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Yamaha YZF-R1B 2012 User Manual

Yamaha YZF-R1B 2012
556 pages
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SERVICE MANUAL
YZF-R1(B)
2012
1KB-28197-E0
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys
email: info@motomatrix.co.uk

Table of Contents

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Yamaha YZF-R1B 2012 Specifications

General IconGeneral
Displacement998 cc
Compression Ratio12.7:1
Transmission6-speed
Final DriveChain
FrameAluminum Deltabox
Front Suspension43 mm inverted fork, fully adjustable
Front Tire120/70 ZR17
Rear Tire190/55 ZR17
Engine TypeLiquid-cooled, 4-stroke, DOHC, inline 4-cylinder
Bore x Stroke78.0mm x 52.2mm
Max Power182 hp (134.2 kW) @ 12, 500 rpm
Max Torque83.6 lb-ft (112.4 Nm) @ 10, 000 rpm
Fuel SystemFuel Injection
IgnitionTCI
Rear SuspensionSingle shock, fully adjustable
Rear Brake220mm disc, single-piston caliper
Fuel Capacity4.8 gallons
Wet Weight206 kg
Width28.1 in
Wheelbase55.7 in
Ground Clearance5.3 in (135 mm)
Seat Height32.8 in

Summary

General Information

Identification

Locating vehicle identification number and model label for spare parts.

Features

Overview of the Fuel Injection (FI) system, YCC-T, YCC-I, and Traction Control System (TCS).

Important Information

Guidance on preparation for disassembly, replacement parts, and handling of electronic components.

Special Tools

List of specialized tools required for maintenance and assembly, including part numbers.

Specifications

General Specifications

Vehicle dimensions, weight, maximum load, and model identification for various regions.

Engine Specifications

Detailed technical data for engine type, displacement, fuel, oil, lubrication, cooling system, and components.

Chassis Specifications

Specifications for frame, wheels, tires, brakes, suspension, swingarm, and drive chain.

Electrical Specifications

Specifications for voltage, ignition system, engine control unit, battery, lighting, indicators, and fuses.

Tightening Torques

Specifications for tightening torques of various engine and chassis fasteners, with general guidelines.

Lubrication Points and Lubricant Types

Lists lubrication points and recommended lubricants for engine and chassis components.

Lubrication System Chart and Diagrams

Illustrates the engine oil lubrication system flow with numbered components.

Cooling System Diagrams

Diagrams illustrating the coolant flow through the radiator, hoses, and engine components.

Cable Routing

Diagrams and instructions for routing electrical wires and cables on the motorcycle.

Periodic Checks and Adjustments

Periodic Maintenance

Chart detailing scheduled maintenance tasks based on odometer readings and annual checks.

General Maintenance and Lubrication Chart

Overview of routine maintenance and lubrication tasks with their recommended intervals.

Checking the Fuel Line

Procedure to inspect fuel hoses for damage, cracks, or loose connections.

Checking the Spark Plugs

Steps for inspecting, cleaning, and adjusting spark plugs for optimal engine performance.

Adjusting the Valve Clearance

Detailed procedure for measuring and adjusting valve clearance on a cold engine.

Synchronizing the Throttle Bodies

Procedure for synchronizing throttle bodies using vacuum gauges for optimal engine response.

Checking the Throttle Body Joints

Inspection of throttle body joints for any cracks or damage.

Checking the Crankcase Breather Hose

Inspection of the crankcase breather hose for damage, cracks, or loose connections.

Checking the Exhaust System

Inspection of exhaust pipes, chambers, mufflers, and gaskets for damage or leaks.

Adjusting the Exhaust Gas Volume

Procedure to adjust exhaust gas volume via the diagnostic mode for emissions control.

Checking the Air Induction System

Reference to the detailed check of the air induction system found elsewhere in the manual.

Replacing the Air Filter Element

Step-by-step guide for replacing the air filter element, including necessary precautions.

Adjusting the Clutch Cable Free Play

Procedure for checking and adjusting clutch cable free play at the handlebar and engine.

Checking the Brake Operation

Procedure to verify the proper functioning of both front and rear brake systems.

Checking the Brake Fluid Level

Method for checking brake fluid level, adding recommended fluid, and safety warnings.

Adjusting the Front Disc Brake

Procedure for adjusting the front brake lever position for optimal reach and feel.

Checking the Front Brake Pads

Inspection of front brake pad wear and replacement guidelines when indicators are reached.

Adjusting the Rear Disc Brake

Procedure for checking and adjusting the rear brake pedal position for rider comfort.

Checking the Rear Brake Pads

Inspection of rear brake pad wear and replacement guidelines when indicators are reached.

Bleeding the Hydraulic Brake System

Comprehensive procedure for bleeding air from the hydraulic brake system to restore proper function.

