Yamaha FJR13AY 2009 Service Manual

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2009

SERVICE MANUAL

FJR13AY(C)

FJR13AEY(C)

LIT-11616-22-73

3P6-28197-12

Table of Contents

Chapters

Table of Contents

Troubleshooting

Summary of Contents for Yamaha FJR13AY 2009

Page 1 2009 SERVICE MANUAL FJR13AY(C) FJR13AEY(C) LIT-11616-22-73 3P6-28197-12...
Page 2 EAS20050 FJR13AY(C)/FJR13AEY(C) SERVICE MANUAL ©2008 by Yamaha Motor Corporation, U.S.A. First edition, September 2008 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-22-73...
Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
Page 4 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 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 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............1-18 ABS WARNING LIGHT AND OPERATION..........1-21 OUTLINE OF THE YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE) ....................1-22 INSTRUMENT FUNCTIONS ..............1-25 IMPORTANT INFORMATION ............... 1-29 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-29 REPLACEMENT PARTS.................1-29...
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) 2. Buffer chamber (depressurizing phase) 3. Raised piston 1-13...
Page 23 FEATURES • 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. 17 18 21 22 1.
Page 24: Abs Operation
FEATURES • Some types of malfunctions are not recorded in the memory of the ABS ECU (e.g., a blown ABS ECU fuse). • 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.
Page 25 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 26 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: 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 28 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 29 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 30: 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 31: Outline Of The Ycc-S (Yamaha Chip Controlled-Shift) System (Fjr13Ae)
* 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 (FJR13AE) 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 32 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 33 • 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 34: 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 35 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 36 FEATURES Refer to “SIGNALING SYSTEM” on page 8-39. Ambient temperature, instantaneous fuel consumption and average fuel consumption modes 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 37 FEATURES Instantaneous fuel consumption mode Self-diagnosis device 1. Instantaneous fuel consumption 1. Fault code display This display shows the distance that can be trav- This model is equipped with a self-diagnosis de- eled on 1.0 US.gal of fuel under the current vice for various electrical circuits.
Page 38: 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 39: 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 40: 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 • Coupler • If there is no continuity, clean the terminals. •...
Page 41: 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 42 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 43 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Damper rod holder 4-83, 4-84 90890-01447 YM-01447 Slide metal installer 4-85 90890-01508 YM-01508 Fork seal driver 4-85, 4-86 90890-01502 YM-A0948 Ring gear fix bolt (M14) 4-107 90890-01524 YM-01524 M14×P1.5 Final gear backlash band 4-107 90890-01511 Middle drive gear lash tool...
Page 44 5-11, 5-76, 7-9 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, 5-108, ® 6-13 (Three Bond No.1215 Valve spring compressor 5-26, 5-31...
Page 45 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 46 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Damper spring compressor 5-93, 5-94 90890-04090 Bearing retainer wrench 5-94 90890-04140 Middle drive shaft bearing retainer wrench YM-04140 Gear lash measurement tool 5-97 90890-01467 YM-01467 Piston pin puller set 5-112 90890-01304 Piston pin puller YU-01304 YU-01304 Piston ring compressor...
Page 47 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Weight 5-131 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 48 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pressure gauge 90890-03153 YU-03153 Fuel pressure adapter 90890-03176 YM-03176 Ignition checker 8-236 90890-06754 Opama pet-4000 spark checker YM-34487 1-39...
Page 49: 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....................2-26 CHASSIS....................2-28 LUBRICATION SYSTEM CHART AND DIAGRAMS........
Page 50: General Specifications
GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model FJR13A 3P6N (USA) FJR13A 3P6P (California) FJR13AE 2D2N (USA) FJR13AE 2D2P (California) Dimensions Overall length 2230 mm (87.8 in) Overall width 750 mm (29.5 in) Overall height 1450 mm (57.1 in) Seat height 805 mm (31.7 in) Wheelbase 1545 mm (60.8 in)
Page 51: 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 52 ENGINE SPECIFICATIONS 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 93.3–122.7 kPa (13.5–17.8 psi) (0.93–1.23 kgf/cm²)
Page 53 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 54 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 55 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 56 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 57 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 58: 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 59 CHASSIS SPECIFICATIONS Front brake Type Dual disc brake Operation Right hand operation 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)
Page 60 CHASSIS SPECIFICATIONS Spring rate K1 8.30 N/mm (47.39 lb/in) (0.85 kgf/mm) Spring stroke K1 0.0–135.0 mm (0.00–5.31 in) Inner tube outer diameter 48.0 mm (1.89 in) Inner tube bending limit 0.2 mm (0.01 in) Optional spring available Recommended oil Ohlins R & T43 (ACC-RT43F-00-00) Quantity 696.0 cm³...
Page 61: 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 FUA0025/MITSUBISHI Ignition coil Model/manufacturer JO383/DENSO Minimum ignition spark gap 6.0 mm (0.24 in) 1.53–2.07 Ω...
Page 62 Engine trouble warning light ABS warning 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 63 ELECTRICAL SPECIFICATIONS 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) FJR13AE 0.71–0.91 V Resistance FJR13AE 4.0–6.0 kΩ...
Page 64: 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 65: 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 66 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 67 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size 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 10 Nm (1.0 m·kg, 7.2 ft·lb) Clutch hose union bolt...
Page 68 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size 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) (FJR13AE) Clutch actuator bracket bolt 19 Nm (1.9 m·kg, 13 ft·lb) (FJR13AE) Clutch actuator bracket bolt 10 Nm (1.0 m·kg, 7.2 ft·lb)
Page 69 TIGHTENING TORQUES Cylinder head tightening sequence: Crankcase tightening sequence: 19 22 2-20...
Page 70: 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 71 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 72 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Storage compartment bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) T-bar bolt 37 Nm (3.7 m·kg, 27 ft·lb) Rear fender bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) 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.
Page 73 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Sidestand switch screw 4 Nm (0.4 m·kg, 2.9 ft·lb) Centerstand nut 55 Nm (5.5 m·kg, 40 ft·lb) Centerstand bracket nut 55 Nm (5.5 m·kg, 40 ft·lb) 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...
Page 74 TIGHTENING TORQUES Front wheel axle pinch bolt 1. Insert the front wheel axle from the right side and tighten it with the flange bolt from the left side to 91 Nm (9.1 m·kg, 66 ft·lb). 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.
Page 75: 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 76 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 77: 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 78: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-29...
Page 79 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 80: Lubrication Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-31...
Page 81 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 82 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
Page 83 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Drive axle 3. Oil delivery pipe 1 2-34...
Page 84 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
Page 85 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 86 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-37...
Page 87 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 88 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-39...
Page 89 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 90: Cooling System Diagrams
COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-41...
Page 91 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 92 COOLING SYSTEM DIAGRAMS 2-43...
Page 93 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 94: Cable Routing (Fjr13A)
CABLE ROUTING (FJR13A) EAS20430 CABLE ROUTING (FJR13A) 2-45...
Page 95 CABLE ROUTING (FJR13A) 1. Right grip warmer lead (for optional grip warmer) N. Fasten the main switch lead and right handlebar switch lead with a plastic locking tie at the location 2. Brake hose (front brake master cylinder to brake shown in the illustration.
Page 96 CABLE ROUTING (FJR13A) 14 15 2-47...
Page 97 CABLE ROUTING (FJR13A) 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 98 CABLE ROUTING (FJR13A) 4 5 6 7 8 9 12 13 2-49...
Page 99 CABLE ROUTING (FJR13A) 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 100 CABLE ROUTING (FJR13A) 2-51...
Page 101 CABLE ROUTING (FJR13A) 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 (for optional grip warmer) 8. Left radiator fan 9.
Page 102 CABLE ROUTING (FJR13A) 36 33 13 14 2-53...
Page 103 CABLE ROUTING (FJR13A) 1. Grip warmer couplers (for optional grip warmers) D. Fasten the leads (to oil level switch and crankshaft position sensor) that branch off from the wire 2. Handlebar switch couplers harness to the guide on the holder with a plastic 3.
Page 104 CABLE ROUTING (FJR13A) 2-55...
Page 105 CABLE ROUTING (FJR13A) 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 106 CABLE ROUTING (FJR13A) 5 6 7 L 30 2-57...
Page 107 CABLE ROUTING (FJR13A) 1. Spark plug lead #1 L. Route the fuel tank breather hose (joint to rollover valve) next to the wire harness and pass it through 2. Spark plug lead #2 the guide. (for California only) 3. Clutch hose M.
Page 108 CABLE ROUTING (FJR13A) 2-59...
Page 109 CABLE ROUTING (FJR13A) 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 110 CABLE ROUTING (FJR13A) 2-61...
Page 111 CABLE ROUTING (FJR13A) 1. Windshield drive unit P. Secure the plastic locking tie by inserting the projection on the tie into the hole in the rear of the 2. Thermistor windshield drive unit/meter assembly stay. 3. Windshield drive unit lead 4.
Page 112 CABLE ROUTING (FJR13A) 2-63...
Page 113 CABLE ROUTING (FJR13A) 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 114: Cable Routing (Fjr13Ae)
CABLE ROUTING (FJR13AE) ET3P66048 CABLE ROUTING (FJR13AE) 11 10 2-65...
Page 115 CABLE ROUTING (FJR13AE) 1. Right grip warmer lead M. Fasten the right handlebar switch lead, right grip warmer lead, and main switch lead with a plastic 2. Brake hose (front brake master cylinder to brake locking tie at the location shown in the illustration. pipe/lower joint assembly) Position the buckle of the plastic locking tie under 3.
