2003 YAMAHA YZF-R1 brake pads

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
6-26
6
EAU00713
Adjusting the rear brake light
switch The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction
a. To
make the brake light come on later,
turn the adjusting nut in direction
b.
EAU00721
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU00725
Front brake pads
Each front brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator groove. If a brake
pad has worn to the point that the wear
indicator groove has almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
1. Rear brake light switch
2. Rear brake light switch adjusting nut
1. Brake pad wear indicator grooveFront
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
EAU04396
Rear brake pads
Each rear brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
Check the brake pad wear as follows.
1. Remove the brake caliper bolt,
and then tilt the caliper forward to
inspect the wear indicator groove.
If a brake pad has worn to the
point that the wear indicator
groove has almost disappeared,
have a Yamaha dealer replace the
brake pads as a set.2. Install the brake caliper bolt, and
then tighten it to the specified
torque.
EAU04856
Checking the brake fluid level Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake flu-
id level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
1. Brake caliper bolt Rear
1. Brake pad wear indicator groove
Tightening torque:
Brake caliper bolt:
27 Nm (2.7 m·kgf)
1. Minimum level markFront
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6 Observe these precautions:


When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.


Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.


Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.


Be careful that water does not en-
ter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU03976
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the master cylin-
ders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.

Oil seals: Replace every two
years.


Brake hoses: Replace every four
years.
1. Minimum level mark
Recommended brake fluid: DOT 4RearRear
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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)
U5PWE1.book Page 42 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