OWNER’S MANUAL YZF-R1S(C) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.12-5.
U5VY10E0.
U5VY10E0.book Page 1 Thursday, December 11, 2003 8:48 AM INTRODUCTION EAU10080 Congratulations on your purchase of the Yamaha YZF-R1(C). This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle.
U5VY10E0.book Page 1 Thursday, December 11, 2003 8:48 AM IMPORTANT MANUAL INFORMATION EAU10130 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
U5VY10E0.book Page 2 Thursday, December 11, 2003 8:48 AM IMPORTANT MANUAL INFORMATION AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.
U5VY10E0.book Page 3 Thursday, December 11, 2003 8:48 AM IMPORTANT MANUAL INFORMATION EAU10192 AFFIX DEALER LABEL HERE YZF-R1S(C) OWNER’S MANUAL ©2003 by Yamaha Motor Corporation, U.S.A. 1st edition, December 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan.
U5VY10E0.book Page 1 Thursday, December 11, 2003 8:48 AM TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 Location of important labels ...........1-5 PRE-OPERATION CHECKS ............. 4-1 Pre-operation check list ................. 4-2 DESCRIPTION ..................................2-1 Left view ..........................................2-1 Right view ........................................2-2 Controls and instruments ................2-3 OPERATION AND IMPORTANT RIDING POINTS ..................
U5VY10E0.book Page 2 Thursday, December 11, 2003 8:48 AM TABLE OF CONTENTS Supporting the motorcycle ............6-39 Front wheel ...................................6-40 Rear wheel ...................................6-42 Troubleshooting ............................6-43 Troubleshooting charts .................6-44 MOTORCYCLE CARE AND STORAGE ..........................................7-1 Care ................................................7-1 Storage ...........................................
U5VY10E0.book Page 1 Thursday, December 11, 2003 8:48 AM SAFETY INFORMATION EAU10280 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: ● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION.
U5VY10E0.book Page 2 Thursday, December 11, 2003 8:48 AM SAFETY INFORMATION 1 ● ● turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). • Always obey the speed limit and never travel faster than warranted by road and traffic conditions. • Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control.
U5VY10E0.book Page 3 Thursday, December 11, 2003 8:48 AM SAFETY INFORMATION Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of 201 kg (443 lb) (CAL) / 202 kg (445 lb) (U49). When loading within this weight limit, keep the following in mind: ● Cargo and accessory weight should be kept as low and close to the motorcycle as possible.
U5VY10E0.book Page 4 Thursday, December 11, 2003 8:48 AM SAFETY INFORMATION 1 Gasoline and exhaust gas ● GASOLINE IS HIGHLY FLAMMABLE: • Always turn the engine off when refueling. • Take care not to spill any gasoline on the engine or exhaust system when refueling. • Never refuel while smoking or in the vicinity of an open flame. ● Never start the engine or let it run for any length of time in a closed area.
U5VY10E0.book Page 5 Thursday, December 11, 2003 8:48 AM SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.
U5VY10E0.book Page 6 Thursday, December 11, 2003 8:48 AM SAFETY INFORMATION 1 Cleaning with alkaline or acid cleaner, gasoline or solvent will damage windshield. Use neutral detergent. HOW TO LAYOUT FUEL HOSES FUEL DELIVERY FUEL TANK #4 1 California only 5 CAUTION #3 5JW-00 #1 #2 2 PRESS. REGULATOR FUEL PUMP (FUEL FILTER) 5VY-2178A-00 3 PREMIUM UNLEADED GASOLINE ONLY 91 Min.
U5VY10E0.book Page 7 Thursday, December 11, 2003 8:48 AM SAFETY INFORMATION 7 10 1 3JJ-28446-A1 8 9 290 kPa, {2.
U5VY10E0.book Page 1 Thursday, December 11, 2003 8:48 AM DESCRIPTION EAU10410 Left view 2 1. 2. 3. 4. 5. 6. 7. 8. 9. Main fuse (page 6-32) 10.Owner’s tool kit (page 6-1) 11.Engine oil drain bolt (page 6-11) 12.
U5VY10E0.book Page 2 Thursday, December 11, 2003 8:48 AM DESCRIPTION EAU10420 Right view 2 9. Shock absorber assembly rebound damping force adjusting screw (page 3-18) 10.Coolant reservoir (page 6-14) 1. 2. 3. 4. 5. Luggage strap holder (page 3-21) Helmet holder (page 3-16) Passenger seat lock (page 3-15) Rear brake fluid reservoir (page 6-23) Shock absorber assembly compression damping force adjusting screw (page 3-18) 6. Engine oil filler cap (page 6-11) 7. Air filter element (page 6-16) 8.
