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