Yamaha FJR1300R 2001 Manuals

Manuals and User Guides for Yamaha FJR1300R 2001. We have 1 Yamaha FJR1300R 2001 manual available for free PDF download: Service Manual

Yamaha FJR1300R 2001 Service Manual (617 pages)

Brand: Yamaha | Category: Motorcycle | Size: 17.15 MB

General Information

6
Specifications

6
Periodic Checks and Adjustments

6
Chassis

6
Engine

6
Cooling System

6
Electrical System

6
Troubleshooting

6
- Table of Contents
  7
Chapter 1 General Information

12
Motorcycle Identification

12
- Vehicle Identification Number
  12
- Model Code
  12
Features

13
- Outline
  13
- Fi System
  14
- Components
  16
Gen Info

28
- Fuel Injection System
  28
- Three-Way Catalytic Converter System
  37
- Air Induction System
  41
- Components
  42
Important Information

46
- Preparation for Removal and Disassembly
  46
- Replacement Parts
  46
- Gaskets, Oil Seals and O-Rings
  46
- Lock Washers/Plates and Cotter Pins
  47
- Bearings and Oil Seals
  47
- Circlips
  47
- Checking the Connections
  48
Special Tools

49
Spec

54
Chapter 2 Specifications

57
General Specifications

57
Engine Specifications

58
Chassis Specifications

67
Electrical Specifications

71
Conversion Table

74
General Tightening Torque Specifications

74
Tightening Torques

75
- Engine Tightening Torques
  75
- Chassis Tightening Torques
  79
Lubrication Points and Lubricant Types

81
- Engine Lubrication Points and Lubricant Types
  81
- Chassis Lubrication Points and Lubricant Types
  83
Oil Flow Diagrams

84
Cooling System Diagrams

94
Cable Routing

98
Chk Adj

113
Chapter 3 Periodic Checks and Adjustments

116
Introduction

116
Periodic Maintenance and Lubrication Intervals

116
Seats and Fuel Tank

118
- Seats
  118
- Fuel Tank
  119
- T-Bar
  120
- Removing the Fuel Tank
  121
- Removing the Fuel Pump
  121
- Installing the Fuel Pump
  122
- Installing the Fuel Hose
  122
- Installing the T-Bar
  122
Air Filter Case

123
Cowlings and Covers

125
- Cowlings
  125
- Covers
  129
Engine

130
- Adjusting the Valve Clearance
  130
- Synchronizing the Throttle Bodies
  136
- Checking and Adjusting the Exhaust Gas at Idle
  139
- Adjusting the Exhaust Gas Volume
  141
- Checking the Exhaust Gas at Idle
  142
- Adjusting the Engine Idling Speed
  143
- Adjusting the Throttle Cable Free Play
  145
- Checking the Spark Plugs
  147
- Checking the Ignition Timing
  148
- Measuring the Compression Pressure
  150
- Checking the Engine Oil Level
  152
- Changing the Engine Oil
  154
- Measuring the Engine Oil Pressure
  156
- Adjusting the Clutch Lever
  158
- Checking the Clutch Fluid Level
  158
- Bleeding the Hydraulic Clutch System
  159
- Cleaning the Air Filter Element
  161
- Checking the Throttle Body Joints
  162
- Checking the Fuel and Vacuum Hoses
  163
- Checking the Crankcase Breather Hose
  163
- Checking the Exhaust System
  164
- Checking the Coolant Level
  165
- Checking the Cooling System
  166
- Changing the Coolant
  167
- Adjusting the Front Brake
  170
- Adjusting the Rear Brake
  171
- Checking the Brake Fluid Level
  172
- Checking the Brake Pads
  173
- Adjusting the Rear Brake Light Switch
  174
- Checking the Brake Hoses
  174
- Bleeding the Hydraulic Brake System
  175
- Adjusting the Shift Pedal
  176
- Checking the Final Drive Oil Level
  177
- Changing the Final Drive Oil
  177
- Checking and Adjusting the Steering Head
  178
- Checking the Front Fork
  180
- Adjusting the Front Fork Legs
  181
- Adjusting the Rear Shock Absorber Assembly
  183
- Checking the Tires
  185
- Checking the Wheels
  186
- Checking and Lubricating the Cables
  187
- Lubricating the Levers and Pedals
  187
- Lubricating the Sidestand
  187
- Lubricating the Centerstand
  188
- Lubricating the Rear Suspension
  188
Electrical System

189
- Checking and Charging the Battery
  189
- Checking the Fuses
  194
- Replacing the Headlight Bulbs
  196
- Adjusting the Headlight Beams
  197
Chas