Page 116 CABLE ROUTING (FJR13AE) 14 15 2-67...
Page 117 CABLE ROUTING (FJR13AE) 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 118 CABLE ROUTING (FJR13AE) 4 5 6 7 11 12 13 14 15 2-69...
Page 119 CABLE ROUTING (FJR13AE) 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 120 CABLE ROUTING (FJR13AE) 2-71...
Page 121 CABLE ROUTING (FJR13AE) 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 122 CABLE ROUTING (FJR13AE) 37 38 12 13 2-73...
Page 123 CABLE ROUTING (FJR13AE) 1. Grip warmer couplers B. Secure the plastic band by inserting the projection on the band into the hole in the windshield drive 2. Hand shift switch couplers unit/meter assembly stay, and then fasten the 3. Handlebar switch couplers handlebar switch leads, grip warmer leads, hand 4.
Page 124 CABLE ROUTING (FJR13AE) 2-75...
Page 125 CABLE ROUTING (FJR13AE) 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 126 CABLE ROUTING (FJR13AE) 5 6 7 8 L 29 2-77...
Page 127 CABLE ROUTING (FJR13AE) 1. Spark plug lead #1 L. Route the fuel tank breather hose (joint to rollover valve) next to the wire harness and pass it through 2. Spark plug lead #2 the guide. (for California only) 3. Front wheel sensor lead M.
Page 128 CABLE ROUTING (FJR13AE) 2-79...
Page 129 CABLE ROUTING (FJR13AE) 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 130 CABLE ROUTING (FJR13AE) 2-81...
Page 131 CABLE ROUTING (FJR13AE) 1. Windshield drive unit P. Secure the plastic locking tie by inserting the projection on the tie into the hole in the rear of the 2. Thermistor windshield drive unit/meter assembly stay. 3. Windshield drive unit lead 4.
Page 132 CABLE ROUTING (FJR13AE) 2-83...
Page 133 CABLE ROUTING (FJR13AE) 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 134 CABLE ROUTING (FJR13AE) 2-85...
Page 135: Periodic Checks And Adjustments
PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM (FJR13A) .................. 3-1 GENERAL MAINTENANCE AND LUBRICATION CHART (FJR13A)..3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM (FJR13AE) ................3-3 GENERAL MAINTENANCE AND LUBRICATION CHART (FJR13AE) ..3-4 ENGINE ......................3-6 ADJUSTING THE VALVE CLEARANCE ..........
Page 136 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 .........3-30 BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)......
Page 138: Periodic Maintenance
√ √ age. • Replace any damaged parts. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. EAU32185 GENERAL MAINTENANCE AND LUBRICATION CHART (FJR13A) INITIAL...
Page 139 25 * Front and rear √ √ √ √ √ √ • Check operation. brake switches • Apply Yamaha chain and ca- √ √ √ √ √ √ 26 * Control cables ble lube or engine oil SAE 10W-30 thoroughly.
Page 140: Periodic Maintenance Chart For The Emission Control System (Fjr13Ae)
• Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.
Page 141: General Maintenance And Lubrication Chart (Fjr13Ae)
√ √ age. • Replace any damaged parts. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. ET3P6G002 GENERAL MAINTENANCE AND LUBRICATION CHART (FJR13AE) INITIAL...
Page 142 • Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.
Page 143: Engine
ENGINE EAS20470 ENGINE Valve clearance (cold) Intake 0.15–0.22 mm (0.0059–0.0087 in) EAS20490 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 a.
Page 144 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 145: 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 146 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 147: Adjusting The Engine Idling Speed
ENGINE 9. Measure: 6. Adjust: • Engine idling speed • Engine idling speed Out of specification → Adjust. M MMM M MMM M MMM M MMM M MMM a. Turn the engine idle speed adjustment screw Make sure that the vacuum pressure is within “1”...
Page 148: Checking The Spark Plugs
ENGINE M MMM M MMM M MMM M MMM M MMM Handlebar side a. Slide back the rubber covers “1”. b. Loosen the locknut “2”. c. Turn the adjusting nut “3” in direction “a” or “b” until the specified throttle cable free play is obtained.
Page 149: Checking The Ignition Timing
ENGINE 10.Install: ECA13320 NOTICE • T-bar Before removing the spark plugs, blow away Refer to “GENERAL CHASSIS” on page 4-1. any dirt accumulated in the spark plug wells • Fuel tank with compressed air to prevent it from falling Refer to “FUEL TANK” on page 7-1. into the cylinders.
Page 150: Measuring The Compression Pressure
ENGINE EAS20710 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cyl- inders. Insufficient compression pressure will result in a loss of performance. 1. Measure: • Valve clearance 5. Install: Out of specification → Adjust. • Fuel tank Refer to “ADJUSTING THE VALVE CLEAR- Refer to “FUEL TANK”...
Page 151: Checking The Engine Oil Level
ENGINE • Rider seat Standard compression pressure Refer to “GENERAL CHASSIS” on page 4-1. (at sea level) 1600 kPa/400 r/min (227.6 EAS20730 CHECKING THE ENGINE OIL LEVEL psi/400 r/min) (16.0 kgf/cm²/400 1. Stand the vehicle on a level surface. r/min) Minimum–maximum 1390–1790 kPa (197.7–254.6 psi) •...
Page 152: Changing The Engine Oil
ENGINE grade of CD “c” or higher and do not use 5. If the oil filter cartridge is also to be replaced, oils labeled “ENERGY CONSERVING II” perform the following procedure. “d”. M MMM M MMM M MMM M MMM M MMM a.
Page 153: Measuring The Engine Oil Pressure
ENGINE EAS20820 MEASURING THE ENGINE OIL PRESSURE Engine oil quantity 1. Check: Total amount • Engine oil level 4.90 L (5.18 US qt) (4.31 Imp.qt) Below the minimum level mark → Add the Without oil filter cartridge re- placement recommended engine oil to the proper level. 3.80 L (4.02 US qt) (3.34 Imp.qt) 2.
Page 154: Adjusting The Clutch Lever (Fjr13A Only)
ENGINE EAS20890 Engine oil pressure Possible causes CHECKING THE CLUTCH FLUID LEVEL (FJR13A) • Faulty oil pump 1. Stand the vehicle on a level surface. • Clogged oil filter Below specification • Leaking oil passage • Broken or dam- Place the vehicle on the centerstand. aged oil seal 2.
Page 155: Checking The Clutch Fluid Level (Fjr13Ae)
ENGINE 4. Install: ET3P66026 CHECKING THE CLUTCH FLUID LEVEL • Left side cover (FJR13AE) Refer to “GENERAL CHASSIS” on page 4-1. 1. Stand the vehicle on a level surface. EAS20900 BLEEDING THE HYDRAULIC CLUTCH Place the vehicle on the centerstand. SYSTEM (FJR13A) 2.
Page 156: Bleeding The Hydraulic Clutch System (Fjr13Ae)
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 157 ENGINE k. Engage the clutch by turning the manual clutch operation bolt in direction “b” until it Turn the clutch operation bolt in a continuous stops. motion, without allowing the pressure plate to 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 158: Checking The Vehicle After Bleeding The Hydraulic Clutch System (Fjr13Ae 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 FJR13AE 2.8 mm (0.11 in) or CLUTCH SYSTEM (FJR13AE)”...
Page 159: Cleaning The Air Filter Element (Fjr13A)
ENGINE e. Shift the transmission into neutral, and then ET3P66028 CLEANING THE AIR FILTER ELEMENT raise the centerstand. (FJR13AE) 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 160: Checking The Throttle Body Joints
ENGINE • Fuel tank breather/overflow hose “2” (except for California) When installing the air filter element into the air Cracks/damage → Replace. filter case cover, make sure their sealing surfac- Loose connection → Connect properly. es are aligned to prevent any air leaks. EC3P61005 NOTICE EAS21010...
Page 161: 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 162: Checking The Cooling System
ENGINE Below the minimum level mark → Add the recommended coolant to the proper level. ECA13470 NOTICE • 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 163 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 164 ENGINE • If coolant is swallowed, induce vomiting and get immediate medical attention. ECA13480 NOTICE • 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 165: Chassis
CHASSIS EAS21140 CHASSIS Brake pedal position 42.0 mm (1.65 in) (below the top of the rider footrest) EAS21160 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 166: 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 NOTICE After adjusting the brake pedal position, make sure there is no brake drag. L LLL L LLL L LLL L LLL L LLL...
Page 167: 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 NOTICE Loose → Tighten the holder bolts. The amount of wear may differ for the brake 3.
Page 168: 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 NOTICE • Bleed the brake system in the following or- der. • 1st step: Front brake calipers •...
Page 169: Adjusting The Shift Pedal (Fjr13A)
CHASSIS EC3P61029 NOTICE 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 (i), and then fill the brake master cylinder res- Check that the groove “c”...
Page 170: 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 171: Adjusting The Handlebar Position
CHASSIS c. Loosen the lower ring nut completely and 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 172: 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 173: 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 174: 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 NOTICE L LLL L LLL L LLL L LLL L LLL Never go beyond the maximum or minimum adjustment positions.
Page 175: 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 176: Adjusting The Rider Seat Height
CHASSIS M MMM M MMM M MMM M MMM M MMM 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 177: 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 178 CHASSIS Tire air pressure (measured on cold tires) Loading condition 0–90 kg (0–198 lb) Front 270 kPa (39 psi) (2.70 kgf/cm²) Rear 290 kPa (42 psi) (2.90 kgf/cm²) Loading condition FJR13A 90–212 kg (198–467 lb) (USA) 1. Tire tread depth FJR13A 90–211 kg (198–465 lb) 2.
Page 179: Checking The Wheels
After a tire or wheel has been changed or re- approved by Yamaha is used on this vehicle. placed, always balance the wheel. Front tire EAS21690...
Page 180: Lubricating The Sidestand
CHASSIS EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. Recommended lubricant Lithium-soap-based grease EAS21730 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal-to-metal moving parts of the centerstand. 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.
Page 181: 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 8-213.
Page 182 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 183 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 184 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...........4-53 REMOVING THE REAR BRAKE MASTER CYLINDER ......
Page 185 REAR SHOCK ABSORBER ASSEMBLY ............4-93 HANDLING THE REAR SHOCK ABSORBER ........4-95 DISPOSING OF A REAR SHOCK ABSORBER ........4-95 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY....4-95 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ....4-95 CHECKING THE CONNECTING ARM AND RELAY ARM.....4-96 INSTALLING THE RELAY ARM..............4-96 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ....
Page 186 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 187 GENERAL CHASSIS Removing the front cowling assembly (FJR13A) 10 Nm (1.0 m kg, 7.2 ft • • 32 Nm (3.2 m kg, 23 ft • • 17 19 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft •...
Page 188 GENERAL CHASSIS Removing the front cowling assembly (FJR13A) 10 Nm (1.0 m kg, 7.2 ft • • 32 Nm (3.2 m kg, 23 ft • • 17 19 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft •...
