2002 Yamaha YZF-R1 Maintenance Schedule and Service Intervals

This is the maintenance schedule and associated service intervals for the 2002 Yamaha YZF-R1.

2002 Yamaha YZF-R1 Maintenance Schedule

Below is the maintenance schedule for the 2002 Yamaha YZF-R1

The maintenance for the 2002 Yamaha YZF-R1 is broken into two sections: periodic maintenance for emission control systems, and general maintenance and lubrication.

Periodic Maintenance Emission Control System

No.		Item	Routine	600 mi (1,000 km) or 1 month	4000 mi (7000 km) or 6 months	8000 mi (13000 km) or 12 months	12000 mi (19000 km) or 18 months	16000 mi (25000 km) or 24 months	20000 mi (31000 km) or 30 months
1	*	Valve clearance	•Check and adjust valve clearance when engine is cold	Every 26600 mi (42000 km)
2	*	Spark plug	•Check condition •Adjust gap and clean •Replace every 8000 mi (13000 km) or 12 months		•	Replace	•	Replace	•
3	*	Crankcase ventiation system	•Check ventilation hose for cracks or damage •Replace if necessary		•	•	•	•	•
4	*	Fuel line	•Check fuel hoses and vacuum hose for cracks or damage •Replace if necessary		•	•	•	•	•
5	*	Exhaust system	•Check for leakage •Retighten if necessary •Replace gasket(s) if necessary		•	•	•	•	•
6	*	Elecronic fuel injection	•Check and adjust engine idle speed and syncronization	•	•	•	•	•	•
7	*	Evaporative emission control system (For California only)	•Check control system for damage •Replace if necessary				•		•
8	*	Air induction system	•Check the air cut valve and reed valve for damage •Replace any damaged parts if necessary		•	•	•	•	•

* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer

General Maintenance and Lubrication Chart

No.		Item	Routine	600 mi (1,000 km) or 1 month	4000 mi (7000 km) or 6 months	8000 mi (13000 km) or 12 months	12000 mi (19000 km) or 18 months	16000 mi (25000 km) or 24 months	20000 mi (31000 km) or 30 months
1		Engine oil	•Replace. (warm-up engine before draining) (See NOTE on page 6-7)	•	•	•	•	•	•
2	*	Engine oil filter cartridge	•Replace at initial 600 mi (1000 km) or 1 month, and thereafter every 8000 mi (13000 km) or 12 months	•		•		•
3	*	Air filter element	•Clean with compress air •Replace if necessary		•	•	•	•	•
4	*	Cooling system	•Check hose for cracks or damage •Replace if necessary		•	•	•	•	•
			•Replace with ethylene glycol anti-freeze coolant every 24 months					Replace
5	*	Brake system	•Check operation, pad wear, and fluid leakage. (See NOTE page 6-7) •Correct if necessary	•	•	•	•	•	•
6	*	Clutch	•Check operation •Adjust or replace cable	•	•	•	•	•	•
7	*	Control cable	•Apply Yamaha chain and chain lube or engine oil SAE 10W-30 thoroughly	•	•	•	•	•	•
8	*	Swingarm pivot bearing	•Check bearing assembly for looseness •Moderately repack with lithium-soap-based grease every 16000 mi (25000 km) or 24 months			•		• Repack
9	*	Rear suspension link pivots	•Check operation •Correct if necessary			•		•
10	*	Shock absorber assembly	•Check operation and oil leakage •Replace if necessary		•	•	•	•	•
11	*	Front fork	•Check operation and leakage •Repair if necessary		•	•	•	•	•
12	*	Steering bearings	•Check bearing assembly for looseness •Moderately repack with lithium-soap-based grease every 16000 mi (25000 km) or 24 months		•	•	•	• Repack	•
13		Brake and clutch lever pivot shafts	•Apply chain lube or lithium-soap-based grease lightly	•	•	•	•	•	•
14		Brake pedal	•Apply chain lube or lithium-soap-based grease lightly		•	•	•	•	•
15	*	Drive chain	•Check chain slack/alignment condition •Adjust and lubricate chain Yamaha chain and cable lube or engine oil SAE10W-30 thoroughly	Every 600 mi (1000 km) or after washing the motorcycle or riding the rain
16	*	Wheel bearings	•Check bearing for smooth rotation		•	•	•	•	•
17	*	Sidestand pivot	•Check operation •Apply chain lube or lithium-soap-based grease lightly		•	•	•	•	•
18	*	Sidestand switch	•Check and clean or replace if necessary	•	•	•	•	•	•
19	*	Chasis fasteners	•Check all chassis fittings and fasteners •Correct if necessary		•	•	•	•	•

* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer

Note: From 24000 mi (37000 km) or 36 months, follow the maintenance intervals starting from 4000 mi (7000 km) or 6 months

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

•Hydraulic brake system
• After disassembling the brake master cylinder and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required
• Every two years replace the internal components of the brake master cylinder and caliper and change the brake fluid
• Replace the brake hose every four years, or if cracked or damaged.

•Engine oil type

Yamalube 4 (20W40) or SAE20W40 (API SE) motor oil for temperatures 40°F (5°C) or above
Yamalube 4 (10W30) or SAE10W30 type (API SE) motor oil for temperatures 60°F (15°C) or below

About the 2002 Yamaha YZF-R1

A new fuel injection system was introduced for the 2002 year, which worked like a carburetor by employing a CV carburetor slide controlled by vacuum created by the engine. With a similar power output to the 2000-2001 bike, the engine remained largely the same. One notable improvement was the use of new cylinder sleeves of a high silicon content alloy containing magnesium that minimized heat induced distortion, reducing oil consumption. Also in 2002, Yamaha released the newly developed Deltabox frame, which, with its hydro formed construction, reduced the total number of frame welds.