Looking for 02/03 Yamaha R1 parts? Used R1 5PW spares…
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.
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!) |
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 |
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 |
2002 YZF-R1 fuel pump (normally mounted inside the petrol tank)
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 |
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| 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 |
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| Air filter: | Hiflo part no: HFA4916 |
| Air filter type: | Element (wet) |
10w40 Semi-synthetic oil
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 |
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| Battery location: | Under the riders seat |
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CT12B-4 Gel battery for the Yamaha R1 5PW
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) |
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| Rear Suspension: | Spring, gas filled monoshock |
| Rear shock travel: | 65mm |
2002 YZF-R1 rear (pillion) seat lock location (on the left side of the bike)
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 |
2002 YZF-R1 4 pot front brake caliper
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) |
2002 YZF-R1 5PW clocks
2002 YZF-R1 5PW digital clock display
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 |
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| 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 |
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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 |
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).
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 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 (Yamaha paret no: 5PW8591A00)
Looking for 02/03 Yamaha R1 parts? Used R1 5PW parts…
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