Yamaha R1 2003 Manuals

Manuals and User Guides for Yamaha R1 2003. We have 1 Yamaha R1 2003 manual available for free PDF download: Service Manual

Yamaha R1 2003 Service Manual (439 pages)

Brand: Yamaha | Category: Motorcycle | Size: 17.69 MB

General Information

8
Specifications

8
- Table of Contents
  10
Periodic Checks and Adjustments

8
Chassis

8
Engine

8
Cooling System

8
Fuel Injection System

8
Electrical System

8
Troubleshooting

20
Chapter 1 General Information

22
Motorcycle Identification

22
- Vehicle Identification Number
  22
- Model Label
  22
Features

23
- Outline of Fi System
  23
- Fi System
  24
- Components
  26
- Fuel Injection System
  37
- Three-Way Catalytic Converter System
  40
- Instrument Function
  41
Important Information

44
- Preparation for Removal and Disassembly
  44
- Replacement Parts
  44
- Gaskets, Oil Seals and O-Rings
  44
- Lock Washers/Plates and Cotter Pins
  45
- Bearings and Oil Seals
  45
- Circlips
  45
Checking the Connections

46
Special Tools

47
Chapter 2 Specifications

51
Spec

51
General Specifications

51
Engine Specifications

52
Chassis Specifications

61
Electrical Specifications

65
Tightening Torques

67
- General Tightening Torque Specifications
  67
Conversion Table

67
Lubrication Points and Lubricant Types

73
- Engine
  73
- Chassis
  74
Cooling System Diagrams

75
Engine Oil Lubrication Chart

79
Lubrication Diagrams

80
Cable Routing

85
Chapter 3 Periodic Checks and Adjustments

96
Introduction

96
Chk Adj

96
Periodic Maintenance Chart for the Emission Control System

96
General Maintenance and Lubrication Chart

96
Seats

98
Fuel Tank

99
- Removing the Fuel Tank
  100
- Removing the Fuel Pump
  100
- Installing the Fuel Pump
  101
- Installing the Fuel Hose
  101
Cowlings

102
Air Filter Case

103
Engine

104
- Adjusting the Valve Clearance
  104
- Synchronizing the Throttle Bodies
  109
- Adjusting the Engine Idling Speed
  111
- Adjusting the Throttle Cable Free Play
  112
- Checking the Spark Plugs
  114
- Measuring the Compression Pressure
  115
- Checking the Engine Oil Level
  118
- Changing the Engine Oil
  119
- Adjusting the Clutch Cable Free Play
  121
- Replacing the Air Filter Element
  123
- Checking the Fuel and Breather Hoses
  124
- Checking the Crankcase Breather Hose
  124
- Checking the Exhaust System
  125
- Adjusting the Exup Cables
  126
- Checking the Coolant Level
  127
- Checking the Cooling System
  128
- Changing the Coolant
  129
Chassis

132
- Adjusting the Front Brake
  132
- Adjusting the Rear Brake
  133
- Checking the Brake Fluid Level
  134
- Checking the Front and Rear Brake Pads
  135
- Adjusting the Rear Brake Light Switch
  135
- Checking the Front and Rear Brake Hoses
  136
- Bleeding the Hydraulic Brake System
  136
- Adjusting the Shift Pedal
  138
- Adjusting the Drive Chain Slack
  138
- Lubricating the Drive Chain
  140
- Checking and Adjusting the Steering Head
  140
- Checking the Front Fork
  143
- Adjusting the Front Fork Legs
  144
- Adjusting the Rear Shock Absorber Assembly
  147
- Checking the Tires
  149
- Checking the Wheels
  151
- Checking and Lubricating the Cables
  152
- Lubricating the Levers and Pedals
  152
- Lubricating the Sidestand
  152
- Lubricating the Rear Suspension
  152
Electrical System

153
- Checking and Charging the Battery
  153
- Checking the Fuses
  158
- Replacing the Headlight Bulbs
  160
- Adjusting the Headlight Beam
  161
Chapter 4 Chassis

162
Front Wheel and Brake Discs

162
- Front Wheel
  163
- Removing the Front Wheel
  164
- Checking the Front Wheel
  164
- Checking the Brake Discs
  166
- Installing the Front Wheel
  167
- Adjusting the Front Wheel Static Balance
  168
Chas

162
Rear Wheel and Brake Disc

170
- Rear Wheel
  171
- Removing the Rear Wheel
  173
- Checking the Rear Wheel
  174
- Checking the Rear Wheel Drive Hub
  174
- Checking and Replacing the Rear Wheel Sprocket
  175
- Installing the Rear Wheel
  175
- Adjusting the Rear Wheel Static Balance
  176
Front and Rear Brakes

