Yamaha YZF-R1 2003 Manual

FOREWORD
This Supplementary Service Manual 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 Supplemen-
tary Service Manual together with the following manual.
YZF-R1 (P) 2002 SERVICE MANUAL: 5PW1-AE1
YZF-R1 (R) 2003
SUPPLEMENTARY
SERVICE MANUAL
E2002 by Yamaha Motor Co., Ltd.
First Edition, August 2002
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.

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.
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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.

12
4
5
7
8
3
6
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HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each
page indicate the current chapter.
Refer to “SYMBOLS”.
2Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s) ap-
pears.
3Sub-section titles appear in smaller print than the section title.
4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8Jobs requiring more information (such as special tools and technical data) are described sequen-
tially.

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
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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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL
CHECKING THE SWITCHES 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTING SYSTEM 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIGNALING SYSTEM 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SIGNALING SYSTEM 19. . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING
FAULTY LIGHTING OR SIGNALING SYSTEM 21. . . . . . . . . . . . . . . . . . . .
HEADLIGHT DOES NOT COME ON 21. . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT BULB BURNT OUT 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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