2003 YAMAHA YZF-R1 warning

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
6-35
6
EW000116
WARNING
_

Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al-
ways shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
EXTERNAL: Flush with plenty
of water.
INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a physician.
EYES: Flush with water for
15 minutes and seek prompt
medical attention.


Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed
space.


KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
_To store the battery
1. If the motorcycle will not be used
for more than one month, remove
the battery, fully charge it, and
then place it in a cool, dry place.
2. If the battery will be stored for
more than two months, check it at
least once a month and fully
charge it if necessary.
3. Fully charge the battery before in-
stallation.
4. After installation, make sure that
the battery leads are properly con-
nected to the battery terminals.
EC000102
CAUTION:_

Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.


To charge a sealed-type (MF)
battery, a special (constant-
voltage) battery charger is re-
quired. Using a conventional
battery charger will damage the
battery. If you do not have ac-
cess to a sealed-type (MF) bat-
tery charger, have a Yamaha
dealer charge your battery.
_
U5PWE1.book Page 35 Monday, July 8, 2002 10:28 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-37
6
EAU04503
Replacing a headlight bulb This motorcycle is equipped with
quartz bulb headlights. If a headlight
bulb burns out, replace it as follows.
1. Disconnect the headlight coupler,
and then remove the bulb cover.2. Unhook the headlight bulb holder,
and then remove the defective
bulb.
EW000119
WARNING
_ Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down. _3. Place a new headlight bulb into
position, and then secure it with
the bulb holder.
1. Headlight bulb cover
2. Headlight coupler
1. Headlight bulb holder
1. Do not touch the glass part of the bulb.
U5PWE1.book Page 37 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
U5PWE1.book Page 41 Monday, July 8, 2002 10:28 AM

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
6-46
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
7-3
7Cleaning the titanium muffler
This model is equipped with a titanium
muffler, which requires the following
special care.

Use only a soft, clean cloth or
sponge with mild detergent and
water to clean the titanium muffler.
However, if the muffler cannot be
thoroughly cleaned with mild de-
tergent, alkaline products and a
soft brush may be used.


Never use compounds or other
special treatments to clean the ti-
tanium muffler, as they will remove
the finish on the outer surface of
the muffler.


Even the smallest amounts of oil,
such as from oily towels or finger-
prints, will leave stains on the tita-
nium muffler, which can be
removed with a mild detergent.


Note that the thermally induced
discoloring of the portion of the ex-
haust pipe leading into the titani-
um muffler is normal and cannot
be removed.After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts.
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
5. Use spray oil as a universal clean-
er to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
EWA00031
WARNING
_

Make sure that there is no oil or
wax on the brakes or tires.


If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac-
etone, and wash the tires with
warm water and a mild deter-
gent. Before riding at higher
speeds, test the motorcycle’s
braking performance and cor-
nering behavior.
_
U5PWE1.book Page 3 Monday, July 8, 2002 10:28 AM