Yamaha YZF-R1(P) 2002 Operating and installation instructions

Yamaha Motor Co., Ltd.
2002
YZF-R1(P)
5PW1-SE1
SERVICE
INFORMATION

Yamaha Motor Co., Ltd.
FOREWORD
This service information has been prepared to introduce new service and data for the
YZF-R1(P) 2002. For complete service information procedures, it is necessary to use
this Service Information together with the following manual.
YZF-R1(P) 2002 SERVICE MANUAL: 5PW1-ME1

NOTE:
WARNING
CAUTION:
EAS00003
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 of its models. Modifications and sig-
nificant 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 MANUAL 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
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
GENERAL TIGHTINING TORQUES SPECIFICATIONS . . . . . . . . . . . . 18
ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . . . 24
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS . . . . . . . . 36
YZF-R1 WIRING DIAGRAM

1-1
MOTORCYCLE IDENTIFICATION GEN
INFO
EAS00014
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1is stamped
into the right side of the steering head pipe.
EAS00018
MODEL LABEL
The model label 1is affixed to the frame. This
information will be needed to order spare parts.
1

2-1
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Model code 5PW1 (A) (B) (CH) (D) (E) (GB) (GR) (I)
(NL) (P) (S) (ZA)
5PW2 (F)
5PW3 (AUS)
SSS
SSS
SSS
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
2,040 mm
705 mm
1,105 mm
820 mm
1,395 mm
140 mm
3,900 mm
SSS
SSS
SSS
SSS
SSS
SSS
SSS
Weight
Wet (with oil and a full fuel tank)
Maximum load (except motorcycle)
193 kg
202 kg
SSS
SSS
2

2-2
ENGINE SPECIFICATIONS SPEC
ENGINE SPECIFICATIONS
Item Standard Limit
Engine
Engine type
Displacement
Cylinder arrangement
Bore stroke
Compression ratio
Engine idling speed
Vacuum pressure at engine idling
speed
Standard compression pressure
(at sea level)
Liquid-cooled, 4-stroke, DOHC
998 cm3
Forward-inclined parallel 4-cylinder
74 58 mm
11.8 : 1
1,000 X1,100 r/min
25.3 kPa (190 mmHg)
1,450 kPa (14.5 kg/cm2) at 400 r/min
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
Fuel
Recommended fuel
Fuel tank capacity
Total (including reserve)
Reserve only
Premium unleaded gasoline only
17 L
3.5 L
SSS
SSS
SSS
Engine oil
Lubrication system
Recommended oil
Quantity
Total amount
Without oil filter cartridge
replacement
With oil filter cartridge replacement
Oil pressure (hot)
Relief valve opening pressure
Wet sump
SAE20W40SE or SAE10W30SE
3.8 L
2.9 L
3.1 L
45 kPa at 1,100 r/min
(0.45 kg/cm2at 1,100 r/min)
480 X560 kPa (4.8 X5.6 kg/cm2)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
3

2-3
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Oil filter
Oil filter type
Bypass valve opening pressure
Cartridge (paper)
80 X120 kPa (0.8 X1.2 kg/cm2)
SSS
SSS
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip
clearance
Outer-rotor-to-oil-pump-housing
clearance
Trochoid
0.01 X0.10 mm
0.09 X0.15 mm
SSS
0.18 mm
0.22 mm
Cooling system
Radiator capacity
Radiator cap opening pressure
Radiator core
Width
Height
Depth
Coolant reservoir
Capacity
Water pump
Water pump type
Reduction ratio
Max. impeller shaft tilt
2.45 L
95 X125 kPa (0.95 X1.25 kg/cm2)
340 mm
295.8 mm
27 mm
0.24 L
Single suction centrifugal pump
68/43 28/28 (1.581)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
0.15 mm
Starting system type Electric starter
Electric fuel injection
Type
Manufacturer
INP-731/4
NIPPON INJECTOR
SSS
SSS
Spark plugs
Model (manufacturer) quantity
Spark plug gap
CR9EIA 9/IU27D (NGK/DENSO) 4
0.8 X0.9 mm
SSS
SSS
Cylinder head
Volume
Max. warpage
13.45 X14.05 cm3
SSS
SSS
0.1 mm
4

