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YZF-R1(B) 2012
Yamaha YZF-R1(B) 2012 User Manual
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REAR BRAKE
4-46
Disassembl
ing the r
ear brake mast
er cyli
nder
Order
Job/P
arts to remove
Q’ty
Remarks
1
Brake master cylinder y
oke
1
2
Adjusting nut
1
3
Brake master cylinder kit
1
4D
u
s
t
c
o
v
e
r
1
5
Circlip
1
6
Hose joint
1
7O
-
r
i
n
g
1
8
Brake master cylinder body
1
F
or installation, re
verse the remo
val proce-
dure.
204
206
Table of Contents
Important
3
Important Manual Information
3
How to Use this Manual
4
Symbols
5
Table of Contents
7
General Information
9
Model Label
10
Vehicle Identification Number
10
Features
11
Outline of the FI System
11
FI System
12
Aims and Advantages of Using YCC-T System
13
Mechanism Characteristics
13
YCC-T (Yamaha Chip Controlled Throttle) YCC-I (Yamaha Chip Controlled Intake)
13
Aims and Advantages of Using YCC-I System
14
YCC-T/YCC-I System Outline
15
YCC-T/YCC-I Control Outline
16
OUTLINE of the TCS (Traction Control System)
17
TCS (Traction Control System) Layout
17
TCS (Traction Control System) Block Diagram
18
TCS (Traction Control System) Function
18
Setting the Traction Control System
19
Resetting
20
Instrument Functions
21
Multi-Function Meter Unit
21
Tachometer
21
Clock and Stopwatch Modes
22
Instantaneous Fuel Consumption Mode
23
Odometer, Tripmeter, Instantaneous Fuel Consumption and Average Fuel Consumption Modes
23
Average Fuel Consumption Mode
24
Coolant Temperature Display
24
Drive Mode Display
24
Transmission Gear Display
24
Air Intake Temperature Display
25
Self-Diagnosis Device
25
Traction Control System Mode Display
25
Display Brightness and Shift Timing Indicator Light Control Mode
26
To Adjust the Brightness of the Multifunction Meter Displays and Tachometer
26
To Set the Shift Timing Indicator Light Activity Function
26
To Set the Shift Timing Indicator Light Deactivation Function
27
Gaskets, Oil Seals and O-Rings
29
Important Information
29
Lock Washers/Plates and Cotter Pins
29
Preparation for Removal and Disassembly
29
Replacement Parts
29
Bearings and Oil Seals
30
Circlips
30
Checking the Connections
31
Handling the Electronic Parts
32
Special Tools
33
To Set the Shift Timing Indicator Light Activation Function
27
D-Mode (Drive Mode)
27
Specifications
41
General Specifications
42
Engine Specifications
43
Chassis Specifications
50
Electrical Specifications
53
General Tightening Torque Specifications
56
Tightening Torques
56
Engine Tightening Torques
57
Connecting Rod Cap Bolt
60
Crankcase Bolt (Main Journal)
60
Cylinder Head Nut
60
Chassis Tightening Torques
61
Front Wheel Axle Pinch Bolt
63
Lower Bracket Pinch Bolt
63
Engine
65
Lubrication Points and Lubricant Types
65
Chassis
67
Engine Oil Lubrication Chart
68
Lubrication System Chart and Diagrams
68
Lubrication Diagrams
70
Cooling System Diagrams
86
Cable Routing
90
Periodic Checks and Adjustments
117
Introduction
120
Periodic Maintenance Chart for the Emission Control System
120
General Maintenance and Lubrication Chart
121
Checking the Fuel Line (Primary Injectior)
123
Checking the Fuel Line (Secondary Injector)
123
Checking the Spark Plugs
123
Adjusting the Valve Clearance
124
Valve Lapper
127
Checking the Throttle Body Synchronization
128
Synchronizing the Throttle Bodies
128
Adjusting the Throttle Body Synchronization
129
Checking the Crankcase Breather Hose
130
Checking the Exhaust System
130
Checking the Throttle Body Joints
130
Adjusting the Exhaust Gas Volume
131
Checking the Air Induction System
132
Replacing the Air Filter Element
132
Adjusting the Clutch Cable Free Play
133
Engine Side
133
Handlebar Side
133
Checking the Brake Fluid Level
