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Table Of Contents - Yamaha YZF-R1(B) 2012 Service Manual

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Service manual (556 pages)

Table Of Contents

Table of Contents

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Table of Contents

Important Manual Information3

How To Use This Manual4

Table Of Contents7

General Information9

Vehicle Identification Number10

Outline Of The Fi System11

Ycc-T (Yamaha Chip Controlled Throttle) Ycc-I (Yamaha Chip Controlled Intake)13

Mechanism Characteristics13

Aims And Advantages Of Using Ycc-T System13

Aims And Advantages Of Using Ycc-I System14

Ycc-T/Ycc-I System Outline15

Ycc-T/Ycc-I Control Outline16

Outline Of The Tcs (Traction Control System)17

Tcs (Traction Control System) Layout17

Tcs (Traction Control System) Block Diagram18

Tcs (Traction Control System) Function18

Setting The Traction Control System19

Instrument Functions21

Multi-Function Meter Unit21

Clock And Stopwatch Modes22

Odometer, Tripmeter, Instantaneous Fuel Consumption And Average Fuel Consumption Modes23

Instantaneous Fuel Consumption Mode23

Transmission Gear Display24

Drive Mode Display24

Coolant Temperature Display24

Average Fuel Consumption Mode24

Air Intake Temperature Display25

Traction Control System Mode Display25

Self-Diagnosis Device25

Display Brightness And Shift Timing Indicator Light Control Mode26

To Adjust The Brightness Of The Multifunction Meter Displays And Tachometer26

To Set The Shift Timing Indicator Light Activity Function26

D-Mode (Drive Mode)27

To Set The Shift Timing Indicator Light Activation Function27

To Set The Shift Timing Indicator Light Deactivation Function27

Important Information29

Preparation For Removal And Disassembly29

Replacement Parts29

Gaskets, Oil Seals And O-Rings29

Lock Washers/Plates And Cotter Pins29

Bearings And Oil Seals30

Checking The Connections31

Handling The Electronic Parts32

Special Tools33

Specifications41

General Specifications42

Engine Specifications43

Chassis Specifications50

Electrical Specifications53

Tightening Torques56

General Tightening Torque Specifications56

Engine Tightening Torques57

Cylinder Head Nut60

Connecting Rod Cap Bolt60

Crankcase Bolt (Main Journal)60

Chassis Tightening Torques61

Lower Bracket Pinch Bolt63

Front Wheel Axle Pinch Bolt63

Lubrication Points And Lubricant Types65

Lubrication System Chart And Diagrams68

Engine Oil Lubrication Chart68

Lubrication Diagrams70

Cooling System Diagrams86

Cable Routing90

Periodic Checks And Adjustments117

Introduction120

Periodic Maintenance Chart For The Emission Control System120

General Maintenance And Lubrication Chart121

Checking The Fuel Line (Primary Injectior)123

Checking The Fuel Line (Secondary Injector)123

Checking The Spark Plugs123

Adjusting The Valve Clearance124

Valve Lapper127

Synchronizing The Throttle Bodies128

Checking The Throttle Body Synchronization128

Adjusting The Throttle Body Synchronization129

Checking The Throttle Body Joints130

Checking The Exhaust System130

Checking The Crankcase Breather Hose130

Adjusting The Exhaust Gas Volume131

Checking The Air Induction System132

Replacing The Air Filter Element132

Adjusting The Clutch Cable Free Play133

Handlebar Side133

Checking The Brake Operation134

Checking The Brake Fluid Level134

Adjusting The Front Disc Brake135

Checking The Front Brake Pads135

Adjusting The Rear Disc Brake135

Checking The Rear Brake Pads136

Bleeding The Hydraulic Brake System136

Checking The Front Brake Hoses137

Checking The Rear Brake Hose138

Checking The Wheels138

Checking The Tires138

Checking The Wheel Bearings140

Checking The Swingarm Operation140

Adjusting The Drive Chain Slack140

Lubricating The Drive Chain141

Checking And Adjusting The Steering Head141

Checking The Steering Damper142

Checking The Chassis Fasteners142

Lubricating The Brake Lever142

Lubricating The Clutch Lever142

Lubricating The Pedal142

Adjusting The Shift Pedal143

Checking The Front Fork143

Lubricating The Sidestand143

Checking The Sidestand Switch143

Adjusting The Front Fork Legs144

Rebound Damping144

Compression Damping145

Spring Preload145

Checking The Rear Shock Absorber Assembly145