U5VY10E0.book Page 3 Thursday, December 11, 2003 8:48 AM DESCRIPTION EAU10430 Controls and instruments 2 1. 2. 3. 4. 5. 6. 7.
U5VY10E0.book Page 1 Thursday, December 11, 2003 8:48 AM INSTRUMENT AND CONTROL FUNCTIONS EAU10460 NOTE: The headlights come on automatically when the engine is started and stay on until the key is turned to “OFF”, even if the engine stalls. Main switch/steering lock To lock the steering EAU10660 OFF All electrical systems are off. The key can be removed. The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering.
U5VY10E0.book Page 2 Thursday, December 11, 2003 8:48 AM INSTRUMENT AND CONTROL FUNCTIONS To unlock the steering EAU11001 Indicator and warning lights EAU11060 Neutral indicator light “ ” This indicator light comes on when the transmission is in the neutral position. EAU11080 High beam indicator light “ ” This indicator light comes on when the high beam of the headlight is switched on. 3 EAU11250 1. Push. 2. Turn. Push the key in, and then turn it to “OFF” while still pushing it.
U5VY10E0.book Page 3 Thursday, December 11, 2003 8:48 AM INSTRUMENT AND CONTROL FUNCTIONS ● This model is also equipped with a self-diagnosis device for the oil level detection circuit. If the oil level detection circuit is defective, the following cycle will be repeated until the malfunction is corrected: The oil level warning light will flash ten times, then go off for 2.5 seconds. If this occurs, have a Yamaha dealer check the vehicle.
U5VY10E0.book Page 4 Thursday, December 11, 2003 8:48 AM INSTRUMENT AND CONTROL FUNCTIONS Coolant temperature Display Conditions Under 39 °C (Under 103 °F) What to do Message “LO” is displayed. OK. Go ahead with riding. 40–116 °C (104–242 °F) Temperature is displayed. OK. Go ahead with riding. 117–139 °C (243–283 °F) Temperature display flashes. Warning light comes on. Stop the vehicle and allow it to idle until the coolant temperature goes down.
U5VY10E0.book Page 5 Thursday, December 11, 2003 8:48 AM INSTRUMENT AND CONTROL FUNCTIONS EAU11530 Engine trouble warning light “ ” This warning light comes on or flashes when an electrical circuit monitoring the engine is defective. When this occurs, have a Yamaha dealer check the selfdiagnosis system. (See page 3-5 for an explanation of the self-diagnosis device.) The electrical circuit of the warning light can be checked by turning the key to “ON”.
U5VY10E0.
U5VY10E0.book Page 7 Thursday, December 11, 2003 8:48 AM INSTRUMENT AND CONTROL FUNCTIONS 3. Push the “SELECT” button, and the minute digits will start flashing. 4. Push the “RESET” button to set the minutes. 5. Push the “SELECT” button and then release it to start the clock. Odometer, tripmeter, and stopwatch modes 1. Coolant temperature display/air intake temperature display 2. Odometer/tripmeters/fuel reserve tripmeter/stopwatch 3.
U5VY10E0.book Page 8 Thursday, December 11, 2003 8:48 AM INSTRUMENT AND CONTROL FUNCTIONS NOTE: When the coolant temperature display is selected, “C” is displayed for one second, and then the coolant temperature is displayed. ECA10020 CAUTION: 3 Do not operate the engine if it is overheated. Air intake temperature display The air intake temperature display indicates the temperature of the air drawn into the air filter case.
U5VY10E0.book Page 9 Thursday, December 11, 2003 8:48 AM INSTRUMENT AND CONTROL FUNCTIONS ● Shift timing indicator light brightness: This function allows you to adjust the brightness of the indicator light to suit your preference. NOTE: ● To make any settings in this mode, you have to cycle through all of its functions. However, if the key is turned to “OFF” or the engine is started before completing the procedure, only the settings made before the “SELECT” button was last pushed will be applied.
U5VY10E0.book Page 10 Thursday, December 11, 2003 8:48 AM INSTRUMENT AND CONTROL FUNCTIONS To set the shift timing indicator light deactivation function 3 NOTE: ● The shift timing indicator light deactivation function can be set between 7000 r/min and 15000 r/min. From 7000 r/min to 12000 r/min, the indicator light can be set in increments of 500 r/min. From 12000 r/min to 15000 r/min, the indicator light can be set in increments of 200 r/min.
