Yamaha Yzfr1P Yzfr1Pc 2002 Service Manual & Yzf-R1P(C) Assembly Manual & User Guide (MT016641)

Yamaha Yzfr1P Yzfr1Pc 2002 Service Manual & Yzf-R1P(C) Assembly Manual & User Guide (MT016641)

• This manual presented for you in electronic format you can just print out the page you need then dispose of it when you have completed your task. This manual has detailed illustrations as well as step by step written instructions with the necessary diagrams or pictures. These manuals are your number one source for repair and service information, specifically written for the do-it-yourself as well as the experienced mechanics worldwide used to use this factory manual to fix your vehicle. Using this repair manual is an inexpensive way to keep your car working properly. it is this level of detail, along with illustrations, that guide the reader through each service, repairs, maintenance procedure.
• Yamaha_YZFR1P_YZFR1PC_2002_Service_Manual &_YZF-R1P(C)_Assembly_Manual & user Guide

  Yamaha_YZFR1P_YZFR1PC_2002_Service_Manual
  
  Pages 439

  GENERAL INFORMATION
  
  MOTORCYCLE IDENTIFICATION
  
  VEHICLE IDENTIFICATION NUMBER -MODEL LABEL –
  
  FEATURES
  
  OUTLINE OF FI SYSTEM -FI SYSTEM -COMPONENTS -FUEL INJECTION SYSTEM -THREE-WAY CATALYTIC CONVERTER SYSTEM -INSTRUMENT FUNCTION –
  
  IMPORTANT INFORMATION
  
  PREPARATION FOR REMOVAL AND DISASSEMBLY -REPLACEMENT PARTS -GASKETS, OIL SEALS AND O-RINGS -LOCK WASHERS/PLATES AND COTTER PINS -BEARINGS AND OIL SEALS -CIRCLIPS –
  
  CHECKING THE CONNECTIONS -SPECIAL TOOLS

  CHAPTER 1
  
  SPECIFICATIONS
  
  GENERAL SPECIFICATIONS -ENGINE SPECIFICATIONS -CHASSIS SPECIFICATIONS -ELECTRICAL SPECIFICATIONS -CONVERSION TABLE -TIGHTENING TORQUES -GENERAL TIGHTENING TORQUE SPECIFICATIONS -ENGINE TIGHTENING TORQUES -CHASSIS TIGHTENING TORQUES -LUBRICATION POINTS AND LUBRICANT TYPES ENGINE -CHASSIS -COOLING SYSTEM DIAGRAMS -ENGINE OIL LUBRICATION CHART -LUBRICATION DIAGRAMS -CABLE ROUTING

  CHAPTER 2
  
  PERIODIC CHECKS AND ADJUSTMENTS-INTRODUCTION -PERIODIC MAINTENANCE CHART
  
  FOR THE EMISSION CONTROL SYSTEM -GENERAL MAINTENANCE AND LUBRICATION CHART –
  
  SEATS -FUEL TANK –
  
  REMOVING THE FUEL TANK -REMOVING THE FUEL PUMP -INSTALLING THE FUEL PUMP -INSTALLING THE FUEL HOSE -COWLINGS -AIR FILTER CASE -ENGINE -ADJUSTING THE VALVE CLEARANCE -SYNCHRONIZING THE THROTTLE BODIES -ADJUSTING THE ENGINE IDLING SPEED -ADJUSTING THE THROTTLE CABLE FREE PLAY -CHECKING THE SPARK PLUGS -MEASURING THE COMPRESSION PRESSURE -CHECKING THE ENGINE OIL LEVEL -CHANGING THE ENGINE OIL -ADJUSTING THE CLUTCH CABLE FREE PLAY -REPLACING THE AIR FILTER ELEMENT -CHECKING THE FUEL AND BREATHER HOSES -CHECKING THE CRANKCASE BREATHER HOSE -CHECKING THE EXHAUST SYSTEM -ADJUSTING THE EXUP CABLES -CHECKING THE COOLANT LEVEL -CHECKING THE COOLING SYSTEM -CHANGING THE COOLANT –
  
  CHASSIS -ADJUSTING THE FRONT BRAKE -ADJUSTING THE REAR BRAKE -CHECKING THE BRAKE FLUID LEVEL -CHECKING THE FRONT AND REAR BRAKE PADS -ADJUSTING THE REAR BRAKE LIGHT SWITCH –
  
