2002 to 2003 Yamaha YZF-R1 5PW Specs

Yamaha

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Yamaha YZF-R1

Yamaha YZF-R1 5PW specs…..

The Yamaha YZF-R1 5PW was a fully faired sports bike manufactured between 2002 and 2003 (in the UK). The R1 had a 998cc inline 4 cylinder engine and was the 1st of the R1s to use a fuel injection system (earlier models used carbs). The 5PW model also had a black frame (earlier models had a silver frame) and a slim, LED rear tail light as standard.

5PW LED rear light
Yamaha R1 5PW LED rear light

The 2002 model also included numerous minor engine mods (inc new and improved cylinder sleeves), a new Deltabox frame and a new 4 into 2 into 1 exhaust with a catalytic converter and titanium exhaust headers.
In February 2004 the bike was replaced by the redesigned R1 5VY model.

Basic model info…

Manufacturer: Yamaha
Model: YZF-R1
Yamaha model code: 5PW
CC: 998cc
Engine type: Inline 4 cylinder (4 stroke)
Years in production: 2002 to 2003
Style of bike: Fully faired sports bike
Insurance: Group 17 (of 17 – Estimated) – Need an insurance quote before you buy one? Try Confused.com
Preceded by: 2000 to 2001 YZF-R1 (5JJ model)
Succeeded by: 2004 to 2006 YZF-R1 (5VY model)
ULEZ compliance: NOT ULEZ compliant (so don’t waste money on a cert of conformity!)
Yamaha R1 headlight
Yamaha R1 headlight on
Headlight from a 2002 R1 shown both in and out of the fairing

Models and years (in the UK)

YZF-R1 (Jan 2002 to Jan 2003)…..
Model code: 5PW
Description: 998cc Sports bike updated from the previous (5JJ) model with fuel injection system, LED rear light, black, Deltabox III frame, numerous engine mods, 4 into 2 into 1 exhaust system with titanium headers and all new bodywork.
Available colours: Blue/white, red/white or silver
Cost new: £8899
YZF-R1 (Feb 2003 to Jan 2004)…..
Model code: 5PW
Description: Same as above model.
Available colours: Blue/white, red/white or silver
Cost new: £8399
YZF-R1 front
YZF-R1 left front/side
YZF-R1 left side
YZF-R1 left rear/side
YZF-R1 rear
YZF-R1 right rear/side
YZF-R1 right side
YZF-R1 right front/side
360 degree View of a 2002 YZF-R1 in silver

Engine and gearbox stuff…..

Displacement: 998 cc
Engine type: Inline 4 cylinder (4 stroke)
Number of cylinders: 4
Cylinder compression: Normal (standard): 1450kpa (206psi)
Minimum: 1350kpa (192psi)
Maximum: 1500kpa (213psi)
Piston to bore clearance: 0.010 to 0.035mm – Maximum: 0.12mm
Bore and stroke: 74mm x 58mm
Compression ratio: 11.8 : 1
Engine idle speed: 1000 to 1100rpm
Cam shaft configuration: Double overhead cam (DOHC)
Valves: 20 valves (5 valves per cylinder)
Valve clearance (inlet): 0.0010 to 0.0037mm (when cold)
Valve clearance (exhaust): 00.020 to 0.047mm (when cold)
Cooling system: Liquid cooled
Clutch: Wet multi plate clutch – EBC part no: CK2350 for the clutch and CSK903 for the springs (don’t forget a clutch tool to hold it!)
Clutch cable free play: 10 to 15mm
Gearbox: 6 Speed, manual clutch (1st gear down, 2nd to 6th gear up. Neutral between 1st and 2nd gears)
Gearbox oil: From engine (doesn’t need a separate gearbox oil)
Power: 152 bhp
Torque: 104.9 nm
Top speed (estimated): 167 mph
0 to 60 time (estimated): 2.9 seconds
Final drive: Chain drive
YZF-R1 fuel pump
2002 YZF-R1 fuel pump (normally mounted inside the petrol tank)
YZF-R1 throttle bodies
2002 YZF-R1 throttle bodies

Carb, fuel and oil stuff…..

