2003 YAMAHA YZF-R1 check engine

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
6-40
6 2. Remove the socket (together with
the bulb) by pulling it out.
3. Remove the defective bulb by pull-
ing it out.
4. Insert a new bulb into the socket.
5. Install the socket (together with
the bulb) by pushing it in.
6. Install the license plate light unit by
installing the screws.
EAU01579
Supporting the motorcycle Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other mainte-
nance requiring the motorcycle to
stand upright. Check that the motor-
cycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed un-
der the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un-
der the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placing
a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
1. License plate light bulb
2. License plate light unit
U5PWE1.book Page 40 Monday, July 8, 2002 10:28 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-46
6
EAU02990
Troubleshooting charts Starting problems or poor engine performance
EW000125
WARNING
_ Keep away open flames and do not smoke while checking or working on the fuel system. _CT-1AE
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plugs
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
DryWet
Open the throttle halfway and operate
the electric starter.
U5PWE1.book Page 46 Monday, July 8, 2002 10:28 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-47
6Engine overheating
EW000070
WARNING
_

Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.


After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hiss-
ing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
_CT-2AENOTE:_ If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant
as soon as possible. _
Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.Add coolant. (See NOTE.)
Start the engine. If the engine overheats again,
have a
Yamaha dealer check
and repair the cooling system.
There is
leakage.
There is
no leakage.
U5PWE1.book Page 47 Monday, July 8, 2002 10:28 AM

MOTORCYCLE CARE AND STORAGE
7-5
7a. Remove the spark plug caps
and spark plugs.
b. Pour a teaspoonful of engine
oil into each spark plug bore.
c. Install the spark plug caps onto
the spark plugs, and then place
the spark plugs on the cylinder
head so that the electrodes are
grounded. (This will limit spark-
ing during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder walls with oil.)
e. Remove the spark plug caps
from the spark plugs, and then
install the spark plugs and the
spark plug caps.
EWA00003
WARNING
_ To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over. _
4. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
5. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
6. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
7. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place (less
than 0 °C or more than 30 °C). For
more information on storing the
battery, see page 6-35.
NOTE:_ Make any necessary repairs before
storing the motorcycle. _
U5PWE1.book Page 5 Monday, July 8, 2002 10:28 AM

INDEXAAir filter element, replacing ..................... 6-17
Anti-theft alarm ...................................... 3-11BBattery ................................................... 6-34
Brake and clutch levers, checking and
lubricating ............................................ 6-31
Brake fluid, changing ............................. 6-28
Brake fluid level, checking...................... 6-27
Brake lever............................................. 3-13
Brake light switch (rear), adjusting ......... 6-26
Brake pads, checking............................. 6-26
Brake pedal............................................ 3-14
Brake pedal, lubricating.......................... 6-32
Brake pedal position, adjusting .............. 6-25CCables, checking and lubricating............ 6-31
Care.........................................................7-1
Catalytic converter ................................. 3-16
Clutch lever ............................................ 3-13
Clutch lever free play, adjusting ............. 6-24
Conversion table ......................................8-5
Coolant .................................................. 6-13
Changing .......................................... 6-14
Checking .......................................... 6-13
Coolant temperature warning light............3-4
Cowlings and panels, removing and
installing ................................................6-5
DDimmer switch ....................................... 3-11
Drive chain, lubricating .......................... 6-30
Drive chain slack ................................... 6-29
Adjusting .......................................... 6-29
Checking .......................................... 6-29EEngine break-in ....................................... 5-3
Engine idling speed ............................... 6-19
Engine oil and oil filter cartridge ............... 6-9
Engine speed indicator light..................... 3-4
Engine stop switch................................. 3-12
Engine trouble warning light .................... 3-4
EXUP system ........................................ 3-24FFront fork, adjusting ............................... 3-19
Front fork, checking ............................... 6-33
Fuel ....................................................... 3-15
Fuel consumption, tips for reducing ......... 5-3
Fuel level warning light ............................ 3-3
Fuel tank breather hose ......................... 3-16
Fuel tank cap ......................................... 3-14
Fuses, replacing .................................... 6-36HHandlebar switches ............................... 3-11
Hazard switch ........................................ 3-12
Headlight bulb, replacing ....................... 6-37
Helmet holders ...................................... 3-18
High beam indicator light ......................... 3-4
Horn switch ........................................... 3-12
IIdentification numbers ..............................9-1
Ignition circuit cut-off system ..................3-25
Indicator and warning lights......................3-2KKey identification number .........................9-1LLicense plate light bulb, replacing...........6-39
Luggage strap holders ...........................3-23MMain switch/steering lock .........................3-1
Model label ..............................................9-2
Multi-function display................................3-6NNeutral indicator light ...............................3-4OOil level warning light ...............................3-3PParking.....................................................5-4
Part locations ...........................................2-1
Pass switch ............................................3-11
Periodic maintenance and
lubrication chart .....................................6-2
Pre-operation check list ............................4-1
U5PWE1.book Page 1 Monday, July 8, 2002 10:28 AM

INDEX
SSafety information.................................... 1-1
Seats ..................................................... 3-17
Passenger seat ................................ 3-17
Rider seat ........................................ 3-17
Shifting .................................................... 5-2
Shift pedal ............................................. 3-13
Shift points (for Switzerland only)............. 5-3
Shock absorber assembly, adjusting ..... 3-21
Sidestand .............................................. 3-24
Sidestand, checking and lubricating....... 6-32
Spark plugs, checking ............................. 6-8
Specifications .......................................... 8-1
Starting the engine .................................. 5-1
Start switch ............................................ 3-12
Steering, checking ................................. 6-33
Storage.................................................... 7-4
Storage compartment ............................ 3-19
Supporting the motorcycle ..................... 6-40TTachometer ........................................... 3-11
Tail/brake light ....................................... 6-38
Throttle cable free play, adjusting .......... 6-20
Throttle grip and cable, checking and
lubricating............................................ 6-31
Tires ...................................................... 6-21
Tool kit..................................................... 6-1
Troubleshooting..................................... 6-45
Troubleshooting charts .......................... 6-46
Turn signal indicator lights ....................... 3-2
Turn signal light bulb, replacing ............. 6-39
Turn signal switch .................................. 3-12
VValve clearance, adjusting .................... 6-20
Vehicle identification number................... 9-1WWheel bearings, checking ..................... 6-34
Wheel (front) ......................................... 6-41
Installing .......................................... 6-42
Removing ........................................ 6-41
Wheel (rear) .......................................... 6-43
Installing .......................................... 6-44
Removing ........................................ 6-43
Wheels .................................................. 6-24
U5PWE1.book Page 2 Monday, July 8, 2002 10:28 AM