Page 189 GENERAL CHASSIS Removing the front cowling assembly (FJR13AE) 10 Nm (1.0 m kg, 7.2 ft • • 32 Nm (3.2 m kg, 23 ft • • 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft •...
Page 190 GENERAL CHASSIS Removing the front cowling assembly (FJR13AE) 10 Nm (1.0 m kg, 7.2 ft • • 32 Nm (3.2 m kg, 23 ft • • 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft •...
Page 191 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 192 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 193 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 194: General Chassis
GENERAL CHASSIS ET3P61037 REMOVING THE SIDE PANELS 1. Remove: • Side panel “1” 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 195: 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 196 GENERAL CHASSIS 4-11...
Page 197 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 198 GENERAL CHASSIS Removing the air filter case (FJR13A) 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 199 GENERAL CHASSIS Removing the air filter case (FJR13A) 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 200 GENERAL CHASSIS Removing the air filter case (FJR13AE) 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 (FJR13AE) 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: 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 203 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 204: Removing The Front Wheel
FRONT WHEEL EAS21900 M MMM M MMM M MMM M MMM M MMM REMOVING THE FRONT WHEEL a. Clean the surface of the front wheel hub. ECA3P6D002 b. Remove the oil seals “1” with a flathead NOTICE screwdriver. Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away To prevent damaging the wheel or wheel sensor from the front wheel hub “1”, otherwise the...
Page 205: 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 206: Assembling The Front Wheel
FRONT WHEEL EAS21960 ASSEMBLING THE FRONT WHEEL Wheel sensor rotor deflection ECA3P6D003 limit NOTICE 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 207: 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 208: 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 209 FRONT WHEEL EC3P61022 NOTICE 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 210: 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 211 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 212: Removing The Rear Wheel
REAR WHEEL EAS22050 ET3P6D002 REMOVING THE REAR WHEEL DISASSEMBLING THE REAR WHEEL ECA3P6D013 ECA3P6D003 NOTICE NOTICE 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 213: Checking The Rear Wheel
REAR WHEEL EAS22200 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR ECA3P6D008 NOTICE • 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 214: 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 NOTICE 2. Rear wheel The bearing retainer has left-handed 2. Install: threads. To tighten the retainer, turn it coun- • Wheel bearings terclockwise.
Page 215: Installing The Rear Wheel (Rear Brake Disc)
REAR WHEEL EAS22170 ECA14470 INSTALLING THE REAR WHEEL (REAR NOTICE 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 216 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 NOTICE To route the rear wheel sensor lead, refer to “CABLE ROUTING (FJR13A)”...
Page 217: 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 218 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 219 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 220 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 221 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 222: 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 223: 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. 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 224: 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) Brake caliper bolt Put the end of the brake hoses into a container...
Page 225: 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 226: Removing The Front Brake Master Cylinder
FRONT BRAKE ECA13540 NOTICE 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 227: 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: • Brake master cylinder “1” To collect any remaining brake fluid, place a •...
Page 228 FRONT BRAKE Refer to “CHECKING THE BRAKE FLUID 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. Fill: •...
Page 229 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 230 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 231 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 232 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 233 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 234 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 235: 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 236: Removing The Rear Brake Caliper
REAR BRAKE 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 NOTICE a. Connect a clear plastic hose “1” tightly to the •...
Page 237: 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 238: 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 239: Removing The Rear Brake Master Cylinder
REAR BRAKE 4. Remove: • Rear brake caliper bolts • Rear brake caliper 5. Install: • Brake pad springs • Rear brake pads • Brake pad shims • Rear brake caliper bolts • Rear brake caliper Refer to “REPLACING THE REAR BRAKE PADS”...
Page 240: Assembling The Rear Brake Master Cylinder
REAR BRAKE 2. Check: • Brake master cylinder kit Damage/scratches/wear → Replace. 3. Check: • Brake fluid reservoir Cracks/damage → Replace. • Brake fluid reservoir diaphragm Cracks/damage → Replace. 4. Check: • Brake hose Cracks/damage/wear → Replace. 2. Install: • Rear brake light switch “1” EAS22730 ASSEMBLING THE REAR BRAKE MASTER CYLINDER...
Page 241 REAR BRAKE 4. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-31. 5. 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: 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 243 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 244 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 7 Nm (0.7 m...
Page 245 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 7 Nm (0.7 m...
Page 246 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 247: Removing The Hydraulic Unit Assembly
ABS (ANTI-LOCK BRAKE SYSTEM) 2. Disconnect: ET3P6D003 REMOVING THE HYDRAULIC UNIT • ABS ECU coupler “1” ASSEMBLY ECA3P6D018 NOTICE 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 248: 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 249 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 250 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 251: 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 8-167.) 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 252 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 253 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. • The reaction-force pulsating action consists of quick pulses.
Page 254: Trial Run
ABS (ANTI-LOCK BRAKE SYSTEM) ECA3P6D020 NOTICE • 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 255: Handlebars
HANDLEBARS EAS22850 HANDLEBARS Removing the left handlebar (FJR13A) 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 Left handlebar switch Grip end Handlebar grip For installation, reverse the removal proce- dure.
Page 256 HANDLEBARS Removing the left handlebar (FJR13AE) 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 257 HANDLEBARS Removing the right handlebar (FJR13A) 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 handlebar switch lead Lead holder Right handlebar switch...
Page 258 HANDLEBARS Removing the right handlebar (FJR13AE) 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...
Page 259: Removing The Handlebars
HANDLEBARS EAS22870 EWA13700 REMOVING THE HANDLEBARS WARNING 1. Stand the vehicle on a level surface. Do not touch the handlebar grip until the rub- EWA13120 ber adhesive has fully dried. WARNING Securely support the vehicle so that there is no danger of it falling over. There should be 1–3 mm (0.04–0.12 in) of clear- ance “a”...
Page 260 HANDLEBARS 5. Install: • Right handlebar • Align the projection “a” on the throttle cable • Left handlebar housing with the hole “b” in the right handlebar. • There should be 1–3 mm (0.04–0.12 in) of Fit the projections on each handlebar into the clearance “c”...
Page 261: Installing The Handlebars (Fjr13Ae)
HANDLEBARS 10.Install: EWA13700 WARNING • Clutch master cylinder assembly Do not touch the handlebar grip until the rub- • Clutch master cylinder holder “1” ber adhesive has fully dried. Clutch master cylinder holder bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) There should be 1–3 mm (0.04–0.12 in) of clear- ance “a”...
Page 262 HANDLEBARS 5. Install: • Hand shift switch “1” • Lead holder 2 “2” • Align the projection “a” on the hand shift switch with hole “b” on the left handlebar. • When installing the hand shift switch, route the left grip warmer lead “3” and left handlebar switch lead “4”...
Page 263 HANDLEBARS 10.Install: • Front brake master cylinder assembly • Front brake master cylinder holder “1” Front brake master cylinder hold- er bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) • Install the brake master cylinder holder with the “UP” mark facing up. •...
Page 264: 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 265 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 266 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 267: 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 268: 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. Do not install the fork spring. b. Place the front fork leg in a press and gradu- ally apply pressure to remove the oil seal.
Page 269: 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 270 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 271 FRONT FORK Recommended oil Ohlins R & T43 (ACC-RT43F-00- Quantity 696.0 cm³ (23.53 US oz) (24.55 Imp.oz) ECA14230 NOTICE • Be sure to use the recommended fork oil. Other oils may have an adverse effect on 7. Remove: front fork performance. •...
Page 272: 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) •...
Page 273 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 274: 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 275 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: 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 NOTICE...
Page 277 STEERING HEAD • Lock washer “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 3-33. 3. Install: • Upper bracket • Steering stem nut Temporarily tighten the steering stem nut. 4. Install: • Front fork legs Refer to “FRONT FORK” on page 4-79. Temporarily tighten the upper and lower bracket pinch bolts.
Page 278: 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 279 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 280: Handling The Rear Shock Absorber
REAR SHOCK ABSORBER ASSEMBLY EAS23180 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 • Rear shock absorber assembly lower bolt “1” the rear shock absorber, read and make sure •...
Page 281: 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 282: 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 283 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 284: Removing The Swingarm
SWINGARM EAS23350 EAS23360 REMOVING THE SWINGARM CHECKING THE SWINGARM 1. Stand the vehicle on a level surface. 1. Check: EWA13120 • Swingarm WARNING Bends/cracks/damage → Replace. Securely support the vehicle so that there is 2. Check: no danger of it falling over. •...
Page 285 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) 4-100...