U5VY10E0.book Page 11 Thursday, December 11, 2003 8:48 AM INSTRUMENT AND CONTROL FUNCTIONS EAU12400 Dimmer switch “ / ” Set this switch to “ ” for the high beam and to “ ” for the low beam. ECA10050 EAU12820 Clutch lever CAUTION: See page 5-1 for starting instructions prior to starting the engine. EAU12460 Turn signal switch “ / ” To signal a right-hand turn, push this switch to “ ”. To signal a left-hand turn, push this switch to “ ”. When released, the switch returns to the center position.
U5VY10E0.book Page 12 Thursday, December 11, 2003 8:48 AM INSTRUMENT AND CONTROL FUNCTIONS EAU12870 EAU33850 Shift pedal Brake lever 1. Shift pedal 1. Brake lever 2. Brake lever position adjusting knob 3. Distance between brake lever and handlebar grip 4. “ ” mark 3 The shift pedal is located on the left side of the engine and is used in combination with the clutch lever when shifting the gears of the 6-speed constant-mesh transmission equipped on this motorcycle.
U5VY10E0.book Page 13 Thursday, December 11, 2003 8:48 AM INSTRUMENT AND CONTROL FUNCTIONS EAU12941 Brake pedal EAU13070 NOTE: The fuel tank cap cannot be closed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked. Fuel tank cap EWA11090 WARNING Make sure that the fuel tank cap is properly closed before riding. 1. Brake pedal The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal.
U5VY10E0.book Page 14 Thursday, December 11, 2003 8:48 AM INSTRUMENT AND CONTROL FUNCTIONS EAU13210 Fuel ECA10070 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EAU13380 3 1. Fuel tank filler tube 2. Fuel level Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. Recommended fuel: PREMIUM UNLEADED GASOLINE ONLY Fuel tank capacity: 18.0 L (4.
U5VY10E0.book Page 15 Thursday, December 11, 2003 8:48 AM INSTRUMENT AND CONTROL FUNCTIONS EAU13430 Catalytic converter EAU33860 Seats This model is equipped with a catalytic converter in the exhaust chamber. Rider seat EWA10860 WARNING The exhaust system is hot after operation. Make sure that the exhaust system has cooled down before doing any maintenance work. To remove the rider seat Pull back the rear of the rider seat as shown, remove the bolts, and then pull the seat off. 1. Projection 2.
U5VY10E0.book Page 16 Thursday, December 11, 2003 8:48 AM INSTRUMENT AND CONTROL FUNCTIONS 2. While holding the key in that position, lift the front of the passenger seat and pull it forward. 3 EAU33870 Helmet holders To install the passenger seat 1. Insert the projection on the rear of the passenger seat into the seat holder as shown, and then push the front of the seat down to lock it in place. 1. Helmet holder The helmet holders are located on the bottom of the passenger seat. 1. Projection 2.
U5VY10E0.book Page 17 Thursday, December 11, 2003 8:48 AM INSTRUMENT AND CONTROL FUNCTIONS EAU14741 Adjusting the front fork This front fork is equipped with spring preload adjusting bolts, rebound damping force adjusting screws and compression damping force adjusting screws. EWA10180 load and thereby soften the suspension, turn the adjusting bolt on each fork leg in direction (b).
U5VY10E0.book Page 18 Thursday, December 11, 2003 8:48 AM INSTRUMENT AND CONTROL FUNCTIONS Compression damping force ECA10100 CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings. 3 1. Compression damping force adjusting screw To increase the compression damping force and thereby harden the compression damping, turn the adjusting screw on each fork leg in direction (a).
U5VY10E0.book Page 19 Thursday, December 11, 2003 8:48 AM INSTRUMENT AND CONTROL FUNCTIONS To increase the spring preload and thereby harden the suspension, turn the adjusting ring in direction (a). To decrease the spring preload and thereby soften the suspension, turn the adjusting ring in direction (b). NOTE: ● Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber. ● Use the special wrench included in the owner’s tool kit to make the adjustment.
U5VY10E0.book Page 20 Thursday, December 11, 2003 8:48 AM INSTRUMENT AND CONTROL FUNCTIONS Compression damping force 3 1. Compression damping force adjusting screw To increase the compression damping force and thereby harden the compression damping, turn the adjusting screw in direction (a). To decrease the compression damping force and thereby soften the compression damping, turn the adjusting screw in direction (b).