2-4
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Camshafts
Drive system
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft-journal-to-camshaft-
cap clearance
Intake camshaft lobe dimensions
Measurement A
Measurement B
Exhaust camshaft lobe dimensions
Measurement A
Measurement B
Max. camshaft runout
Chain drive (right)
24.500 X24.521 mm
24.459 X24.472 mm
0.028 X0.062 mm
32.5 X32.6 mm
24.95 X25.05 mm
32.95 X33.05 mm
24.95 X25.05 mm
SSS
SSS
SSS
SSS
SSS
32.4 mm
24.85 mm
32.85 mm
24.85 mm
0.03 mm
5

2-5
ENGINE SPECIFICATIONS SPEC
Head Diameter Face Width Seat Width Margin Thickness
Item Standard Limit
Timing chain
Model/number of links
Tensioning system
RH2015/130
Automatic
SSS
SSS
Valves, valve seats, valve guides
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
0.11 X0.20 mm
0.21 X0.27 mm
SSS
SSS
Valve head diameter A
Intake
Exhaust
Valve face width B
Intake
Exhaust
Valve seat width C
Intake
Exhaust
Valve margin thickness D
Intake
Exhaust
Valve stem diameter
Intake
Exhaust
Valve guide inside diameter
Intake
Exhaust
Valve-stem-to-valve-guide clearance
Intake
Exhaust
Valve stem runout
Valve seat width
Intake
Exhaust
22.9 X23.1 mm
24.4 X24.6 mm
1.76 X2.90 mm
1.76 X2.90 mm
0.9 X1.1 mm
0.9 X1.1 mm
0.5 X0.9 mm
0.5 X0.9 mm
3.975 X3.990 mm
4.465 X4.480 mm
4.000 X4.012 mm
4.500 X4.512 mm
0.010 X0.037 mm
0.020 X0.047 mm
SSS
0.9 X1.1 mm
0.9 X1.1 mm
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
3.945 mm
4.43 mm
4.05 mm
4.55 mm
0.08 mm
0.10 mm
0.01 mm
SSS
SSS
6

2-6
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Valve springs
Free length
Intake
Exhaust
Installed length (valve closed)
Intake
Exhaust
Compressed spring force
(installed)
Intake
Exhaust
Spring tilt
Intake
Exhaust
Winding direction (top view)
Intake
Exhaust
38.9 mm
40.67 mm
34.5 mm
35 mm
82 X96 N (8.2 X9.6 kg)
110 X126 N (11.0 X12.6 kg)
SSS
SSS
Clockwise
Clockwise
37.0 mm
38.6 mm
SSS
SSS
SSS
SSS
2.5_/
1.7 mm
2.5_/
1.8 mm
SSS
SSS
Cylinders
Cylinder arrangement
Bore stroke
Compression ratio
Bore
Max. taper
Max. out-of-round
Forward-inclined, parallel 4-cylinder
74 58 mm
11.8 : 1
74.00 X74.01 mm
SSS
SSS
SSS
SSS
SSS
SSS
0.05 mm
0.05 mm
7

2-7
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Piston
Piston-to-cylinder clearance
Diameter D
Height H
Piston pin bore (in the piston)
Diameter
Offset
Offset direction
Piston pins
Outside diameter
Piston-pin-to-piston-pin-bore
clearance
Piston rings
Top ring
Ring type
Dimensions (B T)
End gap (installed)
Ring side clearance
2nd ring
Ring type
Dimensions (B T)
End gap (installed)
Ring side clearance
Oil ring
Dimensions (B T)
End gap (installed)
0.010 X0.035 mm
73.975 X73.990 mm
5 mm
17.002 X17.013 mm
0.5 mm
Intake side
16.991 X17.000 mm
0.002 X0.022 mm
Barrel
0.90 2.75 mm
0.32 X0.44 mm
0.030 X0.065 mm
Taper
0.8 2.8 mm
0.43 X0.58 mm
0.020 X0.055 mm
1.5 2.6 mm
0.10 X0.35 mm
0.12 mm
SSS
SSS mm
17.043 mm
SSS
SSS
16.971 mm
0.072 mm
SSS
SSS
0.69 mm
0.115 mm
SSS
SSS
0.93 mm
0.115 mm
SSS
SSS
8

