Yamaha FJR1300 - Service Manual

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LIT-11616-16-18 5JW-28197-10

FJR1300R

FJR1300RC

SERVICE MANUAL

Main Page

Default Chapter4
- Periodic Checks and4
General Information5
Specifications5
- Table of Contents7
Periodic Checks and Adjustments5
Chassis5
Engine5
Cooling System5
Fuel Injection System5
Electrical System5
Troubleshooting17
Chapter 1 General Information19
Motorcycle Identification19
- Vehicle Identification Number19
- Model Code19
Features20
- Outline20
- Fi System21
- Components23
- Fuel Injection System35
- Three-Way Catalytic Converter System44
- Air Induction System48
- Components49
Important Information53
- Preparation for Removal and Disassembly53
- Replacement Parts53
- Gaskets, Oil Seals and O-Rings53
- Lock Washers/Plates and Cotter Pins54
- Bearings and Oil Seals54
- Circlips54
- Checking the Connections55
Special Tools56
Chapter 2 Specifications61
Spec61
General Specifications61
Engine Specifications62
Chassis Specifications71
Electrical Specifications75
Conversion Table78
General Tightening Torque Specifications78
- Tightening Torques79
Lubrication Points and Lubricant Types85
- Engine Lubrication Points and Lubricant Types85
- Chassis Lubrication Points and Lubricant Types87
Oil Flow Diagrams88
Cooling System Diagrams98
Cable Routing102
Chapter 3 Periodic Checks and Adjustments117
Introduction117
Periodic Maintenance Chart for the Emission Control System117
General Maintenance and Lubrication Chart117
Chk Adj117
Seats and Fuel Tank120
- Seats120
- Fuel Tank121
- T-Bar122
- Removing the Fuel Tank123
- Removing the Fuel Pump123
- Installing the Fuel Pump124
- Installing the Fuel Hose124
- Installing the T-Bar124
Air Filter Case125
Cowlings and Covers127
- Cowlings127
- Covers131
Engine132
- Adjusting the Valve Clearance132
- Synchronizing the Throttle Bodies138
- Adjusting the Engine Idling Speed141
- Adjusting the Throttle Cable Free Play142
- Checking the Spark Plugs144
- Checking the Ignition Timing145
- Measuring the Compression Pressure147
- Checking the Engine Oil Level149
- Changing the Engine Oil151
- Measuring the Engine Oil Pressure153
- Adjusting the Clutch Lever155
- Checking the Clutch Fluid Level155
- Bleeding the Hydraulic Clutch System156
- Cleaning the Air Filter Element158
- Checking the Throttle Body Joints159
- Checking the Fuel and Vacuum Hoses160
- Checking the Crankcase Breather Hose160
- Checking the Exhaust System161
- Checking the Coolant Level162
- Checking the Cooling System163
- Changing the Coolant164
Chassis167
- Adjusting the Front Brake167
- Adjusting the Rear Brake168
- Checking the Brake Fluid Level169
- Checking the Brake Pads170
- Adjusting the Rear Brake Light Switch171
- Checking the Brake Hoses171
- Bleeding the Hydraulic Brake System172
- Adjusting the Shift Pedal173
- Checking the Final Drive Oil Level174
- Changing the Final Drive Oil175
- Checking and Adjusting the Steering Head175
- Checking the Front Fork177
- Adjusting the Front Fork Legs178
- Adjusting the Rear Shock Absorber Assembly180
- Checking the Tires182
- Checking the Wheels183
- Checking and Lubricating the Cables184
- Lubricating the Levers and Pedals184
- Lubricating the Sidestand184
- Lubricating the Centerstand185
- Lubricating the Rear Suspension185
Electrical System186
- Checking and Charging the Battery186
- Checking the Fuses191
- Replacing the Headlight Bulbs193
- Adjusting the Headlight Beams194
Chapter 4 Chassis197
Front Wheel and Brake Discs197
- Removing the Front Wheel199
- Checking the Front Wheel199
- Checking the Brake Discs201
- Installing the Front Wheel202
- Adjusting the Front Wheel Static Balance203
Chas197
Rear Wheel and Brake Disc205
- Removing the Rear Wheel207
- Checking the Rear Wheel207
- Installing the Rear Wheel208
- Adjusting the Rear Wheel Static Balance208
Front and Rear Brakes209
- Front Brake Pads209
- Rear Brake Pads210
- Replacing the Front Brake Pads211
- Replacing the Rear Brake Pads213
- Front Brake Master Cylinder216
- Rear Brake Master Cylinder219
- Disassembling the Front Brake Master Cylinder222
- Disassembling the Rear Brake Master Cylinder222
- Checking the Front and Rear Brake Master Cylinders223
- Assembling and Installing the Front Brake Master Cylinder224