U5VY10E0.book Page 21 Thursday, December 11, 2003 8:48 AM INSTRUMENT AND CONTROL FUNCTIONS EAU15181 Luggage strap holders EAU15280 Sidestand This model is equipped with Yamaha’s EXUP (EXhaust Ultimate Power valve) system. This system boosts engine power by means of a valve that regulates the diameter of the exhaust pipe. The EXUP system valve is constantly adjusted in accordance with the engine speed by a computer-controlled servomotor. The sidestand is located on the left side of the frame.
U5VY10E0.book Page 22 Thursday, December 11, 2003 8:48 AM INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer repair it if it does not function properly. 3 EAU15311 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. ● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled.
U5VY10E0.book Page 23 Thursday, December 11, 2003 8:48 AM INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is turned on. 3. Turn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? YES NOTE: This check is most reliable if performed with a warmed-up engine. NO The neutral switch may be defective.
U5VY10E0.book Page 1 Thursday, December 11, 2003 8:48 AM PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences.
U5VY10E0.book Page 2 Thursday, December 11, 2003 8:48 AM PRE-OPERATION CHECKS EAU15602 Pre-operation check list ITEM CHECKS PAGE Fuel • Check fuel level in fuel tank. • Refuel if necessary. • Check fuel line for leakage. 3-14 Engine oil • Check oil level in engine. • If necessary, add recommended oil to specified level. • Check vehicle for oil leakage. 6-11 Coolant • Check coolant level in reservoir. • If necessary, add recommended coolant to specified level. • Check cooling system for leakage.
U5VY10E0.book Page 3 Thursday, December 11, 2003 8:48 AM PRE-OPERATION CHECKS ITEM CHECKS PAGE Throttle grip • Make sure that operation is smooth. • Check cable free play. • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. 6-18, 6-27 Control cables • Make sure that operation is smooth. • Lubricate if necessary. Drive chain • • • • Check chain slack. Adjust if necessary. Check chain condition. Lubricate if necessary.
U5VY10E0.book Page 1 Thursday, December 11, 2003 8:48 AM OPERATION AND IMPORTANT RIDING POINTS EAU15950 EAU16251 Starting the engine EWA10270 WARNING ● ● ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. Never start the engine or operate it in a closed area for any length of time.
U5VY10E0.book Page 2 Thursday, December 11, 2003 8:48 AM OPERATION AND IMPORTANT RIDING POINTS ECA11130 CAUTION: EAU16671 Shifting ECA10260 CAUTION: ● For maximum engine life, always warm the engine up before starting off. Never accelerate hard when the engine is cold! NOTE: The engine is warm when it quickly responds to the throttle. 5 1. Shift pedal 2. Neutral position ● Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc.
U5VY10E0.book Page 3 Thursday, December 11, 2003 8:48 AM OPERATION AND IMPORTANT RIDING POINTS 4. At the recommended shift points shown in the following table, close the throttle, and at the same time, quickly pull the clutch lever in. 5. Shift the transmission into second gear. (Make sure not to shift the transmission into the neutral position.) 6. Open the throttle part way and gradually release the clutch lever. 7. Follow the same procedure when shifting to the next higher gear.
U5VY10E0.book Page 4 Thursday, December 11, 2003 8:48 AM OPERATION AND IMPORTANT RIDING POINTS ECA10301 EAU17211 CAUTION: Parking After 1000 km (600 mi) of operation, the engine oil must be changed and the oil filter cartridge or element replaced. When parking, stop the engine, and then remove the key from the main switch. 1600 km (1000 mi) and beyond The vehicle can now be operated normally. EWA10310 WARNING ● ECA10310 CAUTION: ● 5 ● Keep the engine speed out of the tachometer red zone.
U5VY10E0.book Page 1 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17231 EAU17300 PERIODIC MAINTENANCE Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of motorcycle inspection, adjustment, and lubrication are explained on the following pages.
U5VY10E0.book Page 2 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10340 WARNING Modifications not approved by Yamaha may cause loss of performance, excessive emissions, and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any changes. EWA12370 WARNING Do not touch the muffler bracket until the exhaust system has cooled. 6 1.
U5VY10E0.book Page 3 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17600 Periodic maintenance chart for the emission control system INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months Fuel line • Check fuel hoses for cracks or damage. • Replace if necessary.