Page 286: 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 287 SHAFT DRIVE Removing the universal joint Order Job/Parts to remove Q’ty Remarks FJR13AE Left footrest assembly/Sidestand Refer to “SHIFT ACTUATOR AND SHIFT ROD (FJR13AE only)” on page 5-73. Shift arm FJR13A Left footrest assembly FJR13A FJR13A Sidestand switch coupler Disconnect. Sidestand FJR13A Drive shaft dust cover...
Page 288 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 289 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 290: 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 291: 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 292: 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 293: 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 294: Disassembling The Final Drive Assembly
SHAFT DRIVE ECA14320 NOTICE 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 295: Removing And Installing The Bearings
(with an appropriate press tool “4” and press) • Bearing “3” (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.
Page 296 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 297 SHAFT DRIVE f = the ring gear bearing thickness constant. ECA14350 NOTICE 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 298: 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 299: Installing The Drive Shaft And Final Drive Assembly (Fjr13A)
SHAFT DRIVE EAS23660 INSTALLING THE DRIVE SHAFT AND FINAL Fork seal driver weight DRIVE ASSEMBLY (FJR13A) 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 300: Installing The Drive Shaft And Final Drive Assembly (Fjr13Ae)
SHAFT DRIVE ET3P66032 INSTALLING THE DRIVE SHAFT AND FINAL Left footrest assembly/sidestand DRIVE ASSEMBLY (FJR13AE) 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 301 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 302 SHAFT DRIVE 4-117...
Page 303 ENGINE ENGINE REMOVAL ..................5-1 REMOVING THE GEAR POSITION SENSOR (FJR13AE only)....5-8 REMOVING THE ENGINE (FJR13A)............5-8 REMOVING THE ENGINE (FJR13AE) .............5-8 INSTALLING THE ENGINE............... 5-8 INSTALLING THE GEAR POSITION SENSOR (FJR13AE only) ...5-11 ADJUSTING THE GEAR POSITION SENSOR (FJR13AE only) ....5-11 CAMSHAFTS....................5-13 REMOVING THE CAMSHAFTS..............5-15 CHECKING THE CAMSHAFTS ..............5-16...
Page 304 CLUTCH ......................5-46 REMOVING THE CLUTCH (FJR13A).............5-60 REMOVING THE CLUTCH (FJR13AE) ..........5-61 CHECKING THE FRICTION PLATES.............5-61 CHECKING THE CLUTCH PLATES ............5-62 CHECKING THE CLUTCH SPRING PLATE...........5-62 CHECKING THE CLUTCH HOUSING ............5-62 CHECKING THE CLUTCH BOSS............5-62 CHECKING THE PRESSURE PLATE ............5-63 CHECKING THE CLUTCH PUSH RODS ..........
Page 305 MIDDLE GEAR ....................5-87 REMOVING THE MIDDLE DRIVE SHAFT ASSEMBLY ......5-93 DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY ....5-93 DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY..... 5-93 CHECKING THE MIDDLE DRIVE SHAFT ASSEMBLY......5-94 CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY .......5-94 ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY .....5-94 ASSEMBLING THE MIDDLE DRIVEN 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 (FJR13A) 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 (FJR13A) 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 (FJR13AE) 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 (FJR13AE) 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 (Fjr13Ae Only)
ENGINE REMOVAL ET3P66033 REMOVING THE GEAR POSITION SENSOR Loosen the spacer bolt with the pivot shaft (FJR13AE only) wrench “1” and pivot shaft wrench adapter “2”. 1. Disconnect: • Gear position sensor coupler 2. Remove: Pivot shaft wrench 90890-01471 • Gear position sensor Frame spanner socket YM-01471 Remove only the screws “1”...
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” • Engine mounting bolt (right front lower side) • Tighten the spacer bolt “1” to specification with “9”...
Page 315 ENGINE REMOVAL Pinch bolt (rear side) 24 Nm (2.4 m·kg, 17 ft·lb) 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 (Fjr13Ae Only)
ENGINE REMOVAL 3. Adjust: • Gear position sensor Refer to “ADJUSTING THE GEAR POSI- TION SENSOR (FJR13AE only)” on page 5-11. ET3P66036 ADJUSTING THE GEAR POSITION SENSOR (FJR13AE only) 1. Check: • Gear position sensor Refer to “CHECKING THE GEAR POSITION ET3P66035 INSTALLING THE GEAR POSITION SENSOR SENSOR (FJR13AE 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 7-5. 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 • 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 NOTICE Camshaft sprocket bolt...
Page 324 CAMSHAFTS ECA13730 NOTICE The camshaft cap bolts must be tightened evenly or damage to the cylinder head, cam- shaft caps, and camshafts will result. 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 EAS24120 M MMM M MMM M MMM M MMM M MMM REMOVING THE CYLINDER HEAD a. Place a straightedge “1” and a thickness 1. Remove: gauge “2” across the cylinder head. • Cylinder head bolts • 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 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 “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 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 NOTICE 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 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 Primary clutch holder 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) 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) 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 7-5. 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” 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 (FJR13A) 90 Nm (9.0 m kg, 65 ft • • 20 19 17 16 15 14 10 Nm (1.0 m kg, 7.2 ft • • 11 10 9,15 8 Nm (0.8 m kg, 5.8 ft • •...
Page 353 CLUTCH Removing the clutch (FJR13A) 90 Nm (9.0 m kg, 65 ft • • 20 19 17 16 15 14 10 Nm (1.0 m kg, 7.2 ft • • 11 10 9,15 8 Nm (0.8 m kg, 5.8 ft • •...
Page 354 CLUTCH Removing the clutch (FJR13AE) 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 355 CLUTCH Removing the clutch (FJR13AE) 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 356 CLUTCH Removing the clutch master cylinder (FJR13A) Order Job/Parts to remove Q’ty Remarks Drain. Refer to “BLEEDING THE HYDRAULIC Clutch fluid CLUTCH SYSTEM (FJR13A)” 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 357 CLUTCH Removing the clutch master cylinder (FJR13A) Order Job/Parts to remove Q’ty Remarks Clutch master cylinder For installation, reverse the removal proce- dure. 5-52...
Page 358 CLUTCH Removing the clutch actuator and clutch master cylinder (FJR13AE) 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 359 CLUTCH Removing the clutch actuator and clutch master cylinder (FJR13AE) 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 360 CLUTCH Disassembling the clutch master cylinder (FJR13A) 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. 5-55...
Page 361 CLUTCH Disassembling the clutch master cylinder (FJR13AE) Order Job/Parts to remove Q’ty Remarks Clutch master cylinder kit Clutch master cylinder body For assembly, reverse the disassembly pro- cedure. *1: These kit parts are used for all models before 2009. *2: This kit part is used for all models after 2009. 5-56...
Page 362 CLUTCH Removing the clutch release cylinder (FJR13A) Order Job/Parts to remove Q’ty Remarks Drain. Refer to “BLEEDING THE HYDRAULIC Clutch fluid CLUTCH SYSTEM (FJR13A)” 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 363 CLUTCH Removing the clutch release cylinder (FJR13AE) Order Job/Parts to remove Q’ty Remarks Drain. Refer to “BLEEDING THE HYDRAULIC Clutch fluid CLUTCH SYSTEM (FJR13AE)” 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 364 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 365: Clutch
CLUTCH EAS25080 REMOVING THE CLUTCH (FJR13A) There is a built-in damper between the clutch 1. Remove: boss and the clutch plate. It is not necessary to • Clutch cover “1” remove the wire circlip “4” and disassemble the built-in damper unless there is serious clutch Loosen each bolt 1/4 of a turn at a time, in stag- chattering.
Page 366: Removing The Clutch (Fjr13Ae)
CLUTCH EAS3P6N001 REMOVING THE CLUTCH (FJR13AE) • 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 driven gear until both primary drive gears are Loosen each bolt 1/4 of a turn at a time, in stag- aligned.
Page 367: 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 368: Checking The Pressure Plate
CLUTCH EAS25250 INSTALLING THE CLUTCH (FJR13A) 1. Install: • Clutch housing “1” • 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 369: Installing The Clutch (Fjr13Ae)
CLUTCH 3. Install: • Clutch plates • Clutch boss assembly “1” (with the recommended lubricant) Recommended lubricant • If the wire circlip “2” has been removed, care- Engine oil fully install a new one. • Install the clutch damper spring “3” with the 7.
Page 370 CLUTCH • Make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly. • Install the clutch boss nut with its large inner di- • Insert a cross-headed screwdriver into one of ameter side facing inward as shown in the illus- the holes of the clutch housing and primary tration.
Page 371: Breaking In The Friction Plates After Replacement (Fjr13Ae Only)
CLUTCH 7. Install: • Friction plates • Clutch plates First, install a friction plate and then alternate be- tween a clutch plate and a friction plate. 8. Install: • Clutch spring bolts Clutch spring bolt b. Apply the rear brake forcefully. 8 Nm (0.8 m·kg, 5.8 ft·lb) c.
Page 372: Checking The Clutch Master Cylinder
CLUTCH • Clutch fluid may damage painted surfaces EAS25290 CHECKING THE CLUTCH MASTER and plastic parts. Therefore, always clean CYLINDER up any spilt fluid immediately. Recommended clutch component replace- • Avoid clutch fluid coming into contact with ment schedule the eyes as it can cause serious injury. •...
Page 373 CLUTCH 3. Fill: EW3P61016 WARNING • Clutch master cylinder reservoir • Install the clutch lever holder with the “UP” (with the specified amount of the recom- mark facing up. mended clutch fluid) • Align the end of the clutch lever holder with Recommended fluid the punch mark “a”...
Page 374: Installing The Clutch Master Cylinder (Fjr13Ae)
CLUTCH 6. Check: EWA13370 WARNING • Clutch lever operation Soft or spongy feeling → Bleed the clutch • Use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to system. deteriorate, causing leakage and poor Refer to “BLEEDING THE HYDRAULIC clutch performance.
Page 375: Installing The Clutch Actuator (Fjr13Ae Only)
CLUTCH 2. Replace: ET3P66070 INSTALLING THE CLUTCH ACTUATOR • Clutch master cylinder kit (FJR13AE only) 1. Install: For 2009 models or later, do not use the shim • Clutch actuator that is included in the replacement clutch master • Clutch master cylinder cylinder kit.
Page 376: 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” Put the end of the clutch hose into a container and pump out the clutch fluid carefully. EAS25340 ASSEMBLING THE CLUTCH RELEASE CYLINDER...
Page 377 CLUTCH 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 (FJR13A)” on page 3-18 and “BLEEDING THE HYDRAULIC CLUTCH SYSTEM (FJR13AE)”...
Page 378: Shift Actuator And Shift Rod (Fjr13Ae Only)
SHIFT ACTUATOR AND SHIFT ROD (FJR13AE only) ET3P66037 SHIFT ACTUATOR AND SHIFT ROD (FJR13AE 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 379 SHIFT ACTUATOR AND SHIFT ROD (FJR13AE 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 380: Removing The Shift Actuator