  CHECKING THE FRONT AND REAR BRAKE HOSES -BLEEDING THE HYDRAULIC BRAKE SYSTEM -DJUSTING THE SHIFT PEDAL -ADJUSTING THE DRIVE CHAIN SLACK -LUBRICATING THE DRIVE CHAIN -CHECKING AND ADJUSTING THE STEERING HEAD -CHECKING THE FRONT FORK -ADJUSTING THE FRONT FORK LEGS -ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY -CHECKING THE TIRES -CHECKING THE WHEELS -CHECKING AND LUBRICATING THE CABLES -LUBRICATING THE LEVERS AND PEDALS –
  
  LUBRICATING THE SIDESTAND -LUBRICATING THE REAR SUSPENSION
  
  ELECTRICAL SYSTEM –
  
  CHECKING AND CHARGING THE BATTERY -CHECKING THE FUSES -REPLACING THE HEADLIGHT BULBS –
  
  ADJUSTING THE HEADLIGHT BEAM

  CHAPTER 3
  
  CHASSIS
  
  FRONT WHEEL AND BRAKE DISCS –
  
  FRONT WHEEL -REMOVING THE FRONT WHEEL -CHECKING THE FRONT WHEEL -CHECKING THE BRAKE DISCS -INSTALLING THE FRONT WHEEL -ADJUSTING THE FRONT WHEEL STATIC BALANCE –
  
  REAR WHEEL AND BRAKE DISC –
  
  REAR WHEEL -REMOVING THE REAR WHEEL -CHECKING THE REAR WHEEL -CHECKING THE REAR WHEEL DRIVE HUB -CHECKING AND REPLACING THE REAR WHEEL SPROCKET -INSTALLING THE REAR WHEEL –
  
  ADJUSTING THE REAR WHEEL STATIC BALANCE –
  
  FRONT AND REAR BRAKES –
  
  FRONT BRAKE PADS -REAR BRAKE PADS -REPLACING THE FRONT BRAKE PADS -REPLACING THE REAR BRAKE PADS -FRONT BRAKE MASTER CYLINDER -REAR BRAKE MASTER CYLINDER -DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER -DISASSEMBLING THE REAR BRAKE MASTER CYLINDER -CHECKING THE FRONT-AND REAR BRAKE MASTER CYLINDERS -ASSEMBLING AND INSTALLING-THE FRONT BRAKE MASTER CYLINDER -ASSEMBLING THE REAR BRAKE MASTER CYLINDER -FRONT BRAKE CALIPERS –
  
  REAR BRAKE CALIPER -DISASSEMBLING THE FRONT BRAKE CALIPERS -DISASSEMBLING THE REAR BRAKE CALIPER -CHECKING THE FRONT AND REAR BRAKE CALIPERS -ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS -ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER –
  
  FRONT FORK –
  
  REMOVING THE FRONT FORK LEGS -DISASSEMBLING THE FRONT FORK LEGS -CHECKING THE FRONT FORK LEGS -ASSEMBLING THE FRONT FORK LEGS -INSTALLING THE FRONT FORK LEGS –
  
  HANDLEBARS –
  
  REMOVING THE HANDLEBARS -CHECKING THE HANDLEBARS -INSTALLING THE HANDLEBARS –
  
  STEERING HEAD –
  
  REMOVING THE LOWER BRACKET -CHECKING THE STEERING HEAD -INSTALLING THE STEERING HEAD –
  
  REAR SHOCK ABSORBER ASSEMBLY –
  
  HANDLING THE REAR SHOCK ABSORBER-AND GAS CYLINDER -DISPOSING OF A REAR SHOCK ABSORBER
  
  AND GAS CYLINDER -REMOVING THE REAR SHOCK ABSORBER ASSEMBLY -CHECKING THE REAR SHOCK ABSORBER ASSEMBLY -INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY –
  
  SWINGARM AND DRIVE CHAIN
  
  REMOVING THE SWINGARM -REMOVING THE DRIVE CHAIN -CHECKING THE SWINGARM -CHECKING THE DRIVE CHAIN -INSTALLING THE SWINGARM –
  
  CHAPTER 4
  
  OVERHAULING THE ENGINE
  
  ENGINE –
  
  DRIVE SPROCKET -EXHAUST PIPE -LEADS AND HOSES -ENGINE -INSTALLING THE ENGINE –
  
  CAMSHAFT –
  
  CYLINDER HEAD COVERS -CAMSHAFTS -REMOVING THE CAMSHAFTS -CHECKING THE CAMSHAFTS –
  
  CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS,-AND TIMING CHAIN GUIDES -CHECKING THE TIMING CHAIN TENSIONER -INSTALLING THE CAMSHAFTS
  