134
Checking the Brake Operation
134
Adjusting the Front Disc Brake
135
Adjusting the Rear Disc Brake
135
Checking the Front Brake Pads
135
Bleeding the Hydraulic Brake System
136
Checking the Rear Brake Pads
136
Checking the Front Brake Hoses
137
Checking the Rear Brake Hose
138
Checking the Tires
138
Checking the Wheels
138
Adjusting the Drive Chain Slack
140
Checking the Swingarm Operation
140
Checking the Wheel Bearings
140
Checking and Adjusting the Steering Head
141
Lubricating the Drive Chain
141
Checking the Chassis Fasteners
142
Checking the Steering Damper
142
Lubricating the Brake Lever
142
Lubricating the Clutch Lever
142
Lubricating the Pedal
142
Adjusting the Shift Pedal
143
Checking the Front Fork
143
Checking the Sidestand Switch
143
Lubricating the Sidestand
143
Adjusting the Front Fork Legs
144
Rebound Damping
144
Adjusting the Rear Shock Absorber Assembly
145
Checking the Rear Shock Absorber Assembly
145
Compression Damping
145
Spring Preload
145
Compression Damping (for Fast Compression Damping)
146
Compression Damping (for Slow Compression Damping)
146
Checking the Connecting Arm and Relay Arm
147
Checking the Engine Oil Level
147
Changing the Engine Oil
148
Measuring the Engine Oil Pressure
149
Oil Pressure Adapter H
149
Checking the Coolant Level
150
Checking the Cooling System
150
Changing the Coolant
151
Adjusting the Rear Brake Light Switch
152
Adjusting the Throttle Cable Free Play
153
Checking and Charging the Battery
153
Checking and Lubricating the Cables
153
Checking the Fuses
153
Lubricating the Rear Suspension
153
Adjusting the Headlight Beams
154
Replacing the Headlight Bulbs
154
Chassis
157
Removing the Seats and Battery
160
General Chassis
160
Removing the Side Cowlings
161
Removing the ECU and Rectifier/Regulator
162
Removing the Air Ducts
163
Removing the Front Cowling Assembly
164
General Chassis
164
Removing the Meter and Headlight
165
Removing the Rear Fender
167
Disassembling the License Plate/Turn Signal Light Assembly
168
Installing the Quick Fastener (Push Type)
169
Removing the Quick Fastener (Push Type)
169
Removing the Quick Fastener (Screw Type)
169
Installing the Quick Fastener (Screw Type)
169
Installing the Quick Fastener (Pull Type)
170
Installing the Passenger Seat Lock Cylinder
170
Removing the Front Turn Signal Lights
170
Installing the Front Turn Signal Lights
170
Removing the Lower Cowlings
171
Installing the Lower Cowlings
171
Removing the Side Cowling Inner Panels
171
Installing the Side Cowling Inner Panels
171
Installing the Air Intake Ducts
172
Installing the Air Chamber Covers
172
Installing the Intake Air Duct Covers
172
Removing the Intake Air Duct Covers
172
Removing the Windshield
173
Installing the Windshield
173
Installing the Mirror Fitting Plates
173
Removing the Upper Tail Cover
173
Installing the Upper Tail Cover
174
Installing the Tail/Brake Light
174
Adjusting the Rider Footrests
174
Removing the Front Wheel and Brake Discs
176
Front Wheel
176
Disassembling the Front Wheel
177
Removing the Front Wheel
178
Checking the Front Wheel
178
Maintenance of the Front Speed Sensor and Sensor Rotor
179
Adjusting Thr Front Wheel Static Balance
181
Installing the Front Wheel (Front Brake Discs)
182
Rear Wheel
184
Removing the Rear Wheel
184
Removing the Brake Disc and Rear Wheel Sprocket
185
Disassembling the Rear Wheel
186
Checking the Rear Wheel
187
Assembling the Rear Wheel
188
Checking the Rear Wheel Drive Hub
188
Checking and Replacing the Rear
188
Adjusting the Rear Wheel Static Balance
189
Installing the Rear Wheel
189
Front Brake
190
Removing the Front Brake Pads
190
Removing the Front Brake Master Cylinder
191
Disassembling the Front Brake Master Cylinder