- Assembling the Rear Brake Master Cylinder226
- Front Brake Calipers229
- Rear Brake Caliper231
- Disassembling the Front Brake Calipers233
- Checking the Front and Rear Brake Calipers235
- Assembling and Installing the Front Brake Calipers236
- Assembling and Installing the Rear Brake Caliper238
Hydraulic Clutch242
- Clutch Master Cylinder242
- Disassembling the Clutch Master Cylinder244
- Checking the Clutch Master Cylinder246
- Assembling and Installing the Clutch Master Cylinder247
- Clutch Release Cylinder250
- Disassembling the Clutch Release Cylinder251
- Checking the Clutch Release Cylinder253
- Assembling and Installing the Clutch Release Cylinder253
Front Fork256
- Removing the Front Fork Legs259
- Disassembling the Front Fork Legs259
- Checking the Front Fork Legs261
- Assembling the Front Fork Legs262
- Installing the Front Fork Legs266
Handlebars268
- Left Handlebar268
- Right Handlebar269
- Removing the Handlebars270
- Checking the Handlebars270
- Installing the Handlebars271
Steering Head274
- Removing the Lower Bracket276
- Checking the Steering Head276
- Installing the Steering Head277
Rear Shock Absorber Assembly and Relay Arm279
- Handling the Rear Shock Absorber281
- Disposing of a Rear Shock Absorber281
- Removing the Rear Shock Absorber Assembly281
- Checking the Rear Shock Absorber Assembly282
- Checking the Connecting Arm and Relay Arm282
- Installing the Relay Arm283
- Installing the Rear Shock Absorber Assembly283
Swingarm284
- Removing the Swingarm286
- Checking the Swingarm286
- Installing the Swingarm287
Shaft Drive289
- Troubleshooting289
- Checking the Final Drive Oil for Contamination and Checking the Shaft Drive for Leaks292
- Measuring the Ring Gear Backlash293
- Adjusting the Ring Gear Backlash294
- Measuring the Ring-Gear-To-Stopper-Bolt Clearance295
- Adjusting the Ring-Gear-To-Stopper-Bolt Clearance295
- Removing the Left Footrest Bracket301
- Disassembling the Final Drive Assembly301
- Removing and Installing the Ring Gear Bearings302
- Aligning the Final Drive Pinion Gear and Ring Gear304
- Checking the Drive Shaft309
- Installing the Universal Joint and Final Drive Assembly309
Chapter 5 Engine310
- Mufflers and Exhaust Pipe Assembly310
- Leads and Hoses311
- Engine311
- Installing the Engine315
Eng310
Camshafts317
- Cylinder Head Cover317
- Camshafts318
- Removing the Camshafts320
- Checking the Camshafts321
- Checking the Camshaft Sprockets322
- Checking the Timing Chain Tensioner323
- Installing the Camshafts323
Cylinder Head328
- Removing the Cylinder Head329
- Checking the Cylinder Head329
- Installing the Cylinder Head330
Valves and Valve Springs332
- Removing the Valves333
- Checking the Valves and Valve Guides334
- Checking the Valve Seats336
- Checking the Valve Springs338
- Checking the Valve Lifters339
- Installing the Valves340
Generator and Starter Clutch342
- Generator Rotor and Starter Clutch342
- Stator Assembly344
- Removing the Generator345
- Removing the Starter Clutch346
- Checking the Starter Clutch346
- Installing the Starter Clutch347
- Installing the Generator347
Pickup Coil Rotor349
- Removing the Pickup Coil Rotor351
- Installing the Pickup Coil Rotor351
Clutch353
- Clutch Cover353
- Clutch354
- Removing the Clutch356
- Checking the Friction Plates357
- Checking the Clutch Plates358
- Checking the Clutch Spring Plate358
- Checking the Clutch Housing358
- Checking the Clutch Boss359
- Checking the Pressure Plate359
- Checking the Clutch Push Rods359
- Checking the Primary Driven Gear359
- Installing the Clutch360
Shift Shaft363
- Checking the Shift Shaft365
- Checking the Stopper Lever365
- Installing the Shift Shaft365
Oil Pan and Oil Pump367
- Oil Pump369
- Removing the Oil Pan370
- Checking the Oil Pump370
- Checking the Relief Valve371
- Checking the Oil Delivery Pipes371
- Checking the Oil Strainer371
- Assembling the Oil Pump371
- Installing the Oil Pump372
- Installing the Oil Strainer372
- Installing the Oil Pan372
Middle Gear374
- Removing the Middle Gear378
- Disassembling the Middle Drive Shaft Assembly379
- Disassembling the Middle Driven Shaft Assembly379
- Checking the Middle Drive Shaft Assembly379
- Checking the Middle Driven Shaft Assembly380