  CYLINDER HEAD –
  
  REMOVING THE CYLINDER HEAD -CHECKING THE CYLINDER HEAD -INSTALLING THE CYLINDER HEAD –
  
  VALVES AND VALVE SPRINGS –
  
  REMOVING THE VALVES -CHECKING THE VALVES AND VALVE GUIDES -CHECKING THE VALVE SEATS –
  
  CHECKING THE VALVE SPRINGS -CHECKING THE VALVE LIFTERS -INSTALLING THE VALVES –
  
  GENERATOR –
  
  REMOVING THE GENERATOR -INSTALLING THE GENERATOR –
  
  PICKUP COIL –
  
  REMOVING THE PICKUP COIL ROTOR -INSTALLING THE PICKUP COIL ROTOR –
  
  CLUTCH –
  
  CLUTCH COVER -PULL LEVER SHAFT -CLUTCH -REMOVING THE CLUTCH -CHECKING THE FRICTION PLATES -CHECKING THE CLUTCH PLATES -CHECKING THE CLUTCH HOUSING -CHECKING THE CLUTCH BOSS -CHECKING THE PRESSURE PLATE -CHECKING THE PULL LEVER SHAFT AND PULL ROD –
  
  CHECKING THE STARTER CLUTCH -INSTALLING THE CLUTCH –
  
  SHIFT SHAFT -SHIFT SHAFT AND STOPPER LEVER -CHECKING THE SHIFT SHAFT -CHECKING THE STOPPER LEVER -INSTALLING THE SHIFT SHAFT
  
  OIL PAN AND OIL PUMP –
  
  OIL PUMP -REMOVING THE OIL PAN -CHECKING THE OIL PUMP -CHECKING THE RELIEF VALVE –
  
  CHECKING THE OIL DELIVERY PIPES -CHECKING THE OIL STRAINER -ASSEMBLING THE OIL PUMP –
  
  INSTALLING THE OIL PUMP -INSTALLING THE OIL STRAINER -INSTALLING THE OIL PAN –
  
  CRANKCASE -DISASSEMBLING THE CRANKCASE -CHECKING THE CRANKCASE -CHECKING THE BEARINGS AND OIL SEALS -CHECKING THE SPROCKET AND CHAINS -ASSEMBLING THE CRANKCASE –
  
  CONNECTING RODS AND PISTONS –
  
  REMOVING THE CONNECTING RODS AND PISTONS -REMOVING THE CRANKSHAFT ASSEMBLY -CHECKING THE CYLINDER AND PISTONS -CHECKING THE PISTON RINGS -CHECKING THE PISTON PINS -CHECKING THE BIG END BEARINGS -INSTALLING THE CONNECTING ROD AND PISTON –
  
  CRANKSHAFT –
  
  CHECKING THE CRANKSHAFT -CHECKING THE CRANKSHAFT JOURNAL BEARINGS -INSTALLING THE CRANKSHAFT –
  
  TRANSMISSION –
  
  REMOVING THE TRANSMISSION -CHECKING THE SHIFT FORKS -CHECKING THE SHIFT DRUM ASSEMBLY –
  
  CHECKING THE TRANSMISSION -INSTALLING THE TRANSMISSION

  CHAPTER 5
  
  COOLING SYSTEM
  
  RADIATOR –
  
  CHECKING THE RADIATOR -INSTALLING THE RADIATOR –
  
  OIL COOLER –
  
  CHECKING THE OIL COOLER -INSTALLING THE OIL COOLER –
  
  THERMOSTAT –
  
  CHECKING THE THERMOSTAT -ASSEMBLING THE THERMOSTAT ASSEMBLY -INSTALLING THE THERMOSTAT ASSEMBLY –
  
  WATER PUMP –
  
  DISASSEMBLING THE WATER PUMP -CHECKING THE WATER PUMP -ASSEMBLING THE WATER PUMP –

  CHAPTER 6
  
  FUEL INJECTION SYSTEM
  
  FUEL INJECTION SYSTEM –
  
  WIRING DIAGRAM -ECU‘S SELF-DIAGNOSTIC FUNCTION -SUBSTITUTE CHARACTERISTICS OPERATION CONTROL-(FAIL-SAFE ACTION) -FAIL-SAFE ACTIONS TABLE -TROUBLESHOORING CHART –
  
