Yamaha Sports YZF-R1 (2002 European model) debuts at Milan Show Now with fuel injection and new frame for even better cornering performance

Yamaha Motor Co., Ltd. unveils its 2002 European market model of the Yamaha Sports YZF-R1 at the Milan Bicycle and Motorcycle Show that runs for eight days beginning on Sep. 18. This marks the first substantial model change in the four years since the introduction of the original YZF-R1 that won the hearts of motorcycle enthusiasts worldwide as a "super cornering machine" that set a new standard in the supersport liter bike category.

This new YZF-R1 mounts a new-spec engine that boasts improved power development characteristics, especially in the high-speed range, thanks to major changes in the intake/exhaust specifications, centering on the adoption of a fuel injection system. At the same time, the new Deltabox III frame is a further evolution of the existing Deltabox II type that achieves a roughly 30 percent improvement in torsion rigidity. What's more, a variety of other new technologies, weight reduction measures, optimization of dimensions and an overall reduction in machine weight have combined to take the YZF-R1's legendary cornering performance to yet another dimension.

Yamaha Sports YZF-R1(2002 European market model)

In the European 126cc and over sports bike market (excluding scooters) that presently has a total annual demand of about 560,000 units (projection for 2001), the supersport model category accounts for about 30 percent of the demand. In this category are numerous models that are highly representative of the unique character of the various motorcycle makers, making it a class that receives special attention for its influence on the world motorcycle market as a whole.

The YZF-R1 that debuted as a 1998 model was developed around the concept of a machine with "a 1000cc engine on a 600cc class body " and this ideal was achieved by means of a super lightweight, compact design engine mounted on the new Deltabox II frame rich in technologies straight from Yamaha's GP machines. The high-level cornering performance born of this model's balance of the three elements of performance, lightweight body and handling, won it the support of enthusiasts and since its release in '98 it has become a leading model in the European market with (sales) registrations of some 42,000 units through the year 2000.

The new YZF-R1 has been developed for fans who loved the former R1 for the exciting world of cornering performance it offered but who were also waiting for next-generation R1 with even greater handling performance in the high-speed range, with power development that is even more linear in response to the throttle and with handling performance that lets you attack the turns even more aggressively.

The guiding concept for the new R1 was a "Dynamic Cornering Performer" and the aims of the design and development work were to create "a machine that you can draw the ultimate performance out of to really enjoy aggressive cornering," and also "a machine that gives the rider an experience of cornering exhilaration through real unity of man and machine and man-machine communication."

1) First fuel injection system with free piston on a production motorcycle
The new YZF-R1 inherits the same format liquid-cooled 4-stroke, DOHC, forward-inclined, 4-cylinder 5-valve 998cc engine with forged pistons and plated cylinders and the same high-spec bore-stroke, combustion chamber shape and cam profile as the former YZF-R1, but it adds the first suction piston-fitted fuel injection system ever on a production motorcycle to achieve outstanding power development characteristics worthy of the next-generation supersport leader.

This "fuel injection with suction piston" system uses the motion of the free piston to regulate air intake flow all the way down to the low-speed range to ensure optimum air volume. What's more, microcomputer control drawing on data from the various sensors is employed to ensure optimum fuel supply with the right air/fuel mixture ratio and injection characteristics.
This makes it easier to set the optimum air/fuel mixture for the low rpm range and provides a sense of control that feels like a carburetor driven engine. It is also characterized by the fact that it makes possible better power development in the high-speed range as well.
To accommodate the new fuel injection system, the intake port has been shortened by 30 mm to optimize performance.

Furthermore, features like cylinder sleeves made of a high silicon-content aluminum alloy, carburized conrods fastened with bolts with tightening plasticity and new-design piston rings all serve to heighten reliability. Also the engine coloring has been changed from silver and black to a new low-gloss black for an even more impressive appearance.

2)New air cleaner box design
A new air cleaner box design has been adopted with the fresh-air intake duct toward the front to minimize the effects of hot air coming from the engine and thus contribute to better power development in the high rpm range. Also, the air filter was changed from a box type to a plate type. Furthermore, the funnel in the joint portion was made shorter to improve airflow and thus boost torque characteristics.

3)Lightweight titanium exhaust pipe and new muffler design, two-rod type EXUP valve
Switching to titanium material for the exhaust pipe resulted in a weight reduction of 1 kg. To increase compatibility with the fuel injection system, the existing 4-into-1 exhaust pipe format has been changed to a 4- 2- 1 format. In addition, the pipe between the collecting points of the four exhaust pipes in the muffler and the silencer has been made straighter by reducing the number of "bends" in order to reduce exhaust resistance while at the same time creating a more dynamic exterior image.

