Yamaha 2013 FJR1300AS Manuals

Manuals and User Guides for Yamaha 2013 FJR1300AS. We have 1 Yamaha 2013 FJR1300AS manual available for free PDF download: Service Manual

Yamaha 2013 FJR1300AS Service Manual

Yamaha 2013 FJR1300AS Service Manual (786 pages)

Brand: Yamaha | Category: Motorcycle | Size: 23.24 MB

Table of Contents

Table of Contents

7
- How to Use this Manual
  4
- Symbols
  5
- General Information
  9
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
    
    Outline of the Fi System
    11
    
    Fi System
    12
    
    OUTLINE of the YCC-S (Yamaha Chip Controlled-Shift) SYSTEM and YCC-T (Yamaha Chip Controlled-Throttle)
    13
    
    Outline of the Cruise Control System
    18
    
    Outline of the Unified Brake System
    26
    
    Outline of the Abs
    28
    
    Abs Component Functions
    32
    
    Abs Operation
    38
    
    Abs Self-Diagnosis Function
    41
    
    Abs Warning Light and Operation
    44
    
    OUTLINE of the TCS (Traction Control System)
    45
    
    Multi-Function Meter Unit
    48
  - Important Information
    59
    
    Preparation for Removal and Disassembly
    59
    
    Replacement Parts
    59
    
    Gaskets, Oil Seals and O-Rings
    59
    
    Lock Washers/Plates and Cotter Pins
    59
    
    Bearings and Oil Seals
    60
    
    Circlips
    60
    
    Rubber Parts
    60
  - Basic Service Information
    61
    
    Quick Fasteners
    61
    
    Electrical System
    62
  - Special Tools
    66
Specifications

77
- General Specifications
  78
- Engine Specifications
  79
- Chassis Specifications
  87
- Electrical Specifications
  90
- Tightening Torques
  93
- Lubrication Points and Lubricant Types
  105
  - Engine
    105
  - Chassis
    107
- Lubrication System Chart and Diagrams
  108
  - Engine Oil Lubrication Chart
    108
  - Lubrication Diagrams
    110
- Cooling System Diagrams
  120
- Cable Routing
  124
Periodic Checks and Adjustments

145
- General Maintenance and Lubrication Chart
  148
- Introduction
  148
- Periodic Maintenance
  148
- Periodic Maintenance Chart for the Emission Control System
  148
- Chassis
  149
  - Checking the Fuel Line
    151
  - Checking the Spark Plugs
    151
  - Adjusting the Valve Clearance
    152
  - Checking the Engine Idling Speed
    154
  - Synchronizing the Throttle Bodies
    155
  - Checking the Exhaust System
    156
  - Adjusting the Exhaust Gas Volume
    157
  - Checking the Air Induction System
    158
  - Checking the Crankcase Breather Hose
    158
  - Cleaning the Air Filter Element
    158
  - Checking the Clutch Fluid Level
    159
  - Bleeding the Hydraulic Clutch System
    159
  - Checking the Vehicle after Bleeding the Hydraulic Clutch System
    161
  - Adjusting the Front Disc Brake
    162
  - Checking the Brake Fluid Level
    163
  - Bleeding the Hydraulic Brake System (Abs)
    164
  - Checking the Front Brake Pads
    165
  - Adjusting the Rear Disc Brake
    165
  - Checking the Rear Brake Pads
    166
  - Checking the Brake Hoses
    166
  - Checking the Wheels
    166
  - Checking the Tires
    166
  - Checking the Wheel Bearings
    168
  - Checking the Swingarm Pivot
    168
  - Lubricating the Swingarm Pivot
    168
  - Checking and Adjusting the Steering Head
    168
  - Lubricating the Steering Head
    169
  - Checking the Chassis Fasteners
    169
  - Lubricating the Lever
    169
  - Lubricating the Pedals
    169
  - Checking the Sidestand
    170
  - Lubricating the Sidestand
    170
  - Checking the Centerstand
    170
  - Lubricating the Centerstand
    170
  - Checking the Sidestand Switch
    170
  - Checking the Front Fork
    170
  - Adjusting the Damping Force of the Front Fork Legs and Rear Shock Absorber Assembly
    170
  - Checking the Rear Suspension
    171
  - Adjusting the Preload of the Rear Shock Absorber Assembly
    171
  - Lubricating the Rear Suspension
    173
  - Checking the Engine Oil Level
    173
- Engine
  174
  - Changing the Engine Oil
    174
  - Measuring the Engine Oil Pressure
    175
  - Checking the Coolant Level
    176
  - Checking the Cooling System
    176
  - Changing the Coolant
    177
- Cooling System
  178
Chassis