Checking the Front Brake Hoses

Inspection of front brake hoses and clamps for any signs of damage, wear, or looseness.

Checking the Rear Brake Hose

Inspection of rear brake hose and clamp for any signs of damage, wear, or looseness.

Checking the Wheels

Inspection of wheels for damage or out-of-round conditions that may require replacement.

Checking the Tires

Procedure for checking tire surfaces, tread depth, wear indicators, and tire pressure.

Checking the Wheel Bearings

Procedure for checking wheel bearings for looseness or damage.

Checking the Swingarm Operation

Procedure to check swingarm operation and for excessive play.

Adjusting the Drive Chain Slack

Procedure for measuring and adjusting drive chain slack, emphasizing correct tension.

Lubricating the Drive Chain

Guidance on cleaning and lubricating the drive chain, specifying recommended lubricants.

Checking and Adjusting the Steering Head

Procedure for checking steering head for binding or looseness and adjusting it.

Checking the Steering Damper

Reference to the detailed procedure for checking the steering damper's functionality.

Checking the Chassis Fasteners

Instruction to ensure all chassis fasteners are properly tightened.

Lubricating the Brake Lever

Lubrication of critical pivot points for smooth brake lever operation.

Lubricating the Clutch Lever

Lubrication of critical pivot points for smooth clutch lever operation.

Lubricating the Pedal

Lubrication of critical pivot points for smooth pedal operation.

Adjusting the Shift Pedal

Procedure for adjusting the shift pedal position by modifying the shift rod length.

Checking the Sidestand

Procedure to check the sidestand for proper operation.

Lubricating the Sidestand

Lubrication of the sidestand's pivoting point and moving parts.

Checking the Sidestand Switch

Reference to checking the sidestand switch within the Electrical Components section.

Checking the Front Fork

Inspection of front fork legs for damage, leaks, and proper operation of suspension.

Adjusting the Front Fork Legs

Procedure for adjusting spring preload and damping settings on front fork legs.

Checking the Rear Shock Absorber Assembly

Reference to checking the rear shock absorber assembly's condition and function.

Adjusting the Rear Shock Absorber Assembly

Procedure for adjusting spring preload and damping settings on the rear shock absorber.

Checking the Connecting Arm and Relay Arm

Reference to checking the connecting arm and relay arm components.

Checking the Engine Oil Level

Procedure for checking engine oil level, ensuring it is between minimum and maximum marks.

Measuring the Engine Oil Pressure

Method for measuring engine oil pressure, including diagnostic steps for low pressure.

Changing the Engine Oil

Step-by-step guide for draining engine oil and replacing the oil filter cartridge.

Checking the Coolant Level

Procedure for checking coolant level, with handling precautions.

Checking the Cooling System

Inspection of cooling system components like radiator, hoses, and water pump for damage.

Changing the Coolant

Procedure for draining and refilling the cooling system with the correct coolant mixture.

Checking the Front Brake Light Switch

Reference to checking the front brake light switch within the Electrical Components section.

Adjusting the Rear Brake Light Switch

Procedure for adjusting the rear brake light switch for correct activation timing.

Checking and Lubricating the Cables

Inspection of control cables for damage and lubrication of sheaths.

Adjusting the Throttle Cable Free Play

Procedure for checking and adjusting throttle cable free play.

Lubricating the Rear Suspension

Lubrication of the rear suspension's pivot points and moving parts.

Checking and Charging the Battery

Procedure for checking battery charge state and proper charging methods.

Checking the Fuses

Procedure for checking fuses for continuity and replacing blown fuses.

Replacing the Headlight Bulbs

Step-by-step instructions for replacing headlight bulbs, including safety precautions.

Adjusting the Headlight Beams

Procedure for adjusting headlight beams vertically and horizontally.

Chassis

General Chassis

Procedures for removing and installing seats, cowlings, ECU, air ducts, mirrors, and windshield.

Front Wheel

Detailed procedures for removing, disassembling, checking, and installing the front wheel assembly.

Rear Wheel

Detailed procedures for removing, disassembling, checking, and installing the rear wheel assembly.

Front Brake

Comprehensive procedures for servicing front brake components including pads, calipers, and master cylinder.

Rear Brake

Comprehensive procedures for servicing rear brake components including pads, caliper, and master cylinder.

Handlebars

Procedures for removing, checking, and installing handlebars, grips, switches, and control levers.

Front Fork

Detailed procedures for removing, disassembling, checking, and assembling the front fork legs.

Steering Head

Procedures for removing, checking, and installing steering head components, including bearings.

Rear Shock Absorber Assembly

Procedures for handling, removing, and checking the rear shock absorber assembly.

Swingarm

Procedures for removing, checking, and installing the swingarm, including pivot shaft and drive chain.

Chain Drive

Procedures for removing, checking, cleaning, lubricating, and installing the drive chain and sprockets.

