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FJR1300AS
Owner’s manual

2008

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Read this manual carefully before operating this vehicle.

OWNER’S MANUAL

FJR1300AS

2D2-28199-E3

Related Manuals for Yamaha FJR1300AS

Summary of Contents for Yamaha FJR1300AS

Page 1
Read this manual carefully before operating this vehicle. OWNER’S MANUAL FJR1300AS 2D2-28199-E3…
Page 2
Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. DECLARATION of CONFORMITY Company: YAMAHA MOTOR ELECTRONICS CO., LTD. Address: 1450-6, Mori, Mori-Machi, Shuchi-gun, Shizuoka-Ken, 437-0292 Japan Hereby declare that the product:…
Page 3
Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your FJR1300AS. The Owner’s Manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury.
Page 4: Important Manual Information

IMPORTANT MANUAL INFORMATION EAU10132 Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
Page 5
IMPORTANT MANUAL INFORMATION EAU10200 FJR1300AS OWNER’S MANUAL ©2008 by Yamaha Motor Co., Ltd. 1st edition, September 2008 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
Page 6: Table Of Contents

TABLE OF CONTENTS SAFETY INFORMATION ….1-1 Accessory box ……3-27 General maintenance and Adjusting the headlight beams ..3-27 lubrication chart ……6-3 DESCRIPTION ……..2-1 Handlebar position ……. 3-28 Removing and installing panels ..6-7 Left view ……….2-1 Opening and closing the Checking the spark plugs ….
Page 7
TABLE OF CONTENTS Checking and lubricating the centerstand and sidestand ..6-25 Lubricating the swingarm pivots …6-26 Lubricating the rear suspension …6-26 Checking the front fork ….6-27 Checking the steering ….6-27 Checking the wheel bearings ..6-28 Battery ……….6-28 Replacing the fuses ……6-29 Headlight bulb ……6-31 Front turn signal light ….6-31 Replacing a rear turn signal light…
Page 8: Safety Information

SAFETY INFORMATION EAU10283 Safe Riding • Ride where other motorists can Perform the pre-operation checks each see you. Avoid riding in another time you use the vehicle to make sure it motorist’s blind spot. Be a Responsible Owner is in safe operating condition. Failure to Many accidents involve inexperi- As the vehicle’s owner, you are respon- inspect or maintain the vehicle properly…
Page 9
SAFETY INFORMATION due to excessive speed or under- This motorcycle is designed for on- A passenger should also observe cornering (insufficient lean angle road use only. It is not suitable for the above precautions. for the speed). off-road use. • Always obey the speed limit and Avoid Carbon Monoxide Poisoning never travel faster than warrant- Protective apparel…
Page 10
Yamaha accessories, which are avail- of the motorcycle is changed. To avoid to minimize imbalance or instabili- able only from a Yamaha dealer, have the possibility of an accident, use ex- been designed, tested, and approved treme caution when adding cargo or Shifting weights can create a sud- by Yamaha for use on your vehicle.
Page 11: Specifications

• Accessories fitted to the handle- Use caution when adding electri- genuine Yamaha accessories, recog- bar or the front fork area can cal accessories. If electrical acces- nize that some aftermarket accessories…
Page 12: Description

DESCRIPTION EAU10410 Left view 1. Accessory box (page 3-27) 9. YCC-S clutch fluid reservoir (page 6-22) 2. Front fork spring preload adjusting bolt (page 3-29) 10.Shock absorber assembly spring preload adjusting lever (page 3-31) 3. Front fork rebound damping force adjusting knob (page 3-29) 11.Air filter element (page 6-17) 4.
Page 13: Right View

DESCRIPTION EAU10420 Right view 1. Storage compartment (page 3-26) 9. Shock absorber assembly rebound damping force adjusting knob (page 3-31) 2. Fuel tank cap (page 3-20) 10.Rear brake fluid reservoir (page 6-22) 3. Fuse box (page 6-29) 4. Windshield (page 3-15) 5.
Page 14: Controls And Instruments

DESCRIPTION EAU10430 Controls and instruments 1. Rear view mirror (page 3-29) 9. Throttle grip (page 6-17) 2. Left handlebar switches (page 3-15) 10.Main switch/steering lock (page 3-3) 3. Tachometer (page 3-7) 11.Headlight beam adjusting knob (page 3-27) 4. Speedometer (page 3-7) 12.Grip warmer adjusting knob (page 3-32) 5.
Page 15: Instrument And Control Functions

Immobilizer system This is not an automatic transmission, This vehicle features the YCC-S only the clutch system is automatic. (Yamaha Chip Controlled-Shift) sys- The gears must be shifted by the rider. tem. The basic function of this system allows the rider to shift gears without the use of a clutch lever.
Page 16
Do not expose any key to exces- a Yamaha dealer to have them re-reg- sively high temperatures. istered. Do not use the key with the red Do not place any key close to bow for driving.
Page 17: Main Switch/Steering Lock

INSTRUMENT AND CONTROL FUNCTIONS EAU10471 EAU26811 To lock the steering Main switch/steering lock All electrical circuits are supplied with power; the meter lighting, taillights, li- cense plate light and auxiliary lights come on, and the engine can be start- ed. The key cannot be removed. The headlights come on automatically when the engine is started and stay on until the key is turned to “OFF”.
Page 18: Indicator And Warning Lights

INSTRUMENT AND CONTROL FUNCTIONS To unlock the steering ECA11020 EAU11003 Indicator and warning lights NOTICE Do not use the parking position for an extended length of time, other- wise the battery may discharge. 1. Push. 1. Left turn signal indicator light “ ”…
Page 19
Stop the vehicle when it is safe to do so, Even if the oil level is sufficient, the curs, have a Yamaha dealer check the and park it away from traffic. Have a warning light may flicker when riding on self-diagnosis system.
Page 20
ABS may not work cor- Yamaha dealer check the electrical cir- then while rotating the rear wheel, push rectly. If this occurs, have a Yamaha cuit. the shift pedal rod and pivot forward un- til the transmission is in the neutral po- dealer check the system as soon as When the key is turned to “OFF”…
Page 21: Speedometer

INSTRUMENT AND CONTROL FUNCTIONS EAU11601 EAU11872 EAU40537 Speedometer Tachometer Multi-function display 1. Tachometer 1. Tachometer 1. Multi-function display 2. Speedometer 2. Tachometer red zone 2. Select button 3. Multi-function display 3. Reset button The electric tachometer allows the rider The speedometer shows the riding EWA14431 to monitor the engine speed and keep it WARNING…
Page 22
INSTRUMENT AND CONTROL FUNCTIONS a fuel reserve tripmeter (which Odometer and tripmeter modes case, pushing the select button switch- shows the distance traveled on the es the display between the various trip- fuel reserve) meter and odometer modes in the a clock following order: Trip F →…
Page 23
INSTRUMENT AND CONTROL FUNCTIONS Clock Fuel meter play segments will start flashing. If this occurs, have a Yamaha dealer check the electrical circuit. Coolant temperature meter 1. Clock 1. Fuel meter 2. Select button The fuel meter indicates the amount of 3.
Page 24
INSTRUMENT AND CONTROL FUNCTIONS ECA10021 Ambient temperature, instanta- Ambient temperature mode NOTICE neous fuel consumption and aver- fuel consumption modes Do not continue to operate the en- (except for the UK) gine if it is overheating. Transmission gear display 1. Ambient temperature This display shows the ambient tem- perature from –9 °C to 50 °C in 1 °C in- 1.
Page 25
INSTRUMENT AND CONTROL FUNCTIONS The accuracy of the temperature When the display is set to “L/100 The average fuel consumption display reading may be affected when km”, the amount of fuel necessary can be set to either “AV_ _._ km/L” or riding slowly (approximately under to travel 100 km under the current “AV_ _._ L/100 km”.
Page 26
50 °C will not be displayed. If there is a malfunction, “– –.–” will Air → MPG → AV_ _._ MPG → Air The accuracy of the temperature be displayed. Have a Yamaha dealer reading may be affected when check the vehicle. Ambient temperature mode riding slowly [approximately under 20 km/h (12.5 mi/h)] or when…
Page 27
When the average fuel consumption such an error code, note the code num- mode is selected, the display flashes ber, and then have a Yamaha dealer for five seconds, and then “AV_ _._ check the vehicle. MPG” (average distance that can be traveled using 1.0 Imp.gal of fuel) is…
Page 28: Anti-Theft Alarm (Optional)

If the multi-function display indicates error code when the key is turned to any error codes, note the code number, “ON”. and then have a Yamaha dealer check the vehicle. If the multi-function display indicates er- ror code 52, this could be caused by transponder interference.
Page 29: Handlebar Switches

INSTRUMENT AND CONTROL FUNCTIONS EAU12347 Right position. To cancel the turn signal Handlebar switches lights, push the switch in after it has re- turned to the center position. Left EAU12493 Windshield position adjusting switch “ ” To move the windshield up, push this switch in direction (a).
Page 30
INSTRUMENT AND CONTROL FUNCTIONS EAU12500 EAU12733 EAU40381 Horn switch “ ” Hazard switch “ ” Hand shift control switch Press this switch to sound the horn. With the key in the “ON” or “ ” posi- tion, use this switch to turn on the haz- EAU12660 ard lights (simultaneous flashing of all Engine stop switch “…
Page 31: Shift Pedal

INSTRUMENT AND CONTROL FUNCTIONS and release this switch after start- EAU40493 Shift pedal ing the engine to enable hand shifting. 1. Shift pedal 2. Bolt 1. Shift pedal 3. Standard position This vehicle is equipped with a con- 2. Move the shift pedal to the desired stant-mesh 5-speed transmission.
Page 32: Hand Shift Lever

INSTRUMENT AND CONTROL FUNCTIONS EAU40481 EAU26823 EAU39540 Hand shift lever “ ”/“ ” Brake lever Brake pedal The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handle- bar grip. 1.
Page 33: Abs

INSTRUMENT AND CONTROL FUNCTIONS EAU39531 al are even slightly applied, a vi- bration can be felt at the lever and The Yamaha ABS (Anti-lock Brake pedal, but these do not indicate a System) features a dual electronic con- malfunction. trol system, which acts on the front and When the ABS is activated, the rear brakes independently.
Page 34: Fuel Tank Cap

INSTRUMENT AND CONTROL FUNCTIONS EAU13074 EAU13221 Fuel tank cap Fuel The fuel tank cap cannot be closed un- Make sure there is sufficient gasoline in less the key is in the lock. In addition, the tank. the key cannot be removed if the cap is EWA10881 WARNING not properly closed and locked.
Page 35
EWA15151 WARNING as well as to the exhaust system. Gasoline is poisonous and can Your Yamaha engine has been de- cause injury or death. Handle gaso- signed to use regular unleaded gaso- line with care. Never siphon gaso- line with a research octane number of line by mouth.
Page 36: Fuel Tank Breather/Overflow Hose

INSTRUMENT AND CONTROL FUNCTIONS EAU39451 EAU13445 ECA10701 Fuel tank breather/overflow Catalytic converters NOTICE hose This vehicle is equipped with catalytic Use only unleaded gasoline. The use converters in the exhaust system. of leaded gasoline will cause unre- EWA10862 pairable damage to the catalytic WARNING converter.
Page 37: Seats

INSTRUMENT AND CONTROL FUNCTIONS EAU39492 To install the passenger seat Seats 1. Insert the projections on the rear of the passenger seat into the seat Passenger seat holders as shown, and then push the front of the seat down to lock it To remove the passenger seat in place.
Page 38: Adjusting The Rider Seat Height

INSTRUMENT AND CONTROL FUNCTIONS 2. Install the passenger seat. EAU39632 Adjusting the rider seat height The rider seat height can be adjusted to Make sure that the seats are prop- one of two positions to suit the rider’s erly secured before riding. preference.
Page 39
INSTRUMENT AND CONTROL FUNCTIONS 6. Align the projection on the bottom of the rider seat with the “H” posi- tion slot, and then push the rear of the seat down to lock it in place as shown. 1. Rider seat height position adjuster 1.
Page 40: Storage Compartment

208 kg (459 lb) for the ve- tion slot, and then push the rear of hicle. the seat down to lock it in place as shown. 1. Storage compartment 2. Yamaha CYCLELOK (optional) This storage compartment is designed 1. “L” position slot hold genuine Yamaha CYCLELOK.
Page 41: Accessory Box

INSTRUMENT AND CONTROL FUNCTIONS EAU39480 2. Remove the key. EAU39611 Accessory box Adjusting the headlight ECA11800 The accessory box is located beside beams NOTICE the meter panel. The headlight beam adjusting knobs Do not place heat-sensitive items in are used to raise or lower the height of the accessory box.
Page 42: Handlebar Position

The handlebars can be adjusted to one ings of three positions to suit the rider’s pref- The cowlings can be tilted back 30 mm erence. Have a Yamaha dealer adjust (1.18 in) for added ventilation to suit the the position of the handlebars. riding conditions.
Page 43: Rear View Mirrors

INSTRUMENT AND CONTROL FUNCTIONS EAU39671 EAU14732 Rear view mirrors Adjusting the front fork The rear view mirrors of this vehicle can EWA10180 WARNING be folded forward or backward for park- ing in narrow spaces. Fold the mirrors Always adjust both fork legs equal- back to their original position before ly, otherwise poor handling and loss riding.
Page 44
INSTRUMENT AND CONTROL FUNCTIONS To increase the spring preload and Rebound damping force Compression damping force thereby harden the suspension, turn the adjusting bolt on each fork leg in di- rection (a). To decrease the spring pre- load thereby soften suspension, turn the adjusting bolt on each fork leg in direction (b).
Page 45: Adjusting The Shock Absorber Assembly

INSTRUMENT AND CONTROL FUNCTIONS EAU14914 For riding solo, move the spring preload Adjusting the shock absorber adjusting lever in direction (b). For Although the total number of clicks of a assembly riding with a passenger, move the damping force adjusting mechanism This shock absorber assembly is spring preload adjusting lever in direc- may not exactly match the above spec-…
Page 46: Grip Warmer Adjusting Knob

Take the shock the grip warmer adjusting knob of clicks or turns of the damping force absorber assembly to a Yamaha to the “HI” position. adjusting mechanism. This adjustment dealer for any service.
Page 47: Sidestand

INSTRUMENT AND CONTROL FUNCTIONS EAU15301 below and have a Yamaha dealer re- Sidestand pair it if it does not function proper- The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the vehicle upright.
Page 48: Ignition Circuit Cut-Off System

INSTRUMENT AND CONTROL FUNCTIONS EAU40524 Ignition circuit cut-off system The ignition circuit cut-off system (com- prising the sidestand switch and brake light switches) has the following func- tions. It prevents starting when the side- stand is up, but neither brake is ap- plied.
Page 49
• 3. Turn the key on. If a malfunction is noted, have a Yamaha 4. Shift the transmission into the neutral position. dealer check the system before riding. 5. Keep the front or rear brake applied.
Page 50: Auxiliary Dc Jack

INSTRUMENT AND CONTROL FUNCTIONS EAU39652 Auxiliary DC jack ECA15430 NOTICE The accessory connected to the auxiliary DC jack should not be used with the engine turned off, and the load must never exceed 30 W (2.5 A), otherwise the battery may dis- charge.
Page 51: For Your Safety — Pre-Operation Checks

• If necessary, add recommended coolant to specified level. 6-15 • Check cooling system for leakage. • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check brake pads for wear. Front brake • Replace if necessary.
Page 52
• Make sure that operation is smooth. • Check cable free play. Throttle grip 6-17, 6-24 • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. • Make sure that operation is smooth. Control cables 6-24 •…
Page 53
FOR YOUR SAFETY – PRE-OPERATION CHECKS ITEM CHECKS PAGE • Check operation of ignition circuit cut-off system. Sidestand switch 3-33 • If system is not working correctly, have Yamaha dealer check vehicle.
Page 54: Operation And Important Riding Points

Yamaha dealer. The front or rear brake is applied gine in case of a turnover. In this…
Page 55: Shifting

(see page 5-2) with the front or rear brake applied. The neutral indicator light should come on. If not, ask a Yamaha dealer to check the electrical circuit. 3. Start the engine by pushing the start switch. NOTICE: For maxi-…
Page 56: Tips For Reducing Fuel Consumption

OPERATION AND IMPORTANT RIDING POINTS The gears can be shifted using either Always return the throttle to the EAU16810 Tips for reducing fuel con- the shift pedal or the hand shift lever. closed position while changing sumption The hand shift lever has to be enabled gears to avoid damaging the en- Fuel consumption depends largely on by pressing the hand shift control…
Page 57: Engine Break-In

When the en- period, immediately have a result in engine overheating must be gine stop switch has been used Yamaha dealer check the vehi- avoided. in an emergency, be sure to ap- cle. ply the front or rear brake while…
Page 58
OPERATION AND IMPORTANT RIDING POINTS Do not park on a slope or on soft ground, otherwise the vehicle may overturn, increasing the risk of a fuel leak and fire. Do not park near grass or other flammable materials which might catch fire.
Page 59: Periodic Maintenance And Adjustment

If If you do not have the tools or experi- you are not familiar with vehicle ser- ence required for a particular job, have vice, have a Yamaha dealer perform a Yamaha dealer perform it for you. service.
Page 60: Periodic Maintenance Chart For The Emission Control System

From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
Page 61: General Maintenance And Lubrication Chart

PERIODIC MAINTENANCE AND ADJUSTMENT EAU1770B General maintenance and lubrication chart ODOMETER READING ANNUAL ITEM CHECK OR MAINTENANCE JOB 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) √ √…
Page 62
PERIODIC MAINTENANCE AND ADJUSTMENT ODOMETER READING ANNUAL ITEM CHECK OR MAINTENANCE JOB 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check bearing play and steering √ √…
Page 63
PERIODIC MAINTENANCE AND ADJUSTMENT ODOMETER READING ANNUAL ITEM CHECK OR MAINTENANCE JOB 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) Engine oil filter car- √ √ √ •…
Page 64
PERIODIC MAINTENANCE AND ADJUSTMENT • Every two years replace the internal components of the brake master cylinders and calipers as well as YCC-S clutch master and release cylinders, and change the brake and YCC-S clutch fluids. • Replace the brake and YCC-S clutch hoses every four years and if cracked or damaged.
Page 65: Removing And Installing Panels

PERIODIC MAINTENANCE AND ADJUSTMENT EAU18771 Removing and installing pan- The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. 1.
Page 66
PERIODIC MAINTENANCE AND ADJUSTMENT 3. Pull the bottom of the panel out- ward, pull the front of the panel downward, and then slide the pan- el forward to release it in the rear as shown. 1. Panel B 1. Panel B 2.
Page 67
PERIODIC MAINTENANCE AND ADJUSTMENT 1. Panel C 1. Panel B 1. Panel B 2. Rear cowling 1. Panel C 1. Panel C 1. Panel B 2. Rear cowling 2. Fuel tank side cover To install the panel 1. Insert the rear of the panel into the 2.
Page 68: Checking The Spark Plugs

0.7–0.8 mm (0.028–0.031 in) such problems yourself. Instead, have 1. Panel C a Yamaha dealer check the vehicle. Clean the surface of the spark plug 3. Install the bolts and the quick fas- If a spark plug shows signs of electrode gasket and its mating surface, and then tener screws.
Page 69: Engine Oil And Oil Filter Cartridge

PERIODIC MAINTENANCE AND ADJUSTMENT EAU19885 Tightening torque: Engine oil and oil filter car- Spark plug: tridge 12.5 Nm (1.25 m·kgf, 9.0 ft·lbf) The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter car- If a torque wrench is not available when tridge replaced at the intervals speci- installing a spark plug, a good estimate…
Page 70
An oil filter wrench is available at a 2. Oil filter cartridge seated. 3. Engine oil drain bolt Yamaha dealer. 7. Install the new oil filter cartridge, 6. Apply a thin coat of clean engine and then tighten it to the specified oil to the O-ring of the new oil filter torque with a torque wrench.
Page 71
If the oil level warning light flickers 3.80 L (4.02 US qt, 3.34 Imp.qt) or remains on, immediately turn the With oil filter cartridge replacement: engine off and have a Yamaha dealer 4.00 L (4.23 US qt, 3.52 Imp.qt) check the vehicle. 6-13…
Page 72: Final Gear Oil

The final gear case must be checked necessary. final gear case. for oil leakage before each ride. If any leakage is found, have a Yamaha deal- The oil level should be at the brim of the er check and repair the vehicle. In addi- filler hole.
Page 73: Coolant

PERIODIC MAINTENANCE AND ADJUSTMENT 6. Install the oil filler bolt, and then EAU20070 Tightening torque: Coolant tighten it to the specified torque. Final gear oil filler bolt: The coolant level should be checked 23 Nm (2.3 m·kgf, 17 ft·lbf) before each ride. In addition, the cool- Tightening torque: ant must be changed at the intervals Final gear oil filler bolt:…
Page 74
Have a hot. NOTICE: If coolant is [EWA15161] Yamaha dealer change the coolant. not available, use distilled water WARNING! Never attempt to remove or soft tap water instead. Do not the radiator cap when the engine is use hard water or salt water hot.
Page 75: Air Filter Element

Check the engine idling speed and, if the periodic maintenance and lubrica- necessary, have it corrected by a tion chart. Have a Yamaha dealer clean Yamaha dealer. or replace the air filter element. Engine idling speed: 1000–1100 r/min…
Page 76: Valve Clearance

270 kPa (2.70 kgf/cm², 39 psi) Rear: from occurring, the valve clearance regarding the specified tires. 290 kPa (2.90 kgf/cm², 42 psi) must be adjusted by a Yamaha dealer 90–208 kg (198–459 lb): at the intervals specified in the periodic Tire air pressure Front: maintenance and lubrication chart.
Page 77
Tire information glass fragments in it, or if the sidewall is high-speed ride. cracked, have a Yamaha dealer re- After extensive tests, only the tires list- place the tire immediately. ed below have been approved for this model by Yamaha Motor Co., Ltd.
Page 78: Cast Wheels

Always adjust the tire air pres- 180/55 ZR17M/C (73W) fore each ride. If any damage is Manufacturer/model: sure according to the operating found, have a Yamaha dealer re- METZELER/Roadtec Z6C conditions. BRIDGESTONE/BT021R F place the wheel. Do not attempt FRONT and REAR:…
Page 79: Ycc-S Clutch

If neces- checked for wear at the intervals spec- check the hydraulic system for leakage sary, have a Yamaha dealer adjust the ified in the periodic maintenance and before each ride. If the YCC-S clutch brake light switch.
Page 80: Checking The Brake And Ycc-S Clutch Fluid Levels

PERIODIC MAINTENANCE AND ADJUSTMENT cator groove has almost disappeared, EAU40591 YCC-S clutch Checking the brake and have a Yamaha dealer replace the YCC-S clutch fluid levels brake pads as a set. Front brake EAU22500 Rear brake pads 1. Minimum level mark…
Page 81: Changing The Brake And Ycc-S Clutch Fluids

YCC-S clutch fluids 6-7.) stalling them. Have a Yamaha dealer change the Be careful that water or dust does Observe these precautions: brake and YCC-S clutch fluids at the in- not enter the brake and YCC-S…
Page 82: Checking And Lubricating The Cables

If a cable is damaged maintenance chart. or does not move smoothly, have a Yamaha dealer check or replace it. WARNING! Damage to the outer sheath may interfere with proper ca- ble operation and will cause the in- cable rust.
Page 83: Checking And Lubricating The Brake Lever

Silicone grease WARNING If the centerstand or sidestand does not move up and down smoothly, have a Yamaha dealer check or re- pair it. Otherwise, the centerstand or sidestand could contact the ground and distract the operator, resulting in a possible loss of control.
Page 84: Lubricating The Swingarm Pivots

PERIODIC MAINTENANCE AND ADJUSTMENT EAUM1650 EAU23250 Recommended lubricant: Lubricating the swingarm piv- Lubricating the rear suspen- Lithium-soap-based grease sion The swingarm pivots must be lubricat- The pivoting points of the rear suspen- ed at the intervals specified in the peri- sion must be lubricated at the intervals odic maintenance and lubrication chart.
Page 85: Checking The Front Fork

2. Hold the lower ends of the front fork does not operate smoothly, tion. WARNING! To avoid injury, fork legs and try to move them for- have a Yamaha dealer check or re- securely support the vehicle so ward and backward. If any free pair it.
Page 86: Checking The Wheel Bearings

WARNING Electrolyte is poisonous and To charge the battery dangerous since it contains sul- Have a Yamaha dealer charge the bat- furic acid, which causes severe tery as soon as possible if it seems to burns. Avoid any contact with have discharged.
Page 87: Replacing The Fuses

NOTICE you do not have access to a con- stant-voltage battery charger, have a Always keep the battery charged. Yamaha dealer charge your battery. Storing a discharged battery can cause permanent battery damage. 1. Main fuse To store the battery 2.
Page 88
PERIODIC MAINTENANCE AND ADJUSTMENT 2. Remove the blown fuse, and then Specified fuses: install a new fuse of the specified Main fuse: amperage. WARNING! Do not 50.0 A Headlight fuse: use a fuse of a higher amperage 25.0 A rating than recommended to Signaling system fuse: avoid causing extensive dam- 15.0 A…
Page 89: Headlight Bulb

If a headlight does not come on, have a If a front turn signal light does not come check the electrical system. Yamaha dealer check its electrical cir- on, have a Yamaha dealer check its cuit or replace the bulb. electrical circuit or replace the bulb. ECA16580…
Page 90: Replacing A Rear Turn Signal Light Bulb Or A Tail/Brake Light Bulb

PERIODIC MAINTENANCE AND ADJUSTMENT EAU27003 6. Install the passenger seat. EAU24312 Replacing a rear turn signal Replacing the license plate light bulb or a tail/brake light light bulb bulb 1. Remove the license plate light unit by removing the screws. 1.
Page 91: Auxiliary Light Bulb

The following troubleshooting charts represent quick and easy procedures for checking these vital systems your- self. However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the motorcycle properly.
Page 92
PERIODIC MAINTENANCE AND ADJUSTMENT heaters or furnaces. Gasoline or gasoline vapors can ignite or ex- plode, causing severe injury or property damage. 6-34…
Page 93: Troubleshooting Charts

Remove the spark plugs and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the battery. 4. Battery The engine turns over The battery is good.
Page 94
Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible.
Page 95: Motorcycle Care And Storage

Rust and corrosion can develop matte colored finished parts. Be ECA10772 even if high-quality components are sure to consult a Yamaha dealer for NOTICE advice on what products to use be- used. A rusty exhaust pipe may go un- Avoid using strong acidic wheel fore cleaning the vehicle.
Page 96
MOTORCYCLE CARE AND STORAGE off any detergent residue using Test the product on a small hid- plenty of water, as it is harmful den part of the windshield to Salt sprayed on roads in the winter may to plastic parts. make sure that it does not leave remain well into spring.
Page 97: Storage

WARNING To prevent corrosion, avoid Contaminants on the brakes or tires Consult a Yamaha dealer for ad- damp cellars, stables (because vice on what products to use. can cause loss of control. of the presence of ammonia)
Page 98
MOTORCYCLE CARE AND STORAGE 3. Perform the following steps to pro- 4. Lubricate all control cables and the tect the cylinders, piston rings, etc. pivoting points of all levers and from corrosion. pedals as well as of the side- a. Remove the spark plug caps stand/centerstand.
Page 99: Specifications

SPECIFICATIONS Dimensions: Engine oil: Fuel injection: Overall length: Type: Throttle body: 2230 mm (87.8 in) SAE 10W-40, SAE 10W-50, SAE 15W-40, Type/quantity: Overall width: SAE 20W-40 or SAE 20W-50 42EHS/1 Spark plug (s): 750 mm (29.5 in) Recommended engine oil grade: Overall height: API service SG type or higher, JASO Manufacturer/model:…
Page 100
SPECIFICATIONS 4th: Tire air pressure (measured on cold Recommended fluid: 28/26 (1.077) DOT 4 tires): 5th: Rear brake: Loading condition: 26/28 (0.929) Type: 0–90 kg (0–198 lb) Chassis: Single disc brake Front: Frame type: Operation: 270 kPa (2.70 kgf/cm², 39 psi) Diamond Right foot operation Rear:…
Page 101
SPECIFICATIONS Headlight: Fuses: Bulb type: Main fuse: Halogen bulb 50.0 A Bulb voltage, wattage × quantity: Headlight fuse: 25.0 A Headlight: 12 V, 60 W/55 W × 2 Signaling system fuse: 15.0 A Tail/brake light: 12 V, 5.0 W/21.0 W × 2 Ignition fuse: 10.0 A Front turn signal light:…
Page 102: Consumer Information

Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi- cle is stolen. KEY IDENTIFICATION NUMBER: 1.
Page 103
The model label is affixed to the frame under the passenger seat. (See page 3-23.) Record the information on this la- bel in the space provided. This informa- tion will be needed when ordering spare parts from a Yamaha dealer.
Page 104
INDEX Engine trouble/YCC-S indicators and warning light ……… 3-5 ABS…………3-19 License plate light bulb, replacing ..6-32 ABS warning light……..3-6 Accessory box……..3-27 Final gear oil ……… 6-14 Main switch/steering lock ……3-3 Air filter element ……..6-17 Front and rear brake pads, checking..
Page 105
INDEX Start switch ……….. 3-16 Steering, checking …….. 6-27 Storage ……….. 7-3 Storage compartment ……3-26 Swingarm pivots, lubricating….6-26 Tachometer ……….3-7 Throttle cable free play, checking..6-17 Throttle grip and cable, checking and lubricating ……….. 6-24 Tires…………6-18 Tool kit …………
Page 108
YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2008.10-0.3×1 CR…