U5VY10E0.book Page 4 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32182 General maintenance and lubrication chart INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months 1 * Air filter element • Check condition and damage. • Replace if necessary. 2 * Clutch • Check operation.
U5VY10E0.book Page 5 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE Swingarm pivot bearings • Check bearing assemblies for looseness. • Moderately repack with lithiumsoap-based grease. Drive chain • Check chain slack/alignment and condition. • Adjust and lubricate chain with a special O-ring chain lubricant thoroughly. 11 * Steering bearings • Check bearing assemblies for looseness.
U5VY10E0.book Page 6 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. 6 ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months 17 * Front fork • Check operation and for oil leakage. • Replace if necessary. √ √ √ √ √ 18 * Shock absorber assembly • Check operation and for oil leakage.
U5VY10E0.book Page 7 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. 25 * ITEM Throttle grip housing and cable ROUTINE 600 mi (1000 km) or 1 month • Check operation and free play. • Adjust the throttle cable free play if necessary. • Lubricate the throttle grip housing and cable.
U5VY10E0.book Page 8 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU18721 EAU33980 Removing and installing the cowling and panels Cowling A To remove the cowling Remove the bolt, loosen and remove the quick fastener screws, slide the cowling backward, and then remove it. The cowling and panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the cowling or a panel needs to be removed and installed.
U5VY10E0.book Page 9 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR 2. Place the cowling in its original position, install and tighten the quick fastener screws, and then install the bolt. EAU19292 Panels A and C 1. Cowling A To remove one of the panels Remove the screw, and then pull the panel off as shown. EAU33990 Panels B and D To install the cowling 1. Insert the projections into the slots, and then slide the cowling forward. To remove one of the panels 1.
U5VY10E0.book Page 10 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR To install the panel 1. Place the panel in its original position, and then install the screw. 2. Install the rider seat. 6 EAU19651 Checking the spark plugs The spark plugs are important engine components, which should be checked periodically, preferably by a Yamaha dealer.
U5VY10E0.book Page 11 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19680 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 specified torque as soon as possible. Canister (for California only) EAU34002 Engine oil and oil filter cartridge The engine oil level should be checked before each ride.
U5VY10E0.book Page 12 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: The engine oil should be between the minimum and maximum level marks. 6 1. 2. 3. 4. Engine oil level check window Maximum level mark Minimum level mark Engine oil filler cap 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 as follows. a. Fit the rubber protector on the special wrench.
U5VY10E0.book Page 13 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Oil filter wrench 2. Engine oil filter cartridge NOTE: An oil filter wrench is available at a Yamaha dealer. 7. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. 1. O-ring 1. Torque wrench NOTE: Make sure that the O-ring is properly seated. 8. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench.
U5VY10E0.book Page 14 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR 10. Add the specified amount of the recommended engine oil, and then install and tighten the oil filler cap with the special wrench. Recommended engine oil: See page 8-1. Oil quantity: Without oil filter cartridge replacement: 2.90 L (3.07 US qt) (2.55 Imp.qt) With oil filter cartridge replacement: 3.10 L (3.28 US qt) (2.73 Imp.
U5VY10E0.book Page 15 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR ● 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. EWA10380 WARNING 1. Maximum level mark 2. Minimum level mark 3.
U5VY10E0.book Page 16 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR The coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart. Have a Yamaha dealer change the coolant. EAU34020 Replacing the air filter element The air filter element should be replaced at the intervals specified in the periodic maintenance and lubrication chart. Replace the air filter element more frequently if you are riding in unusually wet or dusty areas. 1.
U5VY10E0.book Page 17 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR 6. Remove the air filter element. 9. Place the fuel tank in its original position, and then install the bolts. EWA12380 WARNING ● 1. Rubber cap 1. Air filter element 7. Install a new air filter element into the air filter case. ECA10480 CAUTION: ● ● 1. Screw 2.
U5VY10E0.book Page 18 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR 10. Install the panels. 11. Install the rider seat. EAU21380 Adjusting the throttle cable free play 1. Throttle cable free play 6 The throttle cable free play should measure 3.0–5.0 mm (0.12–0.20 in) at the throttle grip. Periodically check the throttle cable free play and, if necessary, have a Yamaha dealer adjust it.
U5VY10E0.book Page 19 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21750 Tires To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified tires. Tire air pressure The tire air pressure should be checked and, if necessary, adjusted before each ride. EWA10500 WARNING ● ● The tire air pressure must be checked and adjusted on cold tires (i.e.