SHIFT ACTUATOR AND SHIFT ROD (FJR13AE 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 381: Adjusting The Foot Shift Switch
SHIFT ACTUATOR AND SHIFT ROD (FJR13AE only) • Shift pedal pivot bolt Shift pedal pivot bolt 16 Nm (1.6 m·kg, 11 ft·lb) ® LOCTITE • Position the projection “a” on the shift pedal be- tween the ends “b” of the spring on the left foot- rest assembly.
Page 382: Installing The Left Footrest Assembly
SHIFT ACTUATOR AND SHIFT ROD (FJR13AE 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 383 SHIFT ACTUATOR AND SHIFT ROD (FJR13AE 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 5-78...
Page 384: 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. FJR13AE Shift rod Refer to “SHIFT ACTUATOR AND SHIFT ROD (FJR13AE only)” on page 5-73. Oil baffle plate 1 Shift arm Circlip...
Page 385: 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. Align the punch mark “a” in the shift shaft with EAS25430 CHECKING THE STOPPER LEVER the slot in the shift arm.
Page 386 SHIFT SHAFT 3. Install: • Front shift arm “1” Front shift arm bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Align the punch mark “a” on the front shift arm with the punch mark “b” on the shift shaft. 5-81...
Page 387: 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 7-5. Exhaust pipe assembly Refer to “ENGINE REMOVAL”...
Page 388 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. 5-83...
Page 389 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. 5-84...
Page 390: 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 391: 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. EAS24990 Tighten the oil pan bolts in stages and in a criss- CHECKING THE OIL STRAINER cross pattern.
Page 392: Middle Gear
MIDDLE GEAR EAS25710 MIDDLE GEAR Removing the middle gear (FJR13A) 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 5-82. Middle gear case cover Middle gear case cover gasket Dowel pin Damper cover Damper...
Page 393 MIDDLE GEAR Removing the middle gear (FJR13A) 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. 5-88...
Page 394 MIDDLE GEAR Removing the middle gear (FJR13AE) 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 5-82. Middle gear case cover Middle gear case cover gasket Dowel pin Damper cover Damper...
Page 395 MIDDLE GEAR Removing the middle gear (FJR13AE) 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. 5-90...
Page 396 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. 5-91...
Page 397 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 398: 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. While holding the middle drive shaft.
Page 399: 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 400: 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 401: 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 specification.
Page 402: 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 THE MIDDLE GEAR BACKLASH”...
Page 403: 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 404 MIDDLE GEAR Round off to the hundredths digit and select the appropriate shim(s). 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 405 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 406: Crankcase
CRANKCASE EAS25540 CRANKCASE Separating the crankcase (FJR13A) 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 407 CRANKCASE Separating the crankcase (FJR13A) 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 408 CRANKCASE Separating the crankcase (FJR13AE) 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 409 CRANKCASE Separating the crankcase (FJR13AE) 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 410 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 411 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 412: 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 1. Thoroughly wash the crankcase halves in a •...
Page 413: Assembling The Crankcase
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 Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings.
Page 414 CRANKCASE 13 21 19 22 ECA13980 NOTICE 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 • Lubricate the bolts “1”–“10” thread and wash- ers with engine oil.
Page 415 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 416: 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 5-101. Connecting rod cap Big end lower bearing Piston pin clip Piston pin Piston Connecting rod Big end upper bearing...
Page 417: 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” Identify the position of each connecting rod so that it can be reinstalled in its original place. 2.
Page 418: 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. 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 419: 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 420: 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 421: 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 5-116. f. Remove the connecting rod and big end bearings. Refer to “REMOVING THE CONNECTING RODS AND PISTONS” on page 5-112. ®...
Page 422 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” 4.
Page 423 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 424 CONNECTING RODS AND PISTONS L LLL L LLL L LLL L LLL L LLL 5-119...
Page 425: Crankshaft
CRANKSHAFT EAS25950 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-101. Front balancer weight Refer to “BALANCERS” on page 5-136. Refer to “CONNECTING RODS AND PIS- Connecting rod caps TONS” on page 5-111. Crankshaft Crankshaft journal upper bearing Crankshaft journal lower bearing...
Page 426: 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 NOTICE (from the lower crankcase) Do not interchange the crankshaft journal bearings.
Page 427: 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. • Align the projections “c” of the crankshaft jour- nal lower bearings with the notches “d”...
Page 428 CRANKSHAFT • 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. 5-123...
Page 429: Transmission
TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks (FJR13A) Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-101. Stopper lever Refer to “SHIFT SHAFT” on page 5-79. Drive axle assembly Bearing Washer Bearing Shift drum retainer...
Page 430 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks (FJR13A) Order Job/Parts to remove Q’ty Remarks Main axle assembly For installation, reverse the removal proce- dure. 5-125...
Page 431 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks (FJR13AE) Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-101. Stopper lever Refer to “SHIFT SHAFT” on page 5-79. Gear position sensor bracket Oil seal Drive axle assembly Bearing Washer...
Page 432 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks (FJR13AE) Order Job/Parts to remove Q’ty Remarks Main axle assembly For installation, reverse the removal proce- dure. 5-127...
Page 433 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 434 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 435 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Drive axle For assembly, reverse the disassembly pro- cedure. 5-130...
Page 436: Removing The Transmission
TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Main axle assembly 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 437: 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 438: Installing The Transmission (Fjr13A)
TRANSMISSION • Be sure to align the projection on the toothed 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 439: Installing The Transmission (Fjr13Ae)
TRANSMISSION 4. Install: • Drive axle assembly • 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: • Shift fork-C •...
Page 440 TRANSMISSION • 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. Oil each gear, shaft, and bearing thoroughly. 6.
Page 441: Balancers
BALANCERS ET3P61031 BALANCERS Removing the front balancer Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-101. Front balancer lever Front balancer shaft Washer Bearing Front balancer gear Damper Front balancer weight For installation, reverse the removal proce- dure.
Page 442 BALANCERS Removing the rear balancer Order Job/Parts to remove Q’ty Remarks Throttle bodies Refer to “THROTTLE BODIES” on page 7-5. 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 443: 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 444: 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) Make sure that the balancer shaft does not ro- tate. L LLL L LLL L LLL L LLL...
Page 445 BALANCERS b. Align the balancer gear punch mark “c” with the primary driven gear point “d” as shown. • 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 446 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) Make sure that the balancer shaft does not ro- tate. L LLL L LLL L LLL L LLL...
Page 447: 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....................6-10 DISASSEMBLING THE WATER PUMP..........6-12 CHECKING THE WATER PUMP ............
Page 448 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 449 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 450 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. 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 451 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 452 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 453 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 454 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 455 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 456 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 457 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 458 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 459 • 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 460 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 After installation, check that the impeller shaft ro- tates smoothly.
Page 461 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 462 WATER PUMP 6-15...
Page 463: Fuel System
FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL TANK ..............7-3 REMOVING THE FUEL PUMP ..............7-3 CHECKING THE FUEL PUMP BODY............7-3 CHECKING THE ROLLOVER VALVES (for California only) ....7-3 INSTALLING THE FUEL PUMP..............7-3 INSTALLING THE FUEL TANK..............7-4 THROTTLE BODIES ..................7-5 CHECKING THE INJECTORS ..............7-8 CHECKING THE THROTTLE BODIES.............7-8 CHECKING THE FUEL PRESSURE ............7-8...
Page 464 FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 10 Nm (1.0 m kg, 7.2 ft • • 16 Nm (1.6 m kg, 11 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
Page 465 FUEL TANK Removing the rollover valve and canister (for California only) Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Side cowlings 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Canister purge hose (throttle body-#1 to 3-way joint) 3-way joint Canister purge hose (throttle body-#4 to 3-way...
Page 466 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 467 FUEL TANK • After installing the fuel hose holder “1”, make sure that the sections “a”, “b”, and “c” of the holder are installed securely. ET3P61018 INSTALLING THE FUEL TANK 1. Install: • Fuel hose (fuel rail side) EC3P61007 NOTICE When installing the fuel hose, make sure that it is securely connected, and that the fuel hose connector cover on the fuel hose is in...
Page 468 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 469 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 470 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 471 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 472 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 473 THROTTLE BODIES 7-10...
