Yamaha YZF-R1(P) 2002 Service Information
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Yamaha YZF-R1(P) 2002 Service Information

Yamaha YZF-R1(P) 2002 Service Information

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

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  • Page 1 2002 YZF-R1(P) 5PW1-SE1 SERVICE INFORMATION Yamaha Motor Co., Ltd.
  • Page 2 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...

  • Page 3: Important Manual Information

    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.
  • Page 4 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 5 CONTENTS GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ....... 1 VEHICLE IDENTIFICATION NUMBER ......1 MODEL LABEL .

  • Page 6: General Information

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

  • Page 7: Specifications

    SPEC GENERAL SPECIFICATIONS 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) Dimensions Overall length 2,040 mm Overall width 705 mm Overall height 1,105 mm Seat height 820 mm Wheelbase...

  • Page 8: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, DOHC Displacement 998 cm Cylinder arrangement Forward-inclined parallel 4-cylinder Bore stroke 58 mm Compression ratio 11.8 : 1 1,000 X 1,100 r/min Engine idling speed Vacuum pressure at engine idling 25.3 kPa (190 mmHg) speed Standard compression pressure...
  • Page 9 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil filter Oil filter type Cartridge (paper) 80 X 120 kPa (0.8 X 1.2 kg/cm Bypass valve opening pressure Oil pump Oil pump type Trochoid 0.01 X 0.10 mm Inner-rotor-to-outer-rotor-tip 0.18 mm clearance 0.09 X 0.15 mm Outer-rotor-to-oil-pump-housing 0.22 mm clearance...
  • Page 10 SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshafts Drive system Chain drive (right) 24.500 X 24.521 mm Camshaft cap inside diameter 24.459 X 24.472 mm Camshaft journal diameter 0.028 X 0.062 mm Camshaft-journal-to-camshaft- cap clearance Intake camshaft lobe dimensions 32.5 X 32.6 mm Measurement A 32.4 mm 24.95 X 25.05 mm...
  • Page 11 SPEC ENGINE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links RH2015/130 Tensioning system Automatic Valves, valve seats, valve guides Valve clearance (cold) 0.11 X 0.20 mm Intake 0.21 X 0.27 mm Exhaust Valve dimensions Head Diameter Face Width Seat Width Margin Thickness Valve head diameter A 22.9 X 23.1 mm...
  • Page 12 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve springs Free length Intake 38.9 mm 37.0 mm Exhaust 40.67 mm 38.6 mm Installed length (valve closed) Intake 34.5 mm Exhaust 35 mm Compressed spring force (installed) 82 X 96 N (8.2 X 9.6 kg) Intake 110 X 126 N (11.0 X 12.6 kg) Exhaust...
  • Page 13 SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston 0.010 X 0.035 mm Piston-to-cylinder clearance 0.12 mm 73.975 X 73.990 mm Diameter D SSS mm Height H 5 mm Piston pin bore (in the piston) 17.002 X 17.013 mm Diameter 17.043 mm Offset 0.5 mm Offset direction...
  • Page 14 SPEC ENGINE SPECIFICATIONS Item Standard Limit Connecting rods 0.031 X 0.055 mm Crankshaft-pin-to-big-end-bearing clearance Bearing color code –1 = Violet 0 = White 1 = Blue 2 = Black Crankshaft 52.40 X 57.25 mm Width A 300.75 X 302.65 mm Width B Max.
  • Page 15 SPEC ENGINE SPECIFICATIONS Item Standard Limit Transmission Transmission type Constant mesh, 6-speed Primary reduction system Spur gear Primary reduction ratio 68/43 (1.581) Secondary reduction system Chain drive Secondary reduction ratio 43/16 (2.688) Operation Left-foot operation Gear ratios 1st gear 35/14 (2.500) 2nd gear 35/19 (1.842) 3rd gear...
  • Page 16 SPEC ENGINE SPECIFICATIONS Item Standard Limit Throttle position sensor 4.85 X 5.15 kΩ at 20_C Resistance Output voltage (at idle) Adjusted by tachometer Throttle bodies Model (manufacturer) quantity 40EIS (MIKUNI) Intake vacuum pressure 25.3 kPa (190 mmHg) 3 X 5 mm Throttle cable free play (at the flange of the throttle grip) of the throttle gri )

  • Page 17: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Diamond Caster angle Trail 103 mm Front wheel Wheel type Cast wheel Size 17 M/C MT3.50 Material Aluminum Wheel travel 120 mm Wheel runout Max. radial wheel runout 1 mm Max.
  • Page 18 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type Tubeless Size 190/50 ZR17 M/C (73W) Model (manufacturer) Pilot SPORT (MICHELIN) D208L (DUNLOP) Tire pressure (cold) 0 X 90 kg 250 kPa (2.5 kgf/cm , 2.5 bar) 90 X 202 kg 290 kPa (2.9 kgf/cm , 2.9 bar) High-speed riding...
  • Page 19 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front suspension Suspension type Telescopic fork Front fork type Coil spring/oil damper Front fork travel 120 mm Spring Free length 251 mm 246 mm Spacer length 74 mm Installed length 244 mm Spring rate (K1) 8.34 N/mm (0.83 kg/mm) 0 X 120 mm Spring stroke (K1)
  • Page 20 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Steering Steering bearing type Angular bearing Rear suspension Suspension type Swingarm (link suspension) Rear shock absorber assembly Coil spring/gas-oil damper type Rear shock absorber assembly 65 mm travel Spring Free length 176.5 mm Installed length 162.5 mm Spring rate (K1) 88.3 N/mm (8.83 kg/mm)

  • Page 21: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V Ignition system Ignition system type Transistorized coil ignition (digital) Ignition timing 5_ BTDC at 1,050 r/min 248 X 372 Ω at 20_C/Gy-B Crankshaft position sensor resistance/color F8T915 (MITSUBISHI) (GB) (S) (D) (NL) Transistorized coil ignition unit (B) (E) (P) (I) model (manufacturer)
  • Page 22 Engine trouble warning light Engine speep indicator light Electric starting system System type Constant mesh Starter motor Model (manufacturer) 5JJ (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...