177
Front Fork

206
- Removing the Front Fork Legs
  209
- Disassembling the Front Fork Legs
  209
- Checking the Front Fork Legs
  211
- Assembling the Front Fork Legs
  212
- Installing the Front Fork Legs
  216
- Removing the Handlebars
  219
- Checking the Handlebars
  219
- Installing the Handlebars
  219
Steering Head

222
- Removing the Lower Bracket
  224
- Checking the Steering Head
  224
- Installing the Steering Head
  225
Rear Shock Absorber Assembly

226
Swingarm and Drive Chain

230
- Removing the Swingarm
  232
- Removing the Drive Chain
  233
- Checking the Swingarm
  233
- Checking the Drive Chain
  234
- Installing the Swingarm
  236
Chapter 5 Overhauling the Engine

237
Eng

237
Engine

237
- Drive Sprocket
  237
- Exhaust Pipe
  238
- Leads and Hoses
  240
- Engine
  241
- Installing the Engine
  243
Camshaft

244
- Cylinder Head Covers
  244
- Camshafts
  245
- Removing the Camshafts
  247
- Checking the Camshafts
  248
- Checking the Timing Chain, Camshaft Sprockets, and Timing Chain Guides
  250
- Checking the Timing Chain Tensioner
  251
- Installing the Camshafts
  251
Cylinder Head

255
- Removing the Cylinder Head
  256
- Checking the Cylinder Head
  256
- Installing the Cylinder Head
  257
Valves and Valve Springs

260
- Removing the Valves
  260
- Checking the Valves and Valve Guides
  261
- Checking the Valve Seats
  263
- Checking the Valve Springs
  264
- Checking the Valve Lifters
  265
- Installing the Valves
  265
Generator

268
- Removing the Generator
  269
- Installing the Generator
  269
Pickup Coil

272
- Removing the Pickup Coil Rotor
  274
- Installing the Pickup Coil Rotor
  274
Clutch

276
- Clutch Cover
  276
- Pull Lever Shaft
  277
- Clutch
  278
- Removing the Clutch
  280
- Checking the Friction Plates
  280
- Checking the Clutch Plates
  281
- Checking the Clutch Housing
  281
- Checking the Clutch Boss
  281
- Checking the Pressure Plate
  282
- Checking the Pull Lever Shaft and Pull Rod
  282
- Checking the Starter Clutch
  282
- Installing the Clutch
  283
Shift Shaft

285
- Shift Shaft and Stopper Lever
  285
- Checking the Shift Shaft
  286
- Checking the Stopper Lever
  286
- Installing the Shift Shaft
  286
Oil Pan and Oil Pump

287
- Oil Pump
  289
- Removing the Oil Pan
  290
- Checking the Oil Pump
  290
- Checking the Relief Valve
  291
- Checking the Oil Delivery Pipes
  291
- Checking the Oil Strainer
  291
- Assembling the Oil Pump
  292
- Installing the Oil Pump
  292
- Installing the Oil Strainer
  293
- Installing the Oil Pan
  293
Crankcase

294
- Disassembling the Crankcase
  296
- Checking the Crankcase
  297
- Checking the Bearings and Oil Seals
  297
- Checking the Sprocket and Chains
  297
- Assembling the Crankcase
  298
Connecting Rods and Pistons

300
- Removing the Connecting Rods and Pistons
  301
- Removing the Crankshaft Assembly
  302
- Checking the Cylinder and Pistons
  302
- Checking the Piston Rings
  304
- Checking the Piston Pins
  305
- Checking the Big End Bearings
  305
- Installing the Connecting Rod and Piston
  308
Crankshaft

312
- Checking the Crankshaft
  313
- Checking the Crankshaft Journal Bearings
  313
- Installing the Crankshaft
  316
Transmission

317
- Removing the Transmission
  323
- Checking the Shift Forks
  323
- Checking the Shift Drum Assembly
  324
- Checking the Transmission
  324
- Installing the Transmission
  325
Chapter 6 Cooling System

326
Radiator

326
- Checking the Radiator
  328
- Installing the Radiator
  329
Cool

326
Oil Cooler

330
- Checking the Oil Cooler
  331
- Installing the Oil Cooler
  331
Thermostat

332
Water Pump

337
- Disassembling the Water Pump
  339
- Checking the Water Pump
  339
- Assembling the Water Pump
  340
Chapter 7 Fuel Injection System