200
Front Wheel and Brake Discs

203
Chapter 4

205
- Removing the Front Wheel
  205
- Checking the Front Wheel
  205
- Checking the Brake Discs
  207
- Installing the Front Wheel
  208
- Adjusting the Front Wheel Static Balance
  209
Rear Wheel and Brake Disc

211
- Removing the Rear Wheel
  213
- Checking the Rear Wheel
  213
- Installing the Rear Wheel
  214
- Adjusting the Rear Wheel Static Balance
  214
Front and Rear Brakes

215
Hydraulic Clutch

248
Handlebars

273
- Left Handlebar
  273
- Right Handlebar
  274
- Installing the Handlebars
  274
Steering Head

279
- Removing the Lower Bracket
  281
- Checking the Steering Head
  281
- Installing the Steering Head
  282
Rear Shock Absorber Assembly and Relay Arm

284
- Removing the Rear Shock Absorber Assembly
  284
- Installing the Rear Shock Absorber Assembly
  284
Swingarm

289
- Removing the Swingarm
  291
- Checking the Swingarm
  291
- Installing the Swingarm
  292
Shaft Drive

294
Eng

315
Chapter 5 Engine

320
- Mufflers and Exhaust Pipe Assembly
  320
- Leads and Hoses
  321
- Engine
  323
- Installing the Engine
  325
Camshafts

327
- Cylinder Head Cover
  327
- Camshafts
  328
- Removing the Camshafts
  330
- Checking the Camshafts
  331
- Checking the Camshaft Sprockets
  332
- Checking the Timing Chain Tensioner
  333
- Installing the Camshafts
  333
Cylinder Head

338
- Removing the Cylinder Head
  339
- Checking the Cylinder Head
  339
- Installing the Cylinder Head
  340
Valves and Valve Springs

343
- Removing the Valves
  344
- Checking the Valves and Valve Guides
  345
- Checking the Valve Seats
  347
- Checking the Valve Springs
  349
- Checking the Valve Lifters
  350
- Installing the Valves
  351
Generator and Starter Clutch

353
- Generator Rotor and Starter Clutch
  353
- Stator Assembly
  355
- Removing the Generator
  356
- Removing the Starter Clutch
  357
- Checking the Starter Clutch
  357
- Installing the Starter Clutch
  358
- Installing the Generator
  358
Pickup Coil Rotor

360
- Removing the Pickup Coil Rotor
  362
- Installing the Pickup Coil Rotor
  362
- Clutch Cover
  364
- Clutch
  364
- Removing the Clutch
  367
- Checking the Friction Plates
  368
- Checking the Clutch Plates
  369
- Checking the Clutch Spring Plate
  369
- Checking the Clutch Housing
  369
- Checking the Clutch Boss
  370
- Checking the Pressure Plate
  370
- Checking the Clutch Push Rods
  370
- Checking the Primary Driven Gear
  370
- Installing the Clutch
  371
Shift Shaft

374
- Checking the Shift Shaft
  376
- Checking the Stopper Lever
  376
- Installing the Shift Shaft
  376
Oil Pan and Oil Pump

378
- Oil Pump
  379
- Removing the Oil Pan
  381
- Checking the Oil Pump
  381
- Checking the Relief Valve
  382
- Checking the Oil Delivery Pipes
  382
- Checking the Oil Strainer
  382
- Assembling the Oil Pump
  382
- Installing the Oil Pump
  383
- Installing the Oil Strainer
  383
- Installing the Oil Pan
  383
Middle Gear

385
Crankcase

401
- Disassembling the Crankcase
  405
- Checking the Crankcase
  406
- Checking the Bearings and Oil Seals
  406
- Checking the Timing Chain and Oil Pump Drive Chain
  407
- Assembling the Crankcase
  407
Connecting Rods and Pistons

411
Crankshaft

423
- Removing the Crankshaft
  424
- Checking the Crankshaft
  424
- Installing the Crankshaft
  427
Transmission

428
- Removing the Transmission
  434
- Checking the Shift Forks
  434
- Checking the Shift Drum Assembly
  435
- Checking the Transmission
  435
- Installing the Transmission
  437
Balancers

438
- Front Balancer
  438
- Rear Balancer
  439
- Checking the Balancer
  440
- Installing the Front Balancer
  440
- Installing the Rear Balancer
  442
Cool

446
Chapter 6 Cooling System

449
Radiator

449
- Checking the Radiator
  451
- Installing the Radiator
  452
Oil Cooler

453
- Checking the Oil Cooler
  454
- Installing the Oil Cooler
  454
Thermostat

456
Water Pump

460
- Disassembling the Water Pump
  463
- Checking the Water Pump
  463
- Assembling the Water Pump
  464
- Installing the Water Pump
  466
Chapter 7 Fuel Injection System