  • Page 23: Tightening Torques

    SPEC CONVERSION TABLE/TIGHTENING TORQUES EAS00028 TIGHTENING TORQUES CONVERSION TABLE EAS00029 GENERAL TIGHTENING TORQUE All specification data in this manual are SPECIFICATIONS listed in SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC dard fasteners with a standard ISO thread unit data to IMPERIAL unit data.
  • Page 24 SPEC TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening Thread torque Item Fastener Q’ty Remarks size size mSkg Spark plugs – 20 + 121_ 2.0 + 121_ Cylinder head (50) (5.0) 20 + 105_ 2.0 + 105_ Cylinder head (50) (5.0) 20 + 140_ 2.0 + 140_ Cylinder head Cap nut...
  • Page 25 SPEC TIGHTENING TORQUES Tightening Thread torque Item Fastener Q’ty Remarks size size mSkg Crankcase (upper and lower) Bolt See note Crankcase (upper and lower) Bolt Crankcase (upper and lower) Bolt Crankcase (upper and lower) Bolt AC magneto cover Bolt Drive sprocker cover Bolt Drive sprocket cover Bolt...
  • Page 26 SPEC TIGHTENING TORQUES Crankcase tightening sequence: 2-20...
  • Page 27 SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening Item Item Thread size Thread size Remarks Remarks Upper bracket and front fork Steering stem nut 11.5 Handlebar and front fork Hnaldebar and upper bracket Lower ring nut NOTE 1. Lower bracket pinch bolts Main switch and handle crown Brake fluid reservoir cap stopper 0.12...
  • Page 28 SPEC TIGHTENING TORQUES Tightening Item Item Thread size Thread size Remarks Remarks Lean angle cut-off switch sensor and battery box Rider footrest bracket and frame Passenger footrest bracket and frame Rear master cylinder Rear brake hose union bolts Sidestand Front wheel axle and bolt Front wheel axle and bolt Rear wheel axle nut 15.0...

  • Page 29: Lubrication Points And Lubricant Types

    Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Yamaha bond Cylinder head cover mating surface No.1215 Yamaha bond Crankcase mating surface No.1215 Yamaha bond Clutch cover (crankcase mating surface) No.1215...
  • Page 30 SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Front wheel oil seal (right and left) Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Rear brake pedal shaft Sidestand pivoting point and metal-to-metal moving parts Throttle grip inner surface...

  • Page 31: Cable Routing

    SPEC CABLE ROUTING EAS00035 CABLE ROUTING 1 Headlight drain plug E Secure the junction of headlight I Insert the headlight relay to the A Make sure to securely insert the lead (including the headlight rib of the headlight body. (No coupler and boot.
  • Page 32 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 33 SPEC CABLE ROUTING A Route the horn lead under the rib H To fuel pump. N Fasten the wire harness, (–) of bracket horn positioning the I Insert the holding clamp of the lead, AC magneto lead and recti- stepped part of protector outside wire harness to the frame.
  • Page 34 SPEC CABLE ROUTING S Route under the wire harness to Z Route the starter motor lead AD Routing position of each lead the assembling point through the clamp inserted to the except the wire harness is not T Insert the holding clamp of the box battery.
  • Page 35 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 36 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 37 SPEC CABLE ROUTING M To turn signal light. N In this area, pass the handlebar switch (right) lead behind of the throttle cable. O Route the coolant temperature sensor lead between the engine 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.
  • Page 38 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 39 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 40 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 41: Periodic Checks And Adjustments

    S The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. S From 50,000 km, repeat the maintenance intervals starting from 10,000 km. S Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING...
  • Page 42 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ODOMETER READING ANNUAL 1,000 km) ITEM CHECK OR MAINTENANCE JOB CHECK CHECK S Make sure that all nuts, bolts and screws are properly Chassis fasteners 15 * (See page 2-21) tightened. S Check operation. Sidestand S Lubricate.
  • Page 43 YZF-R1 2002 WIRING DIAGRAM (for EUR) Main switch Headlight relay (dimmer) AC magneto Fuse (ignition) Rectifier/ regulator CYCLELOCK Fuse (back up) Fuse (signal) Battery Fuse (headlight) Fuse (main) Fuse (fan motor) Fuse (fuel injection) Fan motor relay Starter relay Fan motor Starter motor Multi-function meter Starting circuit cut-off relay...
  • Page 44 YZF-R1 2002 WIRING DIAGRAM (for EUR)
  • Page 45 YZF-R1 P 2002 WIRING DIAGRAM (for AUS) Main switch Fuse (ignition) AC magneto Fuse (signal) Rectifier/ regulator Fuse (headlight) Fuse (back up) Fuse (fan motor) Battery Fan motor relay Fuse (main) Fan motor Fuse (fuel injection) Multi-function meter Starter relay Starter motor Starting circuit cut-off relay Side stand switch...
  • Page 46 YZF-R1 P 2002 WIRING DIAGRAM (for AUS)

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