guide-air.
Y To cord headlight
1
3
Z Route the starter motor lead
through the clamp inserted to the
box 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
Beneath the under bracket,
below the cover steering
AG Throttle cable should not be
placed on the rib of guide-air.
AH To coolant temperature sensor
AI Do not pinch the handlebar
switch lead when assembling
the ignition coil plate.
AJ Pass the filter of throttle body
through the notch of the rub-
ber baffle and release it under
the ignition coil plate.
4