Adjusting The Rear Shock Absorber Assembly145

Compression Damping (For Fast Compression Damping)146

Compression Damping (For Slow Compression Damping)146

Checking The Engine Oil Level147

Checking The Connecting Arm And Relay Arm147

Changing The Engine Oil148

Measuring The Engine Oil Pressure149

Oil Pressure Adapter H149

Checking The Coolant Level150

Checking The Cooling System150

Changing The Coolant151

Adjusting The Rear Brake Light Switch152

Checking And Lubricating The Cables153

Adjusting The Throttle Cable Free Play153

Lubricating The Rear Suspension153

Checking And Charging The Battery153

Checking The Fuses153

Replacing The Headlight Bulbs154

Adjusting The Headlight Beams154

General Chassis160

Removing The Seats And Battery160

Removing The Side Cowlings161

Removing The Ecu And Rectifier/Regulator162

Removing The Air Ducts163

Removing The Front Cowling Assembly164

Removing The Meter And Headlight165

Removing The Rear Fender167

Disassembling The License Plate/Turn Signal Light Assembly168

Removing The Quick Fastener (Screw Type)169

Installing The Quick Fastener (Screw Type)169

Removing The Quick Fastener (Push Type)169

Installing The Quick Fastener (Push Type)169

Installing The Quick Fastener (Pull Type)170

Installing The Passenger Seat Lock Cylinder170

Removing The Front Turn Signal Lights170

Installing The Front Turn Signal Lights170

Removing The Lower Cowlings171

Installing The Lower Cowlings171

Removing The Side Cowling Inner Panels171

Installing The Side Cowling Inner Panels171

Installing The Air Chamber Covers172

Removing The Intake Air Duct Covers172

Installing The Intake Air Duct Covers172

Installing The Air Intake Ducts172

Removing The Windshield173

Installing The Windshield173

Installing The Mirror Fitting Plates173

Removing The Upper Tail Cover173

Installing The Upper Tail Cover174

Installing The Tail/Brake Light174

Adjusting The Rider Footrests174

Removing The Front Wheel And Brake Discs176

Disassembling The Front Wheel177

Removing The Front Wheel178

Checking The Front Wheel178

Maintenance Of The Front Speed Sensor And Sensor Rotor179

Adjusting Thr Front Wheel Static Balance181

Installing The Front Wheel (Front Brake Discs)182

Removing The Rear Wheel184

Removing The Brake Disc And Rear Wheel Sprocket185

Disassembling The Rear Wheel186

Checking The Rear Wheel187

Assembling The Rear Wheel188

Checking The Rear Wheel Drive Hub188

Checking And Replacing The Rear188

Adjusting The Rear Wheel Static Balance189

Installing The Rear Wheel189

Removing The Front Brake Pads190

Removing The Front Brake Master Cylinder191

Disassembling The Front Brake Master Cylinder192

Removing The Front Brake Calipers193

Disassembling The Front Brake Calipers194

Checking The Front Brake Discs195

Replacing The Front Brake Pads196

Checking The Front Brake Calipers199

Installing Teh Front Brake Calipers199

Assembling The Front Brake Calipers199

Checking The Front Brake Master Cylinder201

Assembling The Front Brake Master Cylinder201

Installing The Front Brake Master Cylinder201

Removing The Rear Brake Pads203

Removing The Rear Brake Master Cylinder204

Disassembling The Rear Brake Master Cylinder205

Removing The Rear Brake Calipers206

Disassembling The Rear Brake Caliper207

Checking The Rear Brake Disc208

Replacing The Rear Brake Pads208

Removing The Rear Brake Caliper210

Checking The Rear Brake Caliper210

Assembling The Rear Brake Caliper211

Installing The Rear Brake Caliper211

Checking The Rear Brake Master Cylinder212

Assembling The Rear Brake Master Cylinder213

Installing The Rear Brake Master Cylinder213

Removing The Handlebars215

Checking The Handlebars217

Installing The Handlebars217

Removing The Front Fork Legs220

Disassembling The Front Fork Legs221

Checking The Front Fork Legs225

Assembling The Front Fork Legs225

Installing The Front Fork Legs229

Steering Head231

Removing The Lower Bracket231

Checking The Steering Head233

Installing The Steering Head234

Rear Shock Absorber Assembly235

Removing The Rear Shock Absorber Assembly235

Handling The Rear Shock Absorber236

Disposing Of A Rear Shock Absorber236

Installing The Relay Arm237

Installing The Rear Shock Absorber Assembly237

Removing The Swingarm239