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FJR1300AS(X)
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Summary of Contents for Yamaha FJR1300AS(X)

Page 1
2008 SERVICE MANUAL FJR1300A(X) FJR1300AS(X) 3P6-28197-E2…
Page 2
EAS20040 FJR1300A(X)/FJR1300AS(X) 2008 SERVICE MANUAL ©2007 by Yamaha Motor Co., Ltd. First edition, October 2007 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
Page 3
EAS20070 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Page 4: How To Use This Manual

EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •…
Page 5: Symbols

EAS20100 1. Serviceable with engine mounted SYMBOLS 2. Filling fluid The following symbols are used in this manual 3. Lubricant for easier understanding. 4. Special tool NOTE: 5. Tightening torque The following symbols are not relevant to every 6. Wear limit, clearance vehicle.
Page 7: Table Of Contents

EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING…
Page 9: General Information

ABS COMPONENT FUNCTIONS …………1-10 ABS OPERATION ………………. 1-15 ABS SELF-DIAGNOSIS FUNCTION…………1-17 ABS WARNING LIGHT AND OPERATION……….1-20 OUTLINE OF THE YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS) ………………1-21 INSTRUMENT FUNCTIONS …………..1-24 IMPORTANT INFORMATION …………… 1-30 PREPARATION FOR REMOVAL AND DISASSEMBLY……1-30 REPLACEMENT PARTS……………..
Page 10: Identification

IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.
Page 11: Features

FEATURES EAS20170 FEATURES ET2C01025 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.
Page 12: Fi System

FEATURES ET3P61042 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm², 47.0 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
Page 13: Outline Of The Unified Brake System

OUTLINE OF THE UNIFIED BRAKE SYSTEM The Yamaha unified brake system is a system that operates one set of pistons in the front brakes to- gether with the rear brake when the brake pedal is depressed. Compared to conventional brake sys- tems, the ability to slow the vehicle using the simple operation of the brake pedal is improved.
Page 14: Outline Of The Abs

ET3P61019 OUTLINE OF THE ABS 1. The Yamaha ABS (anti-lock brake system) features an electronic control system, which acts on the front and rear brakes independently. However, one set of pistons in the right front brake caliper is operated together with the rear brake and this set of pistons is operated only if the force used to de- press the brake pedal exceeds a preset level.
Page 15
8. Rear wheel sensor The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles, with a brake lever for operating the front brake and a brake pedal for operating the rear brake. However, part of the front brake is operated together with rear brake.
Page 16
FEATURES • Slip ratio: When the brakes are applied, slipping occurs between the tires and the road surface. This causes a difference between the wheel speed and the chassis speed. Slip ratio is the value that shows the rate of wheel slippage and is defined by the following formula. Chassis speed –…
Page 17
FEATURES The difference between the chassis speed and the wheel speed calculated in the slip ratio formula is equal to the wheel slip. When the wheel speed is suddenly reduced, the wheel has a tendency to lock. When the wheel slip and the wheel speed reduction rate exceed the preset values, the ABS ECU de- termines that the wheel has a tendency to lock.
Page 18
Slip ratio (%) b. Brake force Electronic ABS features The Yamaha ABS (anti-lock brake system) has been developed with the most advanced electronic technology. The ABS control is processed with good response under various vehicle travel conditions. The ABS also includes a highly developed self-diagnosis function. The ABS detects any problem con- dition and allows normal braking even if the ABS is not operating properly.
Page 19: Abs Component Functions

FEATURES ABS block diagram 1. Rear brake master cylinder 10. Proportioning valve 2. Hydraulic unit assembly 11. Rear brake caliper 3. Front brake master cylinder 12. Rear wheel sensor 4. Inlet solenoid valve 13. Metering valve 5. ABS motor 14. ABS warning light 6.
Page 20
FEATURES 3. At low speed 7. Voltage 4. At high speed 8. Time 5. Wheel sensor 6. Wheel sensor rotor ABS warning light The ABS warning light “1” comes on to warn the rider if a malfunction in the ABS occurs. When the main switch is turned to “ON”, the ABS warning light comes on for 2 seconds, then goes off, so that the rider can check if the ABS warning light is disconnected and check if the ABS is operating properly.
Page 21
FEATURES • Hydraulic control valve The hydraulic control valve is composed of a inlet solenoid valve and outlet solenoid valve. The electromagnetic force generated in the inlet solenoid valve varies proportionally with the duty cy- cle control voltage that is supplied to it. Since this voltage is continuously variable, the solenoid valve moves smoothly and the hydraulic pressure is adjusted linearly.
Page 22
FEATURES • Buffer chamber The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating. 1. Buffer chamber (pressurizing phase) 3. Raised piston 2. Buffer chamber (depressurizing phase) • ABS ECU The ABS ECU is integrated with the hydraulic unit to achieve a compact and lightweight design. As shown in the block following diagram, the ABS ECU receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits.
Page 23
FEATURES 29. Front wheel sensor 30. Start switch 31. Starting circuit cut-off relay 32. Starter motor 33. Starter relay 34. MCU (motor control unit) (FJR1300AS only) 35. ECU (engine control unit) The necessary actions are confirmed using the monitor circuit and control signals are transmitted to the hydraulic unit assembly.
Page 24: Abs Operation

FEATURES ET3P61052 ABS OPERATION The ABS hydraulic circuit consists of two systems: the front wheel, and rear wheel. The following de- scribes the system for the front wheel only, excluding the unified brake system. Normal braking (ABS not activated) When the ABS is not activated, the inlet solenoid valve is open and the outlet solenoid valve is closed because a control signal has not been transmitted from the ABS ECU.
Page 25
FEATURES Emergency braking (ABS activated) 1. Depressurizing phase When the front wheel is about to lock, the outlet solenoid valve is opened by the “depressurization” signal transmitted from the ABS ECU. When this occurs, the inlet solenoid valve compresses the spring and closes the brake line from the brake master cylinder.
Page 26: Abs Self-Diagnosis Function

FEATURES 1. Brake master cylinder 8. Brake caliper 2. Brake light switch 9. Wheel sensor 3. ABS motor 10. ABS ECU 4. Hydraulic pump 11. ABS warning light 5. Buffer chamber 12. Brake fluid pressure 6. Outlet solenoid valve 13. Time 7.
Page 27
FEATURES Instances when the ABS warning light comes on 1. The ABS warning light comes on when the main switch is turned to “ON”. The ABS warning light comes on for 2 seconds while the ABS is performing a self-diagnosis, then goes off if there are no problems.
Page 28
FEATURES a. ABS warning light b. Comes on 4. The ABS warning light flashes while riding. If the ABS warning light flashes while riding, there is no problem with the function of the ABS. How- ever, the ABS ECU input has unstable factors. (For details, refer to “ABS TROUBLESHOOTING OUTLINE”…
Page 29: Abs Warning Light And Operation

FEATURES ET3P61054 ABS WARNING LIGHT AND OPERATION ABS warning light • When the main switch is turned to “ON”, the ABS warning light comes on for 2 seconds, then goes off. • The ABS warning light comes on while the start switch is being pushed. •…
Page 30: Outline Of The Ycc-S (Yamaha Chip Controlled-Shift) System (Fjr1300As)

* Wheel lock: A condition that occurs when the rotation of one or both of the wheels has stopped, but the vehicle continues to travel. ET3P66049 OUTLINE OF THE YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS) Concept YCC-S offers more enjoyable and easy riding by eliminating the need for the user to operate the clutch, which also reduces fatigue during long touring.
Page 31
FEATURES 1. YCC-S test coupler 8. Shift actuator 2. YCC-S indicator and warning light 9. YCC-S control relay 3. YCC-S motor control fuse 10. Clutch actuator 4. Hand shift switch 11. Foot shift switch 5. Gear position sensor 12. YCC-S speed sensor 6.
Page 32
• If the YCC-S indicator and warning light come on while riding, stop the vehicle, park it in a safe place, and then contact a Yamaha dealer. Because the YCC-S system stops automatically when the YCC-S indicator and warning light come on, it is impossible to shift since clutch operation is stopped.
Page 33: Instrument Functions

FEATURES Multi-function display ET3P61043 INSTRUMENT FUNCTIONS Speedometer 1. Multi-function display 2. “SELECT” button 3. “RESET” button 1. Tachometer 2. Speedometer EW3P61020 WARNING 3. Multi-function display Be sure to stop the vehicle before making The speedometer shows the riding speed. any setting changes to the multi-function When the key is turned to “ON”, the speedome- display.
Page 34
FEATURES Odometer and tripmeter modes Clock 1. Odometer/tripmeter/fuel reserve tripmeter 1. Clock 2. “SELECT” button 2. “SELECT” button 3. “RESET” button 3. “RESET” button Pushing the “SELECT” button switches the dis- To set the clock: play between the odometer mode “ODO” and 1.
Page 35
FEATURES Refer to “SIGNALING SYSTEM” on page 8-39. Ambient temperature, instantaneous fuel consumption and average fuel consumption modes (except for the UK) Coolant temperature meter 1. Ambient temperature/instantaneous fuel 1. Coolant temperature meter consumption/average fuel consumption 2. “SELECT” button With the key in the “ON” position, the coolant 3.
Page 36
FEATURES • The accuracy of the temperature reading may L of fuel) or “AV _ _._ L/100 km” (average be affected when riding slowly (approximately amount of fuel necessary to travel 100 km) is under 20 km/h) or when stopped at traffic sig- displayed.
Page 37
FEATURES Ambient temperature mode Average fuel consumption mode 1. Ambient temperature 1. Average fuel consumption This display shows the ambient temperature This display shows the average fuel consump- from -9 °C to 50 °C in 1 °C increments. The tem- tion since it was last reset.
Page 38
FEATURES If the multi-function display indicates such an fault code, note the code number, and check the vehicle. Refer to “FUEL INJECTION SYSTEM” on page 8-57. EC3P61042 CAUTION: If the multi-function display indicates an fault code, the vehicle should be checked as soon as possible in order to avoid engine damage.
Page 39: Important Information

5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
Page 40: Bearings And Oil Seals

IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.
Page 41: Checking The Connections

CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: • Lead NOTE: • Coupler • If there is no continuity, clean the terminals. •…
Page 42: Special Tools

SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
Page 43
SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Compression gauge 3-13 90890-03081 Engine compression tester YU-33223 Oil filter wrench 3-15 90890-01426 YU-38411 Oil pressure gauge set 3-16 90890-03120 Oil pressure adapter B 3-16 90890-03124 Vacuum/pressure pump gauge set 3-19 90890-06756 Mityvac brake bleeding tool YS-42423 Magnet base B…
Page 44
SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Damper rod holder 4-82, 4-83 90890-01447 YM-01447 Slide metal installer 4-84 90890-01508 YM-01508 Fork seal driver 4-84, 4-85 90890-01502 YM-A0948 Ring gear fix bolt (M14) 4-106 90890-01524 YM-01524 M14×P1.5 Final gear backlash band 4-106 90890-01511 Middle drive gear lash tool…
Page 45
5-11, 5-72, 7-8 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Rotor holding tool 5-15, 5-18 90890-01235 Universal magneto & rotor holder YU-01235 Yamaha bond No. 1215 5-20, 5-37, 90890-85505 5-40, 5-104, 6-13 ® (Three Bond No.1215 Valve spring compressor 5-26, 5-31…
Page 46
SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide remover (ø5) 5-28 90890-04097 Valve guide remover (5.0 mm) YM-04097 Valve guide installer (ø5) 5-28 90890-04098 Valve guide installer (5.0 mm) YM-04098 Valve guide reamer (ø5) 5-28 90890-04099 Valve guide reamer (5.0 mm) YM-04099 Sheave holder 5-36, 5-37,…
Page 47
SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Damper spring compressor 5-89, 5-90 90890-04090 Bearing retainer wrench 5-90 90890-04140 Middle drive shaft bearing retainer wrench YM-04140 Gear lash measurement tool 5-93 90890-01467 YM-01467 Piston pin puller set 5-108 90890-01304 Piston pin puller YU-01304 YU-01304 Piston ring compressor…
Page 48
SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Weight 5-127 90890-01084 YU-01083-3 YU-01083-3 Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01 YU-24460-01 Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984 YU-33984 Mechanical seal installer 6-13 90890-04078 Water pump seal installer YM-33221-A Middle driven shaft bearing driver 6-13…
Page 49
SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pressure gauge 90890-03153 YU-03153 Fuel pressure adapter 90890-03176 YM-03176 Ignition checker 8-248 90890-06754 Opama pet-4000 spark checker YM-34487 1-40…
Page 50
SPECIAL TOOLS 1-41…
Page 51: Specifications

SPECIFICATIONS GENERAL SPECIFICATIONS ……………. 2-1 ENGINE SPECIFICATIONS …………….2-2 CHASSIS SPECIFICATIONS …………….2-9 ELECTRICAL SPECIFICATIONS …………..2-12 TIGHTENING TORQUES …………….2-15 GENERAL TIGHTENING TORQUE SPECIFICATIONS……2-15 ENGINE TIGHTENING TORQUES…………2-16 CHASSIS TIGHTENING TORQUES…………2-21 LUBRICATION POINTS AND LUBRICANT TYPES ……..2-26 ENGINE………………..
Page 52: General Specifications

GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model FJR1300A 3P6D (Europe except (B) and (F)) (ZA) FJR1300A 3P6E (B) (F) FJR1300A 3P6F (AUS) FJR1300AS 2D2D (Europe except (B) and (F)) (ZA) FJR1300AS 2D2E (B) (F) FJR1300AS 2D2F (AUS) Dimensions Overall length 2230 mm (87.8 in) Overall width 750 mm (29.5 in)
Page 53: Engine Specifications

ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 1298.0 cm³ Cylinder arrangement Forward-inclined parallel 4-cylinder Bore × stroke 79.0 × 66.2 mm (3.11 × 2.61 in) Compression ratio 10.80 :1 Standard compression pressure (at sea level) 1600 kPa/400 r/min (227.6 psi/400 r/min) (16.0 kgf/cm²/400 r/min) Minimum–maximum…
Page 54
ENGINE SPECIFICATIONS Relief valve operating pressure 480.0–560.0 kPa (69.6–81.2 psi) (4.80–5.60 kgf/cm²) Cooling system Radiator capacity (including all routes) 2.60 L (2.75 US qt) (2.29 Imp.qt) Radiator capacity 0.65 L (0.69 US qt) (0.57 Imp.qt) Coolant reservoir capacity (up to the maximum level mark) 0.25 L (0.26 US qt) (0.22 Imp.qt) Radiator cap opening pressure…
Page 55
ENGINE SPECIFICATIONS Limit 24.897 mm (0.9802 in) Camshaft runout limit 0.030 mm (0.0012 in) Timing chain Model/number of links 92RH2015/136 Tensioning system Automatic Valve, valve seat, valve guide Valve clearance (cold) Intake 0.15–0.22 mm (0.0059–0.0087 in) Exhaust 0.18–0.25 mm (0.0071–0.0098 in) Valve dimensions Valve head diameter A (intake) 29.90–30.10 mm (1.1772–1.1850 in)
Page 56
ENGINE SPECIFICATIONS Valve-stem-to-valve-guide clearance (exhaust) 0.020–0.047 mm (0.0008–0.0019 in) Limit 0.105 mm (0.0041 in) Valve stem runout 0.010 mm (0.0004 in) Cylinder head valve seat width (intake) 0.90–1.10 mm (0.0354–0.0433 in) Cylinder head valve seat width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Valve spring Free length (intake) 39.73 mm (1.56 in)
Page 57
ENGINE SPECIFICATIONS Height H 5.0 mm (0.20 in) Offset 0.50 mm (0.0197 in) Offset direction Intake side Piston pin bore inside diameter 19.004–19.015 mm (0.7482–0.7486 in) Limit 19.045 mm (0.7498 in) Piston pin outside diameter 18.991–19.000 mm (0.7477–0.7480 in) Limit 18.971 mm (0.7469 in) Piston-pin-to-piston-pin-bore clearance 0.004–0.024 mm (0.00016–0.00094 in)
Page 58
ENGINE SPECIFICATIONS Small end inside diameter 19.005–19.018 mm (0.7482–0.7487 in) Crankshaft Width A 61.60–63.20 mm (2.425–2.488 in) Width B 325.10–326.30 mm (12.80–12.85 in) Runout limit C 0.030 mm (0.0012 in) Big end side clearance D 0.160–0.262 mm (0.0063–0.0103 in) ® Journal oil clearance (using plastigauge 0.027–0.045 mm (0.0011–0.0018 in) Bearing color code…
Page 59
ENGINE SPECIFICATIONS Drive axle runout limit 0.08 mm (0.0032 in) Shifting mechanism Shift mechanism type Shift drum and guide bar Shift fork guide bar bending limit 0.100 mm (0.0039 in) Air filter Air filter element Dry element Fuel pump Pump type Electrical Model/manufacturer 5JW 21/DENSO…
Page 60: Chassis Specifications

CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 26.00° Trail 109.0 mm (4.29 in) Front wheel Wheel type Cast wheel 17M/C × MT3.50 Rim size Rim material Aluminum Wheel travel 135.0 mm (5.31 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
Page 61
CHASSIS SPECIFICATIONS Front disc brake Disc outside diameter × thickness 320.0 × 4.5 mm (12.60 × 0.18 in) Brake disc thickness limit 4.0 mm (0.16 in) Brake disc deflection limit 0.10 mm (0.0039 in) Brake pad lining thickness (inner) 5.5 mm (0.22 in) Limit 0.5 mm (0.02 in) Brake pad lining thickness (outer)
Page 62
CHASSIS SPECIFICATIONS Optional spring available Recommended oil Suspension oil M1 or Ohlins R & T43 Quantity 696.0 cm³ (23.53 US oz) (24.55 Imp.oz) Level 92.0 mm (3.62 in) Rear suspension Type Swingarm (link suspension) Spring/shock absorber type Coil spring/gas-oil damper Rear shock absorber assembly travel 60.0 mm (2.36 in) Spring free length…
Page 63: Electrical Specifications

ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Transistorized coil ignition (digital) Ignition timing (B.T.D.C.) 5.0°/1050 r/min Engine control unit Model/manufacturer FUA0023/MITSUBISHI (Europe except (B) and (F)) (ZA) (AUS) FUA0024/MITSUBISHI (B) (F) Ignition coil Model/manufacturer JO383/DENSO Minimum ignition spark gap…
Page 64
ABS warning light Immobilizer system indicator light Electric starting system System type Constant mesh Starter motor Model/manufacturer 3P6/YAMAHA Power output 0.80 kW 0.024–0.030 Ω at 20 °C (68 °F) Armature coil resistance Brush overall length 10.8 mm (0.43 in) Limit 3.65 mm (0.14 in)
Page 65
ELECTRICAL SPECIFICATIONS Starting circuit cut-off relay Model/manufacturer G8R-30Y-V3/OMRON 180.0 Ω Coil resistance Headlight relay Model/manufacturer ACM33211 M05/MATSUSHITA 96.0 Ω Coil resistance Radiator fan Model/manufacturer 3P6/DENSO Running rpm 4250 r/min Fan motor relay Model/manufacturer ACM33211 M05/MATSUSHITA 96.0 Ω Coil resistance Gear position sensor Output voltage (at neutral position) FJR1300AS 0.71–0.91 V Resistance…
Page 66: Tightening Torques

TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.
Page 67: Engine Tightening Torques

TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Spark plug 13 Nm (1.3 m·kg, 9.4 ft·lb) Cylinder head bolt See NOTE. Cylinder head bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Camshaft cap bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Cylinder head cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Engine oil check bolt…
Page 68
TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Oil pump housing cover bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Oil level switch bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Throttle body joint clamp screw 3 Nm (0.3 m·kg, 2.2 ft·lb) Air filter case joint clamp screw 4 Nm (0.4 m·kg, 2.9 ft·lb) Air filter case and rear lower fuel…
Page 69
TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Main gallery bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Starter clutch bolt 32 Nm (3.2 m·kg, 23 ft·lb) Use a Clutch boss nut 90 Nm (9.0 m·kg, 65 ft·lb) lock washer. Clutch spring bolt 8 Nm (0.8 m·kg, 5.8 ft·lb) Clutch release cylinder bolt…
Page 70
TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Coolant reservoir bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Coolant reservoir bracket bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Clutch fluid reservoir bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) (FJR1300AS) Clutch actuator bracket bolt 19 Nm (1.9 m·kg, 13 ft·lb) (FJR1300AS) Clutch actuator bracket bolt…
Page 71
TIGHTENING TORQUES Cylinder head tightening sequence: Crankcase tightening sequence: 19 22 2-20…
Page 72: Chassis Tightening Torques

TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolts (right front 49 Nm (4.9 m·kg, 35 ft·lb) lower side) Engine mounting bolts (right front 49 Nm (4.9 m·kg, 35 ft·lb) upper side) Engine mounting bolts (left front 49 Nm (4.9 m·kg, 35 ft·lb) lower side) Engine mounting bolts (left front…
Page 73
TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Lower ring nut (initial tightening 52 Nm (5.2 m·kg, 37 ft·lb) torque) NOTE. Lower ring nut (final tightening 18 Nm (1.8 m·kg, 13 ft·lb) torque) NOTE. Handlebar bolt 23 Nm (2.3 m·kg, 17 ft·lb) Handlebar nut 65 Nm (6.5 m·kg, 47 ft·lb) Clutch master cylinder holder bolt…
Page 74
TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear fender nut 7 Nm (0.7 m·kg, 5.1 ft·lb) Front wheel axle bolt 91 Nm (9.1 m·kg, 66 ft·lb) NOTE. Front wheel axle pinch bolt 21 Nm (2.1 m·kg, 15 ft·lb) Front brake disc bolt 18 Nm (1.8 m·kg, 13 ft·lb) Front wheel sensor bolt…
Page 75
TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Brake pedal bolt 8 Nm (0.8 m·kg, 5.8 ft·lb) Right footrest bracket bolt 28 Nm (2.8 m·kg, 20 ft·lb) Rear brake master cylinder bolt 18 Nm (1.8 m·kg, 13 ft·lb) Rear brake master cylinder lock- 16 Nm (1.6 m·kg, 11 ft·lb) Left footrest assembly bolt 28 Nm (2.8 m·kg, 20 ft·lb)
Page 76
TIGHTENING TORQUES 2. In the order pinch bolt “2” → pinch bolt “1” → pinch bolt “2”, tighten each bolt to 21 Nm (2.1 m·kg, 15 ft·lb) without performing temporary tightening. 3. Check that the right end of the front axle is flush with the front fork. If necessary, manually push the front axle or lightly tap it with a soft hammer until its end is flush with the front fork.
Page 77: Lubrication Points And Lubricant Types

LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Crankshaft pins Piston surfaces Piston pins Connecting rod bolts and nuts Crankshaft journals Camshaft lobes Camshaft journals Balancer absorbers, weights, gears and shafts Valve stems (intake and exhaust) Valve stem ends (intake and exhaust) Water pump impeller shaft…
Page 78
LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant ® Cylinder head cover mating surface Three Bond 1541 Yamaha bond No.1215 Cylinder head cover gasket (Three Bond ® No.1215 Yamaha bond No.1215 Crankcase mating surface (Three Bond ® No.1215 Yamaha bond No.1215…
Page 79: Chassis

LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and upper bearing cover lip Lower bearing dust seal lip Front wheel oil seal lips (right and left) Rear wheel oil seal lips Rear wheel drive hub oil seal Rear wheel drive hub mating surface Rear brake pedal pivoting point Footrest assembly pivoting point…
Page 80: Lubrication System Chart And Diagrams

LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-29…
Page 81
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve assembly 4. Oil filter 5. Oil cooler 6. Main gallery 7. Front balancer shaft 8. Rear balancer shaft 9. Oil nozzle 10. Intake camshaft 11. Exhaust camshaft 12.
Page 82: Lubrication Diagrams

LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-31…
Page 83
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Cylinder head 3. Exhaust camshaft 4. Oil check bolt 5. Main gallery bolt 6. Crankshaft 7. Oil nozzle 2-32…
Page 84
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33…
Page 85
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Drive axle 3. Oil delivery pipe 1 2-34…
Page 86
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35…
Page 87
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil check bolt 2. Crankshaft 3. Oil cooler 4. Oil strainer 5. Oil delivery pipe 3 6. Oil pump 2-36…
Page 88
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-37…
Page 89
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Rear balancer 2. Oil delivery pipe 2 3. Engine oil drain bolt 4. Oil level switch 5. Crankshaft 6. Front balancer 7. Crank pin 8. Oil delivery pipe 3 9. Relief valve assembly 2-38…
Page 90
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-39…
Page 91
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil delivery pipe 2 3. Oil cooler 4. Engine oil drain bolt 5. Oil level switch 6. Oil filter cartridge 7. Oil delivery pipe 3 8. Oil pan 9. Oil pump 2-40…
Page 92: Cooling System Diagrams

COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-41…
Page 93
COOLING SYSTEM DIAGRAMS 1. Thermostat inlet pipe 1 2. Thermostat inlet hose 1 3. Plunger control unit hose 1 4. Plunger control unit hose 2 5. Oil cooler outlet hose 6. Radiator 7. Coolant reservoir breather hose 8. Thermostat inlet pipe 2 9.
Page 94
COOLING SYSTEM DIAGRAMS 2-43…
Page 95
COOLING SYSTEM DIAGRAMS 1. Thermostat inlet pipe 1 2. Thermostat inlet hose 2 3. Radiator inlet hose 4. Radiator 5. Radiator outlet hose 6. Oil cooler outlet hose 7. Water jacket joint inlet hose 8. Water pump outlet pipe 9. Water pump outlet hose 10.
Page 96: Cable Routing (Fjr1300A)

CABLE ROUTING (FJR1300A) EAS20430 CABLE ROUTING (FJR1300A) 2-45…
Page 97
CABLE ROUTING (FJR1300A) 1. Right grip warmer lead N. Fasten the right grip warmer lead to the throttle cables with a plastic locking tie 10 mm (0.39 in) or 2. Brake hose (front brake master cylinder to brake less from the end of the throttle cable boot. Face pipe/lower joint assembly) the end of the plastic locking tie upward or 3.
Page 98
CABLE ROUTING (FJR1300A) 14 15 2-47…
Page 99
CABLE ROUTING (FJR1300A) 1. O sensor lead Fasten the wire harness, right horn (high) leads, and right radiator fan motor lead with a plastic 2. Engine idling speed adjusting cable locking tie, making sure to install the tie on the fan 3.
Page 100
CABLE ROUTING (FJR1300A) 4 5 6 7 8 9 12 13 2-49…
Page 101
CABLE ROUTING (FJR1300A) 1. Rear wheel sensor lead 2. Brake hose (rear brake master cylinder to brake pipe/middle joint assembly) 3. Rear brake fluid reservoir hose 4. Rear brake fluid reservoir 5. Brake pipe (hydraulic unit to metering valve) 6. Hydraulic unit assembly 7.
Page 102
CABLE ROUTING (FJR1300A) 2-51…
Page 103
CABLE ROUTING (FJR1300A) 1. Auxiliary DC jack 2. Left radiator fan motor lead 3. Accessory box solenoid 4. Wire harness 5. Front cowling wire harness 6. Radiator inlet hose 7. Grip warmer control unit leads 8. Left radiator fan 9. Coolant reservoir breather hose 10.
Page 104
CABLE ROUTING (FJR1300A) 30 27 2-53…
Page 105
CABLE ROUTING (FJR1300A) 1. Grip warmer couplers G. Route the gear position switch lead so that the coupler is positioned as shown in the illustration. 2. Handlebar switch couplers H. Pass the fuel tank breather/overflow hose through 3. Right grip warmer lead the guide on the universal joint dust cover.
Page 106
CABLE ROUTING (FJR1300A) 2-55…
Page 107
CABLE ROUTING (FJR1300A) 1. Wire harness 2. ECU (engine control unit) 3. Tail/brake light 4. Rear turn signal light 5. Tail/brake light assembly lead 6. License plate light lead 7. Seat lock cable 8. Stator coil lead 9. Rear shock absorber spring preload adjusting cable 10.
Page 108
CABLE ROUTING (FJR1300A) 4 5 6 7 8 9 10 2-57…
Page 109
CABLE ROUTING (FJR1300A) 1. Spark plug lead #1 L. Route the stator coil lead to the inside of the engine bracket (top) and under the crankcase 2. Spark plug lead #2 breather hose. 3. Clutch hose M. Route the wire harness (to sub-wire harness) 4.
Page 110
CABLE ROUTING (FJR1300A) 2-59…
Page 111
CABLE ROUTING (FJR1300A) 1. License plate light lead 2. Tail/brake light assembly lead 3. Seat lock cable 4. Intake air temperature sensor A. Route the tail/brake light assembly lead and license plate light lead between the rib and the U- lock holder on the rear fender, making sure that the leads are not routed on top of the holder.
Page 112
CABLE ROUTING (FJR1300A) 2-61…
Page 113
CABLE ROUTING (FJR1300A) 1. Windshield drive unit O. Fasten the thermistor lead with a plastic locking tie, and then cut off the excess end of the tie. Be sure 2. Thermistor to fold the protective sleeve against the lead to 3.
Page 114
CABLE ROUTING (FJR1300A) 2-63…
Page 115
CABLE ROUTING (FJR1300A) 1. Hydraulic unit assembly 2. Brake pipe/middle joint assembly 3. Brake pipe (hydraulic unit to metering valve) 4. Brake pipe (hydraulic unit to proportioning valve) 5. Brake pipe/upper joint assembly 6. Brake pipe/lower joint assembly 7. Brake pipe (proportioning valve to rear brake hose) 8.
Page 116: Cable Routing (Fjr1300As)