U5VY10E0.book Page 20 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR Tire inspection EWA10580 WARNING ● ● 1. Tire sidewall 2. Tire wear indicator 3. Tire tread depth 6 Always check the tires before operating the motorcycle. If a tire tread shows crosswise lines (minimum tread depth), if the tire has a nail or glass fragments in it, or if the sidewall is cracked, contact a Yamaha dealer immediately and have the tire replaced. It is dangerous to ride with a worn-out tire.
U5VY10E0.book Page 21 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR Front tire: Size: 120/70 ZR17M/C (58W) Manufacturer/model: MICHELIN/Pilot POWER C DUNLOP/D218FL Rear tire: Size: 190/50 ZR17M/C (73W) Manufacturer/model: MICHELIN/Pilot POWER G DUNLOP/D218L FRONT and REAR: Tire air valve: TR412 Valve core: #9000A (original) ● ● “broken in”.
U5VY10E0.book Page 22 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU33890 Adjusting the clutch lever free play 1. Clutch lever free play adjusting bolt 2. Clutch lever free play 6 The clutch lever free play should measure 10.0–15.0 mm (0.39–0.59 in) as shown. Periodically check the clutch lever free play and, if necessary, adjust it as follows. To increase the clutch lever free play, turn the adjusting bolt at the clutch lever in direction (a).
U5VY10E0.book Page 23 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR Checking the front and rear brake pads point that the wear indicator almost touches the brake disc, have a Yamaha dealer replace the brake pads as a set. The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. Rear brake pads EAU22390 EAU22580 Checking the brake fluid level Front brake EAU22500 EAU22410 Front brake pads 1.
U5VY10E0.book Page 24 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR 6 Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid 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.
U5VY10E0.book Page 25 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22760 NOTE: Using the alignment marks on each side of the swingarm, make sure that both chain pullers are in the same position for proper wheel alignment. Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. EAU22770 To check the drive chain slack 1. Place the motorcycle on a level surface and hold it in an upright position.
U5VY10E0.book Page 26 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Tighten the locknuts, then the axle nut to their specified torques. Tightening torques: Locknut: 16 Nm (1.6 m·kgf, 12 ft·lbf) Axle nut: 150 Nm (15.0 m·kgf, 108 ft·lbf) EAU23021 CAUTION: The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas.
U5VY10E0.book Page 27 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23090 EAU23110 Checking and lubricating the cables Checking and lubricating the throttle grip and cable The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it.
U5VY10E0.book Page 28 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23200 Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Checking and lubricating the sidestand EAUM1650 Lubricating the swingarm pivots The swingarm pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.
U5VY10E0.book Page 29 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23271 EAU23280 Checking the front fork Checking the steering The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.
U5VY10E0.book Page 30 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23290 Checking the wheel bearings EAU23440 Battery The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. 1. Negative battery terminal 2. Battery 3.
U5VY10E0.book Page 31 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10760 WARNING ● ● Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns. Avoid any contact with skin, eyes or clothing and always shield your eyes when working near batteries. In case of contact, administer the following FIRST AID. • EXTERNAL: Flush with plenty of water. • INTERNAL: Drink large quantities of water or milk and immediately call a physician.
U5VY10E0.book Page 32 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU34052 Replacing the fuses The main fuse and the electronic fuel injection fuse are located under the rider seat. (See page 3-15.) 1. Cowling 1. Quick fastener If a fuse is blown, replace it as follows. 6 1. Main fuse 2. Electronic fuel injection spare fuse 3. Electronic fuel injection fuse The fuse box, which contains the fuses for the individual circuits, is located behind the cowling shown.
U5VY10E0.book Page 33 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Fuse box 2. Cowling 5. Remove the blown fuse, and then install a new fuse of the specified amperage. 1. 2. 3. 4. 5. 6. 7. Spare fuse Left radiator fan fuse Right radiator fan fuse Backup fuse (for odometer and clock) Signaling system fuse Ignition fuse Headlight fuse Specified fuses: Main fuse: 50.0 A Backup fuse: 10.0 A Ignition fuse: 15.0 A Headlight fuse: 25.0 A Signaling system fuse: 10.
U5VY10E0.book Page 34 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR 8. Place the cowling in its original position, and then install and tighten the quick fastener screws. EAU33900 Replacing a headlight bulb 1. Headlight bulb cover 2. Headlight coupler 1. Slot 2. Projection 6 NOTE: Make sure that the projections are inserted into the slots. 9. Install the quick fasteners.