2-8
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Connecting rods
Crankshaft-pin-to-big-end-bearing
clearance
Bearing color code
0.031 X0.055 mm
–1 = Violet 0 = White 1 = Blue 2 = Black
SSS
SSS
Crankshaft
Width A
Width B
Max. runout C
Big end side clearance D
Crankshaft-journal-to-crankshaft-
journal-bearing clearance
Bearing color code
52.40 X57.25 mm
300.75 X302.65 mm
SSS
0.160 X0.262 mm
0.029 X0.053 mm
–1 = Violet 0 = White
1 = Blue 2 = Black
3 = Brown
SS
SSS
0.03 mm
SSS
SSS
SSS
Clutch
Clutch type
Clutch release method
Clutch release method operation
Operation
Clutch cable free play (at the end
of the clutch lever)
Friction plates
Thickness
Plate quantity
Clutch plates
Thickness
Plate quantity
Max. warpage
Clutch springs
Free length
Spring quantity
Wet, multiple disc
Outer pull, rack and pinion pull
Cable operation
Left-hand operation
10 X15 mm
2.9 X3.1 mm
8
1.9 X2.1 mm
7
SSS
6.5 mm
1
SSS
SSS
SSS
SSS
SSS
2.8 mm
SSS
SSS
SSS
0.1 mm
SSS
SSS
9

2-9
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratios
1st gear
2nd gear
3rd gear
4nd gear
5th gear
6th gear
Max. main axle runout
Max. drive axle runout
Constant mesh, 6-speed
Spur gear
68/43 (1.581)
Chain drive
43/16 (2.688)
Left-foot operation
35/14 (2.500)
35/19 (1.842)
30/20 (1.500)
28/21 (1.333)
30/25 (1.200)
29/26 (1.115)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
0.08 mm
0.08 mm
Shifting mechanism
Shift mechanism type
Max. shift fork guide bar bending
Guide bar
SSS
SSS
0.1 mm
Air filter type Wet element SSS
Fuel pump
Pump type
Model (manufacturer)
Output pressure
Electrical
5PW (DENSO)
294 kPa (2.94 kg/cm2, 2.94 bar)
SSS
SSS
SSS
10

2-10
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Throttle position sensor
Resistance
Output voltage (at idle)
4.85 X5.15 kΩat 20_C
Adjusted by tachometer
Throttle bodies
Model (manufacturer) quantity
Intake vacuum pressure
Throttle cable free play (at the flange
of the throttle gri
p
)
40EIS (MIKUNI) 4
25.3 kPa (190 mmHg)
3 X5 mm
SSS
SSS
SSS
of
the
throttle
gri )
ID mark
Throttle valve size
5PW1 00 (GB) (S) (D) (NL) (B) (E)
(P) (I) (CH) (A) (GR)
5PW2 10 (F)
#100
SSS
SSS
Max. EXUP cable free play (at the
EXUP valve pulley)
1.5 mm SSS
11

2-11
CHASSIS SPECIFICATIONS SPEC
CHASSIS SPECIFICATIONS
Item Standard Limit
Frame
Frame type
Caster angle
Trail
Diamond
24_
103 mm
SSS
SSS
SSS
Front wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Max. radial wheel runout
Max. lateral wheel runout
Cast wheel
17 M/C MT3.50
Aluminum
120 mm
SSS
SSS
SSS
SSS
SSS
SSS
1 mm
0.5 mm
Rear wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Max. radial wheel runout
Max. lateral wheel runout
Cast wheel
17 M/C MT6.00
Aluminum
130 mm
SSS
SSS
SSS
SSS
SSS
SSS
1 mm
0.5 mm
Front tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 X90 kg
90 X202 kg
High-speed riding
Min. tire tread depth
Tubeless
120/70 ZR17 M/C (58W)
Pilot SPORT E (MICHELIN)
D208FL (DUNLOP)
250 kPa (2.5 kgf/cm2, 2.5 bar)
250 kPa (2.5 kgf/cm2, 2.5 bar)
250 kPa (2.5 kgf/cm2, 2.5 bar)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
1.6 mm
12