192
Removing the Front Brake Calipers
193
Disassembling the Front Brake Calipers
194
Checking the Front Brake Discs
195
Replacing the Front Brake Pads
196
Checking the Front Brake Calipers
199
Installing Teh Front Brake Calipers
199
Assembling the Front Brake Calipers
199
Checking the Front Brake Master Cylinder
201
Assembling the Front Brake Master Cylinder
201
Installing the Front Brake Master Cylinder
201
Removing the Rear Brake Pads
203
Rear Brake
203
Removing the Rear Brake Master Cylinder
204
Disassembling the Rear Brake Master Cylinder
205
Removing the Rear Brake Calipers
206
Disassembling the Rear Brake Caliper
207
Checking the Rear Brake Disc
208
Replacing the Rear Brake Pads
208
Removing the Rear Brake Caliper
210
Checking the Rear Brake Caliper
210
Assembling the Rear Brake Caliper
211
Installing the Rear Brake Caliper
211
Checking the Rear Brake Master Cylinder
212
Assembling the Rear Brake Master Cylinder
213
Installing the Rear Brake Master Cylinder
213
Handlebars
215
Removing the Handlebars
215
Checking the Handlebars
217
Installing the Handlebars
217
Front Fork
220
Removing the Front Fork Legs
220
Disassembling the Front Fork Legs
221
Front Fork
223
Checking the Front Fork Legs
225
Assembling the Front Fork Legs
225
Installing the Front Fork Legs
229
Steering Head
231
Removing the Lower Bracket
231
Checking the Steering Head
233
Installing the Steering Head
234
Checking the Steering Damper
234
Rear Shock Absorber Assembly
235
Removing the Rear Shock Absorber Assembly
235
Checking the Rear Shock Absorber Assembly
236
Disposing of a Rear Shock Absorber
236
Handling the Rear Shock Absorber
236
Checking the Connecting Arm and Relay Arm
237
Installing the Relay Arm
237
Installing the Rear Shock Absorber Assembly
237
Swingarm
239
Removing the Swingarm
239
Checking the Swingarm
242
Installing the Swingarm
242
Chain Drive
244
Removing the Drive Sprocket and Drive Chain
244
Removing the Drive Chain
245
Checking the Drive Chain
245
Checking the Drive Sprocket
246
Installing the Drive Chain
246
Engine
249
Engine Inspection
252
Measuring the Compression Pressure
252
Engine Removal
254
Removing the Exhaust Pipe and Muffler
254
Disconnecting the Leads and Hoses
257
Removing the Engine
259
Installing the Engine
261
Pivot Shaft Wrench Adapter
261
Installing the Exhaust Pipe and Muffler
262
Camshafts
264
Removing the Cylinder Head Cover
264
Removing the Camshafts
265
Removing the Camshafts
267
Checking the Camshafts
268
Checking the Timing Chain and Sprocket
269
Checking the Timing Chain Guides
270
Checking the Timing Chain Tensioner
270
Installing the Camshafts
270
Cylinder Head
275
Removing the Cylinder Head
275
Checking the Cylinder Head
276
Installing the Cylinder Head
276
Removing the Valves and Valve Springs
278
Valves and Valve Springs
278
Removing the Valves
280
Valves and Valve Springs
280
Checking the Valves and Valve Guides
281
Checking the Valve Seats
282
Checking the Valve Springs
284
Checking the Valve Filters
285
Installing the Valves
285
Generator
287
Removing the Generator
287
Installing the Generator
288
Removing the Generator
288
Removing the Starter Clutch
290
Starter Clutch
290
Checking the Starter Clutch
291
Installing the Starter Clutch
291
Pickup Rotor
293
Removing the Pickup Rotor
293
Installing the Pickup Rotor
294
Electric Starter
296
Removing the Starter Motor
296
Disassembling the Starter Motor
297
Checking the Starter Motor
298
Assembling the Starter Motor
299
Oil Pump
301
Removing the Oil Pan and Oil/Water Pump Assembly
301
Disassembling the Oil Pump
303
Checking the Oil Pump
304
Checking the Sprocket and Chain
304
Removing the Oil Pan
304
Checking the Oil Delivery Pipes