Engine

Engine Inspection

Procedures for inspecting the engine, including compression pressure and valve clearance.

Engine Removal

Detailed steps for removing the engine assembly, including exhaust, fairings, and disconnecting systems.

Camshafts

Procedures for removing, checking, and installing camshafts, timing chain, and related components.

Cylinder Head

Procedures for removing, checking, and installing the cylinder head, gasket, and fasteners.

Valves and Valve Springs

Procedures for removing, checking, and installing valves, springs, seals, and guides.

Generator

Procedures for removing and installing the generator cover, rotor, and stator coil assembly.

Starter Clutch

Procedures for removing, checking, and installing the starter clutch assembly and related gears.

Pickup Rotor

Procedures for removing and installing the pickup rotor and its cover.

Electric Starter

Procedures for removing, disassembling, checking, and assembling the starter motor.

Oil Pump

Procedures for removing the oil pan, oil/water pump assembly, and disassembling the oil pump.

Clutch

Procedures for removing, checking, and installing clutch components like plates, springs, and housing.

Shift Shaft

Procedures for removing, checking, and installing the shift shaft and stopper lever.

Crankcase

Procedures for separating, checking, assembling, and tightening crankcase halves and bolts.

Connecting Rods and Pistons

Procedures for removing, checking, and installing connecting rods and pistons, including clearance measurements.

Crankshaft

Procedures for removing, checking, and installing the crankshaft and balancer shaft, including bearing selection.

Transmission

Procedures for removing, disassembling, checking, and installing the transmission, shift drum, and forks.

Cooling System

Radiator

Procedures for removing, checking, and installing the radiator, hoses, and fan.

Oil Cooler

Procedures for removing and installing the oil cooler, including checking hoses and union bolt.

Thermostat

Procedure for checking thermostat operation and assembling/installing the thermostat housing.

Water Pump

Procedures for disassembling, checking, and assembling the water pump, including seals and impeller.

Fuel System

Fuel Tank

Procedures for removing and installing the fuel tank, fuel pump, and side covers.

Air Filter Case

Procedures for removing and installing the air filter case, secondary injectors, and intake funnel assembly.

Throttle Bodies

Procedures for removing, checking, cleaning, and synchronizing throttle bodies and sensors.

Air Induction System

Explanation of the air induction system and procedures for checking hoses, reed valves, and air cut-off valve.

Electrical System

Ignition System

Circuit diagram, troubleshooting for engine stopping, and ignition system components.

Electric Starting System

Circuit diagram and troubleshooting for the electric starting system, including starter motor and relays.

Charging System

Circuit diagram and troubleshooting for the charging system, including battery, stator, and rectifier.

Lighting System

Circuit diagram and troubleshooting for headlights, signals, and indicator lights.

Signaling System

Circuit diagram and troubleshooting for turn signals, brake lights, hazard lights, horn, and warning lights.

Cooling System

Circuit diagram and troubleshooting for cooling system components like radiator fan and coolant sensor.

Fuel Injection System

Circuit diagram, ECU self-diagnostics, fault codes, and troubleshooting for the fuel injection system.

Fuel Pump System

Circuit diagram and troubleshooting for the fuel pump system, including fuses, relays, and pump checks.

Immobilizer System

Circuit diagram, general info, part replacement, key registration, and troubleshooting for the immobilizer system.

Electrical Components

Diagrams illustrating the location of key electrical components on the motorcycle.

Troubleshooting

General Information

General notes on troubleshooting procedures and referring to relevant manual sections.

Starting Failures

Common causes and checks for engine starting failures, categorized by system.

Incorrect Engine Idling Speed

Potential causes for incorrect engine idling speed, including engine, fuel, and throttle body issues.

Poor Medium-and-High-Speed Performance

Troubleshooting steps for poor engine performance at medium and high speeds.

Faulty Gear Shifting

Possible causes and checks for difficult gear shifting.

Shift Pedal Does Not Move

Troubleshooting steps for a non-moving shift pedal, related to shift shaft and drum.

Jumps Out of Gear

Possible causes for the transmission jumping out of gear.

Faulty Clutch

Troubleshooting for clutch slip or drag issues, covering clutch components and engine oil.

Overheating

Potential causes for engine overheating, related to cooling system and engine oil.

Overcooling

Possible causes for engine overcooling, primarily related to thermostat operation.

Poor Braking Performance

Troubleshooting steps for poor brake performance, covering pads, discs, fluid, and caliper issues.

Faulty Front Fork Legs

Troubleshooting for faulty front fork legs, including oil leaks and damping issues.

Unstable Handling

Causes of unstable motorcycle handling, related to handlebars, steering head, fork, swingarm, and rear suspension.

Faulty Lighting or Signaling System

Troubleshooting for issues with headlights, turn signals, brake lights, horn, and indicator lights.

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