The EXUP system has been changed from one rod for four cylinders to two rods (one rod for cylinders 1 and 4 and one for 2 and 3), thus achieving a significant weight reduction and increasing action accuracy. The valves were also changed from the existing guillotine type to butterfly types that reduce valve interference with the exhaust pipe functioning. Also, by positioning the EXUP drive motor on the lower right side of the bike, it has been possible to simplify the wiring between the motor and valves and reduce wire friction loss.

4)Other engine related features
Other features related to the new-spec engine include (1) A new oil cooler design has been adopted that achieves 20 percent better cooling performance thanks to an optimization of the design of the cooling fins, (2) new-design compact radiator (new designs for the cooling fan and hoses, etc.), (3) iridium plugs for highly efficient spark transmission and (4) lightweight rare earth element ACM. What's more, a change has been made in the crank sensor of the pickup coil (4 interval ( 8 interval), in the capacity of the engine control unit and igniter unit. In addition to the changes, the shift feeling has been improved.
Yamaha's "air induction system" that cleans the exhaust by re-burning (oxidizing) the un-combusted components of the exhaust gas has also been adopted, along with a honeycomb type 3-way catalyzer that effectively cleans toxic emissions from the exhaust. As a result, "YZF-R1" achieves the values prescribed by Europe's EU2 regulation for the toxic emissions in the exhaust.

5)Deltabox III frame, a defining feature of the second generation YZF-R1
The frame adopted on this model is the newly designed aluminum frame we call the Deltabox III. The main changes include: (1) 30 percent greater body rigidity, (2) new positioning of the engine mounting and (3) separate-unit aluminum rear frame (Deltabox II has welded single-unit type), etc. Other changes include an increase in the thickness of the outer panel from 3 mm to 3.5 mm, optimization of the stock thickness used in the head assembly, a flat finish for the main frame (eliminates handlebar stop) and increased rigidity in the cross-tube portion of the pivot assembly. The change to a matte black paint finish also serves to accentuate this model's awesome performance.

The mounting position of the engine on the frame has been raised 20mm and mass concentrated in relation to the rolling axis of the rider and machine, making for quicker banking action and more linear handling response. In addition, detailed reviews of each component and dimension led to optimizations of all the specs except the 1395mm short wheelbase and 24-degree caster angle.

6)New large-diameter front fork
The upside-down front fork adopts larger caliber inner tubes of 43mm diameter instead of the existing 41mm. At the same time, a thinner pipe stock has been used for the inner tubes along with localized thinning of the stock of the outer tubes to achieve further weight reduction. Also, the suspension stroke has been shortened from 135 mm to 120 mm and the spring rate optimized to reduce loss during front-rear rocking of the machine. Furthermore, the front fork's offset has been reduced from 35 mm to 25 mm to reduce the inertial moment of the steering assembly.

7)Left-right asymmetrical aluminum rear arm
The aluminum rear arm has also been redesigned with a new asymmetrical configuration comprised of a delta-shaped section on the left side and an arch-shaped section on the right. This helps bring out the full advantages of the long rear arm without sacrificing the positions of engine performance-related components. Furthermore, to accommodate the new engine mounting position, the slant angle of the rear arm has been optimized (9.7 ( 11.8 degrees) to provide quicker handling response.

Also, the spring load rate of the rear suspension has been changed and the adjustment range increased along with an increase in the number of adjustment increments to allow finer adjustment for accommodating different types of riding conditions.

8)New styling to define the second generation R1
The styling image is characterized by a dynamic line that thrusts forward vibrantly from the pivot point, through the engine and out over the front wheel, for a new type of image designed to symbolize Yamaha's next-generation "Top of the Supersport Class" model. The key words for the design concept are (1) fusion of mechanisms, (2) dynamic movements and (3) alluring design.
Also, elements like the rear fender that is painted on the underside as well, similar to the fender of the YZF-R6, and a new LED taillight brings new accents to the impressive rear view.

9)Other chassis related features
Other features of the chassis include, (1) a new riding position that accentuates the overall compactness of this model (and new seat shape), (2) new seat shape (3) a single-unit handlebar made of forged aluminum and processed to reduce unnecessary thickness (formerly attached type), (4) adoption of an aluminum piston on the one-piece MOS front caliper (plus new pad material and hose layout) (5) new rear brake diameter (245 mm to 220 mm) and type caliper, (6) new three-spoke wheels with optimized plate thickness at the rim portion, (7) new drive chain (smaller plate pieces for 200g weight reduction), (8) new-design short-type front fender, (9) new-design flasher lamps with built-in reflector surface and (10) a shift indicator that indicates suitable gearshift timing by means of a lamp based on engine rpm.