CABLE ROUTING (FJR1300AS) ET3P66048 CABLE ROUTING (FJR1300AS) 12 11 2-65…
Page 117
CABLE ROUTING (FJR1300AS) 1. Right grip warmer lead L. Fasten the right grip warmer lead to the throttle cables with a plastic locking tie 10 mm (0.39 in) or 2. Brake hose (front brake master cylinder to brake less from the end of the throttle cable boot. Face pipe/lower joint assembly) the end of the plastic locking tie upward or 3.
Page 118
CABLE ROUTING (FJR1300AS) 14 15 2-67…
Page 119
CABLE ROUTING (FJR1300AS) 1. O sensor lead Fasten the wire harness, right horn (high) leads, and right radiator fan motor lead with a plastic 2. Engine idling speed adjusting cable locking tie, making sure to install the tie on the fan 3.
Page 120
CABLE ROUTING (FJR1300AS) 4 5 6 7 11 12 13 14 15 2-69…
Page 121
CABLE ROUTING (FJR1300AS) 1. Rear wheel sensor lead 2. Brake hose (rear brake master cylinder to brake pipe/middle joint assembly) 3. Rear brake fluid reservoir hose 4. Rear brake fluid reservoir 5. Brake pipe (hydraulic unit to metering valve) 6. Hydraulic unit assembly 7.
Page 122
CABLE ROUTING (FJR1300AS) 2-71…
Page 123
CABLE ROUTING (FJR1300AS) 1. Auxiliary DC jack 2. Left radiator fan motor lead 3. Accessory box solenoid 4. Wire harness 5. Front cowling wire harness 6. Radiator inlet hose 7. Grip warmer control unit leads 8. Left radiator fan 9. Coolant reservoir breather hose 10.
Page 124
CABLE ROUTING (FJR1300AS) 31 32 12 13 2-73…
Page 125
CABLE ROUTING (FJR1300AS) 1. Grip warmer couplers D. Fasten the sidestand switch lead, stator coil lead, and oil level switch lead with a plastic locking tie, 2. Hand shift switch couplers making sure to bundle and fasten the sidestand 3. Handlebar switch couplers switch lead so that the coupler is positioned to the 4.
Page 126
CABLE ROUTING (FJR1300AS) 2-75…
Page 127
CABLE ROUTING (FJR1300AS) 1. Wire harness 2. ECU (engine control unit) 3. MCU (motor control unit) 4. Tail/brake light 5. Rear turn signal light 6. Tail/brake light assembly lead 7. License plate light lead 8. Seat lock cable 9. Foot shift switch lead 10.
Page 128
CABLE ROUTING (FJR1300AS) 6 7 8 9 2-77…
Page 129
CABLE ROUTING (FJR1300AS) 1. Spark plug lead #1 L. Route the stator coil lead to the inside of the engine bracket (top) and under the crankcase 2. Spark plug lead #2 breather hose. 3. Front wheel sensor lead M. Route the wire harness (to sub-wire harness) 4.
Page 130
CABLE ROUTING (FJR1300AS) 2-79…
Page 131
CABLE ROUTING (FJR1300AS) 1. Clutch actuator motor lead 2. Clutch actuator sensor lead 3. License plate light lead 4. Tail/brake light assembly lead 5. Seat lock cable 6. Intake air temperature sensor A. Fasten the clutch actuator motor lead and clutch actuator sensor lead with the band that is used to secure the MCU (motor control unit).
Page 132
CABLE ROUTING (FJR1300AS) 2-81…
Page 133
CABLE ROUTING (FJR1300AS) 1. Windshield drive unit O. Fasten the thermistor lead with a plastic locking tie, and then cut off the excess end of the tie. Be sure 2. Thermistor to fold the protective sleeve against the lead to 3.
Page 134
CABLE ROUTING (FJR1300AS) 2-83…
Page 135
CABLE ROUTING (FJR1300AS) 1. Hydraulic unit assembly 2. Brake pipe/middle joint assembly 3. Brake pipe (hydraulic unit to metering valve) 4. Brake pipe (hydraulic unit to proportioning valve) 5. Brake pipe/upper joint assembly 6. Brake pipe/lower joint assembly 7. Brake pipe (proportioning valve to rear brake hose) 8.
Page 136
CABLE ROUTING (FJR1300AS) 2-85…
Page 137: Periodic Checks And Adjustments

PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE …………….3-1 INTRODUCTION ………………3-1 PERIODIC MAINTENANCE AND LUBRICATION CHART (FJR1300A) ………………..3-1 PERIODIC MAINTENANCE AND LUBRICATION CHART (FJR1300AS) ……………….. 3-3 ENGINE ………………….3-5 ADJUSTING THE VALVE CLEARANCE ……….3-5 SYNCHRONIZING THE THROTTLE BODIES………. 3-7 ADJUSTING THE EXHAUST GAS VOLUME ………..
Page 138
CHASSIS ………………….. 3-28 ADJUSTING THE FRONT DISC BRAKE……….3-28 ADJUSTING THE REAR DISC BRAKE ……….3-28 CHECKING THE BRAKE FLUID LEVEL……….3-29 CHECKING THE FRONT BRAKE PADS ……….3-30 CHECKING THE REAR BRAKE PADS ……….3-30 CHECKING THE BRAKE HOSES…………3-30 ADJUSTING THE REAR BRAKE LIGHT SWITCH ………
Page 140: Periodic Maintenance

UK, a mileage-based maintenance, is performed instead. • From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
Page 141
PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) Clutch lever pivot √ √ √ √ √ • Lubricate with silicone grease. shaft Shift pedal pivot •…
Page 142: Periodic Maintenance And Lubrication Chart (Fjr1300As)

UK, a mileage-based maintenance, is performed instead. • From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
Page 143
PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Adjust engine idling speed √ √ √ √ √ √…
Page 144: Engine

ENGINE EAS20470 ENGINE Valve clearance (cold) Intake EAS20490 0.15–0.22 mm (0.0059–0.0087 in) ADJUSTING THE VALVE CLEARANCE Exhaust The following procedure applies to all of the 0.18–0.25 mm (0.0071–0.0098 in) valves. M MMM M MMM M MMM M MMM M MMM NOTE: a.
Page 145
ENGINE • Measure the valve clearance in the following M MMM M MMM M MMM M MMM M MMM a. Remove the valve lifter “1” and the valve pad sequence. “2” with a valve lapper “3”. Valve clearance measuring sequence Valve lapper Cylinder #1 →…
Page 146: Synchronizing The Throttle Bodies

ENGINE Example: • Install the valve lifter and the valve pad in the If the valve pad is marked “155”, the pad correct place. thickness is 1.55 mm (0.061 in). g. Install the exhaust and intake camshafts, tim- d. Calculate the sum of the values obtained in ing chain and camshaft caps.
Page 147
ENGINE 2. Remove: M MMM M MMM M MMM M MMM M MMM a. With throttle body #3 as standard, adjust • Rider seat throttle bodies #1, #2, and #4 using the air Refer to “GENERAL CHASSIS” on page 4-1. screw “1”.
Page 148: Adjusting The Exhaust Gas Volume

ENGINE 9. Measure: 3. Press the “SELECT” button to select the CO • Engine idling speed adjustment mode “Co” “1” or the diagnostic Out of specification → Adjust. mode “dIAG”. Make sure that the vacuum pressure is within specification. 10.Stop the engine and remove the measuring equipment.
Page 149: Adjusting The Engine Idling Speed

ENGINE NOTE: Direction “a” The CO adjustment volume appears on the Engine idling speed is increased. odometer/tripmeter/fuel reserve tripmeter LCD. Direction “b” • To decrease the CO adjustment volume, press Engine idling speed is decreased. the “RESET” button. • To increase the CO adjustment volume, press the “SELECT”…
Page 150: Checking The Spark Plugs

ENGINE Throttle cable free play Direction “a” 3.0–5.0 mm (0.12–0.20 in) Throttle cable free play is increased. Direction “b” 2. Remove: Throttle cable free play is decreased. • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. d. Tighten the locknut. •…
Page 151: Checking The Ignition Timing

ENGINE EAS20700 CHECKING THE IGNITION TIMING Manufacturer/model NGK/CR8E NOTE: Manufacturer/model Prior to checking the ignition timing, check the DENSO/U24ESR-N wiring connections of the entire ignition system. Make sure all connections are tight and free of 5. Check: corrosion. • Electrode “1” Damage/wear →…
Page 152: Measuring The Compression Pressure

ENGINE 5. Install: 1. Measure: • Fuel tank • Valve clearance Out of specification → Adjust. Refer to “FUEL TANK” on page 7-1. 6. Check: Refer to “ADJUSTING THE VALVE CLEAR- • Ignition timing ANCE” on page 3-5. M MMM M MMM M MMM M MMM…
Page 153: Checking The Engine Oil Level

ENGINE M MMM M MMM M MMM M MMM M MMM 2. Start the engine, warm it up for several min- a. Set the main switch to “ON”. utes, and then turn it off. b. With the throttle wide open, crank the engine 3.
Page 154: Changing The Engine Oil

ENGINE b. Lubricate the O-ring “3” of the new oil filter NOTE: cartridge with a thin coat of engine oil. Before checking the engine oil level, wait a few ECA13390 minutes until the oil has settled. CAUTION: 4. Start the engine, warm it up for several min- Make sure the O-ring “3”…
Page 155: Measuring The Engine Oil Pressure

ENGINE 8. Install: 2. Start the engine, warm it up for several min- • Engine oil filler cap utes, and then turn it off. 9. Start the engine, warm it up for several min- ECA13410 CAUTION: utes, and then turn it off. When the engine is cold, the engine oil will 10.Check: have a higher viscosity, causing the engine…
Page 156: Adjusting The Clutch Lever (Fjr1300A Only)

ENGINE EAS20890 Engine oil pressure Possible causes CHECKING THE CLUTCH FLUID LEVEL (FJR1300A) • Faulty oil pump 1. Stand the vehicle on a level surface. • Clogged oil filter Below specification • Leaking oil passage NOTE: • Broken or dam- Place the vehicle on the centerstand.
Page 157: Checking The Clutch Fluid Level (Fjr1300As)

ENGINE 4. Install: ET3P66026 CHECKING THE CLUTCH FLUID LEVEL • Left side cover (FJR1300AS) Refer to “GENERAL CHASSIS” on page 4-1. 1. Stand the vehicle on a level surface. NOTE: EAS20900 BLEEDING THE HYDRAULIC CLUTCH Place the vehicle on the centerstand. SYSTEM (FJR1300A) 2.
Page 158: Bleeding The Hydraulic Clutch System (Fjr1300As)

ENGINE g. Loosen the bleed screw. This will release the • Rear wheel tension and cause the clutch lever to contact Refer to “REAR WHEEL” on page 4-25. the handlebar grip. • Swingarm h. Tighten the bleed screw and then release the Refer to “SWINGARM”…
Page 159
ENGINE k. Engage the clutch by turning the manual NOTE: clutch operation bolt in direction “b” until it Turn the clutch operation bolt in a continuous stops. motion, without allowing the pressure plate to NOTE: stop in mid-stroke. The following illustration shows the manual clutch operation bolt when viewed from the rear of the vehicle with the swingarm removed.
Page 160: Checking The Vehicle After Bleeding The Hydraulic Clutch System (Fjr1300As Only)

ENGINE e. Disengage the clutch by turning the manual 2. Check: clutch operation bolt. • Shift operation Engine stalls → Check the pressure plate f. Measure the clutch pressure plate stroke. stroke. Clutch pressure plate stroke Refer to “BLEEDING THE HYDRAULIC FJR1300AS 2.8 mm (0.11 in) or CLUTCH SYSTEM (FJR1300AS)”…
Page 161: Cleaning The Air Filter Element (Fjr1300A)

ENGINE e. Shift the transmission into neutral, and then ET3P66028 CLEANING THE AIR FILTER ELEMENT raise the centerstand. (FJR1300AS) f. Shift the transmission into 1st gear, and then 1. Remove: slowly turn the throttle grip and check the • Rider seat starting-off performance of the vehicle.
Page 162: Checking The Throttle Body Joints

ENGINE • Fuel tank breather/overflow hose “2” NOTE: Cracks/damage → Replace. When installing the air filter element into the air Loose connection → Connect properly. filter case cover, make sure their sealing surfac- EC3P61005 es are aligned to prevent any air leaks. CAUTION: Make sure the fuel tank breather/overflow EAS21010…
Page 163: Checking The Exhaust System

ENGINE 3. Install: • Air filter case • T-bar Refer to “GENERAL CHASSIS” on page 4-1. • Fuel tank Refer to “FUEL TANK” on page 7-1. • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. EAS21080 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex- 4.
Page 164: Checking The Cooling System

ENGINE ECA13470 CAUTION: • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if nec- essary, correct the antifreeze concentra- tion of the coolant. • Use only distilled water. However, if dis- tilled water is not available, soft water may be used.
Page 165
ENGINE 7. Drain: EWA13030 WARNING • Coolant A hot radiator is under pressure. Therefore, (from the coolant reservoir) do not remove the radiator cap when the en- 8. Install: gine is hot. Scalding hot fluid and steam may • Coolant reservoir be blown out, which could cause serious in- 9.
Page 166
ENGINE • If coolant is swallowed, induce vomiting and get immediate medical attention. ECA13480 CAUTION: • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if nec- essary, correct the antifreeze concentra- tion of the coolant.
Page 167: Chassis

CHASSIS EAS21140 CHASSIS Brake pedal position 42.0 mm (1.65 in) (below the top EAS21160 of the rider footrest) ADJUSTING THE FRONT DISC BRAKE 1. Adjust: • Brake lever position (distance “a” from the throttle grip to the brake lever) M MMM M MMM M MMM M MMM…
Page 168: Checking The Brake Fluid Level

CHASSIS air must be removed by bleeding the brake system. Air in the brake system will consid- erably reduce braking performance. ECA13510 CAUTION: After adjusting the brake pedal position, make sure there is no brake drag. L LLL L LLL L LLL L LLL L LLL…
Page 169: Checking The Front Brake Pads

CHASSIS 1. Check: EAS21250 CHECKING THE FRONT BRAKE PADS • Brake hoses The following procedure applies to all of the Cracks/damage/wear → Replace. brake pads. 2. Check: EC3P61037 • Brake hose holders CAUTION: Loose → Tighten the holder bolts. The amount of wear may differ for the brake 3.
Page 170: Bleeding The Hydraulic Brake System (Abs)

CHASSIS EAS22780 BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS) EWA14000 WARNING Always bleed the brake system when the brake related parts are removed. EC3P61012 CAUTION: • Bleed the brake system in the following or- der. • 1st step: Front brake calipers •…
Page 171: Adjusting The Shift Pedal (Fjr1300A)

CHASSIS EC3P61029 CAUTION: Direction “a” Shift pedal is raised. Make sure that the main switch is turned to Direction “b” “OFF” before checking the operation of the Shift pedal is lowered. hydraulic unit. k. After operating the ABS, repeat steps (e) to NOTE: (i), and then fill the brake master cylinder res- Check that the groove “c”…
Page 172: Checking The Final Gear Oil Level

CHASSIS 4. Install: • Final gear oil filler bolt Final gear oil filler bolt 23 Nm (2.3 m·kg, 17 ft·lb) EAS21470 CHANGING THE FINAL GEAR OIL 1. Place a container under the final gear case. 2. Remove: • Final gear oil filler bolt “1” a.
Page 173: Adjusting The Handlebar Position

CHASSIS c. Loosen the lower ring nut completely and NOTE: then tighten it to specification with a steering Place the vehicle on a suitable stand so that the nut wrench. front wheel is elevated. EWA13140 WARNING 2. Check: • Steering head Do not overtighten the lower ring nut.
Page 174: Checking The Front Fork

CHASSIS b. Standard position c. Rear position e. Install the handlebar bolts “3” and nuts “2” temporarily. 2. Adjust: • Handlebar position M MMM M MMM M MMM M MMM M MMM a. Remove the plates “1”. f. Tighten the handlebar bolts and nuts. Handlebar bolt 23 Nm (2.3 m·kg, 17 ft·lb) Handlebar nut…
Page 175: Adjusting The Front Fork Legs

CHASSIS EAS21580 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. EWA13150 WARNING • Always adjust both front fork legs evenly. Uneven adjustment can result in poor han- dling and loss of stability. •…
Page 176: Adjusting The Rear Shock Absorber Assembly

CHASSIS EAS21600 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Spring preload ECA13590 CAUTION: L LLL L LLL L LLL L LLL L LLL Never go beyond the maximum or minimum adjustment positions.
Page 177: Adjusting The Side Panels

CHASSIS Direction “a” Rebound damping is increased (sus- pension is harder). Direction “b” Rebound damping is decreased (sus- pension is softer). Rebound damping adjusting posi- tions Minimum b. Pull the side panel to the open position, and 20 click(s) out* then install the quick fastener screws “1”.
Page 178: Adjusting The Rider Seat Height

CHASSIS M MMM M MMM M MMM M MMM M MMM NOTE: To change to the high position Make sure that the side panel is properly in- a. Move the rider seat holder cover “1” to the stalled. lower position as shown. L LLL L LLL L LLL…
Page 179: Checking The Tires

CHASSIS d. Align the low position projection “d” on the bottom of the rider seat with the “L” position slot “e”, and then push the rear of the seat down to lock it in place as shown. L LLL L LLL L LLL L LLL L LLL…
Page 180
1. Tire tread depth and of the same design. No guarantee con- 2. Side wall cerning handling characteristics can be giv- 3. Wear indicator en if a tire combination other than one approved by Yamaha is used on this vehicle. 3-41…
Page 181: Checking The Wheels

CHASSIS EAS21690 CHECKING AND LUBRICATING THE Front tire CABLES Size The following procedure applies to all of the in- 120/70 ZR17M/C (58W) Manufacturer/model ner and outer cables. METZELER/Roadtec Z6G EWA13270 WARNING Manufacturer/model BRIDGESTONE/BT021F F Damaged outer cable may cause the cable to corrode and interfere with its movement.
Page 182: Lubricating The Rear Suspension

CHASSIS Recommended lubricant Lithium-soap-based grease EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension. Recommended lubricant Lithium-soap-based grease 3-43…
Page 183: Electrical System

ELECTRICAL SYSTEM EAS21750 EWA13320 ELECTRICAL SYSTEM WARNING Since the headlight bulb gets extremely hot, EAS21760 keep flammable products and your hands CHECKING AND CHARGING THE BATTERY away from the bulb until it has cooled down. Refer to “ELECTRICAL COMPONENTS” on page 8-225.
Page 184
ELECTRICAL SYSTEM L LLL L LLL L LLL L LLL L LLL 2. Adjust: • Headlight beam (horizontally) M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting screws “1” in direction “a” or “b”. Left headlight Direction “a”…
Page 185
CHASSIS GENERAL CHASSIS………………4-1 REMOVING THE SIDE PANELS ………….. 4-9 INSTALLING THE FRONT COWLING LEFT INNER PANEL 2 ….4-9 INSTALLING THE FRONT COWLING RIGHT INNER PANEL 2…. 4-10 INSTALLING THE SIDE PANELS…………4-10 FRONT WHEEL………………… 4-17 REMOVING THE FRONT WHEEL…………4-19 DISASSEMBLING THE FRONT WHEEL……….
Page 186
REAR BRAKE ………………..4-44 INTRODUCTION ………………4-50 CHECKING THE REAR BRAKE DISC………… 4-50 REPLACING THE REAR BRAKE PADS……….4-50 REMOVING THE REAR BRAKE CALIPER ……….4-51 DISASSEMBLING THE REAR BRAKE CALIPER ……..4-52 CHECKING THE REAR BRAKE CALIPER……….4-52 ASSEMBLING THE REAR BRAKE CALIPER ……..4-52 INSTALLING THE REAR BRAKE CALIPER………..
Page 187
REAR SHOCK ABSORBER ASSEMBLY ………… 4-92 HANDLING THE REAR SHOCK ABSORBER ……..4-94 DISPOSING OF A REAR SHOCK ABSORBER ……..4-94 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY….4-94 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ….4-94 CHECKING THE CONNECTING ARM AND RELAY ARM….. 4-95 INSTALLING THE RELAY ARM…………..
Page 188: General Chassis

GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seats and covers 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 21 Nm (2.1 m kg, 15 ft • • 7 Nm (0.7 m kg, 5.1 ft •…
Page 189
GENERAL CHASSIS Removing the front cowling assembly (FJR1300A) 10 Nm (1.0 m kg, 7.2 ft • • 32 Nm (3.2 m kg, 23 ft • • Order Job/Parts to remove Q’ty Remarks Open the accessory box lid. Left side panel Left side cowling Front left turn signal light coupler Disconnect.
Page 190
GENERAL CHASSIS Removing the front cowling assembly (FJR1300A) 10 Nm (1.0 m kg, 7.2 ft • • 32 Nm (3.2 m kg, 23 ft • • Order Job/Parts to remove Q’ty Remarks Plastic band Disconnect. Plastic holder Disconnect. Handlebar switch coupler Disconnect.
Page 191
GENERAL CHASSIS Removing the front cowling assembly (FJR1300AS) 10 Nm (1.0 m kg, 7.2 ft • • 32 Nm (3.2 m kg, 23 ft • • Order Job/Parts to remove Q’ty Remarks Open the accessory box lid. Left side panel Left side cowling Front left turn signal light coupler Disconnect.
Page 192
GENERAL CHASSIS Removing the front cowling assembly (FJR1300AS) 10 Nm (1.0 m kg, 7.2 ft • • 32 Nm (3.2 m kg, 23 ft • • Order Job/Parts to remove Q’ty Remarks Plastic band Disconnect. Plastic holder Disconnect. Handlebar switch coupler Disconnect.
Page 193
GENERAL CHASSIS Disassembling the front cowling assembly 7 Nm (0.7 m kg, 5.1 ft 7 Nm (0.7 m kg, 5.1 ft • • • • Order Job/Parts to remove Q’ty Remarks Refer to “Removing the front cowling assem- Front cowling assembly bly”.
Page 194
GENERAL CHASSIS Removing the headlight assembly Order Job/Parts to remove Q’ty Remarks Refer to “Disassembling the front cowling Front cowling assembly”. Headlight assembly For installation, reverse the removal proce- dure.
Page 195
GENERAL CHASSIS Removing the windshield drive unit, meter assembly, and relays 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 8 Nm (0.8 m kg, 5.8 ft •…
Page 196: Removing The Side Panels

GENERAL CHASSIS ET3P61037 REMOVING THE SIDE PANELS 1. Remove: • Side panel “1” NOTE: To release a pin on the side panel “1” from its corresponding hinge on the side cowling “2”, push the end “a” of the hinge with a flathead screwdriver.
Page 197: Installing The Front Cowling Right Inner Panel 2

GENERAL CHASSIS e. Fit the lower right corner of inner panel 2 into the front cowling assembly, making sure to align the bolt hole in the panel with the bolt hole in the cowling. i. Insert the adjusting knob shaft into the hole in inner panel 2, making sure to align the projec- tion “a”…
Page 198
GENERAL CHASSIS 4-11…
Page 199
GENERAL CHASSIS Removing the T-bar 37 Nm (3.7 m kg, 27 ft • • 37 Nm (3.7 m kg, 27 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rider seat 4-1. Fuel tank Refer to “FUEL TANK”…
Page 200
GENERAL CHASSIS Removing the air filter case (FJR1300A) 18 Nm (1.8 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft • • (11) 8 Nm (0.8 m kg, 5.8 ft • • 4 Nm (0.4 m kg, 2.9 ft •…
Page 201
GENERAL CHASSIS Removing the air filter case (FJR1300A) 18 Nm (1.8 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft • • (11) 8 Nm (0.8 m kg, 5.8 ft • • 4 Nm (0.4 m kg, 2.9 ft •…
Page 202
GENERAL CHASSIS Removing the air filter case (FJR1300AS) 18 Nm (1.8 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft • • (11) 8 Nm (0.8 m kg, 5.8 ft • • 4 Nm (0.4 m kg, 2.9 ft •…
Page 203
GENERAL CHASSIS Removing the air filter case (FJR1300AS) 18 Nm (1.8 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft • • (11) 8 Nm (0.8 m kg, 5.8 ft • • 4 Nm (0.4 m kg, 2.9 ft •…
Page 204: Front Wheel

FRONT WHEEL EAS21880 FRONT WHEEL Removing the front wheel, brake discs, wheel sensor, and sensor housing 7 Nm (0.7 m kg, 5.1 ft 7 Nm (0.7 m kg, 5.1 ft • • • • 6 Nm (0.6 m kg, 4.3 ft •…
Page 205
FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Front wheel sensor rotor Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-18…
Page 206: Removing The Front Wheel

FRONT WHEEL M MMM M MMM M MMM M MMM M MMM EAS21900 REMOVING THE FRONT WHEEL a. Clean the surface of the front wheel hub. ECA3P6D002 b. Remove the oil seals “1” with a flathead CAUTION: screwdriver. Keep magnets (including magnetic pick-up NOTE: tools, magnetic screwdrivers, etc.) away To prevent damaging the wheel or wheel sensor…
Page 207: Maintenance Of The Front Wheel Sensor And Sensor Rotor

FRONT WHEEL 2. Check: • The front wheel sensor cannot be disas- • Tire sembled. Do not attempt to disassemble it. • Front wheel If faulty, replace with a new one. Damage/wear → Replace. • Keep magnets (including magnetic pick-up Refer to “CHECKING THE TIRES”…
Page 208: Assembling The Front Wheel

FRONT WHEEL EAS21960 ASSEMBLING THE FRONT WHEEL Wheel sensor rotor deflection ECA3P6D003 limit CAUTION: 0.14 mm (0.0055 in) • Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away M MMM M MMM M MMM M MMM M MMM a. Hold the dial gauge at a right angle against from the wheel sensor rotor.
Page 209: Adjusting The Front Wheel Static Balance

FRONT WHEEL b. When the front wheel stops, put an “X ” mark at the bottom of the wheel. L LLL L LLL L LLL L LLL L LLL 2. Install: c. Turn the front wheel 90° so that the “X ”…
Page 210: Installing The Front Wheel (Front Brake Discs)

FRONT WHEEL c. If the heavy spot does not stay in that posi- 2. Check: tion, install a heavier weight. • Front brake discs d. Repeat steps (b) and (c) until the front wheel Refer to “CHECKING THE FRONT BRAKE is balanced.
Page 211
FRONT WHEEL EC3P61022 CAUTION: Distance “a” (between the wheel sensor rotor and wheel sensor Before tightening the wheel axle bolt, push housing) down hard on the handlebars several times 28.89–29.41 mm (1.137–1.158 in) and check if the front fork rebounds smooth- M MMM M MMM M MMM…
Page 212: Rear Wheel

REAR WHEEL EAS22030 REAR WHEEL Removing the rear wheel, brake disc, wheel sensor, and sensor housing 7 Nm (0.7 m kg, 5.1 ft • • 125 Nm (12.5 m kg, 90 ft • • 30 Nm (3.0 m kg, 22 ft •…
Page 213
REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Dust cover Rear wheel drive hub Dust seal Wheel bearing Rear wheel drive hub damper Oil seal Bearing retainer Rear wheel sensor rotor Wheel bearing Spacer Spacer Oil seal Bearing For assembly, reverse the disassembly pro- cedure.
Page 214: Removing The Rear Wheel

REAR WHEEL EAS22050 ET3P6D002 REMOVING THE REAR WHEEL DISASSEMBLING THE REAR WHEEL ECA3P6D013 ECA3P6D003 CAUTION: CAUTION: Keep magnets (including magnetic pick-up • Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away tools, magnetic screwdrivers, etc.) away from the rear wheel hub “1”, otherwise the from the wheel sensor rotor.
Page 215: Checking The Rear Wheel

REAR WHEEL EAS22200 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR ECA3P6D008 CAUTION: • Handle the ABS components with care since they have been accurately adjusted. Keep them away from dirt and do not sub- ject them to shocks. •…
Page 216: Adjusting The Rear Wheel Static Balance

REAR WHEEL Hexagon wrench (41) 90890-01525 YM-01525 Bearing retainer 80 Nm (8.0 m·kg, 58 ft·lb) ® LOCTITE ECA3P6D009 CAUTION: 2. Rear wheel The bearing retainer has left-handed 2. Install: threads. To tighten the retainer, turn it coun- • Wheel bearings terclockwise.
Page 217: Installing The Rear Wheel (Rear Brake Disc)

REAR WHEEL EAS22170 ECA14470 INSTALLING THE REAR WHEEL (REAR CAUTION: BRAKE DISC) Make sure there are no foreign materials in 1. Install: the wheel hub. Foreign materials cause dam- • Rear brake disc age to the inner sensor rotor and wheel sen- sor.
Page 218
REAR WHEEL Distance “a” (between the wheel sensor rotor and wheel sensor housing) 28.89–29.41 mm (1.137–1.158 in) 7. Install: • Rear wheel sensor Rear wheel sensor bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) EC3P66004 CAUTION: To route the rear wheel sensor lead, refer to “CABLE ROUTING (FJR1300A)”…
Page 219: Front Brake

FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 6 Nm (0.6 m kg, 4.3 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 40 Nm (4.0 m kg, 29 ft •…
Page 220
FRONT BRAKE Removing the front brake master cylinder 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)”…
Page 221
FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder push rod Dust boot Circlip Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-34…
Page 222
FRONT BRAKE Removing the front brake calipers 7 Nm (0.7 m kg, 5.1 ft • • 40 Nm (4.0 m kg, 29 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
Page 223
FRONT BRAKE Disassembling the front brake calipers 6 Nm (0.6 m kg, 4.3 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 17 Nm (1.7 m kg, 12 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
Page 224: Introduction

