2003 YAMAHA YZF-R1 brake

PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6
EAU02962
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
EW000112
WARNING
_ Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions. _
EAU04034
Checking and lubricating the
throttle grip and cable The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated or
replaced at the intervals specified in
the periodic maintenance chart.
EAU03164
Checking and lubricating the
brake and clutch levers The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary. Recommended lubricant:
Engine oil
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6
EAU03163
Lubricating the brake pedal The operation of the brake pedal
should be checked before each ride,
and the pedal pivot should be lubricat-
ed if necessary.
EAU03165
Checking and lubricating the
sidestand The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
EW000113
WARNING
_ If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. _
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
U5PWE1.book Page 32 Monday, July 8, 2002 10:28 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
6
EAU02939
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
EW000115
WARNING
_ Securely support the motorcycle so
that there is no danger of it falling
over. _Check the inner tubes for scratches,
damage and excessive oil leakage.To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
EC000098
CAUTION:_ If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it. _
EAU00794
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
EW000115
WARNING
_ Securely support the motorcycle so
that there is no danger of it falling
over. _
U5PWE1.book Page 33 Monday, July 8, 2002 10:28 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
6
EC000104
CAUTION:_ Take care not to damage the follow-
ing parts:

Headlight bulb
Do not touch the glass part of
the headlight bulb to keep it free
from oil, otherwise the transpar-
ency of the glass, the luminosi-
ty of the bulb, and the bulb life
will be adversely affected. Thor-
oughly clean off any dirt and fin-
gerprints on the headlight bulb
using a cloth moistened with al-
cohol or thinner.


Headlight lens
Do not affix any type of tinted
film or stickers to the head-
light lens.
Do not use a headlight bulb of
a wattage higher than speci-
fied.
_4. Install the headlight bulb cover,
and then connect the coupler.
5. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAU03730
Tail/brake light This motorcycle is equipped with an
LED type of tail/brake light.
If the tail/brake light does not come on,
have a Yamaha dealer check it.
U5PWE1.book Page 38 Monday, July 8, 2002 10:28 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-41
6
EAU04532
Front wheel To remove the front wheel
EW000122
WARNING
_

It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no danger
of it falling over.
_1. Loosen the axle bolt, the wheel
axle pinch bolts, and then the
brake caliper bolts.2. Lift the front wheel off the ground
according to the procedure on
page 6-40.
3. Remove the brake hose holder on
each side by removing the bolt
and nut.
4. Remove the brake caliper on each
side by removing the bolts.5. Remove the axle bolt, pull the
wheel axle out, and then remove
the wheel.
ECA00046
CAUTION:_ Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut. _
1. Front wheel axle pinch bolt (× 4)
1. Brake hose holder
2. Bolt and nut
3. Bolt (× 2)
4. Brake caliper
5. Axle bolt
1. Wheel axle
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-42
6
EAU04661
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle.
3. Lower the front wheel so that it is
on the ground.
4. Install the brake calipers by install-
ing the bolts, and then tightening
them to the specified torque.NOTE:_ Make sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brake
discs. _5. Install the brake hose holders by
installing the bolts and nuts.6. Secure the wheel axle by installing
the axle bolt, and then tightening it
to the specified torque.
NOTE:_ While tightening the axle bolt, hold the
wheel axle with a 19-mm hexagon
wrench to keep it from turning. _7. Tighten wheel axle pinch bolts A
and B to the specified torque.8. Tap the outer side of the right fork
leg with a rubber mallet to align it
with the end of the wheel axle.
9. Tighten wheel axle pinch bolts C
and D to the specified torque.
10. While applying the front brake,
push down hard on the handlebar
several times to check for proper
fork operation. Tightening torque:
Brake caliper bolt:
40 Nm (4.0 m·kgf)1. Front wheel axle pinch bolt A
2. Front wheel axle pinch bolt B
3. Front wheel axle pinch bolt C
4. Front wheel axle pinch bolt DTightening torque:
Axle bolt:
91 Nm (9.1 m·kgf)
Tightening torque:
Wheel axle pinch bolt:
18 Nm (1.8 m·kgf)
Tightening torque:
Wheel axle pinch bolt:
18 Nm (1.8 m·kgf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-43
6
EAU04915
Rear wheel To remove the rear wheel
EW000122
WARNING
_

It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no danger
of it falling over.
_1. Loosen the axle nut and the brake
caliper bolts.
2. Lift the rear wheel off the ground
according to the procedure on
page 6-40.3. Remove the axle nut, and then re-
move the brake caliper by remov-
ing the bolts.
ECA00146
CAUTION:_ Do not apply the brake after the
brake caliper has been removed,
otherwise the brake caliper pistons
will be forced out. _4. Loosen the locknut on each side of
the swingarm.
5. Turn the drive chain slack adjust-
ing bolts fully in direction
a.6. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:_ The drive chain does not need to be
disassembled in order to remove and
install the rear wheel. _
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
1. Bolt (× 2)
2. Brake caliper
3. Brake caliper bracket
U5PWE1.book Page 43 Monday, July 8, 2002 10:28 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-44
6 7. While supporting the brake caliper
bracket, pull the wheel axle out.
8. Remove the wheel.
EAU04921
To install the rear wheel
1. Install the wheel and the brake cal-
iper bracket by inserting the wheel
axle from the left-hand side.
2. Install the drive chain onto the rear
sprocket, and then adjust the drive
chain slack. (See page 6-29 for
drive chain slack adjustment pro-
cedures.)
3. Install the axle nut, and then lower
the rear wheel so that it is on the
ground.
4. Install the brake caliper by install-
ing the bolts.NOTE:_ Make sure that there is enough space
between the brake caliper pistons and
brake caliper pad before installing the
brake caliper. _5. Tighten the axle nut and the brake
caliper bolts to the specified
torques.
1. Wheel axle
Tightening torques:
Axle nut:
150 Nm (15.0 m·kgf)
Brake caliper bolt:
27 Nm (2.7 m·kgf)
U5PWE1.book Page 44 Monday, July 8, 2002 10:28 AM