Checking The Swingarm242

Installing The Swingarm242

Removing The Drive Sprocket And Drive Chain244

Removing The Drive Chain245

Checking The Drive Chain245

Checking The Drive Sprocket246

Installing The Drive Chain246

Engine Inspection252

Measuring The Compression Pressure252

Engine Removal254

Removing The Exhaust Pipe And Muffler254

Disconnecting The Leads And Hoses257

Removing The Engine259

Installing The Engine261

Pivot Shaft Wrench Adapter261

Installing The Exhaust Pipe And Muffler262

Removing The Cylinder Head Cover264

Removing The Camshafts265

Checking The Camshafts268

Checking The Timing Chain And Sprocket269

Checking The Timing Chain Guides270

Checking The Timing Chain Tensioner270

Installing The Camshafts270

Cylinder Head275

Removing The Cylinder Head275

Checking The Cylinder Head276

Installing The Cylinder Head276

Valves And Valve Springs278

Removing The Valves And Valve Springs278

Removing The Valves280

Checking The Valves And Valve Guides281

Checking The Valve Seats282

Checking The Valve Springs284

Installing The Valves285

Checking The Valve Filters285

Removing The Generator287

Installing The Generator288

Starter Clutch290

Removing The Starter Clutch290

Checking The Starter Clutch291

Installing The Starter Clutch291

Pickup Rotor293

Removing The Pickup Rotor293

Installing The Pickup Rotor294

Electric Starter296

Removing The Starter Motor296

Disassembling The Starter Motor297

Checking The Starter Motor298

Assembling The Starter Motor299

Removing The Oil Pan And Oil/Water Pump Assembly301

Disassembling The Oil Pump303

Removing The Oil Pan304

Checking The Sprocket And Chain304

Checking The Oil Pump304

Checking The Relief Valve305

Checking The Oil Delivery Pipes305

Checking The Oil Strainer305

Assembling The Oil Pump306

Installing The Oil/Water Pump Assembly306

Installing The Oil Pan307

Removing The Clutch Cover309

Removing The Pull Lever Shaft310

Removing The Clutch311

Checking The Friction Plates314

Checking The Clutch Plates314

Checking The Clutch Springs315

Checking The Clutch Housing315

Checking The Clutch Boss316

Checking The Pressure Plate316

Checking The Primary Drive Gear316

Checking The Primary Driven Gear316

Checking The Pull Lever Shaft And Pull Rod316

Installing The Clutch316

Removing The Shift Shaft And Stopper Lever319

Checking The Shift Shaft320

Checking The Stopper Lever320

Installing The Shift Shaft320

Separating The Crankcase321

Disassembling The Crankcase323

Checking The Crankcase323

Assembling The Crankcase323

Connecting Rods And Pistons325

Removing The Connecting Rods And Pistons325

Checking The Cylinder And Piston326

Checking The Piston Rings327

Checking The Piston Pin328

Checking The Connecting Rods329

Installing The Connecting Rod And Piston332

Removing The Crankshaft336

Removing The Crankshaft And Balancer Shaft337

Checking The Oil Nozzles337

Checking The Crankshaft337

Checking The Balancer Shaft339

Installing The Crankshaft340

Installing The Balancer Assembly341

Transmission342

Removing The Transmission, Shift Drum Assembly, And Shift Forks342

Disassembling The Main Axle Assembly343

Disassembling The Drive Axle Assembly344

Removing The Transmission346

Checking The Shift Forks346

Checking The Shift Drum Assembly347

Checking The Transmission347

Assembling The Main Axle And Drive Axle348

Installing The Transmission348

Cooling System351

Removing The Radiator352

Checking The Radiator354

Installing The Radiator354

Removing The Oil Cooler356

Checking The Oil Cooler358

Installing The Oil Cooler358

Removing The Thermostat359

Checking The Thermostat361

Assembling The Thermostat Assembly361

Installing The Thermostat Assembly362

Disassembling The Water Pump363

Checking The Water Pump364

Assembling The Water Pump364

Removing The Fuel Tank And Fuel Pump368

Removing The Fuel Tank Side Covers370

Removing The Fuel Tank370

Removing The Fuel Pump370

Checking The Fuel Pump Body370

Installing The Fuel Tank371

Installing The Fuel Tank Side Covers371

Air Filter Case372

Removing The Air Filter Case And Secondary Injectors372

Checking The Secondary Injectors (Before Removing)374

Removing The Fuel Hose (Primary Injector Joint Side And Secondary Injector Joint Side)374