305
Checking the Oil Strainer
305
Checking the Relief Valve
305
Assembling the Oil Pump
306
Installing the Oil/Water Pump Assembly
306
Installing the Oil Pan
307
Clutch
309
Removing the Clutch Cover
309
Removing the Pull Lever Shaft
310
Removing the Clutch
311
Removing the Clutch
313
Checking the Clutch Plates
314
Checking the Friction Plates
314
Checking the Clutch Housing
315
Checking the Clutch Springs
315
Checking the Clutch Boss
316
Checking the Pressure Plate
316
Checking the Primary Drive Gear
316
Checking the Primary Driven Gear
316
Checking the Pull Lever Shaft and Pull Rod
316
Installing the Clutch
316
Removing the Shift Shaft and Stopper Lever
319
Shift Shaft
319
Checking the Shift Shaft
320
Checking the Stopper Lever
320
Installing the Shift Shaft
320
Crankcase
321
Separating the Crankcase
321
Assembling the Crankcase
323
Checking the Crankcase
323
Disassembling the Crankcase
323
Connecting Rods and Pistons
325
Removing the Connecting Rods and Pistons
325
Checking the Cylinder and Piston
326
Connecting Rods and Pistons
326
Removing the Connecting Rods and Pistons
326
Checking the Piston Rings
327
Checking the Piston Pin
328
Checking the Connecting Rods
329
Installing the Connecting Rod and Piston
332
Crankshaft
336
Removing the Crankshaft
336
Checking the Crankshaft
337
Checking the Oil Nozzles
337
Removing the Crankshaft and Balancer Shaft
337
Checking the Balancer Shaft
339
Installing the Crankshaft
340
Installing the Balancer Assembly
341
Removing the Transmission, Shift Drum Assembly, and Shift Forks
342
Transmission
342
Disassembling the Main Axle Assembly
343
Disassembling the Drive Axle Assembly
344
Checking the Shift Forks
346
Removing the Transmission
346
Checking the Shift Drum Assembly
347
Checking the Transmission
347
Assembling the Main Axle and Drive Axle
348
Installing the Transmission
348
Cooling System
351
Radiator
352
Removing the Radiator
352
Checking the Radiator
354
Installing the Radiator
354
Oil Cooler
356
Removing the Oil Cooler
356
Checking the Oil Cooler
358
Installing the Oil Cooler
358
Thermostat
359
Removing the Thermostat
359
Assembling the Thermostat Assembly
361
Checking the Thermostat
361
Installing the Thermostat Assembly
362
Water Pump
363
Disassembling the Water Pump
363
Checking the Water Pump
364
Assembling the Water Pump
364
Fuel System
367
Fuel Tank
368
Removing the Fuel Tank and Fuel Pump
368
Checking the Fuel Pump Body
370
Removing the Fuel Pump
370
Removing the Fuel Tank
370
Removing the Fuel Tank Side Covers
370
Installing the Fuel Tank
371
Installing the Fuel Tank Side Covers
371
Air Filter Case
372
Removing the Air Filter Case and Secondary Injectors
372
Checking the Secondary Injectors (before Removing)
374
Removing the Fuel Hose (Primary Injector Joint Side and Secondary Injector Joint Side)
374
Removing the Secondary Injectors
374
Checking the Secondary Injectors
375
Removing the Intake Funnel Assembly
375
Removing the Lower Air Filter Case
375
Checking the Air Filter Case Seal
376
Checking the Intake Funnel
376
Checking the Intake Funnel Operation
376
Installing the Intake Funnel and Lower Air Filter Case
376
Installing the Secondary Injectors
377
Installing the Upper Air Filter Case
377
Installing the Fuel Hose (Primary Injector Joint Side and Secondary Injector Joint Side)
378
Removing the Throttle Body Assembly
379
Throttle Bodies
379
Removing the Primary Injectors
381
Checking and Cleaning the Throttle Bodies
382
Checking the Primary Injectors
382
Checking the Primary Injectors (before Removing)
382
Checking the Injector Pressure
384
Installing the Primary Injectors
384
Checking the Fuel Line Pressure
385
Fuel Pressure Adapter
385