FRONT BRAKE e. Measure the deflection 1.5 mm (0.06 in) be- EAS22220 INTRODUCTION low the edge of the brake disc. EWA14100 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary.
Page 225: Replacing The Front Brake Pads

FRONT BRAKE d. Measure the brake disc deflection. 2. Install: e. If out of specification, repeat the adjustment • Brake pads steps until the brake disc deflection is within • Brake pad spring specification. NOTE: f. If the brake disc deflection cannot be brought Always install new brake pads and a new brake within specification, replace the brake disc.
Page 226: Removing The Front Brake Calipers

FRONT BRAKE 3. Install: • Copper washers • Brake pad bolts • Brake hose (brake pipe/upper joint assembly • Brake caliper to right front brake caliper) “3” • Brake hose (metering valve to right front Brake pad bolt brake caliper) “4” 17 Nm (1.7 m·kg, 12 ft·lb) NOTE: Brake caliper bolt…
Page 227: Checking The Front Brake Calipers

FRONT BRAKE EWA13560 EAS22410 ASSEMBLING THE FRONT BRAKE WARNING CALIPERS • Cover the brake caliper pistons with a rag. EWA3P6D002 Be careful not to get injured when the pis- WARNING tons are expelled from the brake caliper. • Before installation, all internal brake com- •…
Page 228: Removing The Front Brake Master Cylinder

FRONT BRAKE ECA13540 CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 5. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-31. 6. Check: 2.
Page 229: Checking The Front Brake Master Cylinder

FRONT BRAKE • Copper washers “2” EAS22530 INSTALLING THE FRONT BRAKE MASTER • Brake hose (front brake master cylinder to CYLINDER brake pipe/lower joint assembly) “3” 1. Install: NOTE: • Brake master cylinder “1” To collect any remaining brake fluid, place a •…
Page 230
FRONT BRAKE Refer to “CHECKING THE BRAKE FLUID NOTE: LEVEL” on page 3-29. Turn the handlebar to the left and right to make sure the brake hose does not touch other parts (e.g., wire harness, cables, leads). Correct if necessary. 3.
Page 231
REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Rear brake caliper bolt Rear brake caliper Brake pad shim Rear brake pad Brake pad spring For installation, reverse the removal proce- dure. 4-44…
Page 232
REAR BRAKE Removing the rear brake master cylinder 30 Nm (3.0 m kg, 22 ft • • 28 Nm (2.8 m kg, 20 ft • • 28 Nm (2.8 m kg, 20 ft • • 18 Nm (1.8 m kg, 13 ft •…
Page 233
REAR BRAKE Removing the rear brake master cylinder 30 Nm (3.0 m kg, 22 ft • • 28 Nm (2.8 m kg, 20 ft • • 28 Nm (2.8 m kg, 20 ft • • 18 Nm (1.8 m kg, 13 ft •…
Page 234
REAR BRAKE Disassembling the rear brake master cylinder 16 Nm (1.6 m kg, 11 ft • • Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Brake master cylinder push rod Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure.
Page 235
REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-31. Brake hose union bolt Copper washer Brake hose (proportioning valve to rear brake caliper) Rear brake caliper bolt Loosen.
Page 236
REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Rear brake caliper bolt Brake pad shim Rear brake pad Brake pad spring Rear brake caliper bracket Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.
Page 237: Rear Brake

REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA14100 4.5 mm (0.18 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc deflection ventive measures: Refer to “CHECKING THE FRONT BRAKE •…
Page 238: Removing The Rear Brake Caliper

REAR BRAKE NOTE: Recommended lubricant Always install new brake pads, brake pad shims, Silicone grease and brake pad springs as a set. ECA3P6D017 M MMM M MMM M MMM M MMM M MMM CAUTION: a. Connect a clear plastic hose “1” tightly to the •…
Page 239: Disassembling The Rear Brake Caliper

REAR BRAKE EAS22640 CHECKING THE REAR BRAKE CALIPER Recommended brake component replace- ment schedule Brake pads If necessary Piston dust seal Every two years Piston seal Every two years Brake hoses Every four years Every two years and Brake fluid whenever the brake EAS22600 DISASSEMBLING THE REAR BRAKE…
Page 240: Installing The Rear Brake Caliper

REAR BRAKE • Never use solvents on internal brake com- ponents as they will cause the brake caliper piston dust seal and brake caliper piston seal to swell and distort. • Whenever a brake caliper is disassembled, replace the brake caliper piston dust seal and brake caliper piston seal.
Page 241: Removing The Rear Brake Master Cylinder

REAR BRAKE 7. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-31. 8. Check: • Brake fluid level Below the minimum level mark “a” → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”…
Page 242: Checking The Rear Brake Master Cylinder

REAR BRAKE Brake hose union bolt 30 Nm (3.0 m·kg, 22 ft·lb) EW3P66002 WARNING Proper brake hose routing is essential to in- sure safe vehicle operation. Refer to “CABLE ROUTING (FJR1300A)” on page 2-45 and “CABLE ROUTING (FJR1300AS)” on page 2-65.
Page 243
REAR BRAKE EWA13090 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
Page 244: Abs (Anti-Lock Brake System)

ABS (ANTI-LOCK BRAKE SYSTEM) EAS22760 ABS (ANTI-LOCK BRAKE SYSTEM) ET3P61060 ABS COMPONENTS CHART 12,13 1. Brake hose (metering valve to right front brake caliper) 2. Brake hose (brake pipe/upper joint assembly to front brake calipers) 3. Brake hose (front brake master cylinder to brake pipe/lower joint assembly) 4.
Page 245
ABS (ANTI-LOCK BRAKE SYSTEM) Removing the rear fender assembly 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Air filter case 4-1.
Page 246
ABS (ANTI-LOCK BRAKE SYSTEM) Removing the metering valve, proportioning valve, and brake pipes 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 16 Nm (1.6 m kg, 11 ft • • 16 Nm (1.6 m kg, 11 ft •…
Page 247
ABS (ANTI-LOCK BRAKE SYSTEM) Removing the metering valve, proportioning valve, and brake pipes 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 16 Nm (1.6 m kg, 11 ft • • 16 Nm (1.6 m kg, 11 ft •…
Page 248
ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 7 Nm (0.7 m kg, 5.1 ft 7 Nm (0.7 m kg, 5.1 ft • • • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft •…
Page 249: Removing The Hydraulic Unit Assembly

ABS (ANTI-LOCK BRAKE SYSTEM) 2. Disconnect: ET3P6D003 REMOVING THE HYDRAULIC UNIT • ABS ECU coupler “1” ASSEMBLY NOTE: ECA3P6D018 CAUTION: Pull the coupler ejection slider up to disconnect the ABS ECU coupler. Unless necessary, avoid removing and in- stalling the brake pipes of the hydraulic unit assembly.
Page 250: Checking The Proportioning Valve And Metering Valve

ABS (ANTI-LOCK BRAKE SYSTEM) ET3P61057 CHECKING THE PROPORTIONING VALVE AND METERING VALVE 1. Check: • Proportioning valve Cracks/damage → Replace the proportioning valve. • Metering valve Cracks/damage → Replace the metering valve 4. Install: ET3P6D020 CHECKING THE BRAKE PIPES • Brake pipe/lower joint assembly “1” The following procedure applies to all of the •…
Page 251
ABS (ANTI-LOCK BRAKE SYSTEM) • Brake pipe (brake pipe/upper joint assembly to front brake calipers) “3” • Gaskets • Brake pipe union bolts • Brake hose union bolt Brake pipe union bolt 30 Nm (3.0 m·kg, 22 ft·lb) Brake hose union bolt 30 Nm (3.0 m·kg, 22 ft·lb) 9.
Page 252
ABS (ANTI-LOCK BRAKE SYSTEM) 13.Fill: 11.Install: • Brake master cylinder reservoir • Metering valve “1” • Brake fluid reservoir • Brake pipe (metering valve to right front brake (with the specified amount of the recom- caliper) “2” mended brake fluid) •…
Page 253: Hydraulic Unit Operation Tests

ABS (ANTI-LOCK BRAKE SYSTEM) 16.Delete the fault codes. (Refer to “[D-1] DE- LETING THE FAULT CODES” on page 8-179.) 17.Perform a trial run. (Refer to “TRIAL RUN” on page 4-69.) EAS22800 HYDRAULIC UNIT OPERATION TESTS The reaction-force pulsating action generated in the brake lever and brake pedal when the ABS is activated can be tested when the vehicle is 5.
Page 254
ABS (ANTI-LOCK BRAKE SYSTEM) When the main switch is turned to “ON”, a • If the pulse is hardly felt in either the brake single pulse will be generated in the brake le- lever or brake pedal, check that the brake ver “1”.
Page 255
ABS (ANTI-LOCK BRAKE SYSTEM) 10.A reaction-force pulsating action is generated in the brake lever “1” 0.5 second after the brake lever and the brake pedal are operated simultaneously and continues for approxi- mately 1.5 seconds. NOTE: • The reaction-force pulsating action consists of quick pulses.
Page 256: Trial Run

ABS (ANTI-LOCK BRAKE SYSTEM) ECA3P6D020 CAUTION: • Check that the pulsating action is felt in the brake lever, brake pedal, and again in the brake lever, in this order. • If the pulsating action is felt in the brake pedal before it is felt in the brake lever, check that the brake hoses and brake pipes are connected correctly to the hydraulic unit assembly.
Page 257: Handlebars

HANDLEBARS EAS22850 HANDLEBARS Removing the left handlebar (FJR1300A) Order Job/Parts to remove Q’ty Remarks Clutch switch coupler Disconnect. Clutch master cylinder holder Clutch master cylinder assembly Left handlebar Left handlebar switch lead Lead holder 1 Lead holder 2 Left handlebar switch Grip end Handlebar grip For installation, reverse the removal proce-…
Page 258
HANDLEBARS Removing the left handlebar (FJR1300AS) Order Job/Parts to remove Q’ty Remarks Left handlebar Left grip warmer lead Hand shift switch lead Left handlebar switch lead Lead holder 1 Hand shift switch Lead holder 2 Left handlebar switch Grip end Handlebar grip For installation, reverse the removal proce- dure.
Page 259
HANDLEBARS Removing the right handlebar Order Job/Parts to remove Q’ty Remarks Front brake light switch connector Disconnect. Front brake master cylinder holder Front brake master cylinder assembly Grip end Throttle cable housing Throttle cable Disconnect. Throttle grip Right handlebar Right grip warmer lead Right handlebar switch lead Lead holder Right handlebar switch…
Page 260: Removing The Handlebars

HANDLEBARS b. Slide the handlebar grip onto the left handle- EAS22870 REMOVING THE HANDLEBARS bar. 1. Stand the vehicle on a level surface. c. Wipe off any excess rubber adhesive with a EWA13120 clean rag. WARNING EWA13700 Securely support the vehicle so that there is WARNING no danger of it falling over.
Page 261
HANDLEBARS Handlebar bolt 23 Nm (2.3 m·kg, 17 ft·lb) Handlebar nut 65 Nm (6.5 m·kg, 47 ft·lb) NOTE: First tighten the bolts, then tighten the nuts. 8. Install: • Throttle grip 5. Install: • Throttle cables • Right handlebar • Throttle cable housing “1” •…
Page 262: Installing The Handlebars (Fjr1300As)

HANDLEBARS 11.Adjust: 9. Install: • Throttle cable free play • Front brake master cylinder assembly Refer to “ADJUSTING THE THROTTLE CA- • Front brake master cylinder holder “1” BLE FREE PLAY” on page 3-10. Front brake master cylinder hold- Throttle cable free play er bolt 3.0–5.0 mm (0.12–0.20 in) 10 Nm (1.0 m·kg, 7.2 ft·lb)
Page 263
HANDLEBARS • When installing the hand shift switch, route the left grip warmer lead “3” and left handlebar switch lead “4” through the switch as shown in the illustration, making sure to fasten the left grip warmer lead with the lead holder 2. •…
Page 264
HANDLEBARS 8. Tighten: • Handlebar bolts • Handlebar nuts Handlebar bolt 23 Nm (2.3 m·kg, 17 ft·lb) Handlebar nut 65 Nm (6.5 m·kg, 47 ft·lb) NOTE: First tighten the bolts, then tighten the nuts. 10.Install: 9. Install: • Front brake master cylinder assembly •…
Page 265: Front Fork

FRONT FORK EAS22950 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Refer to “GENERAL CHASSIS” on page Front cowling assembly 4-1. Front wheel Refer to “FRONT WHEEL” on page 4-17. Battery holder Negative battery lead Disconnect.
Page 266
FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Cap bolt O-ring Damper adjusting rod Spacer Washer Fork spring Dust seal Oil seal clip Oil seal Washer Damper rod assembly bolt Copper washer…
Page 267
FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks Inner tube Outer tube bushing 1 D = 52 mm (2.05 in), l = 12 mm (0.47 in) Outer tube bushing 2 D = 51 mm (2.01 in), l = 15 mm (0.59 in) Inner tube bushing Outer tube For assembly, reverse the disassembly pro-…
Page 268: Removing The Front Fork Legs

FRONT FORK 1. Hold the nut “1” and loosen the cap bolt “2”. EAS22960 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over.
Page 269: Checking The Front Fork Legs

FRONT FORK M MMM M MMM M MMM M MMM M MMM a. Pull up the inner tube completely, fill it with oil up to the top, and then install the cap bolt. NOTE: Do not install the fork spring. b.
Page 270: Assembling The Front Fork Legs

FRONT FORK • Before assembling the front fork leg, make Fork spring free length sure all of the components are clean. 262.0 mm (10.31 in) 1. Install: Limit 257.0 mm (10.12 in) • Inner tube bushing “1” • Oil flow stopper “2” •…
Page 271
FRONT FORK 4. Install: 6. Install: • Outer tube bushing 2 (D = 51 mm (2.01 in), l • Oil seal “1” = 15 mm (0.59 in)) “1” • Suitable washer “2” (ex: 4SV-23115-00) (with the slide metal installer “2” and fork seal (with the slide metal installer “3”…
Page 272
FRONT FORK Recommended oil Suspension oil M1 or Ohlins R & T43 Quantity 696.0 cm³ (23.53 US oz) (24.55 Imp.oz) ECA14230 CAUTION: • Be sure to use the recommended fork oil. Other oils may have an adverse effect on 7. Remove: front fork performance.
Page 273: Installing The Front Fork Legs

FRONT FORK 14.Measure: • Front fork leg oil level “a” 25 Nm (2.5 m·kg, 18 ft·lb) (from the top of the inner tube, with the outer tube fully compressed and without the fork spring) Out of specification → Correct. Level 92.0 mm (3.62 in) NOTE: •…
Page 274
FRONT FORK • Upper bracket pinch bolt “3” Upper bracket pinch bolt 26 Nm (2.6 m·kg, 19 ft·lb) EWA13680 WARNING Make sure the brake hoses are routed prop- erly. 3. Adjust: • Spring preload • Rebound damping • Compression damping Refer to “ADJUSTING THE FRONT FORK LEGS”…
Page 275: Steering Head

STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 115 Nm (11.5 m kg, 85 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • 2nd 18 Nm (1.8 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft •…
Page 276
STEERING HEAD Removing the lower bracket 115 Nm (11.5 m kg, 85 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • 2nd 18 Nm (1.8 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft •…
Page 277: Removing The Lower Bracket

STEERING HEAD b. Remove the bearing race from the lower EAS23110 REMOVING THE LOWER BRACKET bracket “3” with a floor chisel “4” and ham- 1. Stand the vehicle on a level surface. mer. EWA13120 c. Install new bearing races. WARNING ECA14270 Securely support the vehicle so that there is CAUTION:…
Page 278
STEERING HEAD • Lock washer “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 3-33. 3. Install: • Upper bracket • Steering stem nut NOTE: Temporarily tighten the steering stem nut. 4. Install: • Front fork legs Refer to “FRONT FORK” on page 4-78. NOTE: Temporarily tighten the upper and lower bracket pinch bolts.
Page 279: Rear Shock Absorber Assembly

REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 7 Nm (0.7 m kg, 5.1 ft • • 64 Nm (6.4 m kg, 46 ft • • 40 Nm (4.0 m kg, 29 ft •…
Page 280
REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 7 Nm (0.7 m kg, 5.1 ft • • 64 Nm (6.4 m kg, 46 ft • • 40 Nm (4.0 m kg, 29 ft • • 15 12 16 16 15 14 40 Nm (4.0 m kg, 29 ft…
Page 281: Handling The Rear Shock Absorber

REAR SHOCK ABSORBER ASSEMBLY EAS23180 NOTE: HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that the EWA13740 WARNING rear wheel is elevated. This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling •…
Page 282: Checking The Connecting Arm And Relay Arm

REAR SHOCK ABSORBER ASSEMBLY • Rear shock absorber Gas leaks/oil leaks → Replace the rear shock absorber assembly. • Spring Damage/wear → Replace the rear shock ab- sorber assembly. • Bushing Damage/wear → Replace the rear shock ab- sorber assembly. •…
Page 283: Swingarm

SWINGARM EAS23330 SWINGARM Removing the swingarm 23 Nm (2.3 m kg, 17 ft • • 125 Nm (12.5 m kg, 90 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 115 Nm (11.5 m kg, 85 ft •…
Page 284
SWINGARM Removing the swingarm 23 Nm (2.3 m kg, 17 ft • • 125 Nm (12.5 m kg, 90 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 115 Nm (11.5 m kg, 85 ft • • 28 Nm (2.8 m kg, 20 ft •…
Page 285: Removing The Swingarm

SWINGARM EAS23350 EAS23360 REMOVING THE SWINGARM CHECKING THE SWINGARM 1. Stand the vehicle on a level surface. 1. Check: • Swingarm EWA13120 WARNING Bends/cracks/damage → Replace. Securely support the vehicle so that there is 2. Check: no danger of it falling over. •…
Page 286
SWINGARM 3. Swingarm 4. Connecting arm A. Left side B. Right side 3. Tighten: • Pivot shaft Pivot shaft 23 Nm (2.3 m·kg, 17 ft·lb) • Pivot shaft locknut Pivot shaft locknut 115 Nm (11.5 m·kg, 85 ft·lb) • Pivot shaft nut Pivot shaft nut 125 Nm (12.5 m·kg, 90 ft·lb) 4-99…
Page 287: Shaft Drive

SHAFT DRIVE EAS23550 SHAFT DRIVE Removing the final drive assembly Order Job/Parts to remove Q’ty Remarks Drain. Final gear oil Refer to “CHANGING THE ENGINE OIL” on page 3-15. Rear wheel Refer to “REAR WHEEL” on page 4-25. Final drive assembly For installation, reverse the removal proce- dure.
Page 288
SHAFT DRIVE Removing the universal joint Order Job/Parts to remove Q’ty Remarks FJR1300AS Left footrest assembly/Sidestand Refer to “SHIFT ACTUATOR AND SHIFT ROD (FJR1300AS only)” on page 5-69. Shift arm FJR1300A Left footrest assembly FJR1300A FJR1300A Sidestand switch coupler Disconnect. Sidestand FJR1300A Drive shaft dust cover…
Page 289
SHAFT DRIVE Disassembling the final drive assembly Order Job/Parts to remove Q’ty Remarks Circlip Oil seal Drive shaft Spring Ring gear bearing housing Dust cover Oil seal Stopper bolt Left-hand threads Stopper bolt shim(s) Ring gear shim(s) Ring gear Bearing Thrust washer Coupling gear nut Coupling gear…
Page 290
SHAFT DRIVE Disassembling the final drive assembly Order Job/Parts to remove Q’ty Remarks Final drive pinion gear Bearing Final drive pinion gear shim(s) Final drive pinion gear bearing Ring gear bearing Oil seal Collar Final gear case For assembly, reverse the disassembly pro- cedure.
Page 291: Troubleshooting

SHAFT DRIVE EAS23560 TROUBLESHOOTING Symptom Possible cause 1. A pronounced hesitation or jerky movement A. Bearing damage during acceleration, deceleration or sus- B. Improper gear backlash tained speeds (not to be confused with en- C. Damaged gear teeth gine surging or transmission-related D.
Page 292: Checking The Final Drive Oil For Contamination And Checking The Shaft Drive For Leaks

SHAFT DRIVE NO → 2. Place the vehicle on a suitable Rear wheel bearings and shaft drive bear- stand so that the rear wheel is ele- ings are probably not damaged. Repeat vated and then spin the rear wheel. the test or remove and check the compo- Is the wheel bearing damaged? nents.
Page 293: Adjusting The Final Gear Backlash

SHAFT DRIVE g. Rotate the final drive pinion gear 90°. Final gear backlash h. Reinstall the ring gear fix bolt (M14), final 0.22–0.45 mm (0.0087–0.0177 in) gear backlash band, and dial gauge. i. Repeat steps (d) to (h) three more times (for M MMM M MMM M MMM…
Page 294: Measuring The Ring-Gear-To-Stopper-Bolt Clearance

SHAFT DRIVE b. If it is necessary to increase the final gear backlash by more than 0.2 mm, reduce the thrust washer thickness by 0.2 mm for every 0.2 mm increase of ring gear shim thickness. c. If it is necessary to reduce the final gear back- lash by more than 0.2 mm, increase the thrust washer thickness by 0.2 mm for every 0.2 mm decrease of ring gear shim thickness.
Page 295: Disassembling The Final Drive Assembly

SHAFT DRIVE ECA14320 CAUTION: Coupling gear/middle shaft tool 90890-01229 • The stopper bolt has left-hand threads. To Gear holder tighten the stopper bolt, turn it counter- YM-01229 clockwise. ® • Apply LOCTITE onto the stopper bolt. 3. Remove: • Bearing retainer 4.
Page 296: Removing And Installing The Bearings

(with an appropriate press tool “4” and press) • Bearing “3” NOTE: (with an appropriate press tool “4” and an ap- The bearing can be reused, but Yamaha recom- propriate support for the final gear case) mends installing a new one. 3. Remove: •…
Page 297
SHAFT DRIVE Final drive pinion gear shims Thickness (mm) 0.30 0.40 0.50 Since the final drive pinion gear shims are only available in 0.10 mm increments, round off to the hundredths digit. Hundredth Rounded value 0, 1, 2 3, 4, 5, 6, 7 8, 9 In the example above, the calculated final drive pinion gear shim thickness is 0.51 mm.
Page 298
SHAFT DRIVE f = the ring gear bearing thickness constant. ECA14350 CAUTION: Ring gear bearing thickness The bearing retainer has left-hand threads. 13.00 mm (0.51 in) To tighten the bearing retainer, turn it coun- terclockwise. Example: If the final gear case is marked “51”, the ring Bearing retainer wrench gear bearing housing is marked “35”, the ring 90890-04050…
Page 299: Checking The Drive Shaft

SHAFT DRIVE 4. Stake the coupling gear nut “1” at a cutout “a” in the final drive pinion gear. Ring-gear-to-thrust-washer clear- ance 5. Install: 0.10–0.20 mm (0.0039–0.0079 in) • Ring gear bearing housing (along with the ring gear, but without the f.
Page 300: Installing The Drive Shaft And Final Drive Assembly (Fjr1300A)

SHAFT DRIVE EAS23660 INSTALLING THE DRIVE SHAFT AND FINAL Fork seal driver weight DRIVE ASSEMBLY (FJR1300A) 90890-01184 1. Lubricate: Replacement hammer • Drive shaft spline (final drive pinion gear side) YM-A9409-7 Oil seal installing tool Recommended lubricant 90890-01512 Molybdenum disulfide grease YM-01512 2.
Page 301: Installing The Drive Shaft And Final Drive Assembly (Fjr1300As)

SHAFT DRIVE ET3P66032 INSTALLING THE DRIVE SHAFT AND FINAL Left footrest assembly/sidestand DRIVE ASSEMBLY (FJR1300AS) bolt 1. Lubricate: 65 Nm (6.5 m·kg, 47 ft·lb) Left footrest assembly bolt (M8) • Drive shaft spline (final drive pinion gear side) 28 Nm (2.8 m·kg, 20 ft·lb) Recommended lubricant Left footrest assembly bolt (M10) Molybdenum disulfide grease…
Page 302
SHAFT DRIVE 10.Fill: Fork seal driver weight • Final gear case 90890-01184 Refer to “CHECKING THE FINAL GEAR OIL Replacement hammer LEVEL” on page 3-33. YM-A9409-7 Oil seal installing tool 90890-01512 YM-01512 Installed depth “a” 8.5–10.0 mm (0.33–0.39 in) 6. Install: •…
Page 303
ENGINE ENGINE REMOVAL ………………5-1 REMOVING THE GEAR POSITION SENSOR (FJR1300AS only)… 5-8 REMOVING THE ENGINE (FJR1300A)………… 5-8 REMOVING THE ENGINE (FJR1300AS) ……….5-8 INSTALLING THE ENGINE…………… 5-8 INSTALLING THE GEAR POSITION SENSOR (FJR1300AS only) ..5-11 ADJUSTING THE GEAR POSITION SENSOR (FJR1300AS only) ..5-11 CAMSHAFTS………………..
Page 304
CLUTCH ………………….5-46 REMOVING THE CLUTCH …………..5-58 CHECKING THE FRICTION PLATES…………. 5-58 CHECKING THE CLUTCH PLATES …………5-59 CHECKING THE CLUTCH SPRING PLATE……….. 5-59 CHECKING THE CLUTCH HOUSING ………… 5-59 CHECKING THE CLUTCH BOSS…………5-59 CHECKING THE PRESSURE PLATE ………… 5-60 CHECKING THE CLUTCH PUSH RODS ……….
Page 305
MIDDLE GEAR ………………..5-83 REMOVING THE MIDDLE DRIVE SHAFT ASSEMBLY ……5-89 DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY ….5-89 DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY….. 5-89 CHECKING THE MIDDLE DRIVE SHAFT ASSEMBLY……5-90 CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY ……. 5-90 ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY …..
Page 306: Engine Removal

ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the exhaust pipe assembly 17 Nm (1.7 m kg, 12 ft • • 25 Nm (2.5 m kg, 18 ft • • 20 Nm (2.0 m kg, 14 ft • • 12 Nm (1.2 m kg, 8.7 ft •…
Page 307
ENGINE REMOVAL Disconnecting the leads and hoses (FJR1300A) 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Front fender Refer to “FRONT WHEEL” on page 4-17. Refer to “GENERAL CHASSIS” on page Air filter case 4-1.
Page 308
ENGINE REMOVAL Disconnecting the leads and hoses (FJR1300A) 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Oil level switch coupler Disconnect. Crankshaft position sensor coupler Disconnect. Gear position switch coupler Disconnect. Ground lead Disconnect.
Page 309
ENGINE REMOVAL Disconnecting the leads and hoses (FJR1300AS) 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Front fender Refer to “FRONT WHEEL” on page 4-17. Refer to “GENERAL CHASSIS”…
Page 310
ENGINE REMOVAL Disconnecting the leads and hoses (FJR1300AS) 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Clutch release cylinder Dowel pin Crankcase breather hose Stator coil coupler Disconnect.
Page 311
ENGINE REMOVAL Removing the engine 8 Nm (0.8 m kg, 5.8 ft 45 Nm (4.5 m kg, 32 ft • • 49 Nm (4.9 m kg, 35 ft • • • • 45 Nm (4.5 m kg, 32 ft • •…
Page 312: Engine

ENGINE REMOVAL Removing the engine 8 Nm (0.8 m kg, 5.8 ft 45 Nm (4.5 m kg, 32 ft • • 49 Nm (4.9 m kg, 35 ft • • • • 45 Nm (4.5 m kg, 32 ft • •…
Page 313: Removing The Gear Position Sensor (Fjr1300As Only)

ENGINE REMOVAL ET3P66033 NOTE: REMOVING THE GEAR POSITION SENSOR Loosen the spacer bolt with the pivot shaft (FJR1300AS only) wrench “1” and pivot shaft wrench adapter “2”. 1. Disconnect: • Gear position sensor coupler 2. Remove: Pivot shaft wrench 90890-01471 •…
Page 314
ENGINE REMOVAL • Engine mounting bolt (left front lower side) “6” Spacer bolt • Spacers “7” 18 Nm (1.8 m·kg, 13 ft·lb) • Engine mounting bolt (right front upper side) “8” NOTE: • Engine mounting bolt (right front lower side) •…
Page 315
ENGINE REMOVAL Pinch bolt (rear side) 24 Nm (2.4 m·kg, 17 ft·lb) NOTE: Tighten the pinch bolts (rear side) one at a time, making sure to tighten the first bolt again after tightening the second bolt. 11.Tighten: • Engine mounting bolts (top) “15” 13.Install: (temporarily tighten) •…
Page 316: Installing The Gear Position Sensor (Fjr1300As Only)

ENGINE REMOVAL 3. Adjust: • Gear position sensor Refer to “ADJUSTING THE GEAR POSI- TION SENSOR (FJR1300AS only)” on page 5-11. ET3P66036 ADJUSTING THE GEAR POSITION SENSOR (FJR1300AS only) 1. Check: • Gear position sensor Refer to “CHECKING THE GEAR POSITION ET3P66035 INSTALLING THE GEAR POSITION SENSOR SENSOR (FJR1300AS only)”…
Page 317
ENGINE REMOVAL L LLL L LLL L LLL L LLL L LLL 3. Check: • Gear position setting Refer to “Diagnostic code table (Diagnostic code No. Sh_ _65)”. 5-12…
Page 318: Camshafts

CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover 10 Nm (1.0 m kg, 7.2 ft • • 13 Nm (1.3 m kg, 9.4 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Right side cowling 4-1.
Page 319
CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Throttle bodies Refer to “THROTTLE BODIES” on page 7-4. Pickup rotor cover Refer to “PICKUP ROTOR” on page 5-39. Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap Exhaust camshaft cap Intake camshaft Exhaust camshaft Intake camshaft sprocket…
Page 320: Removing The Camshafts

CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Align: • “T” mark on the pickup rotor (with the crankcase mating surface) M MMM M MMM M MMM M MMM M MMM a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the “T”…
Page 321: Checking The Camshafts

CAMSHAFTS 3. Measure: EAS23850 CHECKING THE CAMSHAFTS • Camshaft runout 1. Check: Out of specification → Replace. • Camshaft lobes Blue discoloration/pitting/scratches → Re- Camshaft runout limit place the camshaft. 0.030 mm (0.0012 in) 2. Measure: • Camshaft lobe dimensions “a” and “b” Out of specification →…
Page 322: Checking The Camshaft Sprockets

CAMSHAFTS NOTE: • Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. • Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance ® with the Plastigauge Camshaft cap bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) a.
Page 323: Installing The Camshafts

CAMSHAFTS 2. Install: L LLL L LLL L LLL L LLL L LLL • Timing chain “1” EAS24010 INSTALLING THE CAMSHAFTS • Exhaust camshaft “2” 1. Install: • Intake camshaft “3” • Exhaust camshaft sprocket (with the camshaft sprockets) • Intake camshaft sprocket ECA13740 CAUTION: Camshaft sprocket bolt…
Page 324
CAMSHAFTS ECA13730 CAUTION: The camshaft cap bolts must be tightened evenly or damage to the cylinder head, cam- shaft caps, and camshafts will result. NOTE: Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out.
Page 325
Timing chain tensioner cap bolt surfaces of the cylinder head cover and cylin- 6 Nm (0.6 m·kg, 4.3 ft·lb) der head cover gasket. • Apply Yamaha bond No.1215 “2” onto the mat- L LLL L LLL L LLL L LLL…
Page 326
CAMSHAFTS 5-21…
Page 327: Cylinder Head

CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head (10) 25 Nm (2.5 m kg, 18 ft • • 2nd 25 Nm (2.5 m kg, 18 ft • • Final Specified angle 175–185˚ 12 Nm (1.2 m kg, 8.7 ft •…
Page 328: Removing The Cylinder Head

CYLINDER HEAD M MMM M MMM M MMM M MMM M MMM EAS24120 REMOVING THE CYLINDER HEAD a. Place a straightedge “1” and a thickness 1. Remove: gauge “2” across the cylinder head. • Cylinder head bolts NOTE: • Loosen the bolts in the proper sequence as shown.
Page 329
CYLINDER HEAD Cylinder head bolt (M10) 25 Nm (2.5 m·kg, 18 ft·lb) e. Tighten the cylinder head bolts further to reach the specified angle 175–185° in the proper tightening sequence as shown. Cylinder head bolt (M10) Final Specified angle 175–185° L LLL L LLL L LLL…
Page 330
VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-22. Valve lifter Valve pad Valve cotter Upper spring seat Intake valve spring Exhaust valve spring Intake valve Exhaust valve…
Page 331: Valves And Valve Springs

VALVES AND VALVE SPRINGS EAS24280 NOTE: REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components. “1” and the valve spring compressor attachment NOTE: “2”.
Page 332
VALVES AND VALVE SPRINGS 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide. • Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” — Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance (intake) b. Install the new valve guide with the valve 0.010–0.037 mm (0.0004–0.0015 guide installer “2”…
Page 333: Checking The Valve Seats

VALVES AND VALVE SPRINGS Valve guide remover (ø5) Valve stem runout 90890-04097 0.010 mm (0.0004 in) Valve guide remover (5.0 mm) YM-04097 Valve guide installer (ø5) 90890-04098 Valve guide installer (5.0 mm) YM-04098 Valve guide reamer (ø5) 90890-04099 Valve guide reamer (5.0 mm) YM-04099 L LLL L LLL…
Page 334
VALVES AND VALVE SPRINGS NOTE: For the best lapping results, lightly tap the valve seat while rotating the valve back and forth be- tween your hands. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion.
Page 335: Checking The Valve Springs

VALVES AND VALVE SPRINGS EAS24310 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: • Valve spring free length “a” Out of specification → Replace the valve spring. Free length (intake) 39.73 mm (1.56 in) Limit b.
Page 336
VALVES AND VALVE SPRINGS 2. Lubricate: • Valve stem “1” • Valve stem seal “2” (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3. Lubricate: • Valve stem end (with the recommended lubricant) b. Smaller pitch Recommended lubricant 5. Install: Engine oil •…
Page 337
VALVES AND VALVE SPRINGS 6. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. ECA13800 CAUTION: Hitting the valve tip with excessive force could damage the valve. 7. Lubricate: • Valve lifter (with the recommended lubricant) Recommended lubricant Engine oil…
Page 338: Generator And Starter Clutch

GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Refer to “GENERAL CHASSIS” on page Air filter case 4-1.
Page 339
GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch Order Job/Parts to remove Q’ty Remarks Starter clutch For installation, reverse the removal proce- dure. 5-34…
Page 340
GENERATOR AND STARTER CLUTCH Removing the stator coil assembly Order Job/Parts to remove Q’ty Remarks Stator coil assembly lead holder Stator coil assembly For installation, reverse the removal proce- dure. 5-35…
Page 341: Removing The Generator

GENERATOR AND STARTER CLUTCH EAS24490 REMOVING THE GENERATOR 1. Remove: • Generator rotor bolt “1” • Washer NOTE: While holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt. Sheave holder EAS24560 REMOVING THE STARTER CLUTCH 90890-01701 1.
Page 342: Installing The Starter Clutch

Sheave holder 90890-01701 Primary clutch holder YS-01880-A 3. Apply: • Sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 90890-85505 ® (Three Bond No.1215 EAS24500 INSTALLING THE GENERATOR 1. Install: • Woodruff key •…
Page 343
GENERATOR AND STARTER CLUTCH 4. Install: • Generator cover gasket • Generator cover Generator cover bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) NOTE: Tighten the generator cover bolts in stages and in a crisscross pattern. 5-38…
Page 344: Pickup Rotor

PICKUP ROTOR EAS24520 PICKUP ROTOR Removing the pickup rotor 12 Nm (1.2 m kg, 8.7 ft • • 15 Nm (1.5 m kg, 11 ft • • 45 Nm (4.5 m kg, 32 ft • • 4 Nm (0.4 m kg, 2.9 ft •…
Page 345: Removing The Pickup Rotor

When installing the pickup rotor, align the groove “a” in the crankshaft sprocket with the projection “b” in the pickup rotor. 3. Apply: • Sealant (onto the crankshaft position sensor lead grommet) Yamaha bond No. 1215 90890-85505 ® (Three Bond No.1215 5-40…
Page 346
PICKUP ROTOR 4. Install: • Pickup rotor cover gasket • Pickup rotor cover Pickup rotor cover bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) NOTE: Tighten the pickup rotor cover bolts in stages and in a crisscross pattern. 5-41…
Page 347: Electric Starter

ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Throttle bodies Refer to “THROTTLE BODIES” on page 7-4. Starter motor lead Disconnect. Starter motor assembly For installation, reverse the removal proce- dure. 5-42…
Page 348
ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Brush Brush seat (along with brushes) Washer Lock washer Oil seal Bearing Starter motor rear cover Collar O-ring Starter motor yoke Armature assembly For assembly, reverse the disassembly pro- cedure.
Page 349: Checking The Starter Motor

ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR Pocket tester 1. Check: 90890-03112 • Commutator Analog pocket tester Dirt → Clean with 600 grit sandpaper. YU-03112-C 2. Measure: • Commutator diameter “1” Armature coil Out of specification → Replace the starter Commutator resistance “1”…
Page 350: Assembling The Starter Motor

ELECTRIC STARTER 7. Check: • Gear teeth Damage/wear → Replace the gear. 8. Check: • Bearing • Oil seal Damage/wear → Replace the defective part(s). EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: • Brush seat “1” NOTE: Align the slot “a” on the brush seat with the tab “b”…
Page 351
CLUTCH EAS25060 CLUTCH Removing the clutch cover 12 Nm (1.2 m kg, 8.7 ft • • (10) 12 Nm (1.2 m kg, 8.7 ft 12 Nm (1.2 m kg, 8.7 ft • • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”…
Page 352
CLUTCH Removing the clutch 90 Nm (9.0 m kg, 65 ft • • 18 17 10 Nm (1.0 m kg, 7.2 ft • • 11 10 9,12 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Parts to remove Q’ty Remarks Rear balancer…
Page 353
CLUTCH Removing the clutch 90 Nm (9.0 m kg, 65 ft • • 18 17 10 Nm (1.0 m kg, 7.2 ft • • 11 10 9,12 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Parts to remove Q’ty Remarks Thrust washer…
Page 354
CLUTCH Removing the clutch master cylinder (FJR1300A) Order Job/Parts to remove Q’ty Remarks Drain. Refer to “BLEEDING THE HYDRAULIC Clutch fluid CLUTCH SYSTEM (FJR1300A)” on page 3-18. Clutch master cylinder reservoir cap Clutch master cylinder reservoir diaphragm holder Clutch master cylinder reservoir diaphragm Clutch lever Clutch master cylinder push rod pin Clutch switch coupler…
Page 355
CLUTCH Removing the clutch master cylinder (FJR1300A) Order Job/Parts to remove Q’ty Remarks Clutch master cylinder For installation, reverse the removal proce- dure. 5-50…
Page 356
CLUTCH Removing the clutch actuator and clutch master cylinder (FJR1300AS) 7 Nm (0.7 m kg, 5.1 ft • • 19 Nm (1.9 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft •…
Page 357
CLUTCH Removing the clutch actuator and clutch master cylinder (FJR1300AS) 7 Nm (0.7 m kg, 5.1 ft • • 19 Nm (1.9 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft •…
Page 358
CLUTCH Disassembling the clutch master cylinder (FJR1300A) Order Job/Parts to remove Q’ty Remarks Clutch master cylinder push rod Dust boot Circlip Washer Clutch master cylinder kit Clutch master cylinder body For assembly, reverse the disassembly pro- cedure. 5-53…
Page 359
CLUTCH Disassembling the clutch master cylinder (FJR1300AS) Order Job/Parts to remove Q’ty Remarks Clutch master cylinder kit Clutch master cylinder body For assembly, reverse the disassembly pro- cedure. 5-54…
Page 360
CLUTCH Removing the clutch release cylinder (FJR1300A) Order Job/Parts to remove Q’ty Remarks Drain. Refer to “BLEEDING THE HYDRAULIC Clutch fluid CLUTCH SYSTEM (FJR1300A)” on page 3-18. Clutch hose union bolt Copper washer Clutch hose Disconnect. Clutch release cylinder Dowel pin Plate For installation, reverse the removal proce- dure.
Page 361
CLUTCH Removing the clutch release cylinder (FJR1300AS) Order Job/Parts to remove Q’ty Remarks Drain. Refer to “BLEEDING THE HYDRAULIC Clutch fluid CLUTCH SYSTEM (FJR1300AS)” on page 3-19. Clutch hose union bolt Copper washer Clutch hose Disconnect. Clutch release cylinder Dowel pin Plate For installation, reverse the removal proce- dure.
Page 362
CLUTCH Disassembling the clutch release cylinder 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Clutch release cylinder piston Clutch release cylinder spring Clutch release cylinder piston seal Bleed screw Clutch release cylinder body For assembly, reverse the disassembly pro- cedure.
Page 363: Clutch

CLUTCH EAS25080 NOTE: REMOVING THE CLUTCH • Insert a cross-headed screwdriver into one of 1. Remove: the holes of the clutch housing and primary • Clutch cover “1” driven gear, and then rotate the inner primary NOTE: driven gear until both primary drive gears are Loosen each bolt 1/4 of a turn at a time, in stag- aligned.
Page 364: Checking The Clutch Plates

CLUTCH EAS25130 CHECKING THE CLUTCH SPRING PLATE 1. Check: • Clutch spring plate Damage → Replace. 2. Check: • Clutch spring plate seat Damage → Replace. EAS25150 CHECKING THE CLUTCH HOUSING 1. Check: A. Friction plate 1, 3 • Clutch housing dogs B.
Page 365: Checking The Pressure Plate

CLUTCH EAS25250 INSTALLING THE CLUTCH 1. Install: • Clutch housing “1” NOTE: • Make sure that the projections “a” in the clutch housing align with the slots “b” in the oil pump drive sprocket. • Make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly.
Page 366
CLUTCH 3. Install: 6. Lubricate: • Clutch boss “1” • Friction plates • Clutch plates • Lock washer “2” (with the recommended lubricant) • Clutch boss nut “3” Recommended lubricant Clutch boss nut Engine oil 90 Nm (9.0 m·kg, 65 ft·lb) 7.
Page 367: Breaking In The Friction Plates After Replacement (Fjr1300As Only)

CLUTCH • If any connection on the hydraulic clutch ET3P66068 BREAKING IN THE FRICTION PLATES system is disconnected, the entire clutch AFTER REPLACEMENT (FJR1300AS only) system must be disassembled, drained, 1. If the friction plates are replaced, perform the cleaned, properly filled, and bled after reas- following procedure to break them in.
Page 368: Checking The Clutch Master Cylinder

CLUTCH EAS25290 EW3P61016 CHECKING THE CLUTCH MASTER WARNING CYLINDER • Install the clutch lever holder with the “UP” mark facing up. Recommended clutch component replace- ment schedule • Align the end of the clutch lever holder with the punch mark “a” on the left handlebar. Piston seal Every two years •…
Page 369: Installing The Clutch Master Cylinder (Fjr1300As)

CLUTCH 3. Fill: 6. Check: • Clutch master cylinder reservoir • Clutch lever operation Soft or spongy feeling → Bleed the clutch (with the specified amount of the recom- mended clutch fluid) system. Refer to “BLEEDING THE HYDRAULIC Recommended fluid CLUTCH SYSTEM (FJR1300A)”…
Page 370: Replacing The Clutch Master Cylinder (Fjr1300As Only)

CLUTCH 2. Measure EWA13370 WARNING • Shim (clutch master cylinder kit) “1” thickness • Use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance. • Refill with the same type of clutch fluid that is already in the system.
Page 371: Installing The Clutch Actuator (Fjr1300As Only)

CLUTCH ET3P66070 Pressure plate INSTALLING THE CLUTCH ACTUATOR Action stroke (FJR1300AS only) 1. Install: Pressure plate stroke • Clutch actuator before replacing the • Clutch master cylinder clutch master cylin- Select diagnostic der kit was 2.90 mm code No. Sh_ _66 in •…
Page 372: Removing The Clutch Release Cylinder

CLUTCH ET3P61024 REMOVING THE CLUTCH RELEASE CYLINDER 1. Remove: • Clutch hose union bolt “1” • Copper washers “2” • Clutch hose “3” NOTE: Put the end of the clutch hose into a container and pump out the clutch fluid carefully. EAS25340 ASSEMBLING THE CLUTCH RELEASE CYLINDER…
Page 373
CLUTCH NOTE: In order to ensure a correct reading of the clutch fluid level, make sure that the top of the reservoir is horizontal. 3. Bleed: • Clutch system Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM (FJR1300A)” on page 3-18 and “BLEEDING THE HYDRAULIC CLUTCH SYSTEM (FJR1300AS)”…
Page 374: Shift Actuator And Shift Rod (Fjr1300As Only)

SHIFT ACTUATOR AND SHIFT ROD (FJR1300AS only) ET3P66037 SHIFT ACTUATOR AND SHIFT ROD (FJR1300AS only) Removing the shift actuator, shift rod and foot shift switch 4 Nm (0.4 m kg, 2.9 ft • • 20 Nm (2.0 m kg, 14 ft •…
Page 375
SHIFT ACTUATOR AND SHIFT ROD (FJR1300AS only) Removing the shift actuator, shift rod and foot shift switch 4 Nm (0.4 m kg, 2.9 ft • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft •…
Page 376: Removing The Shift Actuator

SHIFT ACTUATOR AND SHIFT ROD (FJR1300AS only) ET3P66038 REMOVING THE SHIFT ACTUATOR 1. Remove: • Shift actuator M MMM M MMM M MMM M MMM M MMM a. Pass a suitable 5 mm diameter rod “1” through the holes in the rear shift arm and shift actuator to secure the shift rod.
Page 377: Adjusting The Foot Shift Switch

SHIFT ACTUATOR AND SHIFT ROD (FJR1300AS only) • Shift pedal pivot bolt Shift pedal pivot bolt 16 Nm (1.6 m·kg, 11 ft·lb) ® LOCTITE NOTE: • Position the projection “a” on the shift pedal be- tween the ends “b” of the spring on the left foot- rest assembly.
Page 378: Installing The Left Footrest Assembly

SHIFT ACTUATOR AND SHIFT ROD (FJR1300AS only) Shift actuator rear bolt 20 Nm (2.0 m·kg, 14 ft·lb) Shift actuator front bolt 20 Nm (2.0 m·kg, 14 ft·lb) L LLL L LLL L LLL L LLL L LLL ET3P66041 INSTALLING THE LEFT FOOTREST ASSEMBLY 1.
Page 379
SHIFT ACTUATOR AND SHIFT ROD (FJR1300AS only) Shift rod front locknut 7 Nm (0.7 m·kg, 5.1 ft·lb) Shift rod rear locknut 10 Nm (1.0 m·kg, 7.2 ft·lb) h. Pull out the rod from the holes. L LLL L LLL L LLL L LLL L LLL 5-74…
Page 380: Shift Shaft

SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Clutch housing Refer to “CLUTCH” on page 5-46. FJR1300AS Shift rod Refer to “SHIFT ACTUATOR AND SHIFT ROD (FJR1300AS only)” on page 5-69. Oil baffle plate 1 Shift arm Circlip…
Page 381: Checking The Shift Shaft

SHIFT SHAFT 3. Install: EAS25420 CHECKING THE SHIFT SHAFT • Shift arm “1” 1. Check: • Shift shaft Shift arm bolt Bends/damage/wear → Replace. 10 Nm (1.0 m·kg, 7.2 ft·lb) • Shift shaft spring Damage/wear → Replace. NOTE: Align the punch mark “a” in the shift shaft with EAS25430 CHECKING THE STOPPER LEVER the slot in the shift arm.
Page 382
SHIFT SHAFT 3. Install: • Front shift arm “1” Front shift arm bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) NOTE: Align the punch mark “a” on the front shift arm with the punch mark “b” on the shift shaft. 5-77…
Page 383: Oil Pump

OIL PUMP EAS24920 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-15. Throttle bodies Refer to “THROTTLE BODIES” on page 7-4. Exhaust pipe assembly Refer to “ENGINE REMOVAL”…
Page 384
OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Relief valve assembly For installation, reverse the removal proce- dure. 5-79…
Page 385
OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil pump housing cover Oil pump inner rotor Oil pump outer rotor Washer Oil pump driven sprocket Oil pump housing For assembly, reverse the disassembly pro- cedure. 5-80…
Page 386: Checking The Oil Pump

OIL PUMP EAS24960 CHECKING THE OIL PUMP Inner-rotor-to-outer-rotor-tip 1. Check: clearance • Oil pump driven sprocket Less than 0.12 mm (0.0047 in) • Oil pump housing Limit 0.20 mm (0.0079 in) • Oil pump housing cover Cracks/damage/wear → Replace the defec- Outer-rotor-to-oil-pump-housing clearance tive part(s).
Page 387: Checking The Oil Strainer

OIL PUMP 1. Check: • Oil pan • Oil delivery pipes Oil pan bolt Damage → Replace. 12 Nm (1.2 m·kg, 8.7 ft·lb) Obstruction → Wash and blow out with com- pressed air. NOTE: EAS24990 Tighten the oil pan bolts in stages and in a criss- CHECKING THE OIL STRAINER cross pattern.
Page 388: Middle Gear

MIDDLE GEAR EAS25710 MIDDLE GEAR Removing the middle gear (FJR1300A) Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Oil pan/Oil pump Refer to “OIL PUMP” on page 5-78. Middle gear case cover Middle gear case cover gasket Dowel pin Damper cover Damper…
Page 389
MIDDLE GEAR Removing the middle gear (FJR1300A) Order Job/Parts to remove Q’ty Remarks Spacer Middle driven gear Bearing retainer Bearing Middle drive pinion gear shim Bearing For installation, reverse the removal proce- dure. 5-84…
Page 390
MIDDLE GEAR Removing the middle gear (FJR1300AS) Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Oil pan/Oil pump Refer to “OIL PUMP” on page 5-78. Middle gear case cover Middle gear case cover gasket Dowel pin Damper cover Damper…
Page 391
MIDDLE GEAR Removing the middle gear (FJR1300AS) Order Job/Parts to remove Q’ty Remarks Middle driven gear Bearing retainer Bearing Middle drive pinion gear shim Bearing For installation, reverse the removal proce- dure. 5-86…
Page 392
MIDDLE GEAR Disassembling the middle drive shaft assembly Order Job/Parts to remove Q’ty Remarks Spring retainer Spring seat Damper spring Damper driven cam Damper drive cam Middle drive shaft For assembly, reverse the disassembly pro- cedure. 5-87…
Page 393
MIDDLE GEAR Disassembling the middle driven shaft assembly Order Job/Parts to remove Q’ty Remarks Oil seal Middle driven pinion gear nut Middle driven shaft Middle driven pinion gear Bearing retainer Bearing Middle driven shaft bearing housing For assembly, reverse the disassembly pro- cedure.
Page 394: Removing The Middle Drive Shaft Assembly

MIDDLE GEAR EAS25730 REMOVING THE MIDDLE DRIVE SHAFT ASSEMBLY 1. Remove: • Middle drive pinion gear nut “1” • Lock washer “2” M MMM M MMM M MMM M MMM M MMM a. Straighten the lock washer tab. b. Loosen the middle drive pinion gear nut. NOTE: While holding the middle drive shaft.
Page 395: Checking The Middle Drive Shaft Assembly

MIDDLE GEAR 4. Check: • Bearings Damage/pitting → Replace. EAS25790 CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1. Check: • Middle driven pinion gear Galling/pitting/wear → Replace. 2. Check: c. Remove the middle driven pinion gear nut. • Bearings Damage/pitting → Replace. L LLL L LLL L LLL…
Page 396: Installing The Middle Drive Shaft Assembly

MIDDLE GEAR Bearing retainer 110 Nm (11.0 m·kg, 80 ft·lb) L LLL L LLL L LLL L LLL L LLL EAS25860 INSTALLING THE MIDDLE DRIVE SHAFT ASSEMBLY d. Lock the threads with a drift punch. 1. Tighten: • Bearing retainer “1” M MMM M MMM M MMM…
Page 397: Installing The Middle Driven Shaft Assembly

MIDDLE GEAR • Middle drive pinion gear nut “2” • Middle driven shaft end cover M MMM M MMM M MMM M MMM M MMM • Middle driven shaft bearing housing bolts a. Tighten the middle drive pinion gear nut to NOTE: specification.
Page 398: Measuring The Middle Gear Backlash

MIDDLE GEAR a. 14 mm (0.55 in) EAS25880 MEASURING THE MIDDLE GEAR d. While gently turning the middle driven shaft BACKLASH back and forth, measure the middle gear 1. Measure: backlash. • Middle gear backlash Out of specification → Refer to “ADJUSTING NOTE: THE MIDDLE GEAR BACKLASH”…
Page 399: Aligning The Middle Gear

MIDDLE GEAR • After tightening the middle driven shaft bearing Hundredth Rounded value housing bolts, loosen them until the clearance 0, 1, 2 between the crankcase and the housing is ap- proximately 2 mm (0.08 in), when measured 3, 4, 5, 6, 7 with a thickness gauge “1”.
Page 400
MIDDLE GEAR Round off to the hundredths digit and select the appropriate shim(s). NOTE: In the above example, the calculated number is 0.51. The chart instructs you to round off the 1 to 0. Thus, the shim thickness is 0.50 mm. Hundredth Rounded value 0, 1, 2…
Page 401
MIDDLE GEAR “d” is 33.97 (i.e., 34.00 + (- 0.03) = 33.97) “e” is 54.49 If the lower crankcase is marked “95” “f” is 87.95 (i.e., 87.00 + 0.95 = 87.95) “B” = 33.97 + 54.49 — 87.95 = 0.51 Round off to the hundredths digit and select the appropriate shim(s).
Page 402: Crankcase

CRANKCASE EAS25540 CRANKCASE Separating the crankcase (FJR1300A) 10 Nm (1.0 m kg, 7.2 ft 20 Nm (2.0 m kg, 14 ft • • • • 2nd 20 Nm (2.0 m kg, 14 ft (10) • • 24 Nm (2.4 m kg, 17 ft •…
Page 403
CRANKCASE Separating the crankcase (FJR1300A) 10 Nm (1.0 m kg, 7.2 ft 20 Nm (2.0 m kg, 14 ft • • • • 2nd 20 Nm (2.0 m kg, 14 ft • • (10) 24 Nm (2.4 m kg, 17 ft •…
Page 404
CRANKCASE Separating the crankcase (FJR1300AS) 10 Nm (1.0 m kg, 7.2 ft 20 Nm (2.0 m kg, 14 ft • • • • 2nd 20 Nm (2.0 m kg, 14 ft (10) • • 24 Nm (2.4 m kg, 17 ft •…
Page 405
CRANKCASE Separating the crankcase (FJR1300AS) 10 Nm (1.0 m kg, 7.2 ft 20 Nm (2.0 m kg, 14 ft • • • • 2nd 20 Nm (2.0 m kg, 14 ft (10) • • 24 Nm (2.4 m kg, 17 ft •…
Page 406
CRANKCASE Removing the oil baffle plate and bearings 10 Nm (1.0 m kg, 7.2 ft • • 70 Nm (7.0 m kg, 50 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft •…
Page 407
CRANKCASE Removing the oil baffle plate and bearings 10 Nm (1.0 m kg, 7.2 ft • • 70 Nm (7.0 m kg, 50 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft •…
Page 408: Disassembling The Crankcase

CRANKCASE mating surfaces. Work slowly and carefully EAS25550 DISASSEMBLING THE CRANKCASE and make sure the crankcase halves sepa- 1. Place the engine upside down. rate evenly. 2. Remove: • Crankcase bolts EAS25580 CHECKING THE CRANKCASE NOTE: 1. Thoroughly wash the crankcase halves in a •…
Page 409: Assembling The Crankcase

Recommended lubricant Engine oil 2. Apply: • Sealant (onto the crankcase mating surfaces and oil baffle plate 2) Yamaha bond No. 1215 90890-85505 ® (Three Bond No.1215 NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings.
Page 410
CRANKCASE 13 21 19 22 ECA13980 CAUTION: Before tightening the crankcase bolts, make sure the transmission gears shift correctly when the shift drum assembly is turned by hand. 6. Install: • Crankcase bolts NOTE: • Lubricate the bolts “1”–“10” thread and wash- ers with engine oil.
Page 411
CRANKCASE EW3P61014 WARNING Crankcase bolt “11”, “12” 24 Nm (2.4 m·kg, 17 ft·lb) If the bolt is tightened more than the speci- Crankcase bolt “13”, “14” fied angle, do not loosen the bolt and then re- 12 Nm (1.2 m·kg, 8.7 ft·lb) tighten it.
Page 412: Connecting Rods And Pistons

CONNECTING RODS AND PISTONS ET3P61027 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-97. Connecting rod cap Big end lower bearing Piston pin clip Piston pin Piston Connecting rod Big end upper bearing…
Page 413: Removing The Connecting Rods And Pistons

CONNECTING RODS AND PISTONS EAS26030 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the con- necting rods and pistons. 1. Remove: • Connecting rod cap “1” NOTE: Identify the position of each connecting rod so that it can be reinstalled in its original place.
Page 414: Checking The Piston Rings

CONNECTING RODS AND PISTONS M MMM M MMM M MMM M MMM M MMM a. Measure cylinder bore “C” with the cylinder bore gauge. NOTE: Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cylinder. Then, find the average of the measurements. Bore 79.000–79.010 mm (3.1102–…
Page 415: Checking The Piston Pin

CONNECTING RODS AND PISTONS Piston ring Piston ring Top ring Top ring Ring side clearance End gap (installed) 0.030–0.070 mm (0.0012– 0.35–0.45 mm (0.0138–0.0177 0.0028 in) Limit Limit 0.120 mm (0.0047 in) 0.70 mm (0.0276 in) 2nd ring 2nd ring Ring side clearance End gap (installed) 0.020–0.060 mm (0.0008–…
Page 416: Checking The Connecting Rods

CONNECTING RODS AND PISTONS a. Clean the big end bearings, crankshaft pins, Piston pin bore inside diameter and the inside of the connecting rod halves. 19.004–19.015 mm (0.7482– b. Install the big end upper bearing into the con- 0.7486 in) necting rod and the big end lower bearing into Limit the connecting rod cap.
Page 417: Installing The Connecting Rods And Pistons