Fuel system: Fuel injection
Throttle bodies: 4 x Mikuni 40EIS
Fuel injectors: 4 x Nippon INP-731
Throttle cable free play: 3 to 5mm
Throttle stop/idling screw location: Left side, just above the front sprocket cover
Idle speed: 1000 to 1100 rpm
Fuel type: Unleaded petrol
Fuel pump type: Electric (mounted inside the fuel tank)
Fuel output pressure: 94kpa (42.6psi)
Fuel tank capacity: 17 litres (including 3.3 litres reserve)
Lubrication: Wet sump
Engine oil type: 10w40 Motorcycle oil

Note: You can use any semi or fully synthetic oil in the YZF-R1 engine. Although fully synthetic is the best and will offer the best protection for your engine, we normally recommend a good quality semi synth as it’s a good balance between engine protection and price (we DON’T recommend mineral oils or car oils in sports bike engines!). More info…

Engine oil capacity (total after engine stripdown): 3.8 litres
Engine oil capacity (oil change including filter): 3.1 litres
Engine oil capacity (oil change only without filter change): 2.9 litres
Oil filter: Hiflo HF303 / Filtrex OIF006
Oil filter type: Cartridge
Oil pump: Trochoid type oil pump

Note: A Trochoid oil pump has an inner and outer rotor with different numbers of teeth (e.g. the outer rotor can have 5 teeth and the inner can have 4 teeth). The difference in teeth creates uneven spaces inside the pump which causes the oil to move to fill the gaps as the inner rotor rotates (example below, not from a Yamaha engine).

Trochoid pump

Unfortunately, these pumps do suffer from pitting if the incorrect oil has been used in the engine (e.g. car oil or a car based bike oil).

Air filter: Hiflo part no: HFA4916
Air filter type: Element (wet)
10w40 oil
10w40 Semi-synthetic oil
02 to 03 YZF-R1 oil filter
2002 to 2003 YZF-R1 oil filter (Hiflo HF303)

Electric stuff…..

Ignition type: Transistorized coil ignition (CDI/ECU)
Starter: Electric start
Electrical system voltage: 12 volts
Electrical system capacity: 35 amps (through the rectifier)
Normal system output: 14 volts / 32 amps at 5,000 rpm
Regulated voltage (with engine running): 14.1 to 14.9 volts
Spark plug: 4 x NGK CR9EIA-9
Spark plug gap: 0.8 to 0.9mm
Spark plug torque: 13nm
Spark plug ignition: 4 x combined spark plug cap and coil
Fuse box fuses
Main fuse: 50 Amp (1x)
Fuel injection and Headlight fuse: 15 Amp (1x)
Signalling system fuse: 20 Amp (1x)
Ignition fuse: 15 Amp (1x)
Radiator fan motor fuse: 15 Amp (1x)
Backup clock/speedo fuse: 5 Amp (1x)
Spare fuses: 20 Amp, 15 amp and 5 amp (1 of each)
Battery
Battery type: YT12B-4 / CT12B-4 (also known as YT12B-BS / CT12B-BS) / Gel filled battery

Notes:

  • The YT12B-4 (aka YT12B-BS) battery is a lead acid 12 volt, 10.5 amp/hour battery and is length: 151mm width: 70mm height: 130mm in size (more info…).
  • The 1st letter(s) of the battery reference code are a manufacturers reference mark and may vary between different battery makes (different battery manufacturers use different 1st letters), so CT12B-4, YT12B-4 and ET12B-4 are all the same battery just from different manufacturers (more info…).
  • Just to make battery reference codes more confusing, this battery is also know as a YT12B-BS battery (so YT12B-4, YT12B-BS, CT12B-BS etc are also all the same battery).
  • Also…… I would personally recommend avoiding buying the cheapest of the cheap type batteries online as they have a horrendous failure rate (and they can be a bug!er to post back when it fails as Royal Mail and alot of couriers won’t accept batteries now).
Battery location: Under the riders seat
Bolts securing riders seat
If you pull back the rear corners of the seat you’ll find 2 allen bolts that hold the seat in place
Yamaha R1 battery under seat
Battery mounted under the riders seat
Yamaha R1 battery
CT12B-4 Gel battery for the Yamaha R1 5PW
Yamaha R1 shock absorber
2002 YZF-R1 rear shock with rebound and compression adjustment

Shocks, brakes and wheels stuff…..