Removing The Secondary Injectors374

Removing The Lower Air Filter Case375

Removing The Intake Funnel Assembly375

Checking The Secondary Injectors375

Checking The Air Filter Case Seal376

Checking The Intake Funnel376

Installing The Intake Funnel And Lower Air Filter Case376

Checking The Intake Funnel Operation376

Installing The Secondary Injectors377

Installing The Upper Air Filter Case377

Installing The Fuel Hose (Primary Injector Joint Side And Secondary Injector Joint Side)378

Throttle Bodies379

Removing The Throttle Body Assembly379

Removing The Primary Injectors381

Checking The Primary Injectors (Before Removing)382

Checking The Primary Injectors382

Checking And Cleaning The Throttle Bodies382

Installing The Primary Injectors384

Checking The Injector Pressure384

Checking The Fuel Line Pressure385

Fuel Pressure Adapter385

Adjusting The Throttle Position Sensor386

Adjusting The Accelerator Position Sensor386

Air Induction System388

Removing The Air Cut-Off Valve Assembly And Hoses390

Removing The Reed Valves391

Air Injection392

Air Cut-Off Valve392

Installing The Air Induction System393

Electrical System395

Ignition System398

Circuit Diagram398

Engine Stopping Due To Sidestand Operation400

Troubleshooting402

Electric Starting System404

Starting Circuit Cut-Off System Operation406

Charging System410

Lighting System414

Signaling System418

Cooling System Circuit Diagram426

Fuel Injection System430

Ecu Self-Diagnostic Function432

Engine Trouble Warning Light Indication And Fi System Operation432

Checking The Engine Trouble Warning Light432

Ecu Detects An Abnormal Signal From A Sensor433

Troubleshooting Method434

The Engine Operation Is Not Normal And The Engine Trouble Warning Light Comes On434

The Engine Operation Is Not Normal But The Engine Trouble Warning Light Does Not Comeon434

Diagnostic Mode435

Sensor Operation Table437

Troubleshooting Details443

Clutch Switch System Malfunction484

Fuel Pump System504

Immobilizer System508

Part Replacement And Key Code Registration Requirements511

Code Re-Registering Key Registration511

Standby Mode511

Standard Key Registration512

Voiding The Standard Key Code513

Standard Key Code Voiding Method513

Self-Diagnosis Fault Code Indication515

Immobilizer System Indicator Light Fault Code Indication516

Electrical Components518

Checking The Switches522

Checking The Bulbs And Bulb Sockets525

Types Of Bulbs525

Checking The Condition Of The Bulbs525

Checking The Condition Of The Bulb Sockets525

Charging Method Using A Variable-Current (Voltage) Charger529

Charging Method Using A Constant Voltage Charger529

Checking The Relays530

Relay Unit (Starting Circuit Cut-Off Relay)530

Starter Relay530

Checking The Turn Signal/Hazard Relay531

Relay Unit (Fuel Pump Relay)531

Radiator Fan Motor Relay531

Headlight Relay531

Checking The Relay Unit (Diode)532

Checking The Crankshaft Position Sensor534

Checking The Lean Angle Sensor535

Checking The Starter Motor Operation535

Checking The Stator Coil536

Checking The Rectifier/Regulator536

Checking The Horn537

Checking The Oil Level Switch537

Checking The Fuel Sender538

Checking The Rear Speed Sensor538

Checking The Radiator Fan Motor539

Checking The Coolant Temperature Sensor539

Checking The Throttle Position Sensor540

Checking The Accelerator Position Sensor540

Checking The Throttle Servo Motor541

Checking The Air Induction System Solenoid541

Checking The Atmospheric Pressure Sensor542

Checking The Cylinder Identification Sensor542

Checking The Intake Air Pressure Sensor543

Checking The Intake Air Temperature Sensor543

Checking The Steering Damper Solenoid544

Checking The Gear Position Sensor544

Checking The Fuel Injectors545

Starting Failures548

Incorrect Engine Idling Speed548

Poor Medium-And-High-Speed Performance549

Shift Pedal Does Not Move549

Jumps Out Of Gear549

Faulty Clutch549

Poor Braking Performance550

Faulty Front Fork Legs550

Unstable Handling550

Faulty Lighting Or Signaling System551

Wiring Diagram Yzf-R1(B)552

Wiring Diagram555

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Table of Contents

Troubleshooting

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Yzf-r1 2012Yzf-r1b 2012