CONNECTING RODS AND PISTONS e. Tighten the connecting rod nuts. Refer to “INSTALLING THE CONNECTING RODS AND PISTONS” on page 5-112. f. Remove the connecting rod and big end bearings. Refer to “REMOVING THE CONNECTING RODS AND PISTONS” on page 5-108. ®…
Page 418
CONNECTING RODS AND PISTONS 2. Install: a. Top ring • Piston “1” b. Lower oil ring rail (onto the respective connecting rod “2”) c. Upper oil ring rail • Piston pin “3” d. 2nd ring A. Intake side • Piston pin clips “4” NOTE: 4.
Page 419
CONNECTING RODS AND PISTONS • While compressing the piston rings with piston ring compressor “2”, install the connecting rod assembly “1” into the cylinder with the other hand. • Make sure the “Y” marks “a” on the connecting rods face towards the left side of the crank- shaft.
Page 420
CONNECTING RODS AND PISTONS L LLL L LLL L LLL L LLL L LLL 5-115…
Page 421: Crankshaft

CRANKSHAFT EAS25950 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-97. Front balancer weight Refer to “BALANCERS” on page 5-132. Refer to “CONNECTING RODS AND PIS- Connecting rod caps TONS” on page 5-107. Crankshaft Crankshaft journal upper bearing Crankshaft journal lower bearing…
Page 422: Removing The Crankshaft Journal Bearings

CRANKSHAFT EAS26040 REMOVING THE CRANKSHAFT JOURNAL Journal oil clearance (using plas- BEARINGS ® tigauge 1. Remove: 0.027–0.045 mm (0.0011–0.0018 • Crankshaft journal upper bearings (from the upper crankcase) • Crankshaft journal lower bearings ECA13920 CAUTION: (from the lower crankcase) Do not interchange the crankshaft journal NOTE: bearings.
Page 423: Installing The Crankshaft

CRANKSHAFT e. Install the crankshaft journal lower bearings • If J –J are the same, use the same size for all “3” into the lower crankcase and assemble of the bearings. the crankcase halves. NOTE: • Align the projections “c” of the crankshaft jour- nal lower bearings with the notches “d”…
Page 424
CRANKSHAFT NOTE: • Align the projections “a” on the crankshaft jour- nal bearings “1” with the notches “b” in the crankcases. • Be sure to install each crankshaft journal bear- ing in its original place. 5-119…
Page 425: Transmission

TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks (FJR1300A) Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-97. Stopper lever Refer to “SHIFT SHAFT” on page 5-75. Drive axle assembly Bearing Washer Bearing Shift drum retainer…
Page 426
TRANSMISSION Removing the transmission, shift drum assembly, and shift forks (FJR1300A) Order Job/Parts to remove Q’ty Remarks Main axle assembly For installation, reverse the removal proce- dure. 5-121…
Page 427
TRANSMISSION Removing the transmission, shift drum assembly, and shift forks (FJR1300AS) Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-97. Stopper lever Refer to “SHIFT SHAFT” on page 5-75. Gear position sensor bracket Oil seal Drive axle assembly Bearing Washer…
Page 428
TRANSMISSION Removing the transmission, shift drum assembly, and shift forks (FJR1300AS) Order Job/Parts to remove Q’ty Remarks Main axle assembly For installation, reverse the removal proce- dure. 5-123…
Page 429
TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks 2nd pinion gear Toothed lock washer Toothed lock washer retainer 5th pinion gear Toothed spacer Toothed washer Circlip 3rd pinion gear 4th pinion gear Collar Main axle/1st pinion gear Bearing Main axle bearing housing For assembly, reverse the disassembly pro-…
Page 430
TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Middle drive gear Washer 2nd wheel gear Collar Washer 5th wheel gear Circlip Toothed washer 3rd wheel gear Toothed spacer Toothed lock washer Toothed lock washer retainer 4th wheel gear Washer 1st wheel gear Bearing…
Page 431
TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Drive axle For assembly, reverse the disassembly pro- cedure. 5-126…
Page 432: Removing The Transmission

TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Main axle assembly NOTE: Remove the main axle assembly with the slide hammer bolts “1” and weight. Slide hammer bolt 90890-01083 Slide hammer bolt 6 mm 3. Check: YU-01083-1 • Shift fork movement Weight (along the shift fork guide bar) 90890-01084…
Page 433: Assembling The Main Axle And Drive Axle

TRANSMISSION Incorrect → Reassemble the transmission Main axle runout limit axle assemblies. 0.08 mm (0.0032 in) 5. Check: • Transmission gear movement Rough movement → Replace the defective part(s). 6. Check: • Circlips Bends/damage/looseness → Replace. ET3P61030 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1.
Page 434: Installing The Transmission (Fjr1300A)

TRANSMISSION • Be sure to align the projection on the toothed NOTE: lock washer that is between the alignment • When installing the main axle assembly, use a marks “b” with the alignment mark “c” on the re- pin “2” to align the bearing housing hole with tainer.
Page 435: Installing The Transmission (Fjr1300As)

TRANSMISSION 4. Install: • Drive axle assembly NOTE: • The bearing pin “1” must face towards the rear of the upper crankcase. • Make sure the bearing circlip “2” is inserted into the groove in the upper crankcase. 2. Install: •…
Page 436
TRANSMISSION NOTE: • The bearing pin “1” must face towards the rear of the upper crankcase. • Make sure the bearing circlip “2” is inserted into the groove in the upper crankcase. 5. Check: • Transmission Rough movement → Repair. NOTE: Oil each gear, shaft, and bearing thoroughly.
Page 437: Balancers

BALANCERS ET3P61031 BALANCERS Removing the front balancer Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-97. Front balancer lever Front balancer shaft Washer Bearing Front balancer gear Damper Front balancer weight For installation, reverse the removal proce- dure.
Page 438
BALANCERS Removing the rear balancer Order Job/Parts to remove Q’ty Remarks Throttle bodies Refer to “THROTTLE BODIES” on page 7-4. Pickup rotor cover Refer to “PICKUP ROTOR” on page 5-39. Clutch cover Refer to “CLUTCH” on page 5-46. Rear balancer cover Rear balancer cover gasket Rear balancer lever Rear balancer shaft…
Page 439: Checking The Balancers

BALANCERS 2. Align: EAS26120 CHECKING THE BALANCERS • “T” mark on the pickup rotor 1. Check: (with the crankcase mating surface) • Front balancer gear M MMM M MMM M MMM M MMM M MMM Damage/wear → Replace the front balancer a.
Page 440: Installing The Rear Balancer

BALANCERS • Front balancer shaft pinch bolt “2” Front balancer lever bolt 14 Nm (1.4 m·kg, 10 ft·lb) Front balancer shaft pinch bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) NOTE: Make sure that the balancer shaft does not ro- tate. L LLL L LLL L LLL…
Page 441
BALANCERS b. Align the balancer gear punch mark “c” with the primary driven gear point “d” as shown. NOTE: • Make sure that the rear balancer gear teeth and the primary driven gear teeth mesh cor- rectly. • Make sure that the balancer gear punch mark “c”…
Page 442
BALANCERS • Rear balancer shaft pinch bolt “2” Rear balancer lever bolt 14 Nm (1.4 m·kg, 10 ft·lb) Rear balancer shaft pinch bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) NOTE: Make sure that the balancer shaft does not ro- tate. L LLL L LLL L LLL…
Page 443: Cooling System

COOLING SYSTEM RADIATOR …………………. 6-1 CHECKING THE RADIATOR…………..6-3 INSTALLING THE RADIATOR…………..6-3 OIL COOLER………………..6-4 CHECKING THE OIL COOLER …………..6-5 INSTALLING THE OIL COOLER ………….. 6-5 THERMOSTAT ………………..6-6 CHECKING THE THERMOSTAT………….. 6-8 INSTALLING THE THERMOSTAT ASSEMBLY ……..6-8 WATER PUMP………………..
Page 444: Radiator

RADIATOR EAS26380 RADIATOR Removing the radiator 7 Nm (0.7 m kg, 5.1 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft •…
Page 445
RADIATOR Removing the radiator 7 Nm (0.7 m kg, 5.1 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft •…
Page 446: Checking The Radiator

RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.
Page 447: Oil Cooler

OIL COOLER EAS26410 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-15. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-25. Radiator Refer to “RADIATOR” on page 6-1. Exhaust pipe assembly Refer to “ENGINE REMOVAL”…
Page 448: Checking The Oil Cooler

OIL COOLER EAS26420 CHECKING THE OIL COOLER 1. Check: • Oil cooler Cracks/damage → Replace. 2. Check: • Oil cooler inlet hose • Oil cooler outlet hose • Water pump outlet hose • Water pump outlet pipe • Water jacket joint inlet hose Cracks/damage/wear →…
Page 449: Thermostat

THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat assembly 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft •…
Page 450
THERMOSTAT Removing the thermostat assembly 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • •…
Page 451: Checking The Thermostat

THERMOSTAT 2. Check: EAS26450 CHECKING THE THERMOSTAT • Thermostat housing 1. Check: Cracks/damage → Replace. • Thermostat 3. Check: Does not open at 71–85 °C (159.8–185.0 °F) • Thermostat hoses → Replace. • Thermostat pipes • Radiator inlet hose • Thermostat cover/radiator filler pipe •…
Page 452
THERMOSTAT 5. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-3.
Page 453: Water Pump

WATER PUMP EAS26500 WATER PUMP Removing the water pump Order Job/Parts to remove Q’ty Remarks It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil. Refer to “GENERAL CHASSIS” on page Right side cowling 4-1.
Page 454
WATER PUMP Disassembling the water pump Order Job/Parts to remove Q’ty Remarks Water pump housing cover O-ring Circlip Impeller shaft Rubber damper holder Rubber damper Water pump seal Oil seal Bearing Water pump housing For assembly, reverse the disassembly pro- cedure.
Page 455: Disassembling The Water Pump

NOTE: • Install the water pump seal with the special tools. • Before installing the water pump seal, apply Yamaha bond No.1215 (Three Bond ® No.1215 ) “2” to the water pump housing “3”. 6-12…
Page 456: Installing The Water Pump

90890-04078 0.15 mm (0.006 in) Water pump seal installer YM-33221-A Middle driven shaft bearing driv- 90890-04058 Bearing driver 40 mm YM-04058 Yamaha bond No. 1215 90890-85505 ® (Three Bond No.1215 1. Straightedge 2. Impeller 5. Install: • Impeller “1” • Circlip…
Page 457
WATER PUMP 2. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-25. 3. Check: • Cooling system Leaks → Repair or replace any faulty part. 4. Measure: • Radiator cap opening pressure Below the specified pressure →…
Page 458
WATER PUMP 6-15…
Page 459: Fuel System

FUEL SYSTEM FUEL TANK………………… 7-1 REMOVING THE FUEL TANK …………..7-2 REMOVING THE FUEL PUMP …………..7-2 CHECKING THE FUEL PUMP BODY…………7-2 INSTALLING THE FUEL PUMP…………..7-2 INSTALLING THE FUEL TANK…………..7-2 THROTTLE BODIES ………………7-4 CHECKING THE INJECTORS …………..7-7 CHECKING THE THROTTLE BODIES………….
Page 460
FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 10 Nm (1.0 m kg, 7.2 ft 4 Nm (0.4 m kg, 2.9 ft • • 16 Nm (1.6 m kg, 11 ft • • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”…
Page 461: Fuel Tank

FUEL TANK EAS26630 EAS26670 REMOVING THE FUEL TANK CHECKING THE FUEL PUMP BODY 1. Extract the fuel in the fuel tank through the 1. Check: fuel tank cap with a pump. • Fuel pump body Obstruction → Clean. 2. Remove: Cracks/damage →…
Page 462
FUEL TANK 2. Install: • Fuel hose (fuel pump side) • Fuel hose holder EC3P61008 CAUTION: When installing the fuel hose, make sure that it is securely connected, and that the fuel hose holder is in the correct position, other- wise the fuel hose will not be properly in- stalled.
Page 463
THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle bodies 3 Nm (0.3 m kg, 2.2 ft • • 3 Nm (0.3 m kg, 2.2 ft • • Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Refer to “GENERAL CHASSIS”…
Page 464
THROTTLE BODIES Removing the throttle bodies 3 Nm (0.3 m kg, 2.2 ft • • 3 Nm (0.3 m kg, 2.2 ft • • Order Job/Parts to remove Q’ty Remarks Plunger control unit hose 2 Disconnect. Throttle body joint For installation, reverse the removal proce- dure.
Page 465
THROTTLE BODIES Removing the injectors 4 Nm (0.4 m kg, 2.9 ft • • 3.5 Nm (0.35 m kg, 2.53 ft • • Order Job/Parts to remove Q’ty Remarks Throttle position sensor coupler Disconnect. Intake air pressure sensor coupler Disconnect. Cylinder-#1 injector coupler Disconnect.
Page 466
THROTTLE BODIES EAS26980 CHECKING THE INJECTORS Pressure gauge 1. Check: 90890-03153 • Injectors YU-03153 Damage → Replace. Fuel pressure adapter 90890-03176 EAS26990 YM-03176 CHECKING THE THROTTLE BODIES 1. Check: • Throttle bodies Cracks/damage → Replace the throttle bod- ies as a set. 2.
Page 467
THROTTLE BODIES Digital circuit tester 90890-03174 Model 88 Multimeter with ta- chometer YU-A1927 c. Turn the main switch to “ON”. d. Measure the throttle position sensor voltage. e. Adjust the throttle position sensor angle so that the voltage is within the specified range. Output voltage (at idle) 0.63–0.73 V f.
Page 468: Air Induction System

AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM…
Page 469
AIR INDUCTION SYSTEM 1. Reed valve assembly 2. Air induction system hose (3-way joint to reed valve cover) 3. Air induction system hose (air cut-off valve to 3-way joint) 4. Air induction system hose (3-way joint to air cut-off valve) 5.
Page 470
AIR INDUCTION SYSTEM Removing the air cut-off valve Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Refer to “GENERAL CHASSIS” on page T-bar 4-1. Air induction system solenoid coupler Disconnect. Air induction system hose (air filter case joint assembly to 3-way joint) Air induction system hose (3-way joint to hose plug)
Page 471
AIR INDUCTION SYSTEM Removing the reed valves 14 Nm (1.4 m kg, 10 ft • • Order Job/Parts to remove Q’ty Remarks Thermostat inlet pipe 1 Refer to “THERMOSTAT” on page 6-6. Reed valve cover (cylinder-#1) Reed valve cover (cylinders-#2/#3) Reed valve cover (cylinder-#4) Reed valve assembly Reed valve plate…
Page 472
AIR INDUCTION SYSTEM 1. Check: EAS27050 CHECKING THE PRESSURE REGULATOR • Hoses 1. Check: Loose connections → Connect properly. • Pressure regulator Cracks/damage → Replace. Damage → Replace. • Pipes Cracks/damage → Replace. EAS27060 CHECKING THE AIR INDUCTION SYSTEM 2. Check: •…
Page 473: Electrical System

ELECTRICAL SYSTEM IGNITION SYSTEM ………………8-1 CIRCUIT DIAGRAM (1/2) (FJR1300A) …………. 8-1 CIRCUIT DIAGRAM (2/2) (FJR1300A) …………. 8-3 CIRCUIT DIAGRAM (1/2) (FJR1300AS) ……….. 8-5 CIRCUIT DIAGRAM (2/2) (FJR1300AS) ……….. 8-7 ENGINE STOPPING DUE TO SIDESTAND OPERATION……. 8-9 TROUBLESHOOTING …………….8-10 ELECTRIC STARTING SYSTEM …………..
Page 474: General Information

FUEL INJECTION SYSTEM…………….8-57 CIRCUIT DIAGRAM (1/2) (FJR1300A) ……….. 8-57 CIRCUIT DIAGRAM (2/2) (FJR1300A) ……….. 8-59 CIRCUIT DIAGRAM (1/2) (FJR1300AS) ……….8-61 CIRCUIT DIAGRAM (2/2) (FJR1300AS) ……….8-63 ECU SELF-DIAGNOSTIC FUNCTION………… 8-65 SELF-DIAGNOSTIC FUNCTION TABLE ……….8-66 TROUBLESHOOTING METHOD…………8-68 DIAGNOSTIC MODE …………….
Page 475
[D-3] FINAL CHECK …………….8-180 GRIP WARMER SYSTEM …………….8-181 CIRCUIT DIAGRAM (1/2)…………..8-181 CIRCUIT DIAGRAM (2/2)…………..8-183 TROUBLESHOOTING …………….8-185 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) ..8-187 CIRCUIT DIAGRAM (1/2)…………..8-187 CIRCUIT DIAGRAM (2/2)…………..8-189 TROUBLESHOOTING …………….8-191 MAINTENANCE OF THE MCU ………….8-192 MCU (motor control unit) SELF-DIAGNOSTIC FUNCTION ….8-192 SELF-DIAGNOSTIC FUNCTION TABLE ……….8-193…
Page 476
ELECTRICAL COMPONENTS…………..8-225 CHECKING THE SWITCHES ……………8-233 CHECKING THE BULBS AND BULB SOCKETS ………8-238 CHECKING THE FUSES …………..8-239 CHECKING AND CHARGING THE BATTERY……..8-240 CHECKING THE RELAYS …………..8-243 CHECKING THE TURN SIGNAL/HAZARD RELAY……8-245 CHECKING THE RELAY UNIT (DIODE) ……….8-246 CHECKING THE SPARK PLUG CAPS……….8-247 CHECKING THE IGNITION COILS…………8-247 CHECKING THE IGNITION SPARK GAP……….8-248 CHECKING THE CRANKSHAFT POSITION SENSOR……8-248…
Page 478
IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM (1/2) (FJR1300A)
Page 479
IGNITION SYSTEM 1. Main switch 8. Main fuse 9. Battery 15.Gear position switch 20.Coupler 3 (wire harness–front cowling wire harness) 21.Relay unit 24.Sidestand switch 36.Cylinders-#1/#4 ignition coil 37.Spark plug 38.Cylinders-#2/#3 ignition coil 44.ECU (engine control unit) 45.Crankshaft position sensor 46.Lean angle sensor 54.Coupler 4 (wire harness–front cowling wire harness) 59.Ignition fuse…
Page 480
IGNITION SYSTEM ET3P61001 CIRCUIT DIAGRAM (2/2) (FJR1300A) Front cowling wire harness…
Page 481
IGNITION SYSTEM 20.Coupler 3 (wire harness–front cowling wire harness) 54.Coupler 4 (wire harness–front cowling wire harness) 70.Engine stop switch…
Page 482
IGNITION SYSTEM ET3P66001 CIRCUIT DIAGRAM (1/2) (FJR1300AS)
Page 483
IGNITION SYSTEM 1. Main switch 8. Main fuse 9. Battery 18.Relay unit 21.Neutral switch 27.Coupler 3 (wire harness–front cowling wire harness) 36.Sidestand switch 37.Cylinders-#1/#4 ignition coil 38.Spark plug 39.Cylinders-#2/#3 ignition coil 45.ECU (engine control unit) 46.Crankshaft position sensor 49.Lean angle sensor 66.Coupler 5 (wire harness–front cowling wire harness) 72.Ignition fuse…
Page 484
IGNITION SYSTEM ET3P66002 CIRCUIT DIAGRAM (2/2) (FJR1300AS) Front cowling wire harness…
Page 485
IGNITION SYSTEM 27.Coupler 3 (wire harness–front cowling wire harness) 66.Coupler 5 (wire harness–front cowling wire harness) 90.Engine stop switch…
Page 486
IGNITION SYSTEM ET3P61002 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the gear position switch (neutral circuit) and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark.
Page 487
IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar 4. Throttle bodies 5. Storage compartment NG → 1.
Page 488
IGNITION SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch/immobilizer unit. SWITCHES” on page 8-233. OK ↓ NG → 9. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES”…
Page 489
IGNITION SYSTEM 8-12…
Page 490: Electric Starting System

ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM (1/2) (FJR1300A) 8-13…
Page 491
ELECTRIC STARTING SYSTEM 1. Main switch 8. Main fuse 9. Battery 11.Starter relay 12.Starter motor 15.Gear position switch 16.Coupler 1 (wire harness–front cowling wire harness) 20.Coupler 3 (wire harness–front cowling wire harness) 21.Relay unit 22.Starting circuit cut-off relay 24.Sidestand switch 54.Coupler 4 (wire harness–front cowling wire harness) 59.Ignition fuse…
Page 492
ELECTRIC STARTING SYSTEM ET3P61003 CIRCUIT DIAGRAM (2/2) (FJR1300A) Front cowling wire harness 8-15…
Page 493
ELECTRIC STARTING SYSTEM 16.Coupler 1 (wire harness–front cowling wire harness) 20.Coupler 3 (wire harness–front cowling wire harness) 54.Coupler 4 (wire harness–front cowling wire harness) 70.Engine stop switch 71.Start switch 74.Clutch switch 8-16…
Page 494
ELECTRIC STARTING SYSTEM ET3P66005 CIRCUIT DIAGRAM (1/2) (FJR1300AS) 8-17…
Page 495
ELECTRIC STARTING SYSTEM 1. Main switch 8. Main fuse 9. Battery 11.Starter relay 12.Starter motor 14.Coupler 1 (wire harness–front cowling wire harness) 18.Relay unit 19.Starting circuit cut-off relay 21.Neutral switch 27.Coupler 3 (wire harness–front cowling wire harness) 29.Brake light relay 30.Rear brake light switch 36.Sidestand switch 58.MCU (motor control unit)
Page 496
ELECTRIC STARTING SYSTEM ET3P66006 CIRCUIT DIAGRAM (2/2) (FJR1300AS) Front cowling wire harness 8-19…
Page 497
ELECTRIC STARTING SYSTEM 14.Coupler 1 (wire harness–front cowling wire harness) 27.Coupler 3 (wire harness–front cowling wire harness) 66.Coupler 5 (wire harness–front cowling wire harness) 89.Front brake light switch 90.Engine stop switch 91.Start switch 8-20…
Page 498
ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION (FJR1300A) If the engine stop switch is set to “ ” and the main switch is turned “ON” (both switch circuits are closed), the starter motor can only operate if at least one of the following conditions is met: •…
Page 499
ELECTRIC STARTING SYSTEM ET3P66007 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION (FJR1300AS) If the engine stop switch is set to “ ” (the switch circuit is closed), the main switch is turned “ON” (the switch circuit is closed), and the brake lever is squeezed (the front brake light switch circuit is open) or the brake pedal is depressed (the rear brake light switch circuit is open), the starter motor can only op- erate if at least one of the following conditions is met: •…
Page 500
ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING (FJR1300A) The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar 4. Throttle bodies 5. Storage compartment NG → 1. Check the fuses. (Main and ignition) Replace the fuse(s).
Page 501
ELECTRIC STARTING SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch/immobilizer unit. SWITCHES” on page 8-233. OK ↓ NG → 9. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES”…
Page 502
ELECTRIC STARTING SYSTEM ET3P66008 TROUBLESHOOTING (FJR1300AS) The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar 4. Throttle bodies 5. Storage compartment NG → 1. Check the fuses. (Main, signaling system, and igni- tion) Replace the fuse(s).
Page 503
ELECTRIC STARTING SYSTEM NG → 8. Check the brake light relay. Refer to “CHECKING THE RE- Replace the brake light relay. LAYS” on page 8-243. OK ↓ NG → 9. Check the YCC-S control relay. Refer to “CHECKING THE RE- Replace the YCC-S control relay.
Page 504
ELECTRIC STARTING SYSTEM NG → 17.Check the entire starting system wiring. Refer to “CIRCUIT DIAGRAM (1/2) Properly connect or repair the starting sys- (FJR1300AS)” on page 8-17 and tem wiring. “CIRCUIT DIAGRAM (2/2) (FJR1300AS)” on page 8-19. OK ↓ Replace the MCU. 8-27…
Page 505
ELECTRIC STARTING SYSTEM 8-28…
Page 506
CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM Br/L Br/W B/W BB R/G B2 Br/R B/W G/B R/L R/L L/W R/W R/L R/L (BLACK) (GRAY) (BLACK) Br/R Br/R Br/L Br/L Br/L Br/R Br/R Br/L Br/B Br/B Br/L Br/B Br/L R/Y R/W Br/B L/R G/L Br/L…
Page 507
CHARGING SYSTEM 2. Rectifier/regulator 3. AC magneto 8. Main fuse 9. Battery 8-30…
Page 508
CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. NOTE: • Before troubleshooting, remove the following part(s): 1. Front cowling right inner panel 1 NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES”…
Page 509
CHARGING SYSTEM 8-32…
Page 510
LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM (1/2) 8-33…
Page 511
LIGHTING SYSTEM 1. Main switch 8. Main fuse 9. Battery 20.Coupler 3 (wire harness–front cowling wire harness) 31.License plate light 33.Tail/brake light 44.ECU (engine control unit) 54.Coupler 4 (wire harness–front cowling wire harness) 55.Headlight (on/off)/grip warmer relay 56.Hazard lighting fuse 58.Headlight fuse 59.Ignition fuse 8-34…
Page 512
LIGHTING SYSTEM ET3P61004 CIRCUIT DIAGRAM (2/2) Front cowling wire harness 8-35…
Page 513
LIGHTING SYSTEM 20.Coupler 3 (wire harness–front cowling wire harness) 54.Coupler 4 (wire harness–front cowling wire harness) 75.Pass switch 76.Dimmer switch 90.Meter light 91.High beam indicator light 98.Headlight relay (dimmer) 100.Auxiliary light 101.Headlight 8-36…
Page 514
LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlights, high beam indicator light, taillight, license plate light, auxiliary lights or meter light. NOTE: • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3.
Page 515
LIGHTING SYSTEM NG → 8. Check the headlight relay (dimmer). Refer to “CHECKING THE RE- Replace the headlight relay (dimmer). LAYS” on page 8-243. OK ↓ NG → 9. Check the entire lighting system wiring. Properly connect or repair the lighting sys- Refer to “CIRCUIT DIAGRAM (1/2)”…
Page 516
SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM (1/2) (FJR1300A) 8-39…
Page 517
SIGNALING SYSTEM 1. Main switch 5. ABS ECU fuse 7. Backup fuse (odometer, clock, immobilizer system, and windshield drive system) 8. Main fuse 9. Battery 14.Oil level switch 15.Gear position switch 16.Coupler 1 (wire harness–front cowling wire harness) 18.Fuel sender 19.Coupler 2 (wire harness–front cowling wire harness) 20.Coupler 3 (wire harness–front cowling wire…
Page 518
SIGNALING SYSTEM ET3P61005 CIRCUIT DIAGRAM (2/2) (FJR1300A) Front cowling wire harness 8-41…
Page 519
SIGNALING SYSTEM 16.Coupler 1 (wire harness–front cowling wire harness) 19.Coupler 2 (wire harness–front cowling wire harness) 20.Coupler 3 (wire harness–front cowling wire harness) 54.Coupler 4 (wire harness–front cowling wire harness) 67.Turn signal/hazard relay 69.Front brake light switch 72.Hazard switch 78.Turn signal switch 79.Horn switch 84.Neutral indicator light 87.Multi-function meter…
Page 520
SIGNALING SYSTEM ET3P66009 CIRCUIT DIAGRAM (1/2) (FJR1300AS) 8-43…
Page 521
SIGNALING SYSTEM 1. Main switch 5. ABS ECU fuse 7. Backup fuse (odometer, clock, immobilizer system, and windshield drive system) 8. Main fuse 9. Battery 14.Coupler 1 (wire harness–front cowling wire harness) 16.Fuel sender 17.Oil level switch 18.Relay unit 21.Neutral switch 23.ABS ECU (electronic control unit) 25.Rear wheel sensor 26.Coupler 2 (wire harness–front cowling wire…
Page 522
SIGNALING SYSTEM ET3P66010 CIRCUIT DIAGRAM (2/2) (FJR1300AS) Front cowling wire harness 8-45…
Page 523
SIGNALING SYSTEM 14.Coupler 1 (wire harness–front cowling wire harness) 26.Coupler 2 (wire harness–front cowling wire harness) 27.Coupler 3 (wire harness–front cowling wire harness) 66.Coupler 5 (wire harness–front cowling wire harness) 81.Turn signal/hazard relay 86.Turn signal switch 87.Horn switch 89.Front brake light switch 92.Hazard switch 95.Neutral indicator light 98.Multi-function meter…
Page 524
SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or indicator light. • The horn fails to sound. • The fuel meter fails to come on. • The speedometer fails to operate. NOTE: •…
Page 525
SIGNALING SYSTEM Checking the signaling system The horn fails to sound. NG → 1. Check the horn switch. Refer to “CHECKING THE Replace the left handlebar switch. SWITCHES” on page 8-233. OK ↓ NG → 2. Check the horns. Refer to “CHECKING THE Replace the horn(s).
Page 526
SIGNALING SYSTEM NG → 5. Check the diode 2. (FJR1300AS only) Replace the diode. Refer to “CHECKING THE DIODE (FJR1300AS only)” on page 8-257. OK ↓ NG → 6. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM (1/2) (FJR1300A)”…
Page 527
SIGNALING SYSTEM NG → 5. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM (1/2) (FJR1300A)” on page 8-39, “CIR- Properly connect or repair the signaling CUIT DIAGRAM (2/2) (FJR1300A)” system wiring. on page 8-41, “CIRCUIT DIAGRAM (1/2) (FJR1300AS)” on page 8-43, and “CIRCUIT DIAGRAM (2/2) (FJR1300AS)”…
Page 528
SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM (1/2) Properly connect or repair the signaling (FJR1300A)” on page 8-39 and system wiring. “CIRCUIT DIAGRAM (2/2) (FJR1300A)” on page 8-41. OK ↓ Replace the meter assembly. The oil level warning light fails to come on.
Page 529
SIGNALING SYSTEM The speedometer fails to operate. NG → 1. Check the rear wheel sensor. Refer to “MAINTENANCE OF THE Replace the rear wheel sensor. REAR WHEEL SENSOR AND SENSOR ROTOR” on page 4-28. OK ↓ NG → 2. Check the entire speed sensor wir- Properly connect or repair the speed sen- ing.
Page 530
COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-53…
Page 531
COOLING SYSTEM 1. Main switch 8. Main fuse 9. Battery 44.ECU (engine control unit) 48.Coolant temperature sensor 59.Ignition fuse 62.Radiator fan motor relay 63.Left radiator fan motor fuse 64.Left radiator fan motor 65.Right radiator fan motor fuse 66.Right radiator fan motor 8-54…
Page 532
COOLING SYSTEM EAS27320 TROUBLESHOOTING The radiator fan motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar NG → 1. Check the fuses. (Main, ignition, left radiator fan mo- tor, and right radiator fan motor) Replace the fuse(s).
Page 533
COOLING SYSTEM 8-56…
Page 534
FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM (1/2) (FJR1300A) 8-57…
Page 535
FUEL INJECTION SYSTEM 1. Main switch 5. ABS ECU fuse 6. Fuel injection system fuse 8. Main fuse 9. Battery 15.Gear position switch 16.Coupler 1 (wire harness–front cowling wire harness) 17.Fuel pump 20.Coupler 3 (wire harness–front cowling wire harness) 21.Relay unit 23.Fuel pump relay 24.Sidestand switch 26.ABS ECU (electronic control unit)
Page 536
FUEL INJECTION SYSTEM ET3P61006 CIRCUIT DIAGRAM (2/2) (FJR1300A) Front cowling wire harness 8-59…
Page 537
FUEL INJECTION SYSTEM 16.Coupler 1 (wire harness–front cowling wire harness) 20.Coupler 3 (wire harness–front cowling wire harness) 54.Coupler 4 (wire harness–front cowling wire harness) 70.Engine stop switch 87.Multi-function meter 89.Engine trouble warning light 8-60…
Page 538
FUEL INJECTION SYSTEM ET3P66012 CIRCUIT DIAGRAM (1/2) (FJR1300AS) 8-61…
Page 539
FUEL INJECTION SYSTEM 1. Main switch 5. ABS ECU fuse 6. Fuel injection system fuse 8. Main fuse 9. Battery 14.Coupler 1 (wire harness–front cowling wire harness) 15.Fuel pump 18.Relay unit 20.Fuel pump relay 21.Neutral switch 23.ABS ECU (electronic control unit) 25.Rear wheel sensor 27.Coupler 3 (wire harness–front cowling wire harness)
Page 540
FUEL INJECTION SYSTEM ET3P66013 CIRCUIT DIAGRAM (2/2) (FJR1300AS) Front cowling wire harness 8-63…
Page 541
FUEL INJECTION SYSTEM 14.Coupler 1 (wire harness–front cowling wire harness) 27.Coupler 3 (wire harness–front cowling wire harness) 66.Coupler 5 (wire harness–front cowling wire harness) 90.Engine stop switch 98.Multi-function meter 100.Engine trouble warning light 8-64…
Page 542
FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Page 543
FUEL INJECTION SYSTEM a. Main switch “OFF” d. Engine trouble warning light on for 1.4 seconds b. Main switch “ON” c. Engine trouble warning light off EAS27380 SELF-DIAGNOSTIC FUNCTION TABLE If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.
Page 544
FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive Intake air tempera- Intake air temperature sensor: ture sensor Able Able open or short circuit detected. (open or short circuit) sensor No normal signal is received from Able…
Page 545
FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive Faulty ECU memory. (When this ECU internal malfunc- malfunction is detected in the Unable Unable tion ECU, the fault code number might not appear on the meter.) Communication error with the meter Able / un-…
Page 546
FUEL INJECTION SYSTEM 5. Erase the malfunction history in the diagnos- The engine operation is not normal but the tic mode. Refer to “Sensor operation table engine trouble warning light does not come (Diagnostic code No.d:62)”. 1. Check the operation of following sensors and NOTE: actuators in the Diagnostic mode.
Page 547
FUEL INJECTION SYSTEM “d:01 d:70” “d:70 d:01” 7. Verify the operation of the sensor or actuator. • Sensor operation The data representing the operating conditions of the sensor appears on the trip LCD. • Actuator operation Set the engine stop switch to “ ”…
Page 548
FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. A break or disconnection of • Open or short circuit in wire harness. the black/red lead of the • Malfunction in ECU. d:20 ECU is detected. • Defective relay unit (diode). •…
Page 549
FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in front cowling wire Malfunction detected in the harness. primary wire of the cylin- • Open or short circuit in wire harness. d:31 ders-#2/#3 ignition coil.
Page 550
FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in front cowling wire harness. Data from the ECU cannot Er-3 • Open or short circuit in wire harness. — be received correctly. •…
Page 551
FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code d:09 Fuel system voltage Approximately 12.0 Set the engine stop switch (battery voltage) to “ ”, and then compare with the actually measured battery voltage. (If the bat- tery voltage is lower, per- form recharging.) d:20 Sidestand switch…
Page 552
FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code d:62 Malfunction history code erasure • No history — • History exists • Displays the total number of To erase the history, set the malfunctions, including the engine stop switch from current malfunction, that “…
Page 553
FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the injector #4 five times at one-second inter- Check the operating sound d:39 Injector #4 vals. of the injector #4 five times. Illuminates the engine trou- ble warning light. Actuates the air induction system solenoid five times at Check the operating sound…
Page 554
FUEL INJECTION SYSTEM Fault code No.: Code number displayed on the meter when the engine failed to work normally. Refer to “Self-Diagnostic Function table”. Diagnostic code No.: Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOSTIC MODE”…
Page 555
FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the crankshaft posi- tion sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of crankshaft posi- Check for looseness or pinching. Cranking the tion sensor engine.
Page 556
FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor: open or short circuit detected. Diagnostic code No. d:03 Intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •…
Page 557
FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor: open or short circuit detected. Diagnostic code No. d:01 Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle position Check for looseness or pinching. Turning the sensor.
Page 558
FUEL INJECTION SYSTEM Fault code No. Symptom Stuck throttle position sensor is detected. Diagnostic code No. d:01 Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle position Check for looseness or pinching. Starting the en- sensor.
Page 559
FUEL INJECTION SYSTEM Fault code No. Symptom A break or disconnection of the black/red lead of the ECU is detected. Diagnostic code No. d:20 Sidestand switch Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Execute the diagnostic mode. If the transmis- •…
Page 560
FUEL INJECTION SYSTEM Fault code No. Symptom Coolant temperature sensor: open or short circuit detect- Diagnostic code No. d:06 Coolant temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of coolant tempera- Check for looseness or pinching. Turning the ture sensor main switch to “ON”.
Page 561
FUEL INJECTION SYSTEM Fault code No. Symptom Intake air temperature sensor: open or short circuit de- tected. Diagnostic code No. d:05 Intake air temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of intake air tem- Check for looseness or pinching.
Page 562
FUEL INJECTION SYSTEM Fault code No. Symptom No normal signal is received from the O sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of O sensor Check for looseness or pinching. Starting the en- gine, warming it Connections •…
Page 563
FUEL INJECTION SYSTEM Fault code No. Symptom Latch up detected. No normal signal is received from the lean angle sensor. Diagnostic code No. d:08 Lean angle sensor Order Item/components and probable Check or maintenance job Reinstatement cause method The vehicle has overturned. Raise the vehicle upright.
Page 564
FUEL INJECTION SYSTEM Fault code No. Symptom The amount of air-fuel ratio feedback compensation is maintained continuously in the vicinity of the upper limit (lean air-fuel ratio). Diagnostic code No. d:01 Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method…
Page 565
FUEL INJECTION SYSTEM Fault code No. Symptom The amount of air-fuel ratio feedback compensation is maintained continuously in the vicinity of the upper limit (lean air-fuel ratio). Diagnostic code No. d:01 Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method…
Page 566
FUEL INJECTION SYSTEM Fault code No. Symptom The amount of air-fuel ratio feedback compensation is maintained continuously in the vicinity of the lower limit (rich air-fuel ratio). Diagnostic code No. d:01 Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method…
Page 567
FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinders- #1/#4 ignition coil. Diagnostic code No. d:30 Cylinders-#1/#4 ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the en- •…
Page 568
FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinders- #2/#3 ignition coil. Diagnostic code No. d:31 Cylinders-#2/#3 ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the en- •…
Page 569
FUEL INJECTION SYSTEM Fault code No. Symptom Lean angle sensor: open or short circuit detected. Diagnostic code No. d:08 Lean angle sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •…
Page 570
FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the rear wheel sensor. B. Open or short circuit is detected in the neutral circuit of the gear position switch. (FJR1300A) Open or short circuit is detected in the neutral switch. (FJR1300AS) Diagnostic code No.
Page 571
FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the rear wheel sensor. B. Open or short circuit is detected in the neutral circuit of the gear position switch. (FJR1300A) Open or short circuit is detected in the neutral switch. (FJR1300AS) Diagnostic code No.
Page 572
FUEL INJECTION SYSTEM Fault code No. Symptom The ECU is unable to monitor the battery voltage (an open or short circuit in the line to the ECU). Diagnostic code No. d:09 Fuel system voltage Order Item/components and probable Check or maintenance job Reinstatement cause method…
Page 573
FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to the fuel injection system is not normal. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the en- •…
Page 574
FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signals are received from the ECU. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •…
Page 575
FUEL INJECTION SYSTEM Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •…
Page 576
FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM (1/2) 8-99…
Page 577
FUEL PUMP SYSTEM 1. Main switch 6. Fuel injection system fuse 8. Main fuse 9. Battery 17.Fuel pump 20.Coupler 3 (wire harness–front cowling wire harness) 21.Relay unit 23.Fuel pump relay 44.ECU (engine control unit) 54.Coupler 4 (wire harness–front cowling wire harness) 59.Ignition fuse 8-100…
Page 578
FUEL PUMP SYSTEM ET3P61007 CIRCUIT DIAGRAM (2/2) Front cowling wire harness 8-101…
Page 579
FUEL PUMP SYSTEM 20.Coupler 3 (wire harness–front cowling wire harness) 54.Coupler 4 (wire harness–front cowling wire harness) 70.Engine stop switch 8-102…
Page 580
FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar 4. Storage compartment NG → 1. Check the fuses. (Main, ignition, and fuel injection system) Replace the fuse(s).
Page 581
FUEL PUMP SYSTEM 8-104…
Page 582
WINDSHIELD DRIVE SYSTEM EAS27610 WINDSHIELD DRIVE SYSTEM EAS27620 CIRCUIT DIAGRAM (1/2) 8-105…
Page 583
WINDSHIELD DRIVE SYSTEM 1. Main switch 7. Backup fuse (odometer, clock, immobilizer system, and windshield drive system) 8. Main fuse 9. Battery 19.Coupler 2 (wire harness–front cowling wire harness) 54.Coupler 4 (wire harness–front cowling wire harness) 57.Signaling system fuse 8-106…
Page 584
WINDSHIELD DRIVE SYSTEM ET3P61008 CIRCUIT DIAGRAM (2/2) Front cowling wire harness 8-107…
Page 585
WINDSHIELD DRIVE SYSTEM 19.Coupler 2 (wire harness–front cowling wire harness) 54.Coupler 4 (wire harness–front cowling wire harness) 77.Windshield position switch 103.Windshield drive unit 8-108…
Page 586
WINDSHIELD DRIVE SYSTEM EAS27630 TROUBLESHOOTING The windshield fails to move. NOTE: • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar NG → 1. Check that there are no rocks or other foreign material in the wind- Remove the foreign material.
Page 587
WINDSHIELD DRIVE SYSTEM NG → 7. Check the entire windshield drive system wiring. Properly connect or repair the windshield Refer to “CIRCUIT DIAGRAM (1/2)” drive system wiring. on page 8-105 and “CIRCUIT DIA- GRAM (2/2)” on page 8-107. OK ↓ Replace the windshield drive unit.
Page 588
ACCESSORY BOX SYSTEM ET3P61009 ACCESSORY BOX SYSTEM ET3P61010 CIRCUIT DIAGRAM (1/2) Br/L Br/W B/W BB R/G B2 Br/R B/W G/B R/L R/L L/W R/W R/L R/L (BLACK) (GRAY) (BLACK) Br/R Br/R Br/L Br/L Br/L Br/R Br/R Br/L Br/B Br/B Br/L Br/B Br/L R/Y R/W…
Page 589
ACCESSORY BOX SYSTEM 1. Main switch 8. Main fuse 9. Battery 54.Coupler 4 (wire harness–front cowling wire harness) 57.Signaling system fuse 8-112…
Page 590
ACCESSORY BOX SYSTEM ET3P61011 CIRCUIT DIAGRAM (2/2) Front cowling wire harness 8-113…
Page 591
ACCESSORY BOX SYSTEM 54.Coupler 4 (wire harness–front cowling wire harness) 80.Accessory box solenoid 8-114…
Page 592
ACCESSORY BOX SYSTEM ET3P61012 TROUBLESHOOTING The accessory box fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1. Front cowling assembly NG → 1. Check the fuses. (Main and signaling system) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”…
Page 593
ACCESSORY BOX SYSTEM 8-116…
Page 594
IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM (1/2) 8-117…
Page 595
IMMOBILIZER SYSTEM 1. Main switch 7. Backup fuse (odometer, clock, immobilizer system, and windshield drive system) 8. Main fuse 9. Battery 13.Immobilizer unit 16.Coupler 1 (wire harness–front cowling wire harness) 19.Coupler 2 (wire harness–front cowling wire harness) 20.Coupler 3 (wire harness–front cowling wire harness) 44.ECU (engine control unit) 54.Coupler 4 (wire harness–front cowling wire…
Page 596
IMMOBILIZER SYSTEM ET3P61013 CIRCUIT DIAGRAM (2/2) Front cowling wire harness 8-119…
Page 597
IMMOBILIZER SYSTEM 16.Coupler 1 (wire harness–front cowling wire harness) 19.Coupler 2 (wire harness–front cowling wire harness) 20.Coupler 3 (wire harness–front cowling wire harness) 54.Coupler 4 (wire harness–front cowling wire harness) 85.Immobilizer system indicator light 87.Multi-function meter 8-120…
Page 598
IMMOBILIZER SYSTEM EAS27670 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) that can be re-registered with new codes •…
Page 599
IMMOBILIZER SYSTEM Parts to be replaced Main switch/immo- Key registration re- Accesso- bilizer unit Standard quirement ry lock* Main Immobiliz- and key switch er unit √ Standard key is lost New standard key All keys have been Code re-registering √ √…
Page 600
IMMOBILIZER SYSTEM Standby mode a. Main switch “ON” e. Standby mode on b. Main switch “OFF” f. Standby mode off c. LED on d. LED off Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced.
Page 601
IMMOBILIZER SYSTEM Standard key registration a. Main switch “ON” B. Immobilizer system indicator light stops flashing when the registration of the second b. Main switch “OFF” standard key is complete. c. LED on d. LED off e. Less than 5.0 s f.
Page 602
IMMOBILIZER SYSTEM EAS27700 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. NG → 1. Check the fuses. (Main, ignition, and backup) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”…
Page 603
IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code IMMOBILIZER Codes between the 1. Signal received from 1. Place the immo- UNIT key and immobilizer other transponder bilizer unit at unit do not match. (failed to recognize least 50 mm code after ten con- away from the secutive attempts).
Page 604
IMMOBILIZER SYSTEM a. Light on b. Light off 8-127…
Page 605
IMMOBILIZER SYSTEM 8-128…
Page 606
ABS (ANTI-LOCK BRAKE SYSTEM) EAS28790 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27730 CIRCUIT DIAGRAM (1/2) (FJR1300A) 8-129…
Page 607
ABS (ANTI-LOCK BRAKE SYSTEM) 1. Main switch 4. ABS solenoid fuse 5. ABS ECU fuse 8. Main fuse 9. Battery 10.ABS motor fuse 11.Starter relay 16.Coupler 1 (wire harness–front cowling wire harness) 20.Coupler 3 (wire harness–front cowling wire harness) 22.Starting circuit cut-off relay 25.ABS test coupler 26.ABS ECU (electronic control unit) 27.Front wheel sensor…
Page 608
ABS (ANTI-LOCK BRAKE SYSTEM) ET3P61021 CIRCUIT DIAGRAM (2/2) (FJR1300A) Front cowling wire harness 8-131…
Page 609
ABS (ANTI-LOCK BRAKE SYSTEM) 16.Coupler 1 (wire harness–front cowling wire harness) 20.Coupler 3 (wire harness–front cowling wire harness) 54.Coupler 4 (wire harness–front cowling wire harness) 69.Front brake light switch 70.Engine stop switch 71.Start switch 86.ABS warning light 87.Multi-function meter 8-132…
Page 610
ABS (ANTI-LOCK BRAKE SYSTEM) ET3P66014 CIRCUIT DIAGRAM (1/2) (FJR1300AS) 8-133…
Page 611
ABS (ANTI-LOCK BRAKE SYSTEM) 1. Main switch 4. ABS solenoid fuse 5. ABS ECU fuse 8. Main fuse 9. Battery 10.ABS motor fuse 11.Starter relay 14.Coupler 1 (wire harness–front cowling wire harness) 19.Starting circuit cut-off relay 22.ABS test coupler 23.ABS ECU (electronic control unit) 24.Front wheel sensor 25.Rear wheel sensor 27.Coupler 3 (wire harness–front cowling wire…
Page 612
ABS (ANTI-LOCK BRAKE SYSTEM) ET3P66015 CIRCUIT DIAGRAM (2/2) (FJR1300AS) Front cowling wire harness 8-135…
Page 613
ABS (ANTI-LOCK BRAKE SYSTEM) 14.Coupler 1 (wire harness–front cowling wire harness) 27.Coupler 3 (wire harness–front cowling wire harness) 66.Coupler 5 (wire harness–front cowling wire harness) 89.Front brake light switch 90.Engine stop switch 91.Start switch 97.ABS warning light 98.Multi-function meter 8-136…
Page 614
ABS (ANTI-LOCK BRAKE SYSTEM) EAS27740 ABS COMPONENTS CHART 12,13 1. ABS test coupler 2. ABS warning light 3. ABS ECU fuse 4. ABS solenoid fuse 5. ABS motor fuse 6. Proportioning valve 7. Hydraulic unit assembly 8. Rear wheel sensor 9.
Page 615
ABS (ANTI-LOCK BRAKE SYSTEM) 8-138…
Page 616
ABS (ANTI-LOCK BRAKE SYSTEM) EAS27750 ABS COUPLER LOCATION CHART FJR1300A B/Y Y/W Y/L Sb/W Sb/W Y/L Y/W B/Y L/W W W/LG/W G/W W/L W L/W Ch Dg R/G B/W G/R Sb B/L B/W W G/B G/R G/B B/R P B/R G/B G/R B/R L/W Y/W P B/Y R/W G/W Y/L Sb/W Y (GRAY) (GRAY)
Page 617
ABS (ANTI-LOCK BRAKE SYSTEM) 1. Meter assembly coupler 2. ABS test coupler 3. Rear wheel sensor coupler 4. ABS ECU coupler 5. Front wheel sensor coupler 6. Wire harness–front cowling wire harness coupler 8-140…
Page 618
ABS (ANTI-LOCK BRAKE SYSTEM) FJR1300AS B/Y Y/W Y/L Sb/W Sb/W Y/L Y/W B/Y L/W W W/L G/W G/W W/L W L/W Ch Dg R/G B/W G/R Sb B/L Lg/W W G/B G/R G/B B/R P B/R G/B G/R B/R L/W Y/W P B/Y R/W G/W Y/L Sb/W Y (GRAY) (GRAY) B/W Dg…
Page 619
ABS (ANTI-LOCK BRAKE SYSTEM) 1. Meter assembly coupler 2. ABS test coupler 3. Rear wheel sensor coupler 4. ABS ECU coupler 5. Front wheel sensor coupler 6. Wire harness–front cowling wire harness coupler 8-142…
Page 620
ABS (ANTI-LOCK BRAKE SYSTEM) EAS27770 NOTE: MAINTENANCE OF THE ABS ECU If the ABS ECU coupler is clogged with mud or dirt, clean with compressed air. Checking the ABS ECU 1. Check: • Terminals “1” of the ABS ECU Cracks/damages → Replace the hydraulic unit assembly and the brake pipes that are connected to the assembly as a set.
Page 621
ABS (ANTI-LOCK BRAKE SYSTEM) NOTE: The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the main switch was turned on. During this test, a “clicking” noise can be heard from under the seat, and if the brake lever or brake pedal are even slightly applied, a vibration can be felt at the lever and pedal, but these do not indicate a malfunction.
Page 622
ABS (ANTI-LOCK BRAKE SYSTEM) EAS27810 BASIC PROCESS FOR TROUBLESHOOTING [A] Turn the main switch to “ON”, and check the ABS warning light. The ABS warning light (LED) is defective. The wire harness is grounded between the [B-1] Does the ABS warning [C-1] Does only the ABS warning ABS ECU and the meter assembly.
Page 623
ABS (ANTI-LOCK BRAKE SYSTEM) EW3P61011 WARNING When maintenance or checks have been performed on components related to the ABS, be sure to perform a final check before delivering the vehicle to the customer. (Refer to “[D-3] FINAL CHECK” on page 8-180.) EAS27830 [A] CHECKING THE ABS WARNING LIGHT Turn the main switch to “ON”.
Page 624
ABS (ANTI-LOCK BRAKE SYSTEM) 1. The fault code “1” is displayed on the multi-function display (example: fault code AbS_11). 2. The ABS warning light flashes every 0.5 second for more than 6 seconds. The ABS warning light flashes every 0.5 second if a fault code for a past malfunction is not stored in the memory of the ABS ECU.
Page 625
ABS (ANTI-LOCK BRAKE SYSTEM) 2. Disconnect the ABS ECU coupler and check that the ABS warning light comes on when the main switch is turned to “ON”. • If the ABS warning light does not come on, the meter assembly circuit (including the ABS warning light [LED]) is defective.
Page 626
ABS (ANTI-LOCK BRAKE SYSTEM) • If there is no continuity, the front cowling wire harness or the wire harness is defective. Properly re- pair or replace the defective harness. 6. The meter assembly circuit is defective. • Disconnect the ABS ECU coupler. •…
Page 627
ABS (ANTI-LOCK BRAKE SYSTEM) Fault Symptom Check point code No. • Continuity of the front wheel sensor circuit • Wire harness (ABS circuit) No continuity in the front wheel sensor AbS_15 • Connection of the front wheel sensor cou- circuit. pler and ABS ECU coupler •…
Page 628
ABS (ANTI-LOCK BRAKE SYSTEM) Fault Symptom Check point code No. Front wheel will not recover from the • Brake dragging locking tendency even though the sig- • Brake fluid AbS_41 nal is continuously transmitted from the • Hydraulic unit operation tests ABS ECU to release the hydraulic •…
Page 629
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_11 Symptom Front wheel sensor signal is not received prop- AbS_25 erly. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Installed condition of wheel sensor. Check for looseness. Repair or •…
Page 630
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_12 Symptom Rear wheel sensor signal is not received proper- Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Installed condition of wheel sensor. Check for looseness. Repair or • Turn the main replace the wheel sensor if nec- switch to “ON”…
Page 631
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_13 Symptom Incorrect signal from the front wheel sensor is AbS_26 detected. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Installed condition of wheel sensor. Check for looseness. Repair or •…
Page 632
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_14 Symptom Incorrect signal from the rear wheel sensor is AbS_27 detected. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Installed condition of wheel sensor. Check for looseness. Repair or •…
Page 633
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_15 Symptom No continuity in the front wheel sensor circuit. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Wire harness continuity. • Check for continuity between the white terminal “1” and the white terminal “3”…
Page 634
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_15 Symptom No continuity in the front wheel sensor circuit. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Defective wheel sensor. If the above items were per- formed and no malfunctions were found, connect the ABS ECU coupler and front wheel sensor coupler, and then delete the fault…
Page 635
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_16 Symptom No continuity in the rear wheel sensor circuit. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Wire harness continuity. • Check for continuity between the gray terminal “1” and the gray terminal “3”…
Page 636
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_16 Symptom No continuity in the rear wheel sensor circuit. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Defective wheel sensor. If the above items were per- formed and no malfunctions were found, connect the ABS ECU coupler and rear wheel sensor coupler, and then delete the fault…
Page 637
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_17 Symptom Missing pulses detected in the front wheel sen- AbS_45 sor signal. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Installed condition of wheel bearings, Check the components for loose- •…
Page 638
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_21 Symptom Hydraulic unit solenoid circuit is open or short- circuited. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Open or short circuit in solenoid cir- Replace the hydraulic unit as- •…
Page 639
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_23 Symptom Brake light signal is not received properly when main switch is turned to “ON” (brake light cir- cuit, or front or rear brake light switch circuit). Order Item/components and probable Check or maintenance job Reinstatement cause confirmation…
Page 640
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_24 Symptom Brake light signal is not received properly while vehicle is traveling (brake light circuit, or front or rear brake light switch circuit). Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method…
Page 641
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_31 Symptom Solenoid relay is defective. Power is not supplied to the solenoid relay. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Battery voltage Recharge or replace the battery. Turn the main Refer to “CHECKING AND switch to “ON”…
Page 642
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_32 Symptom Hydraulic unit solenoid relay is short-circuited. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Short circuit in solenoid relay. Replace the hydraulic unit as- • Turn the main sembly.
Page 643
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_33 Symptom ABS motor is defective. Power is not supplied to the ABS motor. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Battery voltage Recharge or replace the battery. •…
Page 644
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_34 Symptom Hydraulic unit ABS motor relay is short-circuit- Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Short circuit in ABS motor relay. Replace the hydraulic unit as- • Turn the main sembly.
Page 645
Brake lines • Check the brake lines for kinks and deterioration. EWA3P6D005 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • Check that the connections of the brake lines from the brake…
Page 646
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_41 Symptom Front wheel will not recover from the locking tendency even though the signal is continuous- ly transmitted from the ABS ECU to release the hydraulic pressure (when the battery voltage is normal) Order Item/components and probable Check or maintenance job…
Page 647
(particularly between the hydraulic unit and the rear brake caliper). EWA3P6D005 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • Check that the connections of the brake lines from the brake…
Page 648
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_42 Symptom Rear wheel will not recover from the locking ten- dency even though the signal is continuously transmitted from the ABS ECU to release the hy- draulic pressure. Order Item/components and probable Check or maintenance job Reinstatement cause…
Page 649
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_43 Symptom Incorrect signal from the front wheel sensor is detected. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Installed condition of wheel sensor. Check for looseness. Repair or •…
Page 650
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_44 Symptom Incorrect signal from the rear wheel sensor is detected. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Installed condition of wheel sensor. Check for looseness. Repair or •…
Page 651
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_53 Symptom Power voltage is too low. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Battery voltage Recharge or replace the battery. • Turn the main Refer to “CHECKING AND switch to “ON”…
Page 652
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_54 Symptom Power voltage is too low. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Battery voltage Recharge or replace the battery. • Turn the main Refer to “CHECKING AND switch to “ON”…
Page 653
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_56 Symptom Hydraulic unit sensor power monitor circuit is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Defective internal monitor circuit (sen- Replace the hydraulic unit as- • Turn the main sor power).
Page 654
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_63 Symptom Front wheel sensor power is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Short circuit in wire harness. • Check that there is no short cir- Turn the main cuit between the white terminal switch to “ON”…
Page 655
ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. AbS_64 Symptom Rear wheel sensor power is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Short circuit in wire harness. • Check that there is no short cir- Turn the main cuit between the gray terminal switch to “ON”…
Page 656
ABS (ANTI-LOCK BRAKE SYSTEM) 8. Turn the main switch to “OFF”. ET3P6D017 [D-1] DELETING THE FAULT CODES 9. Disconnect the test coupler adapter from the 1. Connect the test coupler adapter “1” to the ABS test coupler, and then install the protec- ABS test coupler “2”.
Page 657
ABS (ANTI-LOCK BRAKE SYSTEM) b. Measure the ABS ECU voltage. 7. Check: • ABS ECU voltage L LLL L LLL L LLL L LLL L LLL Out of specification → Replace the right han- 6. Check: dlebar switch. • ABS-ECU-to-start-switch-lead continuity No continuity →…
Page 658
GRIP WARMER SYSTEM ET3P66016 GRIP WARMER SYSTEM ET3P66017 CIRCUIT DIAGRAM (1/2) 8-181…
Page 659
GRIP WARMER SYSTEM 1. Main switch 8. Main fuse 9. Battery 20.Coupler 3 (wire harness–front cowling wire harness) 44.ECU (engine control unit) 54.Coupler 4 (wire harness–front cowling wire harness) 55.Headlight (on/off)/grip warmer relay 57.Signaling system fuse 58.Headlight fuse 61.Grip warmer control unit 8-182…
Page 660
GRIP WARMER SYSTEM ET3P66018 CIRCUIT DIAGRAM (2/2) Front cowling wire harness 8-183…
Page 661
GRIP WARMER SYSTEM 20.Coupler 3 (wire harness–front cowling wire harness) 54.Coupler 4 (wire harness–front cowling wire harness) 81.Left grip warmer 82.Right grip warmer 8-184…
Page 662
GRIP WARMER SYSTEM ET3P66019 TROUBLESHOOTING • The grip warmers do not become warm at all. • The grip warmers are abnormally hot while the engine is idling. • The grip warmers do not become very warm while the vehicle is traveling. NOTE: •…
Page 663
GRIP WARMER SYSTEM NG → 2. Disconnect the grip warmer control unit coupler (white/yellow and black/green) and check that the Replace the ECU. temperature does not drop while the engine is running. OK ↓ Replace the grip warmer control unit. The grip warmers do not become very warm while the vehicle is traveling.
Page 664
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) ET3P66056 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) ET3P66057 CIRCUIT DIAGRAM (1/2) 8-187…
Page 665
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) 1. Main switch 8. Main fuse 9. Battery 14.Coupler 1 (wire harness–front cowling wire harness) 19.Starting circuit cut-off relay 23.ABS ECU (electronic control unit) 27.Coupler 3 (wire harness–front cowling wire harness) 29.Brake light relay 30.Rear brake light switch…
Page 666
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) ET3P66058 CIRCUIT DIAGRAM (2/2) Front cowling wire harness 8-189…
Page 667
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) 14.Coupler 1 (wire harness–front cowling wire harness) 27.Coupler 3 (wire harness–front cowling wire harness) 60.Coupler 4 (wire harness–front cowling wire harness) 66.Coupler 5 (wire harness–front cowling wire harness) 68.Coupler 6 (wire harness–front cowling wire harness) 89.Front brake light switch…
Page 668
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) ET3P66059 TROUBLESHOOTING • The hand shift select indicator light fails to come on. • The transmission gear display on the multi-function meter fails to indicate the selected gear. NOTE: • Before troubleshooting, remove the following part(s): 1.
Page 669
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) The transmission gear display on the multi-function meter fails to indicate the selected gear. NG → 1. Check the gear position sensor. Refer to “CHECKING THE GEAR POSITION SENSOR (FJR1300AS only)” on page 8-256 and “AD- Replace the gear position sensor.
Page 670
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) SHIFT Checking the YCC-S indicator and warning light The YCC-S indicator and warning light come on for 1.4 seconds after the main switch has been turned to “ON” and they come on while the start switch is being pushed. If the YCC-S indicator and warning light does not come on under these conditions, the warning light (LED) may be defective.
Page 671
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Able/un- Fault Able/un- able to Symptom Malfunction detecting condition code No. able to start change the shift Overcurrent to clutch Detected current in clutch actuator Sh_ _13* Unable Unable actuator motor motor is too high.
Page 672
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Able/un- Fault Able/un- able to Symptom Malfunction detecting condition code No. able to start change the shift Engine speed signal from ECU Engine speed signal Sh_ _31 does not match multi-function Unable Unable is abnormal.
Page 673
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Able/un- Fault Able/un- able to Symptom Malfunction detecting condition code No. able to start change the shift Braking signal is not No braking signal is received by Sh_ _47 detected while brak- MCU (motor control unit) when ve-…
Page 674
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) 5. Erase the malfunction history in the diagnos- tic mode. Refer to “Diagnostic code table (Di- agnostic code No. Sh_ _62)”. NOTE: Turning the main switch to “OFF” will not erase the malfunction history.
Page 675
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) 6. Select the diagnostic code number corresponding to the fault code number by pushing the hand shift select button and operating the brake lever (or brake pedal) simultaneously. 7. Turn the main switch to “OFF” to cancel the diagnostic mode.
Page 676
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Diagnos- Data displayed on tic code Item meter (reference Checking method value) Sh_ _62 Malfunction history code erasure • No history Sh_ _62 — • History exists 01–09 • If fault codes are stored in the malfunc- •…
Page 677
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Diagnos- Data displayed on tic code Item meter (reference Checking method value) Sh_ _64 Shift actuator opera- Sh_ _64 The shift actuator can be operated in this tion mode. 1. Make sure that the transmission is in NOTE: neutral.
Page 678
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Diagnos- Data displayed on tic code Item meter (reference Checking method value) Sh_ _65 Gear position setting Sh_ _65 The gear position can be set in this mode. 1. Make sure that the transmission is in neutral.
Page 679
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Diagnos- Data displayed on tic code Item meter (reference Checking method value) Sh_ _66 Adjust the clutch en- Sh_ _66 This mode adjust the clutch engagement gagement position point manually. The clutch engagement point while the ve-…
Page 680
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Fault code No. Sh_ _11 Symptom Too low or too high voltage is supplied to the YCC-S system. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •…
Page 681
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Fault code No. Sh_ _13 Symptom Over current to clutch actuator motor. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •…
Page 682
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Fault code No. Sh_ _14 Symptom Over current to shift actuator motor. Order Item/components and probable Check or maintenance job Reinstatement cause method • Connections • Check the coupler for any pins Turning the •…
Page 683
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Fault code No. Sh_ _15 Symptom Abnormal current is detected in clutch or shift actuator motor drive circuit. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •…
Page 684
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Fault code No. Sh_ _16 Symptom Malfunction of clutch or shift actuator motor drive circuit in the MCU (motor control unit). Order Item/components and probable Check or maintenance job Reinstatement cause method Connections •…
Page 685
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Fault code No. Sh_ _17 Symptom Detected clutch actuator position is incorrect. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •…
Page 686
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Fault code No. Sh_ _18 Symptom Detected shift actuator position is incorrect. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •…
Page 687
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Fault code No. Sh_ _19 Symptom Output signal of shift actuator sensor is abnor- mal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •…
Page 688
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Fault code No. Sh_ _21 Symptom Output signal of gear position sensor is abnor- mal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •…
Page 689
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Fault code No. Sh_ _22 Symptom Output signal of foot shift switch is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •…
Page 690
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Fault code No. Sh_ _25 Symptom Error has occurred in the actuator drive circuit in MCU (motor control unit) when main switch is turned to “ON”. Order Item/components and probable Check or maintenance job…
Page 691
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Fault code No. Sh_ _27 Symptom Diagnosis mode is activated at engine start-up. Order Item/components and probable Check or maintenance job Reinstatement cause method YCC-S test coupler • Check that the test coupler Turning the adapter is not connected.
Page 692
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Fault code No. Sh_ _32 Symptom YCC-S speed sensor signal is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •…
Page 693
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Fault code No. Sh_ _35 Symptom Start switch signal is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the • Wire harness MCU (motor control that may be pulled out.
Page 694
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Fault code No. Sh_ _37 Symptom Power supply to clutch or shift actuator motor is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •…
Page 695
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Fault code No. Sh_ _38 Symptom Malfunction of hand shift lever switch (shift up or shift down). Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •…
Page 696
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Fault code No. Sh_ _41 Symptom Coolant temperature sensor signal is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •…
Page 697
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Fault code No. Sh_ _43 Symptom Communication between MCU (motor control unit) and ABS ECU is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •…
Page 698
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Fault code No. Sh_ _45 Symptom Shift operation and gear position do not match. Order Item/components and probable Check or maintenance job Reinstatement cause method Shift rod • Check the shift rod pin hole lo- Turning the cation.
Page 699
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Fault code No. Sh_ _47 Symptom Braking signal is not detected while braking. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •…
Page 700
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Fault code No. Sh_ _49 Symptom Engine idling speed is too high when vehicle is started. Order Item/components and probable Check or maintenance job Reinstatement cause method Clutch operation. • Check the clutch stroke.
Page 701
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS only) Fault code No. Sh_ _52 Symptom Main switch signal is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the • Wire harness MCU (motor control that may be pulled out.
Page 702
ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS FJR1300A 8-225…
Page 703
ELECTRICAL COMPONENTS 1. Windshield drive unit 2. Battery 3. Starter relay 4. ABS motor fuse 5. Front brake light switch 6. Clutch switch 7. Fuse box 2 8. Fuse box 1 9. Right radiator fan motor 10. Left radiator fan motor 11.
Page 704
ELECTRICAL COMPONENTS FJR1300A 8-227…
Page 705
ELECTRICAL COMPONENTS 1. Coolant temperature sensor 2. Throttle position sensor 3. Intake air pressure sensor 4. Brake light relay 5. Intake air temperature sensor 6. Lean angle sensor 7. Hydraulic unit assembly 8. ECU (engine control unit) 9. Relay unit 10.
Page 706
ELECTRICAL COMPONENTS FJR1300AS 8-229…
Page 707
ELECTRICAL COMPONENTS 1. Windshield drive unit 2. Battery 3. Starter relay 4. ABS motor fuse 5. Front brake light switch 6. Fuse box 2 7. Fuse box 1 8. Right radiator fan motor 9. Left radiator fan motor 10. Neutral switch 11.
Page 708
ELECTRICAL COMPONENTS FJR1300AS 8-231…
Page 709
ELECTRICAL COMPONENTS 1. Coolant temperature sensor 2. Throttle position sensor 3. Intake air pressure sensor 4. Brake light relay 5. Intake air temperature sensor 6. Lean angle sensor 7. Hydraulic unit assembly 8. MCU (motor control unit) 9. ECU (engine control unit) 10.
Page 710: Checking The Switches

ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES FJR1300A Y R/Y Br/W R/Y Y Lg B Sb DOWN R/Y L/B Dg Br/W Ch B Br/W Ch Br/L Br/R Br/R R/W R/B Br/L L/W B Br/W (BROWN) (BLACK) (BLUE) 8-233…
Page 711
ELECTRICAL COMPONENTS 1. Front brake light switch 2. Main switch 3. Rear brake light switch 4. Gear position switch 5. Sidestand switch 6. Clutch switch 7. Hazard switch 8. Start switch 9. Engine stop switch 10. Horn switch 11. Dimmer switch 12.
Page 712
ELECTRICAL COMPONENTS FJR1300AS Br/W (BLACK) R/Y Y Lg B Sb DOWN R/Y L/B Dg Br/W Ch O/W Br/L O/B B R/B G/R B/L G/B Shift up Shift down Br/L Br/L Br/R Br/R PUSH Br/L B Br/W Ch R/W R/B (BROWN) L/W B Br/W (BLUE)
Page 713
ELECTRICAL COMPONENTS 1. Front brake light switch 2. Main switch 3. Rear brake light switch 4. Neutral switch 5. Sidestand switch 6. Hazard switch 7. Start switch 8. Engine stop switch 9. Hand shift select button 10. Hand shift lever switch (shift up) 11.
Page 714
ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 CAUTION: Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
Page 715
ELECTRICAL COMPONENTS EAS27990 EW3P61001 CHECKING THE BULBS AND BULB WARNING SOCKETS Since headlight bulbs get extremely hot, NOTE: keep flammable products and your hands Do not check any of the lights that use LEDs. away from them until they have cooled down.
Page 716
ELECTRICAL COMPONENTS Checking the condition of the bulb sockets 3. Replace: The following procedure applies to all of the bulb • Blown fuse sockets. M MMM M MMM M MMM M MMM M MMM a. Turn the main switch to “OFF”. 1.
Page 717
ELECTRICAL COMPONENTS cal system, cause the lighting and ignition level will drop considerably. Therefore, systems to malfunction and could possibly take special care when charging the bat- cause a fire. tery. L LLL L LLL L LLL L LLL L LLL NOTE: 4.
Page 718
ELECTRICAL COMPONENTS • When charging a battery, be sure to remove Example it from the vehicle. (If charging has to be Open-circuit voltage = 12.0 V done with the battery mounted on the vehi- Charging time = 6.5 hours Charge of the battery = 20–30% cle, disconnect the negative battery lead from the battery terminal.) •…
Page 719
ELECTRICAL COMPONENTS b. Connect a charger and ammeter to the bat- NOTE: tery and start charging. If the current is lower than the standard charging NOTE: current written on the battery, this type of battery Set the charging voltage to 16–17 V. If the set- charger cannot charge the MF battery.
Page 720
ELECTRICAL COMPONENTS EAS28040 4. Negative tester probe CHECKING THE RELAYS Check each switch for continuity with the pocket Result tester. If the continuity reading is incorrect, re- Continuity place the relay. (between “3” and “4”) Pocket tester 90890-03112 Relay unit (fuel pump relay) Analog pocket tester YU-03112-C 1.
Page 721
ELECTRICAL COMPONENTS Headlight relay (dimmer) Brake light relay First step: First step: 1. Positive tester probe 1. Positive tester probe 2. Negative tester probe 2. Negative tester probe 3. Negative tester probe Result Continuity Result (between “1” and “2”) Continuity (between “1”…
Page 722
ELECTRICAL COMPONENTS YCC-S control relay (FJR1300AS) 3. Positive tester probe 4. Negative tester probe First step: Result Continuity (between “3” and “4”) ET3P61014 CHECKING THE TURN SIGNAL/HAZARD RELAY 1. Check: L / W • Turn signal/hazard relay input voltage Out of specification → The wiring circuit from 1.
Page 723
ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (DC 20 V) to the Continuity Positive tester probe → sky blue turn signal/hazard relay terminal as shown. “1” Negative tester probe → Pocket tester 90890-03112 FJR1300A black/yellow “2”…
Page 724
ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM M MMM M MMM M MMM M MMM M MMM a. Disconnect the relay unit coupler from the a. Disconnect the ignition coil connectors from wire harness. the ignition coil terminals. b.
Page 725
ELECTRICAL COMPONENTS e. Crank the engine by pushing the start switch “ ” and gradually increase the spark gap un- til a misfire occurs. L LLL L LLL L LLL L LLL L LLL EAS28120 CHECKING THE CRANKSHAFT POSITION SENSOR 1.
Page 726
ELECTRICAL COMPONENTS EWA13810 WARNING Lean angle sensor output voltage Less than 65°: 0.4–1.4 V • A wire that is used as a jumper lead must More than 65°: 3.7–4.4 V have at least the same capacity of the bat- tery lead, otherwise the jumper lead may M MMM M MMM M MMM…
Page 727
ELECTRICAL COMPONENTS d. Measure the charging voltage. • Positive tester probe → white “2” L LLL L LLL L LLL L LLL L LLL • Negative tester probe → EAS28180 white “3” CHECKING THE HORNS The following procedure applies to both of the horns.
Page 728
ELECTRICAL COMPONENTS b. Measure the oil level switch resistance. L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL EAS28190 CHECKING THE OIL LEVEL SWITCH EAS28220 1. Drain: CHECKING THE FUEL SENDER •…
Page 729
ELECTRICAL COMPONENTS EAS28260 CHECKING THE COOLANT TEMPERATURE SENSOR 1. Remove: • Coolant temperature sensor EWA14130 WARNING • Handle the coolant temperature sensor with special care. • Never subject the coolant temperature sen- sor to strong shocks. If the coolant temper- b.
Page 730
ELECTRICAL COMPONENTS EAS28370 CHECKING THE AIR INDUCTION SYSTEM Coolant temperature sensor SOLENOID 18 Nm (1.8 m·kg, 13 ft·lb) 1. Check: • Air induction system solenoid resistance EAS28300 Out of specification → Replace. CHECKING THE THROTTLE POSITION SENSOR Solenoid resistance 1. Remove: 19–25 Ω…
Page 731
ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM • Positive tester probe → a. Connect the pocket tester (DC 20 V) to the pink/white “1” cylinder identification sensor coupler (wire • Negative tester probe → harness side) as shown. black/blue “2”…
Page 732
ELECTRICAL COMPONENTS c. Measure the accessory box solenoid resis- b. Immerse the intake air temperature sensor tance. “1” in a container filled with water “2”. L LLL L LLL L LLL L LLL L LLL NOTE: Make sure that the intake air temperature sensor ET3P66023 CHECKING THE GRIP WARMERS terminals do not get wet.
Page 733
ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM ET3P66024 CHECKING THE GRIP WARMER CONTROL a. Connect the pocket tester (DC 20 V) to the UNIT YCC-S speed sensor coupler (wire harness 1. Check: side) as shown. •…
Page 734
ELECTRICAL COMPONENTS 2. Check: M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (Ω × 1k) to the foot • Gear position sensor maximum resistance shift switch terminals as shown. Out of specification → Replace the gear posi- tion sensor.
Page 735
ELECTRICAL COMPONENTS Continuity Positive tester probe → yellow “1” Negative tester probe → yel- low/green “2” No continuity Positive tester probe → yel- low/green “2” Negative tester probe → yellow “1” M MMM M MMM M MMM M MMM M MMM a.
Page 736
ELECTRICAL COMPONENTS 8-259…
Page 737: Troubleshooting

TROUBLESHOOTING TROUBLESHOOTING………………9-1 GENERAL INFORMATION …………… 9-1 STARTING FAILURES…………….9-1 INCORRECT ENGINE IDLING SPEED ………… 9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ……9-2 FAULTY GEAR SHIFTING……………. 9-2 SHIFT PEDAL DOES NOT MOVE …………9-2 JUMPS OUT OF GEAR…………….9-2 FAULTY CLUTCH ………………9-2 OVERHEATING ………………
Page 738
TROUBLESHOOTING Electrical system EAS28450 TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) NOTE: • Blown, damaged or incorrect fuse The following guide for troubleshooting does not • Improperly installed fuse cover all the possible causes of trouble. It should 3.
Page 739
TROUBLESHOOTING Fuel system Shift drum and shift forks 1. Throttle body(-ies) • Foreign object in a shift drum groove • Damaged or loose throttle body joint • Seized shift fork • Improperly synchronized throttle bodies • Bent shift fork guide bar •…
Page 740
TROUBLESHOOTING • Burnt primary driven gear bushing 2. Ignition system • Damaged clutch release cylinder • Faulty ECU • Match marks not aligned EAS28610 2. Engine oil OVERCOOLING • Incorrect oil level • Incorrect oil viscosity (high) Cooling system • Deteriorated oil 1.
Page 741
TROUBLESHOOTING • Improperly installed lower bracket • Headlight bulb life expired (improperly tightened ring nut) Tail/brake light does not come on • Bent steering stem • Wrong tail/brake light bulb • Damaged ball bearing or bearing race • Too many electrical accessories 2.
Page 742: Wiring Diagram

EAS28740 52. Intake air pressure sensor EAS28750 WIRING DIAGRAM COLOR CODE 53. Anti-theft alarm (OPTION) Black 54. Coupler 4 (wire harness–front FJR1300A(X) 2008 Brown cowling wire harness) 1. Main switch Chocolate 55. Headlight (on/off)/grip warmer 2. Rectifier/regulator Dark green relay 3.
Page 743
ET3P66050 52. Throttle position sensor 107.Hand shift lever switch (shift WIRING DIAGRAM 53. Intake air pressure sensor 54. Shift actuator motor 108.Hand shift lever switch (shift FJR1300AS(X) 2008 55. Shift actuator sensor down) 1. Main switch 56. Clutch actuator sensor 109.Hand shift select button 2.
Page 744
Red/Green Red/Blue Red/White Red/Yellow Sb/W Sky blue/White White/Black White/Blue White/Yellow Yellow/Black Yellow/Green Yellow/Blue Yellow/White…
Page 746
YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN…
Page 747
FJR1300A(X) 2008 FJR1300A(X) 2008 FJR1300A(X) 2008 FJR1300A(X) 2008 FJR1300A(X) 2008 WIRING DIAGRAM (1/2) SCHALTPLAN (1/2) DIAGRAMA ELÉCTRICO (1/2) SCHÉMA DE CÂBLAGE (1/2) SCHEMA ELETTRICO (1/2) R/L R/B G/B G/B R/B Br/L Br/W B/W BB R/G B2 P L/W Y Gy/W L/B O/B O/B L/B Gy/W P/W B/L W/B B…
Page 748
FJR1300A(X) 2008 FJR1300A(X) 2008 FJR1300A(X) 2008 FJR1300A(X) 2008 FJR1300A(X) 2008 WIRING DIAGRAM (2/2) SCHALTPLAN (2/2) DIAGRAMA ELÉCTRICO (2/2) SCHÉMA DE CÂBLAGE (2/2) SCHEMA ELETTRICO (2/2) Front cowling wire harness Faisceau de fils au carénage avant Frontverkleidungs-Kabelbaum Cablaggio elettrico del cupolino Mazo de cables del carenado delantero B/R R/B R/B B/R…
Page 749
FJR1300A(X) 2008 FJR1300A(X) 2008 FJR1300A(X) 2008 FJR1300A(X) 2008 FJR1300A(X) 2008 WIRING DIAGRAM (1/2) SCHALTPLAN (1/2) DIAGRAMA ELÉCTRICO (1/2) SCHÉMA DE CÂBLAGE (1/2) SCHEMA ELETTRICO (1/2) (GRAY) (GRAY) WIRE HARNESS SUB-WIRE HARNESS (GRAY) (BLACK) (GRAY) (BLACK) (GRAY) (BLACK) (BLACK) (BLACK) (BLACK) (DARK GREEN) ( BLUE ) ( BLUE )
Page 750
FJR1300A(X) 2008 FJR1300A(X) 2008 FJR1300A(X) 2008 FJR1300A(X) 2008 FJR1300A(X) 2008 WIRING DIAGRAM (2/2) SCHALTPLAN (2/2) DIAGRAMA ELÉCTRICO (2/2) SCHÉMA DE CÂBLAGE (2/2) SCHEMA ELETTRICO (2/2) Front cowling wire harness Faisceau de fils au carénage avant Frontverkleidungs-Kabelbaum Cablaggio elettrico del cupolino Mazo de cables del carenado delantero (BLACK) (BLACK)
Page 751
FJR1300AS(X) 2008 FJR1300AS(X) 2008 FJR1300AS(X) 2008 FJR1300AS(X) 2008 FJR1300AS(X) 2008 WIRING DIAGRAM (1/2) SCHALTPLAN (1/2) DIAGRAMA ELÉCTRICO (1/2) SCHÉMA DE CÂBLAGE (1/2) SCHEMA ELETTRICO (1/2) R/L R/B G/B G/B R/B R/L O/R B/L Y Gy/W L/B O/B O/B L/B Gy/W Y P/W B/L B W/B B Br/L…
Page 752
FJR1300AS(X) 2008 FJR1300AS(X) 2008 FJR1300AS(X) 2008 FJR1300AS(X) 2008 FJR1300AS(X) 2008 WIRING DIAGRAM (2/2) SCHALTPLAN (2/2) DIAGRAMA ELÉCTRICO (2/2) SCHÉMA DE CÂBLAGE (2/2) SCHEMA ELETTRICO (2/2) Front cowling wire harness Faisceau de fils au carénage avant Frontverkleidungs-Kabelbaum Cablaggio elettrico del cupolino Mazo de cables del carenado delantero W/L R/W R/W L/W…
Page 753
FJR1300AS(X) 2008 FJR1300AS(X) 2008 FJR1300AS(X) 2008 FJR1300AS(X) 2008 FJR1300AS(X) 2008 WIRING DIAGRAM (1/2) SCHALTPLAN (1/2) DIAGRAMA ELÉCTRICO (1/2) SCHÉMA DE CÂBLAGE (1/2) SCHEMA ELETTRICO (1/2) (BLACK) (BLACK) (GRAY) (GRAY) WIRE HARNESS SUB-LEAD1 WIRE HARNESS SUB-WIRE HARNESS WIRE HARNESS SUB-LEAD2 (GRAY) (GRAY) (BLACK) (BLACK)
Page 754
FJR1300AS(X) 2008 FJR1300AS(X) 2008 FJR1300AS(X) 2008 FJR1300AS(X) 2008 FJR1300AS(X) 2008 WIRING DIAGRAM (2/2) SCHALTPLAN (2/2) DIAGRAMA ELÉCTRICO (2/2) SCHÉMA DE CÂBLAGE (2/2) SCHEMA ELETTRICO (2/2) Front cowling wire harness Faisceau de fils au carénage avant Frontverkleidungs-Kabelbaum Cablaggio elettrico del cupolino Mazo de cables del carenado delantero (BLACK) ( BLACK )

Источник

Руководство по эксплуатации и техническому обслуживанию мотоциклов Yamaha FJR1300A.

Издательство: Yamaha Motor Co., Ltd.
Год издания: 2010
Страниц: 105
Формат: PDF
Размер: 6,0 Mb

Руководство по эксплуатации и техническому обслуживанию мотоциклов Yamaha FJR1300AS.

Издательство: Yamaha Motor Co., Ltd.
Год издания: 2009
Страниц: 105
Формат: PDF
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Сборник руководств на английском языке по эксплуатации и техническому обслуживанию мотоциклов Yamaha моделей FJR13AD(C)/AEV(C)/AEY(C)/AV(C)/AX(C)/AZ(C).

Издательство: Yamaha Motor Co., Ltd.
Год издания: 2005-2012
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Сборник руководств на английском языке по эксплуатации и техническому обслуживанию мотоциклов Yamaha моделей FJR1300/A/AP/AS(C)/AT(C)/N/R/RC/S(C)/T(C).

Издательство: Yamaha Motor Co., Ltd.
Год издания: 2001-2010
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Руководство на английском языке по ремонту мотоциклов Yamaha моделей FJR1300 и FJR1300N 2001 года выпуска.

Издательство: Yamaha Motor Co., Ltd.
Год издания: —
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Руководство на английском языке по ремонту мотоциклов Yamaha моделей FJR1300A и FJR1300AV 2006 года выпуска.

Издательство: Yamaha Motor Co., Ltd.
Год издания: 2006
Страниц: 586
Формат: PDF
Размер: 23,3 Mb

Руководство (дополнение) на английском языке по ремонту мотоциклов Yamaha моделей FJR1300, FJR1300A, FRJ1300AS и FRJ1300S 2004 года выпуска.

Издательство: Yamaha Motor Co., Ltd.
Год издания: 2003
Страниц: 44
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Сборник руководств на английском, французском, немецком, испанском и итальянском языках по ремонту мотоциклов Yamaha моделей FJR1300, FJR1300A и др.

Издательство: Yamaha
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View, print and download for free: YAMAHA FJR1300AS 2008 Owners Manual, 104 Pages, PDF Size: 3.62 MB. Search in YAMAHA FJR1300AS 2008 Owners Manual online. CarManualsOnline.info is the largest online database of car user manuals. YAMAHA FJR1300AS 2008 Owners Manual PDF Download.

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Мануалы и руководства по FJR1300.

Разные мануалы и рукаводства для FJR разных годов…

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5JW1-AE5 FJR1300(A) 2004 Supplementary Service Manual.pdf

Supplementary Service Manual

5JW1-AE4 FJR1300(A) 2003 Supplementary Service Manual.pdf

Supplementary Service Manual

Сравнительная таблица Yamaha FJR1300.

Сравнение разных поколений и годов выпуска.

РОН ЭЙРС «НА МИЛЮ ДАЛЬШЕ»

Секреты мотодальнобоя из первых рук

FJR1300 2002 Supplementary Service Manual

Руководство по обслуживанию и ремонту FJR1300 2002. Использовать совместно с руководством FJR1300 2001.

Электрическая схема FJR1300 (USA) (2003)

Цветная схема.
North American FJR1300’s («2003» model)

Маркировки аккумуляторов

Найден в интернете экселевский файлик с расшифровкой маркировок аккумуляторов.

Part Numbers

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1-10 11-14

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Related Manuals for Yamaha FJR1300AS

Summary of Contents for Yamaha FJR1300AS

Page 4: Important Manual Information

Page 6: Table Of Contents

Page 8: Safety Information

Page 11: Specifications

Page 12: Description

Page 13: Right View

Page 14: Controls And Instruments

Page 15: Instrument And Control Functions

Page 17: Main Switch/Steering Lock

Page 18: Indicator And Warning Lights

Page 21: Speedometer

Page 28: Anti-Theft Alarm (Optional)

Page 29: Handlebar Switches

Page 31: Shift Pedal

Page 32: Hand Shift Lever

Page 33: Abs

Page 34: Fuel Tank Cap

Page 36: Fuel Tank Breather/Overflow Hose

Page 37: Seats

Page 38: Adjusting The Rider Seat Height

Page 40: Storage Compartment

Page 41: Accessory Box

Page 42: Handlebar Position

Page 43: Rear View Mirrors

Page 45: Adjusting The Shock Absorber Assembly

Page 46: Grip Warmer Adjusting Knob

Page 47: Sidestand

Page 48: Ignition Circuit Cut-Off System

Page 50: Auxiliary Dc Jack

Page 51: For Your Safety — Pre-Operation Checks

Page 54: Operation And Important Riding Points

Page 55: Shifting

Page 56: Tips For Reducing Fuel Consumption

Page 57: Engine Break-In

Page 59: Periodic Maintenance And Adjustment

Page 60: Periodic Maintenance Chart For The Emission Control System

Page 61: General Maintenance And Lubrication Chart

Page 65: Removing And Installing Panels

Page 68: Checking The Spark Plugs

Page 69: Engine Oil And Oil Filter Cartridge

Page 72: Final Gear Oil

Page 73: Coolant

Page 75: Air Filter Element

Page 76: Valve Clearance

Page 78: Cast Wheels

Page 79: Ycc-S Clutch

Page 80: Checking The Brake And Ycc-S Clutch Fluid Levels

Page 81: Changing The Brake And Ycc-S Clutch Fluids

Page 82: Checking And Lubricating The Cables

Page 83: Checking And Lubricating The Brake Lever

Page 84: Lubricating The Swingarm Pivots

Page 85: Checking The Front Fork

Page 86: Checking The Wheel Bearings

Page 87: Replacing The Fuses

Page 89: Headlight Bulb

Page 90: Replacing A Rear Turn Signal Light Bulb Or A Tail/Brake Light Bulb

Page 91: Auxiliary Light Bulb

Page 93: Troubleshooting Charts

Page 95: Motorcycle Care And Storage

Page 97: Storage

Page 99: Specifications

Page 102: Consumer Information

Related Manuals for Yamaha FJR1300AS(X)

Summary of Contents for Yamaha FJR1300AS(X)

Page 4: How To Use This Manual

Page 5: Symbols

Page 7: Table Of Contents

Page 9: General Information

Page 10: Identification

Page 11: Features

Page 12: Fi System

Page 13: Outline Of The Unified Brake System

Page 14: Outline Of The Abs

Page 19: Abs Component Functions

Page 24: Abs Operation

Page 26: Abs Self-Diagnosis Function

Page 29: Abs Warning Light And Operation