Adjusting the Throttle Position Sensor
386
Adjusting the Accelerator Position Sensor
386
Air Induction System
388
Removing the Air Cut-Off Valve Assembly and Hoses
390
Removing the Reed Valves
391
Checking the Air Induction System
392
Air Injection
392
Air Cut-Off Valve
392
Installing the Air Induction System
393
General Information
395
Electrical System
395
Ignition System
398
Circuit Diagram
398
Engine Stopping Due to Sidestand Operation
400
Troubleshooting
402
Electric Starting System
404
Starting Circuit Cut-Off System Operation
406
Charging System
410
Lighting System
414
Signaling System
418
Cooling System Circuit Diagram
426
Fuel Injection System
430
Ecu Self-Diagnostic Function
432
Engine Trouble Warning Light Indication and FI System Operation
432
Checking the Engine Trouble Warning Light
432
ECU Detects an Abnormal Signal from a Sensor
433
The Engine Operation Is Not Normal but the Engine Trouble Warning Light Does Not Comeon
434
Troubleshooting Method
434
The Engine Operation Is Not Normal and the Engine Trouble Warning Light Comes on
434
Diagnostic Mode
435
Sensor Operation Table
437
Troubleshooting Details
443
Clutch Switch System Malfunction
484
Fuel Pump System
504
Immobilizer System
508
General Information
510
Standby Mode
511
Code Re-Registering Key Registration
511
Part Replacement and Key Code Registration Requirements
511
Standard Key Registration
512
Voiding the Standard Key Code
513
Standard Key Code Voiding Method
513
Self-Diagnosis Fault Code Indication
515
Immobilizer System Indicator Light Fault Code Indication
516
Electrical Components
518
Checking the Switches
522
Checking the Condition of the Bulb Sockets
525
Checking the Condition of the Bulbs
525
Types of Bulbs
525
Checking the Bulbs and Bulb Sockets
525
Checking the Fuses
526
Checking and Charging the Battery
526
Charging Method Using a Variable-Current (Voltage) Charger
529
Charging Method Using a Constant Voltage Charger
529
Checking the Relays
530
Relay Unit (Starting Circuit Cut-Off Relay)
530
Starter Relay
530
Headlight Relay
531
Relay Unit (Fuel Pump Relay)
531
Radiator Fan Motor Relay
531
Checking the Turn Signal/Hazard Relay
531
Checking the Relay Unit (Diode)
532
Checking the Crankshaft Position Sensor
534
Checking the Lean Angle Sensor
535
Checking the Starter Motor Operation
535
Checking the Stator Coil
536
Checking the Rectifier/Regulator
536
Checking the Horn
537
Checking the Oil Level Switch
537
Checking the Fuel Sender
538
Checking the Rear Speed Sensor
538
Checking the Radiator Fan Motor
539
Checking the Coolant Temperature Sensor
539
Checking the Throttle Position Sensor
540
Checking the Accelerator Position Sensor
540
Checking the Throttle Servo Motor
541
Checking the Air Induction System Solenoid
541
Checking the Atmospheric Pressure Sensor
542
Checking the Cylinder Identification Sensor
542
Checking the Intake Air Temperature Sensor
543
Checking the Intake Air Pressure Sensor
543
Checking the Steering Damper Solenoid
544
Checking the Gear Position Sensor
544
Checking the Fuel Injectors
545
Troubleshooting
547
Troubleshooting
548
Starting Failures
548
Incorrect Engine Idling Speed
548
Faulty Clutch
549
Jumps out of Gear
549
Shift Pedal Does Not Move
549
Poor Medium-And-High-Speed Performance
549
Overcooling
550
Poor Braking Performance
550
Faulty Front Fork Legs
550
Unstable Handling
550
Cooling System
550
Faulty Lighting or Signaling System
551
Wiring Diagram YZF-R1(B)
552
Color Code
552
Wiring Diagram
555
4
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Yamaha YZF-R1(B) 2012 Specifications
General
Brand
Yamaha
Model
YZF-R1(B) 2012
Category
Motorcycle
Language
English
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