U5VY10E0.book Page 35 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10790 WARNING Headlight bulbs get very hot. Therefore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down. ● Headlight lens Do not affix any type of tinted film or stickers to the headlight lens. Do not use a headlight bulb of a wattage higher than specified. 3. Place a new headlight bulb into position, and then secure it with the bulb holder. 1.
U5VY10E0.book Page 36 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR ● 1. Headlight bulb holder EWA10790 WARNING 6 Headlight bulbs get very hot. Therefore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down. ● Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected.
U5VY10E0.book Page 37 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24180 Tail/brake light This model is equipped with an LED type of tail/brake light. If the tail/brake light does not come on, have a Yamaha dealer check it. EAU24201 Replacing a turn signal light bulb 1. Remove the turn signal light lens by removing the screw. 1. Screw 2. Remove the defective bulb by pushing it in and turning it counterclockwise. 3.
U5VY10E0.book Page 38 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Remove the defective bulb by pulling 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. 6 EAU33910 Replacing an auxiliary light bulb This model is equipped with two auxiliary lights. If an auxiliary light bulb burns out, replace it as follows. 1.
U5VY10E0.book Page 39 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR 7. Install the auxiliary light bulb cover by installing the quick fastener. NOTE: To install the quick fastener, push the center pin out so that it will protrude from the fastener head, insert the fastener into the auxiliary light bulb cover, and then push the protruding pin in until it is flush with the fastener head. 8. Install the panel.
U5VY10E0.book Page 40 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24360 Front wheel EAU34590 To remove the front wheel EWA10820 3. Remove the brake hose holder and reflector on each side by removing the bolt and nut. 4. Remove the brake caliper on each side by removing the bolts. WARNING ● ● It is advisable to have a Yamaha dealer service the wheel. Securely support the motorcycle so that there is no danger of it falling over. 1. Wheel axle ECA11050 CAUTION: 1.
U5VY10E0.book Page 41 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: Make sure that there is enough space between the brake pads before installing the brake calipers onto the brake discs. Tightening torque: Brake caliper bolt: 35 Nm (3.5 m·kgf, 25 ft·lbf) 5. Install the brake hose holders and reflectors by installing the bolts and nuts. 6. Secure the wheel axle by installing the axle bolt, and then tightening the axle bolt to the specified torque.
U5VY10E0.book Page 42 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25080 Rear wheel EAU25311 To remove the rear wheel EWA10820 WARNING ● ● It is advisable to have a Yamaha dealer service the wheel. Securely support the motorcycle so that there is no danger of it falling over. 1. Loosen the axle nut. 6 1. 2. 3. 4. 5. Axle nut Drive chain slack adjusting bolt Locknut Brake caliper Brake caliper bracket 2.
U5VY10E0.book Page 43 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR ● Make sure that there is enough space between the brake pads before installing the wheel. 1. Retainer 2. Slot 2. Install the drive chain onto the rear sprocket. 3. Install the axle nut, and then lower the rear wheel so that it is on the ground. 4. Adjust the drive chain slack. (See page 6-25.) 5. Tighten the axle nut to the specified torque.
U5VY10E0.book Page 44 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25911 Troubleshooting charts Starting problems or poor engine performance EWA10840 WARNING Keep away open flames and do not smoke while checking or working on the fuel system. 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle.
U5VY10E0.book Page 45 Thursday, December 11, 2003 8:48 AM PERIODIC MAINTENANCE AND MINOR REPAIR Engine overheating EWA10400 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.
U5VY10E0.book Page 1 Thursday, December 11, 2003 8:48 AM MOTORCYCLE CARE AND STORAGE ucts onto seals, gaskets, sprockets, the drive chain and wheel axles. Always rinse the dirt and degreaser off with water. EAU26020 Care While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used.
U5VY10E0.book Page 2 Thursday, December 11, 2003 8:48 AM MOTORCYCLE CARE AND STORAGE den part of the windshield to make sure that it does not leave any marks. If the windshield is scratched, use a quality plastic polishing compound after washing. After normal use Remove dirt with warm water, a mild detergent, and a soft, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bottlebrush for hard-to-reach areas.
U5VY10E0.book Page 3 Thursday, December 11, 2003 8:48 AM MOTORCYCLE CARE AND STORAGE 4. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces. 5. Use spray oil as a universal cleaner 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.