  DIAGNOSTIC MODE -TROUBLESHOOTING DETAILS –
  
  THROTTLE BODIES –
  
  CHECKING THE INJECTOR -CHECKING THE THROTTLE BODY -CHECKING THE PRESSURE REGULATOR –
  
  CHECKING THE FUEL PUMP-AND PRESSURE REGULATOR OPERATION -CHECKING AND ADJUSTING
  
  THE THROTTLE POSITION SENSOR –
  
  AIR INDUCTION SYSTEM
  
  AIR INDUCTION -AIR CUT-OFF VALVE -AIR INDUCTION SYSTEM DIAGRAMS -CHECKING THE AIR INDUCTION SYSTEM –

  CHAPTER 7
  
  ELECTRICAL
  
  ELECTRICAL COMPONENTS –
  
  CHECKING SWITCH CONTINUITY –
  
  CHECKING THE SWITCHES –
  
  CHECKING THE BULBS AND BULB SOCKETS –
  
  TYPES OF BULBS -CHECKING THE CONDITION OF THE BULBS -CHECKING THE CONDITION OF THE BULB SOCKETS -CHECKING THE LEDS –
  
  IGNITION SYSTEM –
  
  CIRCUIT DIAGRAM -TROUBLESHOOTING –
  
  ELECTRIC STARTING SYSTEM –
  
  CIRCUIT DIAGRAM -STARTING CIRCUIT CUT-OFF SYSTEM OPERATION -TROUBLESHOOTING –
  
  STARTER MOTOR -CHECKING THE STARTER MOTOR -ASSEMBLING THE STARTER MOTOR –
  
  CHARGING SYSTEM –
  
  CIRCUIT DIAGRAM -TROUBLESHOOTING –
  
  LIGHTING SYSTEM –
  
  CIRCUIT DIAGRAM -TROUBLESHOOTING -CHECKING THE LIGHTING SYSTEM –
  
  SIGNALING SYSTEM –
  
  CIRCUIT DIAGRAM -TROUBLESHOOTING -CHECKING THE SIGNALING SYSTEM
  
  COOLING SYSTEM –
  
  CIRCUIT DIAGRAM -TROUBLESHOOTING –
  
  FUEL PUMP SYSTEM –
  
  CIRCUIT DIAGRAM -FUEL PUMP SYSTEM -TROUBLESHOOTING -CHECKING THE FUEL PUMP –

  CHAPTER 8
  
  TROUBLESHOOTING
  
  STARTING FAILURES –
  
  ENGINE -FUEL SYSTEM -ELECTRICAL SYSTEMS –
  
  INCORRECT ENGINE IDLING SPEED –
  
  ENGINE -FUEL SYSTEM -ELECTRICAL SYSTEMS –
  
  POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE –
  
  ENGINE -FUEL SYSTEM –
  
  FAULTY GEAR SHIFTING –
  
  SHIFTING IS DIFFICULT -SHIFT PEDAL DOES NOT MOVE -JUMPS OUT OF GEAR –
  
  FAULTY CLUTCH –
  
  CLUTCH SLIPS -CLUTCH DRAGS –
  
  OVERHEATING –
  
  ENGINE -COOLING SYSTEM -FUEL SYSTEM -CHASSIS -ELECTRICAL SYSTEMS –
  
  OVERCOOLING –
  
  COOLING SYSTEM –
  
  POOR BRAKING PERFORMANCE –
  
  FAULTY FRONT FORK LEGS –
  
  LEAKING OIL -MALFUNCTION –
  
  UNSTABLE HANDLING –
  
  FAULTY LIGHTING OR SIGNALING SYSTEM –
  
  HEADLIGHT DOES NOT COME ON -HEADLIGHT BULB BURNT OUT -TAIL/BRAKE LIGHT DOES NOT COME ON TAIL/BRAKE LIGHT BULB BURNT OUT -TURN SIGNAL DOES NOT COME ON -TURN SIGNAL BLINKS SLOWLY
  
  TURN SIGNAL REMAINS LIT -TURN SIGNAL BLINKS QUICKLY -HORN DOES NOT SOUND –
  
  CONSUMER INFORMATION
  
  Yamaha_YZF-R1P(C)_Assembly_Manual
  
  Pages 135
  
  GENERAL INFORMATION
  
  MOTORCYCLE IDENTIFICATION
  
  IDENTIFICATION NUMBERS –
  
  KEY IDENTIFICATION NUMBER –
  
  VEHICLE IDENTIFICATION NUMBER –
  
  MODEL LABEL –
  
  REPORTING SAFETY DEFECTS –
  
  MOTORCYCLE NOISE REGULATION –
  
  MAINTENANCE RECORD –

  DESCRIPTION

  LEFT VIEW –
  
  RIGHT VIEW –
  
  CONTROLS AND INSTRUMENTS –
  
  INSTRUMENT AND CONTROL FUNCTIONS
  
  MAIN SWITCH/STEERING LOCK -INDICATOR AND WARNING LIGHTS -MULTI-FUNCTION DISPLAY -TACHOMETER -HANDLEBAR SWITCHES -CLUTCH LEVER -SHIFT PEDAL -BRAKE LEVER -BRAKE PEDAL –
  