183
- General Chassis
  
  186
  - Removing the Center Rear Cowling
    187
  - Installing the Center Rear Cowling
    187
  - Removing the Rear Cowlings
    187
  - Installing the Rear Cowlings
    187
  - Removing the Side Covers
    188
  - Installing the Side Covers
    188
  - Installing the Seats
    188
  - Adjusting the Side Panels
    192
  - Removing the Front Cowling Inner Panel
    192
  - Installing the Front Cowling Inner Panel
    193
  - Removing the Side Cowlings
    194
  - Installing the Side Cowlings
    194
  - Removing the Windshield Bracket Covers
    197
  - Installing the Windshield Bracket Covers
    197
  - Removing the Center Covers
    197
  - Installing the Center Covers
    197
  - Installing the Front Cowling Assembly
    198
  - Installing the Headlight Beam Adjusting Knob Joints
    198
  - Installing the Windshield Drive Unit
    201
- Front Wheel
  
  207
- Rear Wheel
  
  216
- Front Brake
  
  223
- Rear Brake
  
  235
  - Introduction
    241
  - Checking the Rear Brake Disc
    241
  - Replacing the Rear Brake Pads
    241
  - Removing the Rear Brake Caliper
    242
  - Disassembling the Rear Brake Caliper
    243
  - Checking the Rear Brake Caliper
    243
  - Assembling the Rear Brake Caliper
    243
  - Installing the Rear Brake Caliper
    244
  - Removing the Rear Brake Master Cylinder
    245
  - Checking the Rear Brake Master Cylinder
    245
  - Assembling the Rear Brake Master Cylinder
    246
  - Installing the Rear Brake Master Cylinder
    246
- Abs (Anti-Lock Brake System)
  
  248
- Handlebars
  
  260
  - Adjusting the Handlebar Position
    262
  - Removing the Handlebars
    262
  - Checking the Handlebars
    263
  - Installing the Handlebars
    263
- Front Fork
  
  266
  - Removing the Front Fork Legs
    268
  - Disassembling the Front Fork Legs
    268
  - Checking the Front Fork Legs
    269
  - Assembling the Front Fork Legs
    270
  - Installing the Front Fork Legs
    274
- Steering Head
  
  275
  - Removing the Lower Bracket
    277
  - Checking the Steering Head
    277
  - Installing the Steering Head
    277
- Rear Shock Absorber Assembly
  
  279
- Swingarm
  
  289
  - Removing the Swingarm
    291
  - Checking the Swingarm
    291
  - Installing the Swingarm
    291
- Shaft Drive
  
  293
Engine

309
- Engine Inspection
  
  312
  - Measuring the Compression Pressure
    312
- Engine Removal
  
  314
  - Removing the Gear Position Sensor
    319
  - Removing the Engine
    319
  - Installing the Engine
    319
  - Installing the Gear Position Sensor
    322
  - Adjusting the Gear Position Sensor
    322
- Camshafts
  
  324
  - Removing the Camshafts
    326
  - Checking the Camshafts
    327
  - Checking the Camshaft Sprockets
    328
  - Checking the Timing Chain Guides
    328
  - Checking the Timing Chain Tensioner
    328
  - Installing the Camshafts
    329
- Cylinder Head
  
  333
  - Removing the Cylinder Head
    334
  - Checking the Cylinder Head
    334
  - Installing the Cylinder Head
    334
- Valves and Valve Springs
  
  337
  - Removing the Valves
    337
  - Checking the Valves and Valve Guides
    337
  - Checking the Valve Seats
    339
  - Checking the Valve Springs
    340
  - Checking the Valve Lifters
    341
  - Installing the Valves
    341
- Generator and Starter Clutch
  
  343
  - Removing the Generator
    345
  - Removing the Starter Clutch
    345
  - Checking the Starter Clutch
    345
  - Installing the Starter Clutch
    346
  - Installing the Generator
    346
- Pickup Rotor
  
  348
  - Removing the Pickup Rotor
    349
  - Installing the Pickup Rotor
    349
- Electric Starter
  
  351
  - Checking the Starter Motor
    353
  - Assembling the Starter Motor
    354
- Clutch
  
  355
  - Removing the Clutch
    362
  - Checking the Friction Plates
    362
  - Checking the Clutch Plates
    363
  - Checking the Clutch Spring Plate
    363
  - Checking the Clutch Housing
    363
  - Checking the Clutch Boss
    364
  - Checking the Pressure Plate
    364
  - Checking the Clutch Push Rods
    364
  - Checking the Primary Driven Gear
    364
  - Installing the Clutch
    364
  - Checking the Clutch Actuator Sensor
    366
  - Breaking in the Friction Plates after Replacement
    367
  - Disassembling the Clutch Master Cylinder
    367
  - Checking the Clutch Master Cylinder
    368
  - Assembling the Clutch Master Cylinder
    368
  - Installing the Clutch Master Cylinder
    368
  - Replacing the Clutch Master Cylinder
    369
  - Installing the Clutch Actuator
    369
  - Removing the Clutch Release Cylinder
    370
  - Checking the Clutch Release Cylinder
    370
  - Installing the Clutch Release Cylinder
    370
  - Checking for Stuck Clutch Actuator
    371
- Shift Actuator and Shift Rod
  