470
- Wiring Diagram
  471
- Ecu's Self-Diagnostic Function
  472
- Substitute Characteristics Operation Control (Fail-Safe Action)
  476
- Troubleshooting
  477
- Throttle Bodies
  502
- Checking the Injector
  506
- Checking the Throttle Body
  506
- Checking the Pressure Regulator
  506
- Checking the Fuel Pump and Pressure Regulator Operation
  507
Air Induction System

509
- Air Injection
  509
- Air Cut-Off Valve
  509
- Air Cut-Off Valve Assembly and
  511
- Reed Valves
  512
- Checking the Air Induction System
  513
Elec

514
Electrical Components

517
Chapter 8

517
Checking Switch Continuity

519
Checking the Switches

521
Checking the Bulbs and Bulb Sockets

523
Ignition System

526
- Circuit Diagram
  526
- Troubleshooting
  527
Electric Starting System

531
- Circuit Diagram
  531
- Starting Circuit Cut-Off System Operation
  532
- Troubleshooting
  533
Starter Motor

537
- Checking the Starter Motor
  540
- Assembling the Starter Motor
  542
Charging System

543
- Circuit Diagram
  543
- Troubleshooting
  544
Lighting System

546
- Circuit Diagram
  546
- Troubleshooting
  547
- Checking the Lighting System
  549
Signaling System

553
- Circuit Diagram
  553
- Troubleshooting
  555
- Checking the Signaling System
  556
Cooling System

563
- Circuit Diagram
  563
- Troubleshooting
  564
Fuel Injection System

568
- Checking the Fuel Pump
  575
- Checking and Adjusting the Throttle Position Sensor
  576
Windshield Drive System

580
- Circuit Diagram
  580
Trbl Shtg

583
- Troubleshooting
  584
Chapter 9

587
- Engine
  587
- Fuel System
  587
- Electrical Systems
  587
Starting Problems

587
Incorrect Engine Idling Speed

587
- Engine
  588
- Fuel System
  588
Poor Medium-And-High-Speed Performance

588
Faulty Gear Shifting

588
- Shifting Is Difficult
  588
- Shift Pedal Does Not Move
  588
- Jumps out of Gear
  588
Faulty Clutch

589
- Clutch Slips
  589
- Clutch Drags
  589
Overheating

589
- Engine
  589
- Fuel System
  589
- Chassis
  589
- Electrical Systems
  589
Poor Braking Performance

590
Faulty Front Fork Legs

590
- Leaking Oil
  590
- Malfunction
  590
Unstable Handling

591

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Yamaha FJR1300R 2001 Manuals

Yamaha FJR1300R 2001 Service Manual (617 pages)

Table of Contents

General Information

Specifications

Periodic Checks and Adjustments

Chassis

Engine

Cooling System

Electrical System

Troubleshooting

Chapter 1 General Information

Motorcycle Identification

Features

Gen Info

Important Information

Special Tools

Spec

Chapter 2 Specifications

General Specifications

Engine Specifications

Chassis Specifications

Electrical Specifications

Conversion Table

General Tightening Torque Specifications

Tightening Torques

Lubrication Points and Lubricant Types

Oil Flow Diagrams

Cooling System Diagrams

Cable Routing

Chk Adj

Chapter 3 Periodic Checks and Adjustments

Introduction

Periodic Maintenance and Lubrication Intervals

Seats and Fuel Tank

Air Filter Case

Cowlings and Covers

Engine

Electrical System

Chas

Front Wheel and Brake Discs

Chapter 4

Rear Wheel and Brake Disc

Front and Rear Brakes

Hydraulic Clutch

Handlebars

Steering Head

Rear Shock Absorber Assembly and Relay Arm

Swingarm

Shaft Drive

Eng

Chapter 5 Engine

Camshafts

Cylinder Head

Valves and Valve Springs

Generator and Starter Clutch

Pickup Coil Rotor

Shift Shaft

Oil Pan and Oil Pump

Middle Gear

Crankcase

Connecting Rods and Pistons

Crankshaft

Transmission

Balancers

Cool

Chapter 6 Cooling System

Radiator

Oil Cooler

Thermostat

Water Pump

Chapter 7 Fuel Injection System

Air Induction System

Elec

Electrical Components

Chapter 8

Checking Switch Continuity

Checking the Switches

Checking the Bulbs and Bulb Sockets

Ignition System