Front wheel type: 3 Spoke cast wheel (aluminum rim)
Front tyre size: 120/70-17 (tubeless)
Front tyre pressure: 36 psi (2.5 bar)
Min tread depth: 1.6mm
Rear wheel type: 3 Spoke cast wheel (aluminum rim)
Rear tyre size: 190/55-17 (tubeless)
Rear tyre pressure: 42psi (2.9 bar)
Min tread depth: 1.6mm
Front brake: Dual hydraulic disc brake with calipers
Activated by: Lever on right handle bar
Front caliper type: Hydraulic 4 pot (x2)
Front brake discs: Disc brake MD2074X (EBC) x 2 (1 for each side)
Front brake disc diameter: 298mm
Front brake disc thickness: 5mm
Front brake pads: EBC FA252 (x 2 sets)
Rear brake: Single hydraulic disc brake with caliper
Activated by: Pedal under the right foot
Rear caliper type: Hydraulic 2 pot (x1)
Rear brake disc: Disc brake MD2087LS (EBC)
Rear brake disc diameter: 220mm
Rear brake disc thickness: 5mm
Rear brake pad: EBC FA275 (x 1 set)
Front Suspension: Telescopic upside down fork
Stanchion diameter: 43mm
Fork tube where the bottom fork yoke clamps attach: 54mm
Fork tube where the top fork yoke attaches: 50mm
Length (loose, unsprung): 75.5cm
Length (loose, unsprung) inc top fork adjuster: 78.5cm
Front fork travel: 120mm
Fork oil seal size: 43x55x9.5/10.5
Fork oil: 2.5w Fork oil (NOTE – Please check fork oil weight, theres alot of different opinions out there!)
Fork oil volume: 543ml (per fork)

Note: It’s easier to fill forks with a fork oil syringe

Rear Suspension: Spring, gas filled monoshock
Rear shock travel: 65mm
YZF-R1 pillion seat lock
2002 YZF-R1 rear (pillion) seat lock location (on the left side of the bike)
YZF-R1 under pillion seat
2002 YZF-R1 storage compartment under the rear/pillion seat

Final drive stuff…..

Final drive: Chain
Front sprocket: 16 teeth
Front sprocket bolt torque: 85nm (DON’T forget the locking washer tabs!)
Rear sprocket: 43 teeth
Rear sprocket bolts torque: 100nm
Chain pitch/length: 530 / 114
Chain free play: 40 to 50mm
YZF-R1 front caliper
2002 YZF-R1 4 pot front brake caliper
YZF-R1 exhaust headers
2002 YZF-R1 exhaust downpipes and EXUP servo

Weights, measures ‘n stuff…..

Length (wheelbase): 2040mm
Wheelbase: 1395mm
Height: 1105mm
Seat height: 820mm
Dry weight (no oils, fluids etc): 187kg
Wet weight (with oils, fluids etc): 193kg
Ground clearance: 140mm
Minimum turning circle: 3900mm (3.9 meters)
Maximum load (rider, gear and luggage etc): 202kg
Fuel tank capacity: 17 litres (inc 3.3 litres reserve)
R1 5PW clocks
2002 YZF-R1 5PW clocks
R1 5PW clock display
2002 YZF-R1 5PW digital clock display
R1 5PW clocks at night
2002 YZF-R1 5PW clocks at night time

Service stuff…..

Servicing your bike? You’ll need a YZF-R1 5PW Workshop Manual

Engine oil
Engine oil change frequency: Every 10000km (6214 miles) or 12 months
Engine oil type: 10w40 Motorcycle oil

Note: You can use any semi or fully synthetic oil in the YZF-R1 engine. Although fully synthetic is the best and will offer the best protection for your engine, we normally recommend a good quality semi synth as it’s a good balance between engine protection and price (we DON’T recommend mineral oils or car oils in sports bike engines!). More info…

Engine oil capacity (total after engine stripdown): 3.8 litres
Engine oil capacity (oil change including filter): 3.1 litres
Engine oil capacity (oil change only without filter change): 2.9 litres
Oil drain bolt torque: 43nm
Oil filter: Hiflo HF303 / Filtrex OIF006
Oil filter torque: 17nm
Drive chain
Lubrication: Chain lube
Drive chain lube frequency: Repeat after me……. I MUST LUBE MY CHAIN LITTLE AND OFTEN!!!….. Or use a Scottoiler
Hydraulic brake system (front and rear)
Brake fluid check: Every 10000km (6214 miles) or 12 months
Brake fluid change frequency: Every 24 months
Brake fluid: DOT 4 motorbike brake fluid
Fork oil
Front fork oil check: Every 10000km (6214 miles)
Fork oil: 2.5w Fork oil (NOTE – Please check fork oil weight, theres alot of different opinions out there!)
Fork oil volume: 543ml (per fork)
Cooling system
Coolant check frequency: Every 10000km (6214 miles) or 12 months
Coolant change frequency: Change every 36 months
Coolant system capacity: 2.45 litres
Coolant type: Motorcycle coolant

Note: Be VERY CAREFUL if your opening the radiator cap when it’s hot (steam burns aren’t fun, and I know from painful experience…… I also know why you shouldn’t smoke over an empty petrol tank, but that’s another story and my eyebrows have grown back now!)

