2003 YAMAHA YZF-R1 engine

PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6
ECA00133
CAUTION:_

In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.


Make sure that no foreign mate-
rial enters the crankcase.
_10. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.NOTE:_ After the engine is started, the engine
oil level warning light should go off if the
oil level is sufficient. _
EC000067
CAUTION:_ If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha deal-
er check the vehicle. _11. Turn the engine off, and then
check the oil level and correct it if
necessary.
12. Install the cowling.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6
EAU04897
Coolant The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
To check the coolant level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:_

The coolant level must be checked
on a cold engine since the level
varies with engine temperature.


Make sure that the motorcycle is
positioned straight up when
checking the coolant level. A slight
tilt to the side can result in a false
reading.
_
2. Check the coolant level in the
coolant reservoir.NOTE:_ The coolant should be between the
minimum and maximum level marks. _
3. If the coolant is at or below the min-
imum level mark, remove panel A
(See page 6-7 for panel removal
and installation procedures.), re-
move the reservoir cap, add cool-
ant to the maximum level mark,
and then install the reservoir cap
and the panel.
1. Maximum level mark
2. Minimum level mark
1. Coolant reservoir cap
Coolant reservoir capacity
(up to the maximum level mark):
0.24 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6
EC000080
CAUTION:_

If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.


If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the cool-
ing system will not be protected
against frost and corrosion.


If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
_
EW000067
WARNING
_ Never attempt to remove the radia-
tor cap when the engine is hot. _NOTE:_

The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.


If the engine overheats, see page
6-47 for further instructions.
_
EAU04925
To change the coolant
1. Place the motorcycle on a level
surface and let the engine cool if
necessary.
2. Remove cowlings A and B, and
panel A. (See pages 6-5–6-7 for
cowling and panel removal and in-
stallation procedures.)
3. Place a container under the en-
gine to collect the used coolant.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
64. Remove the clutch cable holder
from the coolant reservoir as
shown.
5. Remove the coolant reservoir by
removing the bolts.
6. Remove the coolant reservoir cap,
and then turn the coolant reservoir
upside down to empty it.
7. Install the coolant reservoir by in-
stalling the bolts, and then install
the clutch cable holder.8. Remove the radiator cap.
EW000067
WARNING
_ Never attempt to remove the radia-
tor cap when the engine is hot. _
9. Remove the coolant drain bolt to
drain the cooling system.
10. Loosen the radiator hose clamp
screw located at the left side of the
engine, and then pull off the hose
to drain the radiator.
1. Bolt (× 2)
2. Radiator cap
3. Coolant reservoir cap
4. Coolant reservoir
5. Clutch cable holder
1. Coolant drain bolt
2. Clamp screw
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6 11. After the coolant is completely
drained, thoroughly flush the cool-
ing system with clean tap water.
12. Install the coolant drain bolt, and
then tighten it to the specified
torque.
NOTE:_ Check the washer for damage and re-
place it if necessary. _13. Connect the radiator hose, and
then tighten the clamp screw.14. Pour the specified amount of rec-
ommended coolant into the radia-
tor and reservoir.
EC000080
CAUTION:_

If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.


If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the cool-
ing system will not be protected
against frost and corrosion.


If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
_
Tightening torque:
Coolant drain bolt:
10 Nm (1.0 m·kgf)
Antifreeze/water mixture ratio:
1:1
Recommended antifreeze:
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Coolant quantity:
Total amount:
2.45 L
Coolant reservoir capacity
(up to the maximum level mark):
0.24 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
615. Install the radiator cap and the
coolant reservoir cap, and then
start the engine and let it idle for
several minutes. During this peri-
od, rev the engine two or three
times between 3,000–5,000 r/min,
and then turn it off.
16. Remove the radiator cap to check
the coolant level in the radiator. If
necessary, add sufficient coolant
until it reaches the top of the radia-
tor, and then install the radiator
cap.
17. Check the coolant level in the res-
ervoir. If necessary, remove the
coolant reservoir cap, add coolant
to the maximum level mark, and
then install the cap.
18. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a Yamaha
dealer check the cooling system.
19. Install the cowlings and the panel.
EAU04572*
Replacing the air filter
element The air filter element should be re-
placed at the intervals specified in the
periodic maintenance and lubrication
chart. Replace the air filter element
more frequently if you are riding in un-
usually wet or dusty areas.
1. Remove the rider seat. (See page
3-17 for rider seat removal and in-
stallation procedures.)
2. Remove the bolt.3. Lift the front of the fuel tank, and
then tilt it back and away from the
air filter case. (Do not disconnect
the fuel hoses!)
EW000071
WARNING
_

Make sure that the fuel tank is
well supported.


Do not tilt or pull the fuel tank
too much, otherwise the fuel
hoses may come loose, which
could cause fuel leakage.
_4. Disconnect the fuel tank breather
hose and the fuel tank overflow
hose.
1. Bolt
1. Fuel tank breather hose
2. Fuel tank overflow hose
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6 5. Remove the air filter case cover by
removing the screws and bolt.6. Pull the air filter element out.
7. Insert a new air filter element into
the air filter case.
EC000082*
CAUTION:_

Make sure that the air filter ele-
ment is properly seated in the
air filter case.


The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
pistons and/or cylinders may
become excessively worn.
_8. Install the air filter case cover by
installing the screws and bolt.
1. Bolt
2. Screw (× 8)
3. Air filter case cover
1. Air filter element
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
69. Connect the fuel tank breather
hose and the fuel tank overflow
hose, place the fuel tank in the
original position, and then install
the bolt.
EWA00067
WARNING
_

Before installing the fuel tank,
make sure that the fuel hoses
are not damaged. If any fuel
hose is damaged, do not start
the engine but have a Yamaha
dealer replace the hose, other-
wise fuel may leak.


Make sure that the fuel hoses
are properly connected and
routed, and not pinched.


Be sure to place the fuel tank
breather hose and the fuel tank
overflow hose in the original po-
sition.
_10. Install the rider seat.
EAU04578
Adjusting the engine idling
speed The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
The engine should be warm before
making this adjustment.NOTE:_ The engine is warm when it quickly re-
sponds to the throttle. _
1. Fuel tank breather hose
2. Fuel tank overflow hose
1. Fuel tank breather hose
2. Fuel tank overflow hose
U5PWE1.book Page 19 Monday, July 8, 2002 10:28 AM