Page 474 AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM 7-11...
Page 475 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 476 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 477 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 478 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 479: Electrical System
ELECTRICAL SYSTEM IGNITION SYSTEM ..................8-1 CIRCUIT DIAGRAM (1/2) (FJR13A) ............8-1 CIRCUIT DIAGRAM (2/2) (FJR13A) ............8-3 CIRCUIT DIAGRAM (1/2) (FJR13AE) ............8-5 CIRCUIT DIAGRAM (2/2) (FJR13AE) ............8-7 ENGINE STOPPING DUE TO SIDESTAND OPERATION.......8-9 TROUBLESHOOTING ................8-10 ELECTRIC STARTING SYSTEM ..............8-13 CIRCUIT DIAGRAM (1/2) (FJR13A) ............8-13 CIRCUIT DIAGRAM (2/2) (FJR13A) ............8-15 CIRCUIT DIAGRAM (1/2) (FJR13AE) .............8-17 CIRCUIT DIAGRAM (2/2) (FJR13AE) .............8-19...
Page 480 FUEL INJECTION SYSTEM................8-57 CIRCUIT DIAGRAM (1/2) (FJR13A) ............8-57 CIRCUIT DIAGRAM (2/2) (FJR13A) ............8-59 CIRCUIT DIAGRAM (1/2) (FJR13AE) .............8-61 CIRCUIT DIAGRAM (2/2) (FJR13AE) .............8-63 ECU SELF-DIAGNOSTIC FUNCTION............8-65 SELF-DIAGNOSTIC FUNCTION TABLE ..........8-66 TROUBLESHOOTING METHOD............8-68 DIAGNOSTIC MODE ................8-69 TROUBLESHOOTING DETAILS ............8-76 FUEL PUMP SYSTEM...................8-99 CIRCUIT DIAGRAM (1/2)................8-99 CIRCUIT DIAGRAM (2/2)..............8-101...
Page 481 [D-3] FINAL CHECK ................8-168 GRIP WARMER SYSTEM (FJR13AE only) ..........8-169 CIRCUIT DIAGRAM (1/2)..............8-169 CIRCUIT DIAGRAM (2/2)..............8-171 TROUBLESHOOTING ................8-173 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) ..8-175 CIRCUIT DIAGRAM (1/2)..............8-175 CIRCUIT DIAGRAM (2/2)..............8-177 TROUBLESHOOTING ................8-179 MAINTENANCE OF THE MCU .............8-180 MCU (motor control unit) SELF-DIAGNOSTIC FUNCTION ....8-180 SELF-DIAGNOSTIC FUNCTION TABLE ..........8-181...
Page 482 ELECTRICAL COMPONENTS..............8-213 CHECKING THE SWITCHES ...............8-221 CHECKING THE BULBS AND BULB SOCKETS .........8-226 CHECKING THE FUSES ..............8-227 CHECKING AND CHARGING THE BATTERY........8-228 CHECKING THE RELAYS ..............8-231 CHECKING THE TURN SIGNAL/HAZARD RELAY......8-233 CHECKING THE RELAY UNIT (DIODE) ..........8-234 CHECKING THE SPARK PLUG CAPS..........8-235 CHECKING THE IGNITION COILS............8-235 CHECKING THE IGNITION SPARK GAP..........8-236 CHECKING THE CRANKSHAFT POSITION SENSOR......8-236...
Page 484 IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM (1/2) (FJR13A)
Page 485 IGNITION SYSTEM 1. Main switch 8. Main fuse 10.Battery 17.Gear position switch 19.Coupler 3 (wire harness–front cowling wire harness) 20.Relay unit 23.Sidestand switch 35.Cylinders-#1/#4 ignition coil 36.Spark plug 37.Cylinders-#2/#3 ignition coil 43.ECU (engine control unit) 44.Crankshaft position sensor 45.Lean angle sensor 52.Coupler 4 (wire harness–front cowling wire harness) 57.Ignition fuse...
Page 486 IGNITION SYSTEM ET3P61001 CIRCUIT DIAGRAM (2/2) (FJR13A) Front cowling wire harness...
Page 487 IGNITION SYSTEM 19.Coupler 3 (wire harness–front cowling wire harness) 52.Coupler 4 (wire harness–front cowling wire harness) 68.Engine stop switch...
Page 488 IGNITION SYSTEM ET3P66001 CIRCUIT DIAGRAM (1/2) (FJR13AE)
Page 489 IGNITION SYSTEM 1. Main switch 8. Main fuse 9. Battery 18.Relay unit 21.Neutral switch 26.Coupler 3 (wire harness–front cowling wire harness) 35.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 48.Lean angle sensor 64.Coupler 5 (wire harness–front cowling wire harness) 70.Ignition fuse...
Page 490 IGNITION SYSTEM ET3P66002 CIRCUIT DIAGRAM (2/2) (FJR13AE) Front cowling wire harness...
Page 491 IGNITION SYSTEM 26.Coupler 3 (wire harness–front cowling wire harness) 64.Coupler 5 (wire harness–front cowling wire harness) 87.Engine stop switch...
Page 492 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 493 IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • 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 494 IGNITION SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-221. OK ↓ NG → 9. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES”...
Page 495 IGNITION SYSTEM 8-12...
Page 496 ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM (1/2) (FJR13A) 8-13...
Page 497 ELECTRIC STARTING SYSTEM 1. Main switch 8. Main fuse 10.Battery 12.Starter relay 13.Starter motor 17.Gear position switch 18.Coupler 2 (wire harness–front cowling wire harness) 19.Coupler 3 (wire harness–front cowling wire harness) 20.Relay unit 21.Starting circuit cut-off relay 23.Sidestand switch 52.Coupler 4 (wire harness–front cowling wire harness) 57.Ignition fuse 8-14...
Page 498 ELECTRIC STARTING SYSTEM ET3P61003 CIRCUIT DIAGRAM (2/2) (FJR13A) Front cowling wire harness 8-15...
Page 499 ELECTRIC STARTING SYSTEM 18.Coupler 2 (wire harness–front cowling wire harness) 19.Coupler 3 (wire harness–front cowling wire harness) 52.Coupler 4 (wire harness–front cowling wire harness) 68.Engine stop switch 69.Start switch 72.Clutch switch 8-16...
Page 500 ELECTRIC STARTING SYSTEM ET3P66005 CIRCUIT DIAGRAM (1/2) (FJR13AE) 8-17...
Page 501 ELECTRIC STARTING SYSTEM 1. Main switch 8. Main fuse 9. Battery 11.Starter relay 12.Starter motor 14.Coupler 2 (wire harness–front cowling wire harness) 18.Relay unit 19.Starting circuit cut-off relay 21.Neutral switch 26.Coupler 3 (wire harness–front cowling wire harness) 28.Brake light relay 29.Rear brake light switch 35.Sidestand switch 57.MCU (motor control unit)
Page 502 ELECTRIC STARTING SYSTEM ET3P66006 CIRCUIT DIAGRAM (2/2) (FJR13AE) Front cowling wire harness 8-19...
Page 503 ELECTRIC STARTING SYSTEM 14.Coupler 2 (wire harness–front cowling wire harness) 26.Coupler 3 (wire harness–front cowling wire harness) 64.Coupler 5 (wire harness–front cowling wire harness) 86.Front brake light switch 87.Engine stop switch 88.Start switch 8-20...
Page 504 ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION (FJR13A) 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 505 ELECTRIC STARTING SYSTEM ET3P66007 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION (FJR13AE) 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 506 ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING (FJR13A) The starter motor fails to turn. • 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 507 ELECTRIC STARTING SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-221. OK ↓ NG → 9. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES”...
Page 508 ELECTRIC STARTING SYSTEM ET3P66008 TROUBLESHOOTING (FJR13AE) The starter motor fails to turn. • 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 509 ELECTRIC STARTING SYSTEM NG → 8. Check the brake light relay. Refer to “CHECKING THE RE- Replace the brake light relay. LAYS” on page 8-231. OK ↓ NG → 9. Check the YCC-S control relay. Refer to “CHECKING THE RE- Replace the YCC-S control relay.
Page 510 ELECTRIC STARTING SYSTEM NG → 17.Check the entire starting system wiring. Refer to “CIRCUIT DIAGRAM (1/2) Properly connect or repair the starting sys- (FJR13AE)” on page 8-17 and tem wiring. “CIRCUIT DIAGRAM (2/2) (FJR13AE)” on page 8-19. OK ↓ Replace the MCU. 8-27...
Page 511 ELECTRIC STARTING SYSTEM 8-28...
Page 512 CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM Br/L Br/W Br/R R/L R/L L/W R/W R/L R/L (BLACK) (GRAY) (BLACK) Br/L L/B L/Y (RED) (RED) Br/L B/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 Br/B Br/B ( BLUE )
Page 513 CHARGING SYSTEM 2. Rectifier/regulator 3. AC magneto 8. Main fuse 10.Battery 8-30...
Page 514 CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. • 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” on page 8-227. OK ↓...
Page 515 CHARGING SYSTEM 8-32...
Page 516 LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM (1/2) 8-33...
Page 517 LIGHTING SYSTEM 1. Main switch 8. Main fuse 10.Battery 19.Coupler 3 (wire harness–front cowling wire harness) 30.License plate light 32.Tail/brake light 43.ECU (engine control unit) 52.Coupler 4 (wire harness–front cowling wire harness) 53.Headlight (on/off)/grip warmer relay 54.Hazard lighting fuse 56.Headlight fuse 57.Ignition fuse 8-34...
Page 518 LIGHTING SYSTEM ET3P61004 CIRCUIT DIAGRAM (2/2) Front cowling wire harness 8-35...
Page 519 LIGHTING SYSTEM 19.Coupler 3 (wire harness–front cowling wire harness) 52.Coupler 4 (wire harness–front cowling wire harness) 73.Dimmer switch 86.Meter light 87.High beam indicator light 92.Front left turn signal/position light 93.Front right turn signal/position light 94.Headlight relay (dimmer) 96.Headlight 8-36...
Page 520 LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlights, high beam indicator light, taillight, license plate light, position lights or meter light. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar NG →...
Page 521 LIGHTING SYSTEM NG → 8. Check the headlight relay (dimmer). Refer to “CHECKING THE RE- Replace the headlight relay (dimmer). LAYS” on page 8-231. OK ↓ NG → 9. Check the entire lighting system wiring. Properly connect or repair the lighting sys- Refer to “CIRCUIT DIAGRAM (1/2)”...
Page 522 SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM (1/2) (FJR13A) 8-39...
Page 523 SIGNALING SYSTEM 1. Main switch 5. ABS ECU fuse 7. Backup fuse (odometer, clock, and windshield drive system) 8. Main fuse 9. Coupler 1 (wire harness–front cowling wire harness) 10.Battery 14.Oil level switch 16.Fuel sender 17.Gear position switch 18.Coupler 2 (wire harness–front cowling wire harness) 19.Coupler 3 (wire harness–front cowling wire harness)
Page 524 SIGNALING SYSTEM ET3P61005 CIRCUIT DIAGRAM (2/2) (FJR13A) Front cowling wire harness 8-41...
Page 525 SIGNALING SYSTEM 9. Coupler 1 (wire harness–front cowling wire harness) 18.Coupler 2 (wire harness–front cowling wire harness) 19.Coupler 3 (wire harness–front cowling wire harness) 52.Coupler 4 (wire harness–front cowling wire harness) 65.Turn signal/hazard relay 67.Front brake light switch 70.Hazard switch 75.Turn signal switch 76.Horn switch 81.Neutral indicator light...
Page 526 SIGNALING SYSTEM ET3P66009 CIRCUIT DIAGRAM (1/2) (FJR13AE) 8-43...
Page 527 SIGNALING SYSTEM 1. Main switch 5. ABS ECU fuse 7. Backup fuse (odometer, clock, and windshield drive system) 8. Main fuse 9. Battery 13.Coupler 1 (wire harness–front cowling wire harness) 14.Coupler 2 (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)
Page 528 SIGNALING SYSTEM ET3P66010 CIRCUIT DIAGRAM (2/2) (FJR13AE) Front cowling wire harness 8-45...
Page 529 SIGNALING SYSTEM 13.Coupler 1 (wire harness–front cowling wire harness) 14.Coupler 2 (wire harness–front cowling wire harness) 26.Coupler 3 (wire harness–front cowling wire harness) 64.Coupler 5 (wire harness–front cowling wire harness) 79.Turn signal/hazard relay 83.Turn signal switch 84.Horn switch 86.Front brake light switch 89.Hazard switch 92.Neutral indicator light 94.Multi-function meter...
Page 530 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. •...
Page 531 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 8-221. OK ↓ NG → 2. Check the horns. Refer to “CHECKING THE Replace the horn(s).
Page 532 SIGNALING SYSTEM NG → 5. Check the diode 2. (FJR13AE only) Refer to “CHECKING THE DIODE Replace the diode. (FJR13AE only)” on page 8-245. OK ↓ NG → 6. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM (1/2) (FJR13A)”...