  372
  - Removing the Shift Actuator
    374
  - Checking the Shift Rod
    374
  - Installing the Foot Shift Sensor
    374
  - Adjusting the Foot Shift Sensor
    375
  - Installing the Left Footrest Assembly
    375
  - Installing the Shift Actuator
    376
  - Checking the Shift Actuator Sensor
    376
  - Checking for Stuck Shift Actuator
    377
  - Adjusting the Shift Pedal
    377
- Shift Shaft
  
  379
  - Checking the Shift Shaft
    380
  - Checking the Stopper Lever
    380
  - Installing the Shift Shaft
    380
- Oil Pump
  
  381
  - Checking the Oil Pump
    384
  - Checking the Relief Valve
    384
  - Checking the Oil Delivery Pipes
    384
  - Checking the Oil Strainer
    385
  - Assembling the Oil Pump
    385
  - Installing the Oil Pan
    385
- Middle Gear
  
  386
- Crankcase
  
  398
  - Disassembling the Crankcase
    402
  - Checking the Crankcase
    402
  - Checking the Oil Delivery Pipes
    402
  - Checking the Bearings and Oil Seal
    402
  - Checking the Timing Chain and Oil Pump Drive Chain
    402
  - Assembling the Crankcase
    403
  - Installing the Oil Pump Drive Sprocket
    405
- Connecting Rods and Pistons
  
  407
  - Removing the Connecting Rods and Pistons
    407
  - Checking the Cylinders and Pistons
    407
  - Checking the Piston Rings
    408
  - Checking the Piston Pin
    409
  - Checking the Connecting Rods
    410
  - Installing the Connecting Rods and Pistons
    411
- Crankshaft
  
  414
  - Removing the Crankshaft Journal Bearings
    415
  - Checking the Oil Nozzles
    415
  - Checking the Crankshaft
    415
  - Installing the Crankshaft
    416
- Transmission
  
  418
  - Removing the Transmission
    423
  - Checking the Shift Forks
    423
  - Checking the Shift Drum Assembly
    423
  - Checking the Transmission
    423
  - Assembling the Main Axle and Drive Axle
    424
  - Installing the Transmission
    425
- Balancers
  
  429
  - Checking the Balancers
    429
  - Installing the Front Balancer
    429
  - Installing the Rear Balancer
    430
Cooling System

433
- Radiator
  
  434
  - Removing the Radiator
    436
  - Checking the Radiator
    436
  - Installing the Radiator
    436
- Oil Cooler
  
  437
  - Checking the Oil Cooler
    438
  - Installing the Oil Cooler
    438
- Thermostat
  
  439
  - Checking the Thermostat
    441
  - Installing the Thermostat Assembly
    441
- Water Pump
  
  443
  - Disassembling the Water Pump
    445
  - Checking the Water Pump
    445
  - Assembling the Water Pump
    445
  - Installing the Water Pump
    446
Fuel System

449
- Fuel Tank
  
  450
  - Removing the Fuel Tank
    451
  - Removing the Fuel Pump
    451
  - Checking the Fuel Pump Body
    451
  - Installing the Fuel Pump
    451
  - Installing the Fuel Tank
    451
- Throttle Bodies
  
  453
  - Checking the Injectors (before Removing)
    456
  - Removing the Injectors
    456
  - Checking the Injectors
    456
  - Checking and Cleaning the Throttle Bodies
    456
  - Checking the Throttle Body Joints
    458
  - Replacing the Throttle Bodies
    458
  - Installing the Injectors
    458
  - Checking the Injector Pressure
    458
  - Checking the Fuel Pressure
    459
  - Adjusting the Throttle Position Sensor
    460
  - Adjusting the Accelerator Position Sensor
    460
- Air Induction System
  
  462
  - Checking the Air Induction System
    466
  - Installing the Air Induction System
    466
  - Electrical System
    467
  - General Information
    468
    
    Ignition System
    472
    
    Electric Starting System
    478
    
    Charging System
    486
    
    Lighting System
    490
    
    Signaling System
    494
    
    Fuel Injection System
    506
    
    Cruise Control System
    560
    
    Fuel Pump System
    578
    
    Accessory Box System
    586
    
    Immobilizer System
    590
    
    Grip Warmer System
    636
    
    Electrical Components
    726
    
    Checking the Switches
    730
  - Troubleshooting
    757
    
    Wiring Diagram
    780

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