2-12
CHASSIS SPECIFICATIONS SPEC
Item Standard Limit
Rear tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 X90 kg
90 X202 kg
High-speed riding
Min. tire tread depth
Tubeless
190/50 ZR17 M/C (73W)
Pilot SPORT (MICHELIN)
D208L (DUNLOP)
250 kPa (2.5 kgf/cm2, 2.5 bar)
290 kPa (2.9 kgf/cm2, 2.9 bar)
250 kPa (2.5 kgf/cm2, 2.5 bar)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
1.6 mm
Front brakes
Brake type
Operation
Recommended fluid
Brake lever free play
Brake discs
Diameter thickness
Min. thickness
Max. deflection
Brake pad lining thickness
Master cylinder inside diameter
Caliper cylinder inside diameter
Dual disc brake
Right hand operation
DOT 4
2.3 X11.5 mm
298 5 mm
SSS
SSS
4.5 mm
14 mm
30.1 mm and 27 mm
SSS
SSS
SSS
SSS
SSS
4.5 mm
0.1 mm
0.5 mm
SSS
SSS
Rear brake
Brake type
Operation
Brake pedal position (from the top
of the brake pedal to the bottom of
the rider footrest bracket)
Recommended fluid
Brake pedal freeplay
Brake discs
Diameter thickness
Min. thickness
Max. deflection
Brake pad lining thickness
Master cylinder inside diameter
Caliper cylinder inside diameter
Single disc brake
Right foot operation
38 X42 mm
DOT 4
4.3 X9.3 mm
220 5 mm
SSS
SSS
5.1 mm
12.7 mm
27 mm and 22.2 mm
SSS
SSS
SSS
SSS
SSS
SSS
4.5 mm
0.15 mm
0.8 mm
SSS
SSS
13

2-13
CHASSIS SPECIFICATIONS SPEC
Item Standard Limit
Front suspension
Suspension type
Front fork type
Front fork travel
Spring
Free length
Spacer length
Installed length
Spring rate (K1)
Spring stroke (K1)
Inner tube outer diameter
Inner tube bending limit
Optional spring available
Fork oil
Recommended oil
Quantity (each front fork leg)
Level (from the top of the inner
tube, with the inner tube fully
compressed, and without the
fork spring)
Spring preload adjusting positions
Minimum
Standard
Maximum
Rebound damping adjusting
positions
Minimum*
Standard*
Maximum*
Compression damping adjusting
positions
Minimum*
Standard*
Maximum*
*from the fully turned-in position
Telescopic fork
Coil spring/oil damper
120 mm
251 mm
74 mm
244 mm
8.34 N/mm (0.83 kg/mm)
0 X120 mm
43 mm
SSS
No
Suspension oil “01”or equivalent
0.543 L
88 mm
8
6
1
26
13
1
20
13
1
SSS
SSS
SSS
246 mm
SSS
SSS
SSS
SSS
SSS
0.2 mm
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
14

2-14
CHASSIS SPECIFICATIONS SPEC
Item Standard Limit
Steering
Steering bearing type Angular bearing SSS
Rear suspension
Suspension type
Rear shock absorber assembly
type
Rear shock absorber assembly
travel
Spring
Free length
Installed length
Spring rate (K1)
Spring stroke (K1)
Optional spring available
Standard spring preload gas/air
pressure
Spring preload adjusting positions
Minimum
Standard
Maximum
Rebound damping adjusting
positions
Minimum*
Standard*
Maximum*
Compression damping adjusting
positions
Minimum*
Standard*
Maximum*
*from the fully turned-in position
Swingarm (link suspension)
Coil spring/gas-oil damper
65 mm
176.5 mm
162.5 mm
88.3 N/mm (8.83 kg/mm)
0 X65 mm
No
1,200 kPa (12 kg/cm2)
1
4
9
20
15
1
20
15
1
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
Swingarm
Free play (at the end of the
swingarm)
Radial
Axial
SSS
SSS
1.0 mm
1.0 mm
Drive chain
Model (manufacturer)
Link quantity
Drive chain slack
Maximum ten-link section
50VA8 (DAIDO)
114
40 X50 mm
SSS
SSS
SSS
SSS
150.1 mm
15