Page 533 SIGNALING SYSTEM NG → 5. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM (1/2) (FJR13A)” on page 8-39, “CIRCUIT Properly connect or repair the signaling DIAGRAM (2/2) (FJR13A)” on page system wiring. 8-41, “CIRCUIT DIAGRAM (1/2) (FJR13AE)” on page 8-43, and “CIRCUIT DIAGRAM (2/2) (FJR13AE)”...
Page 534 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM (1/2) Properly connect or repair the signaling (FJR13A)” on page 8-39 and “CIR- system wiring. CUIT DIAGRAM (2/2) (FJR13A)” on page 8-41. OK ↓ Replace the meter assembly. The oil level warning light fails to come on.
Page 535 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 536 COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-53...
Page 537 COOLING SYSTEM 1. Main switch 8. Main fuse 10.Battery 43.ECU (engine control unit) 47.Coolant temperature sensor 57.Ignition fuse 60.Radiator fan motor relay 61.Left radiator fan motor fuse 62.Left radiator fan motor 63.Right radiator fan motor fuse 64.Right radiator fan motor 8-54...
Page 538 COOLING SYSTEM EAS27320 TROUBLESHOOTING The radiator fan motor fails to turn. • 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 539 COOLING SYSTEM 8-56...
Page 540 FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM (1/2) (FJR13A) 8-57...
Page 541 FUEL INJECTION SYSTEM 1. Main switch 5. ABS ECU fuse 6. Fuel injection system fuse 8. Main fuse 10.Battery 15.Fuel pump 17.Gear position switch 18.Coupler 2 (wire harness–front cowling wire harness) 19.Coupler 3 (wire harness–front cowling wire harness) 20.Relay unit 22.Fuel pump relay 23.Sidestand switch 25.ABS ECU (electronic control unit)
Page 542 FUEL INJECTION SYSTEM ET3P61006 CIRCUIT DIAGRAM (2/2) (FJR13A) Front cowling wire harness 8-59...
Page 543 FUEL INJECTION SYSTEM 18.Coupler 2 (wire harness–front cowling wire harness) 19.Coupler 3 (wire harness–front cowling wire harness) 52.Coupler 4 (wire harness–front cowling wire harness) 68.Engine stop switch 83.Multi-function meter 85.Engine trouble warning light 8-60...
Page 544 FUEL INJECTION SYSTEM ET3P66012 CIRCUIT DIAGRAM (1/2) (FJR13AE) 8-61...
Page 545 FUEL INJECTION SYSTEM 1. Main switch 5. ABS ECU fuse 6. Fuel injection system fuse 8. Main fuse 9. Battery 14.Coupler 2 (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 26.Coupler 3 (wire harness–front cowling wire harness)
Page 546 FUEL INJECTION SYSTEM ET3P66013 CIRCUIT DIAGRAM (2/2) (FJR13AE) Front cowling wire harness 8-63...
Page 547 FUEL INJECTION SYSTEM 14.Coupler 2 (wire harness–front cowling wire harness) 26.Coupler 3 (wire harness–front cowling wire harness) 64.Coupler 5 (wire harness–front cowling wire harness) 87.Engine stop switch 94.Multi-function meter 96.Engine trouble warning light 8-64...
Page 548 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 549 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 550 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 551 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.) Engine has been left idling.
Page 552 FUEL INJECTION SYSTEM 4. Turn the main switch to “OFF” and back to The engine operation is not normal but the “ON”, then check that no fault code number is engine trouble warning light does not come displayed. 1. Check the operation of following sensors and actuators in the Diagnostic mode.
Page 553 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 554 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 555 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 556 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 557 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 558 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 559 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 560 FUEL INJECTION SYSTEM After the check and service of the malfunctioning part has been completed, reset the meter display ac- cording to the reinstatement method. Fault code No.: Code number displayed on the meter when the engine failed to work normally. Refer to “Self-Diagnostic Function table”.
Page 561 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 562 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 563 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 564 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 565 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 566 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 567 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 568 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 569 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 570 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 571 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 572 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 573 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 574 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 575 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 576 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. (FJR13A) Open or short circuit is detected in the neutral switch. (FJR13AE) Diagnostic code No.
Page 577 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. (FJR13A) Open or short circuit is detected in the neutral switch. (FJR13AE) Diagnostic code No.
Page 578 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 579 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 580 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 581 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 582 FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM (1/2) 8-99...
Page 583 FUEL PUMP SYSTEM 1. Main switch 6. Fuel injection system fuse 8. Main fuse 10.Battery 15.Fuel pump 19.Coupler 3 (wire harness–front cowling wire harness) 20.Relay unit 22.Fuel pump relay 43.ECU (engine control unit) 52.Coupler 4 (wire harness–front cowling wire harness) 57.Ignition fuse 8-100...
Page 584 FUEL PUMP SYSTEM ET3P61007 CIRCUIT DIAGRAM (2/2) Front cowling wire harness 8-101...
Page 585 FUEL PUMP SYSTEM 19.Coupler 3 (wire harness–front cowling wire harness) 52.Coupler 4 (wire harness–front cowling wire harness) 68.Engine stop switch 8-102...
Page 586 FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. • 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 587 FUEL PUMP SYSTEM 8-104...
Page 588 WINDSHIELD DRIVE SYSTEM EAS27610 WINDSHIELD DRIVE SYSTEM EAS27620 CIRCUIT DIAGRAM (1/2) Br/L Br/W Br/R R/L R/L L/W R/W R/L R/L (BLACK) (GRAY) (BLACK) Br/L L/B L/Y (RED) (RED) Br/L B/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 Br/B...
Page 589 WINDSHIELD DRIVE SYSTEM 1. Main switch 7. Backup fuse (odometer, clock, and windshield drive system) 8. Main fuse 9. Coupler 1 (wire harness–front cowling wire harness) 10.Battery 52.Coupler 4 (wire harness–front cowling wire harness) 55.Signaling system fuse 8-106...
Page 590 WINDSHIELD DRIVE SYSTEM ET3P61008 CIRCUIT DIAGRAM (2/2) Front cowling wire harness 8-107...
Page 591 WINDSHIELD DRIVE SYSTEM 9. Coupler 1 (wire harness–front cowling wire harness) 52.Coupler 4 (wire harness–front cowling wire harness) 74.Windshield position switch 98.Windshield drive unit 8-108...
Page 592 WINDSHIELD DRIVE SYSTEM EAS27630 TROUBLESHOOTING The windshield fails to move. • 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 593 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 594 ACCESSORY BOX SYSTEM ET3P61009 ACCESSORY BOX SYSTEM ET3P61010 CIRCUIT DIAGRAM (1/2) Br/L Br/W Br/R R/L R/L L/W R/W R/L R/L (BLACK) (GRAY) (BLACK) Br/L L/B L/Y (RED) (RED) Br/L B/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 Br/B...
Page 595 ACCESSORY BOX SYSTEM 1. Main switch 8. Main fuse 10.Battery 52.Coupler 4 (wire harness–front cowling wire harness) 55.Signaling system fuse 8-112...
Page 596 ACCESSORY BOX SYSTEM ET3P61011 CIRCUIT DIAGRAM (2/2) Front cowling wire harness 8-113...
Page 597 ACCESSORY BOX SYSTEM 52.Coupler 4 (wire harness–front cowling wire harness) 77.Accessory box solenoid 8-114...
Page 598 ACCESSORY BOX SYSTEM ET3P61012 TROUBLESHOOTING The accessory box fails to operate. • 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 599 ACCESSORY BOX SYSTEM 8-116...
Page 600 ABS (ANTI-LOCK BRAKE SYSTEM) EAS28790 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27730 CIRCUIT DIAGRAM (1/2) (FJR13A) 8-117...
Page 601 ABS (ANTI-LOCK BRAKE SYSTEM) 1. Main switch 4. ABS solenoid fuse 5. ABS ECU fuse 8. Main fuse 10.Battery 11.ABS motor fuse 12.Starter relay 18.Coupler 2 (wire harness–front cowling wire harness) 19.Coupler 3 (wire harness–front cowling wire harness) 21.Starting circuit cut-off relay 24.ABS test coupler 25.ABS ECU (electronic control unit) 26.Front wheel sensor...
Page 602 ABS (ANTI-LOCK BRAKE SYSTEM) ET3P61021 CIRCUIT DIAGRAM (2/2) (FJR13A) Front cowling wire harness 8-119...
Page 603 ABS (ANTI-LOCK BRAKE SYSTEM) 18.Coupler 2 (wire harness–front cowling wire harness) 19.Coupler 3 (wire harness–front cowling wire harness) 52.Coupler 4 (wire harness–front cowling wire harness) 67.Front brake light switch 68.Engine stop switch 69.Start switch 82.ABS warning light 83.Multi-function meter 8-120...
Page 604 ABS (ANTI-LOCK BRAKE SYSTEM) ET3P66014 CIRCUIT DIAGRAM (1/2) (FJR13AE) 8-121...
Page 605 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 2 (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 26.Coupler 3 (wire harness–front cowling wire...
Page 606 ABS (ANTI-LOCK BRAKE SYSTEM) ET3P66015 CIRCUIT DIAGRAM (2/2) (FJR13AE) Front cowling wire harness 8-123...
Page 607 ABS (ANTI-LOCK BRAKE SYSTEM) 14.Coupler 2 (wire harness–front cowling wire harness) 26.Coupler 3 (wire harness–front cowling wire harness) 64.Coupler 5 (wire harness–front cowling wire harness) 86.Front brake light switch 87.Engine stop switch 88.Start switch 93.ABS warning light 94.Multi-function meter 8-124...
Page 608 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 609 ABS (ANTI-LOCK BRAKE SYSTEM) 8-126...
Page 610 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27750 ABS COUPLER LOCATION CHART FJR13A 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 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) R/B B/R...
Page 611 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 8-128...
Page 612 ABS (ANTI-LOCK BRAKE SYSTEM) FJR13AE 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 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 613 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 8-130...
Page 614 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27770 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 615 ABS (ANTI-LOCK BRAKE SYSTEM) 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 616 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 617 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 8-168.) EAS27830 [A] CHECKING THE ABS WARNING LIGHT Turn the main switch to “ON”.
