Yamaha FJR1300(S) Supplementary Service Manual

Yamaha FJR1300(S) Supplementary Service Manual

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2004
FJR1300(S)
FJR1300A(S)
5JW1-AE5
SUPPLEMENTARY
SERVICE MANUAL

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Summary of Contents for Yamaha FJR1300(S)

  • Page 1 2004 FJR1300(S) FJR1300A(S) 5JW1-AE5 SUPPLEMENTARY SERVICE MANUAL...
  • Page 3 FJR1300(P) 2002 SUPPLEMENTARY SERVICE MANUAL: 5JW1-AE2 FJR1300(R)/FJR1300A(R) 2003 SUPPLEMENTARY SERVICE MANUAL: 5JW1-AE4 FJR1300(S)/FJR1300A(S) 2004 SUPPLEMENTARY SERVICE MANUAL © 2003 by Yamaha Motor Co., Ltd. First edition, September 2003 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
  • Page 4: Important Manual Information

    EAS00002 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
  • Page 5: How To Use This Manual

    EAS00007 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. 1 The manual is divided into chapters.
  • Page 6 EAS00008 SYMBOLS The following symbols are not relevant to SPEC every vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information CHAS 2 Specifications 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system 7 Fuel injection system COOL 8 Electrical system...
  • Page 7: Table Of Contents

    CONTENTS GENERAL INFORMATION ................1 FEATURES ....................1 OUTLINE ....................1 FI SYSTEM ...................2 SPECIFICATIONS ....................3 GENERAL SPECIFICATIONS ..............3 ENGINE SPECIFICATIONS ..............3 ELECTRICAL SPECIFICATIONS .............4 PERIODIC CHECKS AND ADJUSTMENTS ............5 INTRODUCTION ..................5 PERIODIC MAINTENANCE AND LUBRICATION CHART .......5 SEATS AND FUEL TANK .................7 FUEL TANK ..................7 REMOVING THE FUEL TANK ..............9 AIR FILTER CASE ..................10...
  • Page 9: General Information

    FEATURES INFO GENERAL INFORMATION FEATURES OUTLINE The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the com- bustion chamber is created by the volume of the intake air and the fuel that is metered by the jet that is used in the respective carburetor.
  • Page 10: Fi System

    FEATURES INFO FI SYSTEM The fuel pump delivers fuel to the injector via the fuel filter. The fuel pump maintains the fuel pres- sure that is applied to the injector at only 324 kPa (3.24 kg/cm , 46.08 psi). Accordingly, when the energizing signal from the ECU energizes the injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
  • Page 11: Specifications

    GENERAL SPECIFICATIONS/ SPEC ENGINE SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code FJR1300: 5JWG (for Europe) ---- 5JWH (for F) ---- 5JWJ (for Oceania) ---- FJR1300A: 5VS7 (for Europe) ---- 5VS8 (for F) ---- 5VS9 (for Oceania) ---- ENGINE SPECIFICATIONS Item Standard Limit...
  • Page 12: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit Ignition system Ignition system type Transistorized coil ignition (digital) ---- Ignition timing 5° BTDC at 1,050 r/min ---- Advancer type Electric ---- 420.8 ~ 569.3 Ω/Gy–B Pickup coil resistance/color ---- Transistorized coil ignition unit model F8T818 (MITSUBISHI) ---- (manufacturer)
  • Page 13: Periodic Checks And Adjustments

    • From 50,000 km, repeat the maintenance intervals starting from 10,000 km. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1,000 km)
  • Page 14 PERIODIC MAINTENANCE AND LUBRICATION CHART ODOMETER READING (× 1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK Sidestand, center- • Check operation. √ √ √ √ √ stand • Lubricate. √ √ √ √ √ √ 16 * Sidestand switch •...
  • Page 15: Seats And Fuel Tank

