2003 YAMAHA YZF-R1 air filter

DESCRIPTION
2-2
2
Right view13. Luggage strap holders (page 3-23)
14. Helmet holders (page 3-18)
15. Main fuse (page 6-36)
16. Electronic fuel injection fuse (page 6-36)
17. Battery (page 6-34)
18. Rear brake fluid reservoir (page 6-28)19. Air filter element (page 6-18)
20. Radiator cap (page 6-15)
21. Coolant reservoir (page 6-13)
22. Engine oil level check window (page 6-9)
23. Engine oil filler cap (page 6-9)
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6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-2
Removing and installing cowlings and panels ..... 6-5
Checking the spark plugs .................................... 6-8
Engine oil and oil filter cartridge .......................... 6-9
Coolant .............................................................. 6-13
Replacing the air filter element .......................... 6-17
Adjusting the engine idling speed ...................... 6-19
Adjusting the throttle cable free play .................. 6-20
Adjusting the valve clearance ............................ 6-20
Tires ................................................................... 6-21
Cast wheels ....................................................... 6-24
Adjusting the clutch lever free play .................... 6-24
Adjusting the brake pedal position ..................... 6-25
Adjusting the rear brake light switch .................. 6-26
Checking the front and rear brake pads ............. 6-26
Checking the brake fluid level ............................ 6-27
Changing the brake fluid .................................... 6-28
Drive chain slack ................................................ 6-29
Lubricating the drive chain ................................. 6-30
Checking and lubricating the cables .................. 6-31Checking and lubricating the throttle grip and
cable ............................................................... 6-31
Checking and lubricating the brake and
clutch levers .................................................... 6-31
Lubricating the brake pedal ............................... 6-32
Checking and lubricating the sidestand ............ 6-32
Checking the front fork ...................................... 6-33
Checking the steering ....................................... 6-33
Checking the wheel bearings ............................ 6-34
Battery ............................................................... 6-34
Replacing the fuses .......................................... 6-36
Replacing a headlight bulb ................................ 6-37
Tail/brake light ................................................... 6-38
Replacing a turn signal light bulb ...................... 6-39
Replacing the license plate light bulb ................ 6-39
Supporting the motorcycle ................................ 6-40
Front wheel ....................................................... 6-41
Rear wheel ........................................................ 6-43
Troubleshooting ................................................. 6-45
Troubleshooting charts ...................................... 6-46
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_

The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.


From 50,000 km, repeat the maintenance intervals starting from 10,000 km.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_CP-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel lineCheck fuel hoses for cracks or damage.√√√√ √
2*Spark plugsCheck condition.
Clean and regap.√√
Replace.√√
3*ValvesCheck valve clearance.
Adjust.Every 40,000 km
4 Air filter elementReplace.√
5ClutchCheck operation.
Adjust.√√√√√
6*Front brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
8*Brake hosesCheck for cracks or damage.√√√√ √
Replace. (See NOTE on page 6-4.) Every 4 years
9*WheelsCheck runout and for damage.√√√√
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
10
*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
11*Wheel bearingsCheck bearing for looseness or damage.√√√√
12*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50,000 km
13 Drive chainCheck chain slack.
Make sure that the rear wheel is properly aligned.
Clean and lubricate.Every 1,000 km and after washing
the motorcycle or riding in the rain
14*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20,000 km
15*Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.√√√√ √
16 SidestandCheck operation.
Lubricate.√√√√ √
17*Sidestand switchCheck operation.√√√√√ √
18*Front forkCheck operation and for oil leakage.√√√√
19*Shock absorber
assemblyCheck operation and shock absorber for oil leakage.√√√√
20*Rear suspension relay
arm and connecting arm
pivoting pointsCheck operation.√√√√
21*Electronic fuel injectionAdjust engine idling speed and synchronization.√√√√√ √
22 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
23 Engine oil filter cartridgeReplace.√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU04522
NOTE:_

Air filter
This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with com-
pressed air to avoid damaging it.
The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.


Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.
Replace the brake hoses every four years and if cracked or damaged.
_24
*Cooling systemCheck coolant level and vehicle for coolant leakage.√√√√ √
Change. Every 3 years
25*Front and rear brake
switchesCheck operation.√√√√√ √
26 Moving parts and cablesLubricate.√√√√ √
27*Throttle grip housing
and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√√ √
28*Air induction systemCheck the air cut-off valve, reed valve, and hose for
damage.
Replace any damaged parts if necessary.√√√√ √
29*Muffler and exhaust pipeCheck the screw clamp for looseness.√√√√√
30*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
NOTE:_ If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible. _
EAU04913
Engine oil and oil filter
cartridge The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:_ Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. _
2. Start the engine, warm it up for
several minutes, and then turn it off.
3. Wait a few minutes until the oil set-
tles, and then check the oil level
through the check window located
at the bottom-right side of the
crankcase.NOTE:_ The engine oil should be between the
minimum and maximum level marks. _4. If the engine oil is at or below the
minimum level mark, add sufficient
oil of the recommended type to
raise it to the correct level. Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf)1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
4. Engine oil filler cap
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 To change the engine oil (with or
without oil filter cartridge replace-
ment)
1. Remove cowling B. (See page 6-7
for cowling removal and installa-
tion procedures.)
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Place an oil pan under the engine
to collect the used oil.4. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
NOTE:_ Skip steps 5–7 if the oil filter cartridge is
not being replaced. _
5. Remove the oil filter cartridge with
an oil filter wrench.NOTE:_ An oil filter wrench is available at a
Yamaha dealer. _
1. Engine oil drain bolt
1. Oil filter wrench
2. Oil filter cartridge
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
66. Apply a thin coat of engine oil to
the O-ring of the new oil filter car-
tridge.
NOTE:_ Make sure that the O-ring is properly
seated. _
7. Install the new oil filter cartridge,
and then tighten it to the specified
torque with a torque wrench.
8. Install the engine oil drain bolt, and
then tighten it to the specified
torque.NOTE:_ Check the washer for damage and re-
place it if necessary. _
9. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
1. O-ring
1. Torque wrench
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge
replacement:
2.9 L
With oil filter cartridge
replacement:
3.1 L
Total amount (dry engine):
3.8 L
U5PWE1.book Page 11 Monday, July 8, 2002 10:28 AM