Page 618 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 619 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 620 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 621 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 622 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 623 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 624 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 625 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 626 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 627 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 628 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 629 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 630 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 631 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 632 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 633 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 634 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 635 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 636 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 637 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 638 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 639 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 640 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 641 (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 642 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 643 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 644 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 645 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 646 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 647 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 648 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 649 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 650 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 651 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 652 GRIP WARMER SYSTEM (FJR13AE only) ET3P66016 GRIP WARMER SYSTEM (FJR13AE only) ET3P66017 CIRCUIT DIAGRAM (1/2) 8-169...
Page 653 GRIP WARMER SYSTEM (FJR13AE only) 1. Main switch 8. Main fuse 9. Battery 26.Coupler 3 (wire harness–front cowling wire harness) 44.ECU (engine control unit) 64.Coupler 5 (wire harness–front cowling wire harness) 65.Headlight (on/off)/grip warmer relay 68.Signaling system fuse 69.Headlight fuse 72.Grip warmer control unit 8-170...
Page 654 GRIP WARMER SYSTEM (FJR13AE only) ET3P66018 CIRCUIT DIAGRAM (2/2) Front cowling wire harness 8-171...
Page 655 GRIP WARMER SYSTEM (FJR13AE only) 26.Coupler 3 (wire harness–front cowling wire harness) 64.Coupler 5 (wire harness–front cowling wire harness) 114.Left grip warmer 115.Right grip warmer 8-172...
Page 656 GRIP WARMER SYSTEM (FJR13AE only) 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. •...
Page 657 GRIP WARMER SYSTEM (FJR13AE only) 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 658 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) ET3P66056 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) ET3P66057 CIRCUIT DIAGRAM (1/2) 8-175...
Page 659 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) 1. Main switch 8. Main fuse 9. Battery 14.Coupler 2 (wire harness–front cowling wire harness) 19.Starting circuit cut-off relay 23.ABS ECU (electronic control unit) 26.Coupler 3 (wire harness–front cowling wire harness) 28.Brake light relay 29.Rear brake light switch...
Page 660 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) ET3P66058 CIRCUIT DIAGRAM (2/2) Front cowling wire harness 8-177...
Page 661 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) 14.Coupler 2 (wire harness–front cowling wire harness) 26.Coupler 3 (wire harness–front cowling wire harness) 59.Coupler 4 (wire harness–front cowling wire harness) 64.Coupler 5 (wire harness–front cowling wire harness) 66.Coupler 6 (wire harness–front cowling wire harness) 86.Front brake light switch...
Page 662 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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. • Before troubleshooting, remove the following part(s): 1.
Page 663 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 (FJR13AE only)” on page 8-244 and “AD- Replace the gear position sensor.
Page 664 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 665 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 666 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 667 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 668 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) 5. Erase the malfunction history in the diagnos- tic mode. Refer to “Diagnostic code table (Di- agnostic code No. Sh_ _62)”. Turning the main switch to “OFF” will not erase the malfunction history.
Page 669 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 670 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 671 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 neutral.
Page 672 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 673 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 674 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 675 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 676 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 677 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 678 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 679 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 680 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 681 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 682 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 683 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 684 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 685 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 686 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 687 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 688 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 689 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 690 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 691 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 692 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 693 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 694 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 695 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE 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 696 ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS FJR13A 8-213...
Page 697 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 698 ELECTRICAL COMPONENTS FJR13A 8-215...
Page 699 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 700 ELECTRICAL COMPONENTS FJR13AE 8-217...
Page 701 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 702 ELECTRICAL COMPONENTS FJR13AE 8-219...
Page 703 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 704 ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES FJR13A Br/W R/Y L/B Lg B Sb DOWN Dg Br/W Ch B Br/W Ch Br L/B L/Y R/W R/B L/B L/Y (RED) L/W B Br/W (BROWN) (BLACK) (BLUE) 8-221...
Page 705 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 706 ELECTRICAL COMPONENTS FJR13AE Br/W (BLACK) R/Y L/B Lg B Sb DOWN 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/B L/Y Br/L PUSH L/B L/Y (RED) B Br/W Ch R/W R/B (BROWN) L/W B Br/W (BLUE)
Page 707 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 708 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 NOTICE 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 709 ELECTRICAL COMPONENTS EAS27990 EW3P61001 CHECKING THE BULBS AND BULB WARNING SOCKETS Since headlight bulbs get extremely hot, 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 710 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 711 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 4.
Page 712 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 713 ELECTRICAL COMPONENTS b. Connect a charger and ammeter to the bat- tery and start charging. If the current is lower than the standard charging 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 714 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 715 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 716 ELECTRICAL COMPONENTS YCC-S control relay (FJR13AE) 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 717 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 FJR13A black/yellow “2”...
Page 718 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 719 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 720 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 721 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 722 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 723 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 724 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 725 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 726 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 Make sure that the intake air temperature sensor ET3P66023 CHECKING THE GRIP WARMERS (FJR13AE terminals do not get wet.
Page 727 ELECTRICAL COMPONENTS ET3P66020 CHECKING THE YCC-S SPEED SENSOR (FJR13AE only) 1. Check: • YCC-S speed sensor output voltage Out of specification → Replace. Output voltage reading cycle 0.6 V to 4.8 V to 0.6 V to 4.8 V M MMM M MMM M MMM M MMM...
Page 728 ELECTRICAL COMPONENTS ET3P66022 CHECKING THE FOOT SHIFT SWITCH (FJR13AE only) 1. Remove: • Foot shift switch 2. Check: • Foot shift switch maximum resistance Out of specification → Replace the foot shift switch. Resistance 2. Check: FJR13AE 4.0–6.0 kΩ • Gear position sensor maximum resistance Out of specification →...
Page 729 ELECTRICAL COMPONENTS The pocket tester and the analog pocket tester readings are shown in the following table. 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 →...
Page 730 ELECTRICAL COMPONENTS 8-247...
Page 731: 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 ..................9-3 OVERCOOLING..................9-3 POOR BRAKING PERFORMANCE............
Page 732 TROUBLESHOOTING Electrical system EAS28450 TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) • 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 733 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 734 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 735 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 736 EAS28740 52. Coupler 4 (wire harness–front EAS28750 WIRING DIAGRAM COLOR CODE cowling wire harness) Black 53. Headlight (on/off)/grip warmer FJR13AY(C) 2009 Brown relay 1. Main switch Chocolate 54. Hazard lighting fuse 2. Rectifier/regulator Dark green 55. Signaling system fuse 3. AC magneto Green 56.
Page 737 53. Shift actuator motor 107.Horn ET3P66050 WIRING DIAGRAM 54. Shift actuator sensor 108.Front left turn signal/position 55. Clutch actuator sensor light FJR13AEY(C) 2009 56. Clutch actuator motor 109.Front right turn signal/position 1. Main switch 57. MCU (motor control unit) light 2.
Page 738 White/Blue White/Yellow Yellow/Black Yellow/Green Yellow/Blue Yellow/Red Yellow/White...
Page 740 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
Page 741 FJR13AY(C) 2009 WIRING DIAGRAM (1/2) (GRAY) (GRAY) WIRE HARNESS SUB-WIRE HARNESS (GRAY) (BLACK) (GRAY) (GRAY) (BLACK) (GRAY) (BLACK) (BLACK) (RED) (RED) (BLACK) (BLACK) (DARK GREEN) ( BLUE ) ( BLUE ) ( BROWN ) (BLACK) (BLACK) ( BROWN ) (GRAY) ( BLUE ) ( BLUE ) (GRAY)
Page 742 FJR13AY(C) 2009 WIRING DIAGRAM (2/2) Front cowling wire harness (BLACK) (BLACK) (BLACK) (BLACK) (GRAY) (BLACK) DOWN (GRAY) (BLACK) ( BLACK ) (BLACK) ( BLACK ) (GRAY) (GRAY) (BLACK)
Page 743 FJR13AEY(C) 2009 WIRING DIAGRAM (1/2) (BLACK) (BLACK) (GRAY) (GRAY) WIRE HARNESS SUB-LEAD1 WIRE HARNESS SUB-WIRE HARNESS WIRE HARNESS SUB-LEAD2 (GRAY) (GRAY) (GRAY) (BLACK) (BLACK) (RED) (RED) (BLACK) (GRAY) (BLACK) (BLACK) (BLACK) (DARK GREEN) ( BLUE ) ( BLUE ) (GRAY) ( BROWN ) (BLACK) (BLACK)
Page 744 FJR13AEY(C) 2009 WIRING DIAGRAM (2/2) Front cowling wire harness (BLACK) ( BLACK ) ( BLACK ) DOWN (GRAY) (GRAY) (BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (GRAY) (BLACK) (GRAY) PUSH Shift up Shift down...

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Yamaha FJR13AY 2009 Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Chassis

Engine

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