  FUEL TANK CAP -FUEL -CATALYTIC CONVERTER -SEATS -HELMET HOLDERS -STORAGE COMPARTMENT
  
  ADJUSTING THE FRONT FORK -ADJUSTING THE SHOCK ABSORBER ASSEMBLY -LUGGAGE STRAP HOLDERS -EXUP SYSTEM -SIDESTAND -IGNITION CIRCUIT CUT-OFF SYSTEM –
  
  PRE-OPERATION CHECKS

  PRE-OPERATION CHECK LIST –
  
  OPERATION AND IMPORTANT RIDING POINTS

  STARTING AND WARMING UP A COLD ENGINE –
  
  SHIFTING –
  
  ENGINE BREAK-IN –
  
  PARKING –
  
  PERIODIC MAINTENANCE AND MINOR REPAIR
  
  PERIODIC MAINTENANCE –
  
  OWNER‘S TOOL KIT –
  
  PERIODIC MAINTENANCE CHART FOR THE EMISSION
  
  CONTROL SYSTEM –
  
  GENERAL MAINTENANCE AND LUBRICATION CHART –
  
  REMOVING AND INSTALLING COWLINGS AND PANELS –
  
  CHECKING THE SPARK PLUGS –
  
  CANISTER (FOR CALIFORNIA ONLY) –
  
  ENGINE OIL AND OIL FILTER CARTRIDGE –
  
  COOLANT –
  
  REPLACING THE AIR FILTER ELEMENT –
  
  ADJUSTING THE THROTTLE CABLE FREE PLAY –
  
  ADJUSTING THE VALVE CLEARANCE –
  
  TIRES –
  
  CAST WHEELS –
  
  ACCESSORIES AND REPLACEMENT PARTS –
  
  ADJUSTING THE CLUTCH LEVER FREE PLAY –
  
  ADJUSTING THE BRAKE PEDAL POSITION –
  
  ADJUSTING THE REAR BRAKE LIGHT SWITCH –
  
  CHECKING THE FRONT AND REAR BRAKE PADS –
  
  CHECKING THE BRAKE FLUID LEVEL –
  
  CHANGING THE BRAKE FLUID –
  
  DRIVE CHAIN SLACK –
  
  LUBRICATING THE DRIVE CHAIN –
  
  CHECKING AND LUBRICATING THE CABLES –
  
  CHECKING AND LUBRICATING THE THROTTLE
  
  GRIP AND CABLE –
  
  CHECKING AND LUBRICATING THE BRAKE AND
  
  CLUTCH LEVERS –
  
  LUBRICATING THE BRAKE PEDAL –
  
  CHECKING AND LUBRICATING THE SIDESTAND –
  
  CHECKING THE FRONT FORK –
  
  CHECKING THE STEERING –
  
  CHECKING THE WHEEL BEARINGS –
  
  BATTERY –
  
  REPLACING THE FUSES –
  
  REPLACING A HEADLIGHT BULB –
  
  TAIL/BRAKE LIGHT –
  
  REPLACING A TURN SIGNAL LIGHT BULB –
  
  REPLACING THE LICENSE PLATE LIGHT BULB –
  
  SUPPORTING THE MOTORCYCLE –
  
  FRONT WHEEL –
  
  REAR WHEEL –
  
  TROUBLESHOOTING –
  
  TROUBLESHOOTING CHARTS –
  
  MOTORCYCLE CARE AND STORAGE

  CARE –
  
  STORAGE –
  
  SPECIFICATIONS

  SPECIFICATIONS –
  
  CONSUMER INFORMATION

  IDENTIFICATION NUMBERS –
  
  KEY IDENTIFICATION NUMBER –
  
  VEHICLE IDENTIFICATION NUMBER –
  
  MODEL LABEL –
  
  REPORTING SAFETY DEFECTS –
  
  MOTORCYCLE NOISE REGULATION –
  
  MAINTENANCE RECORD –
  
  YAMAHA MOTOR CORPORATION, USA STREET AND
  
  ENDURO MOTORCYCLE LIMITED WARRANTY –
  
  YAMAHA EXTENDED SERVICE (YES) –

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