U5VY10E0.book Page 4 Thursday, December 11, 2003 8:48 AM MOTORCYCLE CARE AND STORAGE 3. Perform the following steps to protect the cylinders, piston rings, etc. from corrosion. a. 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 sparking during the next step.) d.
U5VY10E0.book Page 1 Thursday, December 11, 2003 8:48 AM SPECIFICATIONS Dimensions: Overall length: 2065 mm (81.3 in) Overall width: 720 mm (28.3 in) Overall height: 1105 mm (43.5 in) Seat height: 835 mm (32.9 in) Wheelbase: 1395 mm (54.9 in) Ground clearance: 135 mm (5.31 in) Minimum turning radius: 3400 mm (133.9 in) Weight: With oil and fuel: 193.0 kg (425 lb) (U49) 194.
U5VY10E0.book Page 2 Thursday, December 11, 2003 8:48 AM SPECIFICATIONS 2nd: 33/16 (2.063) 3rd: 37/21 (1.762) 4th: 35/23 (1.522) 5th: 30/22 (1.364) 6th: 33/26 (1.269) Chassis: Frame type: Diamond Caster angle: 24.00 ° Trail: 97.0 mm (3.
U5VY10E0.book Page 3 Thursday, December 11, 2003 8:48 AM SPECIFICATIONS Electrical system: Ignition system: Transistorized coil ignition (digital) Charging system: A.C. magneto Battery: Model: YTZ10S Voltage, capacity: 12 V, 8.6 Ah Headlight: Bulb type: Halogen bulb Bulb voltage, wattage x quantity: 8 Headlight: 12 V, 55.0 W × 4 Tail/brake light: LED Front turn signal/position light: 12 V, 21 W/5.0 W × 2 Rear turn signal light: 12 V, 21.0 W × 2 Auxiliary light: 12 V, 5.
U5VY10E0.book Page 1 Thursday, December 11, 2003 8:48 AM CONSUMER INFORMATION EAU26351 Identification numbers EAU26381 EAU26400 Key identification number Vehicle identification number 1. Key identification number 1. Vehicle identification number The key identification number is stamped into the key tag. Record this number in the space provided and use it for reference when ordering a new key. The vehicle identification number is stamped into the steering head pipe.
U5VY10E0.book Page 2 Thursday, December 11, 2003 8:48 AM CONSUMER INFORMATION EAU33940 Model label 1. Muffler bracket 1. Model label The model label is affixed to the frame under the passenger seat. (See page 3-15.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer. EWA12370 WARNING 9 Do not touch the muffler bracket until the exhaust system has cooled.
U5VY10E0.book Page 3 Thursday, December 11, 2003 8:48 AM CONSUMER INFORMATION EAU26550 Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A.
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U5VY10E0.book Page 5 Thursday, December 11, 2003 8:48 AM CONSUMER INFORMATION EAU26631 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required. It is not acceptable proof of maintenance work.
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U5VY10E0.book Page 7 Thursday, December 11, 2003 8:48 AM CONSUMER INFORMATION EAU26661 YAMAHA MOTOR CORPORATION, U.S.A.
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U5VY10E0.book Page 9 Thursday, December 11, 2003 8:48 AM CONSUMER INFORMATION EAU26750 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.). In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost.
U5VY10E0.book Page 10 Thursday, December 11, 2003 8:48 AM CONSUMER INFORMATION We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your Yamaha Limited Warranty expires. A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need. Yamaha Service Marketing P.O.
U5VY10E0.book Page 1 Thursday, December 11, 2003 8:48 AM INDEX A Front fork, adjusting ..............................3-17 Front fork, checking...............................6-29 Fuel .......................................................3-14 Fuel level warning light............................3-3 Fuel tank cap.........................................3-13 Fuses, replacing....................................6-32 Air filter element, replacing ................... 6-16 Auxiliary light bulb, replacing .......
U5VY10E0.book Page 2 Thursday, December 11, 2003 8:48 AM INDEX Troubleshooting charts ......................... 6-44 Turn signal indicator lights ...................... 3-2 Turn signal light bulb, replacing ............ 6-37 Turn signal switch ................................. 3-11 V Valve clearance, adjusting .................... 6-18 Vehicle identification number .................. 9-1 W Warranty, extended................................. 9-9 Warranty, limited .....................................
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OWNER’S MANUAL YZF-R1S(C) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.12-5.