R1 5PW radiator
2002 YZF-R1 5PW radiator

Useful torque settings…..

Camshaft sprocket: 24nm
Camshaft holder bolt: 10nm
Generator / flywheel rotor bolt: 65nm
Cylinder head cover bolt: 10nm
Clutch hub (center locking nut): 105nm
Spark plugs: 13nm
Front brake disc bolt torque: 18nm
Rear brake disc bolt torque: 18nm
Front wheel spindle: 90nm
Front wheel spindle clamp bolt: 18nm
Rear wheel spindle: 100nm
Front brake caliper bolt: 40nm
Rear brake caliper bolt: 27nm
Front fork pinch bolt (top): 26nm
Front fork pinch bolt (bottom): 26nm
Steering stem nut torque: 115nm
Rear shock mounting nut: 45nm
Shock arm to swing arm nut: 45nm
Shock link to bracket nut: 45nm
Engine oil drain bolt: 43nm
Oil filter: 17nm
Oil pressure switch: 10nm
Front sprocket bolt: 85nm
Front sprocket cover: 12nm
Rear sprocket bolts: 100nm
Side stand mounting bolts: 63nm
Rider footpeg hanger bolt: 28nm
Pillion footpeg hanger bolt: 28nm
YZF-R1 Lockset
2002 Yamaha R1 5PW lockset (ignition, tank and seat locks and key)

Frame number location…..

The frame number is usually stamped onto the right side of the headstock (the front part of the frame just below the handle bars).

YZF-R1 5PW front indicator
Yamaha YZF-R1 5PW built in front indicator

Useless stuff and buying advice…..

Firstly, if your thinking of buying one always HPI check it! The R1 was a highly sought after sports bike with a ‘bad boy’ image so there were loads of stolen ones out there.
The 02 to 03 R1 was a fairly solid and reliable bike, but, due to it’s nature (1000cc sports bike) there are loads of abused, raced and crashed models out there. Basically, you get what you pay for, if it’s cheap and knocking it’s probably been raced/track biked, crashed, thrashed and run on cheapo car oil, so a bike from an owner with a reasonable service history would be worth paying the extra for.
One thing to look out for and check is the charging system, the 02 to 03 R1 suffered from problematic stators (this was a problem on alot of the R1 models), they are known to fail even on low mileage, well cared for bikes so if the charging system isn’t working (or cuts out shortly after running the bike) budget for a new stator and reg/rec.
It’s also worth checking the wheels for leaks around the rims (especially the rear), as is common with older alloy wheels they can suffer from pitting which can lead to air leaks around the wheel rim. This can often (but not always) be temporarily cured by sanding the interior rim (and a good dose of bead sealer) but it will need replacing at some point if it’s leaking.
Other parts to check are fairly common on most bikes this age, upside down forks don’t like UK weather, exhausts don’t like salty roads, fuel pumps don’t last forever etc and be careful of crashed (the bike can take a knock but won’t handle if it’s bent out of shape) and raced ones (ex race bike usually have drilled sump plugs and other parts and often look alot higher mileage then the clocks read).

It’s also worth noting that the 2002 to 2003 YZF-R1 is not ULEZ compliant for riding in the center of London, the emissions are too high (we have a certificate of conformity from the bike in the pics).

2002 R1 fuel tank
2002 R1 5PW Petrol tank in silver

Thanks to 🙂

Silkolene for the service info
YZF-R1 Owners forum where we did find a link to a 02/03 Yam R1 service manual

If you’ve got any questions or useful comments or suggestions please feel free to leave them below 🙂

Disclaimer: The information on this page is correct to the best of our knowledge. But the info should NOT be taken as 100% accurate as we can, occasionally make mistakes!

2002 R1 CDI / ECU
2002 R1 CDI / ECU (Yamaha paret no: 5PW8591A00)

Looking for 02/03 Yamaha R1 parts? Used R1 5PW parts…


Comments

2 responses to “2002 to 2003 Yamaha YZF-R1 5PW Specs”

  1. Whats the 0-60 time?

    1. 2.9 seconds according to the specs (most riders should be able to get 3.5 secs or less)

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