Checking The Clutch Master Cylinder; Assembling The Clutch Master Cylinder; Installing The Clutch Master Cylinder - Yamaha FJR13AG Service Manual

EAS31976
CHECKING THE CLUTCH MASTER
CYLINDER
Recommended clutch component replace-
ment schedule
Piston seal
Clutch hose
Clutch fluid
1. Check:
• Clutch master cylinder body
Cracks/damage → Replace the clutch mas-
ter cylinder.
• Clutch fluid delivery passage
(clutch master cylinder body)
Obstruction → Blow out with compressed air.
2. Check:
• Clutch master cylinder
• Clutch master cylinder kit
Rust/scratches/wear → Replace the clutch
master cylinder and clutch master cylinder kit
as a set.
3. Check:
• Clutch master cylinder reservoir
Cracks/damage → Replace.
• Clutch master cylinder reservoir diaphragm
Damage/wear → Replace.
4. Check:
• Clutch hose
Cracks/damage/wear → Replace.
EAS31977
ASSEMBLING THE CLUTCH MASTER
CYLINDER
EWA13340
WARNING
• Before installation, all internal clutch com-
ponents must be cleaned and lubricated
with clean or new clutch fluid.
• Never use solvents on internal clutch com-
ponents as they will cause the piston seals
to swell and distort.
Every two years
Every four years
Every two years and
whenever the clutch is
disassembled
5-54
• Whenever a clutch master cylinder is disas-
sembled, replace the piston seals.
Specified brake and clutch fluid
DOT 4
EAS31978
INSTALLING THE CLUTCH MASTER
CYLINDER
1. Install:
• Clutch master cylinder "1"
• Clutch master cylinder holder "2"
TIP
• Install the clutch lever holder with the "UP"
mark facing up.
• Align the end of the clutch lever holder with the
punch mark "a" on the left handlebar.
• First, tighten the upper bolt, then the lower bolt.
2
2. Install:
• Copper washers "1"
• Clutch hose "2"
• Clutch hose union bolt "3"
Clutch hose union bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
EWA18510
WARNING
Proper clutch hose routing is essential to in-
sure safe vehicle operation.
ECA18360
NOTICE
When installing the clutch hose onto the
clutch master cylinder, make sure the clutch
pipe "a" touches the projection "b" as
shown.
TIP
Turn the handlebars to the left and to the right to
make sure the clutch hose does not touch other
parts (e.g., wire harness, cables, leads). Correct
if necessary.
CLUTCH
New