Table of Contents
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Table of Contents
Troubleshooting
Related Manuals for Yamaha YZF-R1 2003
Summary of Contents for Yamaha YZF-R1 2003
- Page 3 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.
- Page 4 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.
- Page 5 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. 1 The manual is divided into chapters.
- Page 6 EAS00008 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system COOL 7 Fuel injection system 8 Electrical system...
- Page 7 CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS ........ENGINE SPECIFICATIONS .
- Page 9 ELECTRICAL SPECIFICATIONS Item Standard Limit Electric starting system System type Constant mesh Starter motor Model (manufacturer) 5PW (YAMAHA) Power output 0.9 kW Brushes Overall length 10.8 mm 3.65 mm 5.28 X 7.92 N (528 X 792 g) Spring force 0.009 X 0.011 Ω at 20_C...
- Page 10 SPEC CABLE ROUTING CABLE ROUTING 1 Headlight drain plug E Secure the inner side of the junc- I Insert the headlight relay to the A Make sure to securely insert the tion part of the head light sub rib of the headlight body. (No coupler and boot.
- Page 11 SPEC CABLE ROUTING Handlebar switch (left) Starter lead Main switch (+) lead Throttle position sensor lead (–) lead Guide-air Cover 1 Handlebar switch (right) Injector sub lead Wiring section AI system lead AC magneto lead Oil level switch lead Speed sensor lead Sidestand switch lead (–) lead Rear brake switch lead...
- Page 12 SPEC CABLE ROUTING A Route the horn lead under the rib H To fuel pump. L EXUP servo motor of bracket horn positioning the I Insert the holding clamp of the M To rectifier regulator stepped part of protector outside wire harness to the frame.
- Page 13 SPEC CABLE ROUTING R Route the (–) and AC magneto Z Route the starter motor lead AD Routing position of each lead leads under the wire harness. through the clamp inserted to the except the wire harness is not S Route under the wire harness to box battery.
- Page 14 SPEC CABLE ROUTING AK Pass the filter of throttle body AO Press the lead of the coupler AT Fasten the (+) lead junction through the hole of rubber for ALARM in under the cou- lead by hooking on the pawl of baffle and release it under the pler of ECU.
- Page 15 SPEC CABLE ROUTING Turn signal light lead A Route the clutch cable through I Pass the clutch cable behind the Radiator hose the backward of radiator bracket front fork. Reservoir tank breather hose and inside of coolant breather J Pass the handlebar switch lead (L = 440) hose.
- Page 16 SPEC CABLE ROUTING M To turn signal light. Q Fasten the clutch cable and cool- N In this range, route the right han- ant reservoir tank breather hose dle bar switch lead behind the with the clamp. throttle cable. O Pass the water temperature sen- sor lead between the engine and the radiator hose.
- Page 17 SPEC CABLE ROUTING Ignition coil plate Oil level gauge lead To throttle body Rubber baffle AI system hose Rear brake switch lead Assembling point Sidestand switch lead AC magneto lead Assembling point Fuel return hose Air cleaner box drain hose Fuel tank breather hose A Route the wire harness and ra- Radiator fan motor lead...
- Page 18 SPEC CABLE ROUTING C Clamp the air cleaner drain E Clamp the oil level gauge, side J Pass the fuel tank breather hose hose, fuel tank breather hose, stand switch lead and radiator and fuel tank drain hose by the drain hose, AI system hose, AI hose.
- Page 19 SPEC CABLE ROUTING N Point the tip of the band to the in- T Fasten the EXUP servo motor Y Position the clamp between the ner side. lead with the clamp inserted to clamp of oil level switch lead and O Routing position of each hose the frame.
- Page 20 ELEC CHECKING THE SWITCHES 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.
- Page 21 ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM –13–...
- Page 22 ELEC LIGHTING SYSTEM Main switch Fuse (main) Battery Hi beam indicator light Meter light Pass switch Dimmer switch Headlight License light Tail / brake light Fuse (turn) Fuse (headlight) Headlight relay (on / off) Headlight relay (dimmer) –14–...
- Page 23 ELEC LIGHTING SYSTEM EAS00781 Minimum open-circuit voltage TROUBLESHOOTING 12.8 V or more at 20_C Any of the following fail to light: headlight, S Is the battery OK? high beam indicator light, taillight, auxilia- ry light or meter light. Check: S Clean the battery 1.
- Page 24 ELEC LIGHTING SYSTEM Hi-beam 6. Headlight relay (on/off) Positive battery lead ! yellow S Disconnect the headlight relay (on/off) from Negative battery lead ! black the coupler. S Connect the pocket tester (Ω Positive tester probe ! black/blue 1) and bat- Negative tester probe ! black/yellow tery (12 V) to the headlight relay (on/off) coupler as shown.
- Page 25 ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM –17–...
- Page 26 ELEC SIGNALING SYSTEM Main switch Fuse (back up) Fuse (main) Battery Starting circuit cut-off relay Fuel pump Speed sensor Neutral switch Fuel level warning light Oil level warning light Neutral indicator light Multi–function meter Coolant temperature indicator light Turn signal indicator light (L) Turn signal indicator light (R) Oil level gauge Turn signal relay...
- Page 27 ELEC SIGNALING SYSTEM CHECKING THE SIGNALING SYSTEM S Set the main switch to “ON”. EAS00799 S Measure the voltage (DC 12 V) on brown 1. The turn signal light, turn signal indicator at the turn signal relay coupler (wire harness light or both fail to blink.
- Page 28 ELEC SIGNALING SYSTEM Left turn signal light Positive tester probe ! chocolate Negative tester probe ! ground Right turn signal light Positive tester probe ! dark green Negative tester probe ! ground S Set the main switch to “ON”. S Set the turn signal switch to “ ”...
- Page 29 TRBL FAULTY LIGHTING OR SIGNALING SYSTEM SHTG EAS00866 TROUBLESHOOTING FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT COME ON S Wrong headlight bulb S Too many electrical accessories S Hard charging S Incorrect connection S Improperly grounded circuit S Poor contacts (main or dimmer switch) S Burnt-out headlight bulb S Headlight relay (on/off) S Headlight relay (dimmer)
- Page 30 YZF-R1 (R) 2003 WIRING DIAGRAM (EUR) A.C. magneto Fuse (ignition) Rectifier/ regulator Alarm Main switch Fuse (turn) Fuse (back up) Fuse (signal) Fuse (main) Fuse (headlight) Battery Fuse (fan motor) Fuse (fuel injection) Headlight relay (on / off) Starter relay Headlight relay (dimmer) Starter motor Fan motor relay...
- Page 31 YZF-R1 (R) 2003 WIRING DIAGRAM (OCE) A.C. magneto Fuse (ignition) Rectifier/ regulator Fuse (turn) Main switch Fuse (signal) Fuse (back up) Fuse (headlight) Fuse (main) Fuse (fan motor) Battery Headlight relay (on / off) Fuse (fuel injection) Headlight relay (dimmer) Starter relay Fan motor relay Starter motor...
- Page 35 YZF-R1 (R) 2003 WIRING DIAGRAM (EUR)
- Page 36 YZF-R1 (R) 2003 WIRING DIAGRAM (OCE)