342
- Wiring Diagram
  343
- Ecu's Self-Diagnostic Function
  344
- Substitute Characteristics Operation Control (Fail-Safe Action)
  345
- Fail-Safe Actions Table
  345
- Troubleshooring Chart
  346
- Diagnostic Mode
  347
- Troubleshooting Details
  353
Throttle Bodies

370
Air Induction System

378
- Air Induction
  378
- Air Cut-Off Valve
  378
- Checking the Air Induction System
  380
Chapter 8 Electrical

382
Electrical Components

382
Elec

382
Checking Switch Continuity

384
Checking the Switches

385
Checking the Bulbs and Bulb Sockets

386
- Types of Bulbs
  386
- Checking the Condition of the Bulbs
  387
- Checking the Condition of the Bulb Sockets
  388
- CHECKING the Leds
  388
Ignition System

389
- Circuit Diagram
  389
- Troubleshooting
  390
Electric Starting System

394
- Circuit Diagram
  394
- Starting Circuit Cut-Off System Operation
  395
- Troubleshooting
  396
- Starter Motor
  399
- Checking the Starter Motor
  401
- Assembling the Starter Motor
  402
Charging System

403
- Circuit Diagram
  403
- Troubleshooting
  404
Lighting System

406
- Circuit Diagram
  406
- Troubleshooting
  408
- Checking the Lighting System
  410
Signaling System

413
- Circuit Diagram
  413
- Troubleshooting
  415
- Checking the Signaling System
  415
- Fuel Sender Coupler
  420
Cooling System

422
- Circuit Diagram
  422
- Troubleshooting
  423
Fuel Pump System

426
- Circuit Diagram
  426
- Troubleshooting
  428
- Fuel Pump Coupler
  429
- Checking the Fuel Pump
  430
- Fuel Return Hose
  430
Chapter 9

431
- Engine
  431
- Fuel System
  431
Starting Failures

431
Incorrect Engine Idling Speed

432
- Engine
  432
- Fuel System
  432
Trbl Shtg

432
- Electrical Systems
  432
Poor Medium-And-High-Speed Performance

433
- Engine
  433
- Fuel System
  433
Faulty Gear Shifting

433
- Shifting Is Difficult
  433
- Shift Pedal Does Not Move
  433
- Jumps out of Gear
  433
Faulty Clutch

433
- Clutch Slips
  433
- Clutch Drags
  433
Overheating

434
- Engine
  434
- Cooling System
  434
- Fuel System
  434
- Chassis
  434
- Electrical Systems
  434
Overcooling

434
Poor Braking Performance

434
- Unstable Handling
  435
- Faulty Lighting or Signaling System
  436

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More Yamaha Manuals

Yamaha R1 2003 Manuals

Yamaha R1 2003 Service Manual (439 pages)

Table of Contents

General Information

Specifications

Periodic Checks and Adjustments

Chassis

Engine

Cooling System

Fuel Injection System

Electrical System

Troubleshooting

Chapter 1 General Information

Motorcycle Identification

Features

Important Information

Checking the Connections

Special Tools

Chapter 2 Specifications

Spec

General Specifications

Engine Specifications

Chassis Specifications

Electrical Specifications

Tightening Torques

Conversion Table

Lubrication Points and Lubricant Types

Cooling System Diagrams

Engine Oil Lubrication Chart

Lubrication Diagrams

Cable Routing

Chapter 3 Periodic Checks and Adjustments

Introduction

Chk Adj

Periodic Maintenance Chart for the Emission Control System

General Maintenance and Lubrication Chart

Seats

Fuel Tank

Cowlings

Air Filter Case

Engine

Chassis

Electrical System

Chapter 4 Chassis

Front Wheel and Brake Discs

Chas

Rear Wheel and Brake Disc

Front and Rear Brakes

Front Fork

Steering Head

Rear Shock Absorber Assembly

Swingarm and Drive Chain

Chapter 5 Overhauling the Engine

Eng

Engine

Camshaft

Cylinder Head

Valves and Valve Springs

Generator

Pickup Coil

Clutch

Shift Shaft

Oil Pan and Oil Pump

Crankcase

Connecting Rods and Pistons

Crankshaft

Transmission

Chapter 6 Cooling System

Radiator

Cool

Oil Cooler

Thermostat

Water Pump

Chapter 7 Fuel Injection System

Throttle Bodies

Air Induction System

Chapter 8 Electrical

Electrical Components

Elec

Checking Switch Continuity