- Assembling the Middle Drive Shaft Assembly380
- Assembling the Middle Driven Shaft Assembly380
- Installing the Middle Drive Shaft Assembly381
- Installing the Middle Driven Shaft Assembly382
- Measuring the Middle Gear Backlash383
- Adjusting the Middle Gear Backlash384
- Aligning the Middle Gear387
Crankcase390
- Disassembling the Crankcase394
- Checking the Crankcase395
- Checking the Bearings and Oil Seals395
- Checking the Timing Chain and Oil Pump Drive Chain396
- Assembling the Crankcase396
- Removing the Connecting Rods and Pistons401
- Checking the Cylinders and Pistons402
- Checking the Piston Rings403
- Checking the Piston Pins404
- Checking the Connecting Rods406
- Installing the Connecting Rods and Pistons408
Crankshaft412
- Removing the Crankshaft413
- Checking the Crankshaft413
- Installing the Crankshaft416
Transmission417
- Removing the Transmission423
- Checking the Shift Forks423
- Checking the Shift Drum Assembly424
- Checking the Transmission424
- Installing the Transmission426
Balancers427
- Front Balancer427
- Rear Balancer428
- Checking the Balancer429
- Installing the Front Balancer429
- Installing the Rear Balancer431
Chapter 6 Cooling System434
Cool434
Radiator434
- Checking the Radiator436
- Installing the Radiator437
Oil Cooler438
- Checking the Oil Cooler439
- Installing the Oil Cooler439
Thermostat441
- Checking the Thermostat443
- Assembling the Thermostat Assembly444
- Installing the Thermostat Assembly444
Water Pump445
- Disassembling the Water Pump448
- Checking the Water Pump448
- Assembling the Water Pump449
- Installing the Water Pump451
Chapter 7 Fuel Injection System452
- Wiring Diagram453
- Ecu's Self-Diagnostic Function454
- Substitute Characteristics Operation Control (Fail-Safe Action)458
- Troubleshooting459
- Throttle Bodies484
- Checking the Injector488
- Checking the Throttle Body488
- Checking the Pressure Regulator488
- Checking the Fuel Pump and Pressure Regulator Operation489
Air Induction System491
- Air Injection491
- Air Cut-Off Valve491
- Air Induction System Diagrams492
- Air Cut-Off Valve Assembly and Air Induction System Hoses493
- Reed Valves494
- Checking the Air Induction System495
Canister (for California Only)496
Chapter 8497
Elec497
Electrical Components497
Checking Switch Continuity499
Checking the Switches500
Checking the Bulbs and Bulb Sockets502
- Types of Bulbs502
- Checking the Condition of the Bulbs502
- Checking the Condition of the Bulb Sockets504
Ignition System505
- Circuit Diagram505
- Troubleshooting506
- Circuit Diagram510
- Starting Circuit Cut-Off System Operation511
- Troubleshooting512
Starter Motor516
- Checking the Starter Motor519
- Assembling the Starter Motor521
Charging System522
- Circuit Diagram522
- Troubleshooting523
Lighting System525
- Circuit Diagram525
- Troubleshooting526
- Checking the Lighting System528
Signaling System532
- Circuit Diagram532
- Troubleshooting534
- Checking the Signaling System535
Cooling System542
- Circuit Diagram542
- Troubleshooting543
Fuel Injection System547
- Circuit Diagram547
- Troubleshooting548
- Checking the Fuel Pump554
- Checking and Adjusting the Throttle555
- Position Sensor555
Windshield Drive System559
- Circuit Diagram559
- Troubleshooting562
Chapter 9562
- Engine562
- Fuel System562
Starting Problems562
Incorrect Engine Idling Speed563
- Engine563
- Fuel System563
Trbl Shtg563
- Electrical Systems563
Poor Medium-And-High-Speed Performance564
- Engine564
- Fuel System564
Faulty Gear Shifting564
- Shifting Is Difficult564
- Shift Pedal Does Not Move564
- Jumps out of Gear564
Faulty Clutch565
- Clutch Slips565
- Clutch Drags565
Overheating565
- Engine565
- Cooling System565
- Fuel System565
- Chassis565
- Electrical Systems565
Poor Braking Performance566
Faulty Front Fork Legs566
- Leaking Oil566
- Malfunction566
Unstable Handling567
Faulty Lighting or Signaling System567
- Headlight Does Not Light567
- Headlight Bulb Burnt out567
- Tail/Brake Light Does Not Light567
- Tail/Brake Light Bulb Burnt out567
- Turn Signal Does Not Light567
- Turn Signal Blinks Slowly567
- Turn Signal Remains Lit567
- Turn Signal Blinks Quickly568
- Horn Does Not Sound568

Yamaha FJR1300 - Service Manual

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