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.
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.

12
4
5
7
8
3
6
EAS00007
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
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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

–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

–6–
CABLE ROUTING SPEC
AK Pass the filter of throttle body
through the hole of rubber
baffle and release it under the
ignition coil plate.
AL Route the sub lead coupler be-
hind the ignition coil.
AM Pass the cam shaft position
sensor lead through the hole
of COVER 1 and connect it.
AN After branching the harness,
clamp each lead of the (+) lead
junction, starting circuit cut-off
relay, atmosphere pressure
sensor, lean angle cut-off
switch flasher relay in the
lump. Do not clamp the
ALARM coupler lead.
AO Press the lead of the coupler
for ALARM in under the cou-
pler of ECU.
AP Pay attention not to allow the
lead to slack and get caught
after wiring when assembling
the side cover.
AQ Make sure to hook the har-
ness on the hook of battery
box.
AR Pick-up coil lead
(Should be wired in front of the
clamp.)
AS Neutral switch lead
(Should be wired in front of the
clamp.)
AT Fasten the (+) lead junction
lead by hooking on the pawl of
the box battery.
AU Push the (–) lead coupler into
the down side of wire harness
clamp.
AV Pull in the lead to the position
inside the frame until the dif-
ferent color tape attached to
the lead is invisible outside the
frame bottom edge.

–7–
CABLE ROUTING SPEC
1Turn signal light lead
2Radiator hose
3Reservoir tank breather hose
(L = 440)
4Clutch cable
5Crankshaft position sensor lead
6Rear brake switch lead
7Wiring section
8Coolant breather hose
9Clutch cable
10 Handlebar switch lead
11 Main switch lead
12 Assembling point
13 Assembling point
14 Wiring section
3
3
4
1
A Route the clutch cable through
the backward of radiator bracket
and inside of coolant breather
hose.
B To cord headlight.
C To turn signal light.
D Point the open side to the vehicle
outside.
E Fasten the clutch cable with the
clamp to the inside of the coolant
reservoir tank.
F Fasten the sidestand switch lead
behind the bracket and cut the
tip.
G To fuel tank.
H Pass the throttle cable in front of
the brake hose.
I Pass the clutch cable behind the
front fork.
J Pass the handlebar switch lead
and main switch lead between
the steering stopper and front
fork outer tube.
K Pass the throttle cable, handle-
bar switch lead between the un-
der bracket and the cover steer-
ing. There should be no twist and
crossing of the cable.
L In this area, the handlebar switch
lead (right side) should not be in
front of the throttle cable. It
should not cross the throttle
cable around the guide-air.

–8–
CABLE ROUTING SPEC
M To turn signal light.
N In this range, route the right han-
dle bar switch lead behind the
throttle cable.
O Pass the water temperature sen-
sor lead between the engine and
the radiator hose. Make sure to
push it into the deeper position
so that it is not caught between
the cylinder head cover and the
radiator hose.
P Route the clutch cable through
the inside of radiator hose and
fasten it with the clamp to the ra-
diator.
Q Fasten the clutch cable and cool-
ant reservoir tank breather hose
with the clamp.

–9–
CABLE ROUTING SPEC
1Ignition coil plate
2Rubber baffle
3Assembling point
4Assembling point
5Air cleaner box drain hose
6Radiator fan motor lead
7Oil level switch lead
8Sidestand switch lead
9Clamp
10 EXUP servo motor lead
11 Air cleaner drain hose
12 AI system lead
13 Fuel tank breather hose
14 Fuel tank drain hose (No special
order is required.)
15 Drive sprocket cover
16 Radiator hose
2
1
17 Oil level gauge lead
18 AI system hose
19 Sidestand switch lead
20 Fuel return hose
21 Fuel tank breather hose
22 Fuel feeder hose
23 Fuel tank drain hose
24 Injector sub lead
25 Wire harness
26 To throttle body
27 To air cleaner
28 To fuel tank
29 Crankcase breather hose
30 Assembling point
31 Speed sensor lead
32 EXUP servo motor
33 EXUP servo motor lead
2
34 To throttle body
35 Rear brake switch lead
36 AC magneto lead
A Route the wire harness and ra-
diator fan motor lead through the
hole of the guide-air and fasten
them.
B Wiring section
Above rubber baffle.
Under ignition coil plate.
1

–10–
CABLE ROUTING SPEC
J Pass the fuel tank breather hose
and fuel tank drain hose by the
inner side of the coolant hose.
Do not pinch each hose in the
bottom cowling cowl mounting
section.
K Pass the air cleaner drain by the
inner side of the coolant hose
and release under the coolant
hose. However, do not place out
side of the bottom cowling.
L Route the air cleaner drain hose,
fuel tank breather hose, fuel tank
drain hose, AI system hose and
AI system lead through the
clamp.
M To turn signal light.
E Clamp the oil level gauge, side
stand switch lead and radiator
hose.
F Place the oil level gauge, side
stand switch lead and radiator
hose in the drive sprocket cover.
G Do not pinch the hose.
H Pass the oil level gauge lead and
sidestand switch lead by the in-
ner side of the coolant hose.
I Route the fuel tank breather
hose and fuel tank drain hoses
through the clamp and pass by
the outside of the bottom cowl-
ing. Make the end length of
hoses even.
C Clamp the air cleaner drain
hose, fuel tank breather hose,
drain hose, AI system hose, AI
system lead and AC magneto.
Route the air cleaner drain hose,
fuel tank breather hose and drain
hose outside the AI system
hose, AI system lead and AC
magneto lead. Route the fuel
tank reserve hose and fuel tank
drain hose underneath AC mag-
neto lead and AI system lead
and then to the outside.
D House all the leads in the rib of
the box battery.

–11–
T Fasten the EXUP servo motor
lead with the clamp inserted to
the frame.
U Fasten the wire harness with the
clamp inserted to the hole of bat-
tery box. Point the tip of clamp
upward. Cut the tip according to
the illustration.
V Fasten the EXUP servo motor
lead with the clamp inserted to
the frame.
W Clamp the oil level gauge and
sidestand switch lead.
X Al hose (Pass it through the most
inner side of the air filter drain
hose, fuel tank drain hose and
fuel tank breather hose.)
CABLE ROUTING SPEC
N Point the tip of the band to the in-
ner side.
O Routing position of each hose
except the AI system hose is not
regulated in the clamp.
P Pass all the hoses under the in-
jector sub lead and wire harness.
Q Neutral switch lead:
Route the lead so that it surely
points to the right upward.
R Clamp the lead making slack so
that the harness routes to the
coupler from the downside of the
EXUP serve motor.
S Pay attention to the inserting
direction of the relay.
Y Position the clamp between the
clamp of oil level switch lead and
the radiator coolant hose. The
direction of clamp is not regu-
lated.
Z Route the hoses of the fuel tank
drain and fuel tank breather un-
der the wire harness, injector
sub lead and AI lead.
AA To wiring section .
AB To wiring sections , .
AC To wiring section .
AD Fasten the EXUP servo motor
lead and rear brake switch
lead with the clamp inserted to
the frame.
2
2 3
3

–12–
CHECKING THE SWITCHES ELEC
11 Front brake light switch
12 Oil level gauge
13 Neutral switch
14 Rear brake light switch
1Main switch
2Pass switch
3Dimmer switch
4Clutch switch
5Horn switch
6Turn signal switch
7Hazard switch
8Sidestand switch
9Engine stop switch
10 Start switch
EAS00731
ELECTRICAL
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between the termi-
nals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear !Repair or replace.
Improperly connected !Properly connect.
Incorrect continuity reading !Replace the switch.