    SEATS AND FUEL TANK SEATS AND FUEL TANK EAS00040 FUEL TANK Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Rider seat Refer to “SEATS AND FUEL TANK” in chapter 3. (Manual No.: 5JW1-AE1) Fuel Drain.
  • Page 16 SEATS AND FUEL TANK Order Job/Part Q’ty Remarks Fuel hose Refer to “REMOVING THE FUEL TANK”. Refer to “INSTALLING THE FUEL HOSE” in chapter 3. (Manual No.: 5JW1- AE1) Bolt Fuel tank Refer to “REMOVING THE FUEL TANK”. For installation, reverse the removal procedure.
  • Page 17: Removing The Fuel Tank

    SEATS AND FUEL TANK REMOVING THE FUEL TANK 1. Remove the fuel in the fuel tank through the fuel tank filler hole with a pump. 2. Remove: • fuel hose CAUTION: Although the fuel has been removed from the fuel tank, be careful when removing the fuel hose since there may be fuel remaining in it.
  • Page 18: Air Filter Case

    AIR FILTER CASE EAS00043 AIR FILTER CASE Order Job/Part Q’ty Remarks Removing the air filter case Remove the parts in the order listed. Seats Refer to “SEATS AND FUEL TANK” in chapter 3. (Manual No.: 5JW1-AE1) Fuel tank Refer to “SEATS AND FUEL TANK”. Side covers (left and right) Refer to “COWLINGS AND COVERS”.
  • Page 19 AIR FILTER CASE Order Job/Part Q’ty Remarks Air induction system hose 5 Disconnect. Clamp screw Loosen. Air filter case Air filter case breather hose For installation, reverse the removal procedure. – 11 –...
  • Page 20: Fuel Injection System

    FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 Ignition coil 7 Intake air pressure C Coolant temperature I Engine trouble warn- 2 Air filter case sensor sensor ing light 3 Intake air tempera- 8 Throttle position sensor D Spark plug J Lean angle cut-off 9 Fuel injector E Cylinder identifica-...
  • Page 21: Wiring Diagram (Fjr1300)

    FUEL INJECTION SYSTEM WIRING DIAGRAM (FJR1300) – 13 –...
  • Page 22: Wiring Diagram (Fjr1300A)

    FUEL INJECTION SYSTEM WIRING DIAGRAM (FJR1300A) – 14 –...
  • Page 23 FUEL INJECTION SYSTEM * Table of self-diagnostic fault code numbers displayed on meter Able/ Able/ Able/ Able/ Symptom unable to unable to Symptom unable to unable to start drive start drive No normal signals are received The motorcycle has overturned. from the cylinder identification Able Able...
  • Page 24: Substitute Characteristics Operation Control (Fail-Safe Action)

    FUEL INJECTION SYSTEM SUBSTITUTE CHARACTERISTICS OPERATION CONTROL (FAIL-SAFE ACTION) If the ECU detects an abnormal signal from a sensor while the motorcycle is being driven, the ECU illuminates the engine trouble warning light and provides the engine with substitute characteristic operation instructions that are appropriate for the type of the malfunction.
  • Page 25 FUEL INJECTION SYSTEM Self-diagnostic fault codes, symptoms, and probable causes Diagnostic code indication Code No. Symptom Probable cause of malfunction Diagnostic code No normal signals are received from • Open or short circuit in wiring sub lead. the cylinder identification sensor. •...
  • Page 26 FUEL INJECTION SYSTEM Code No. Symptom Probable cause of malfunction Diagnostic code No normal signals are received from • Open or short circuit in wiring harness. the O sensor. • Defective O sensor. — • Malfunction in ECU. • Improperly installed sensor. The motorcycle has overturned.
  • Page 27 FUEL INJECTION SYSTEM Sensor operation data display verification table NOTE: • Check the intake air temperature and coolant temperature as close as possible to the area in which the respective sensor is mounted. • If it is not possible to check the intake temperature, use the ambient temperature as reference (use the compared values for reference).
  • Page 28 FUEL INJECTION SYSTEM Troubleshooting details Troubleshooting the self-diagnostic fault code Code No. Symptom A break or disconnection of the black/red lead of the ECU is detected. Used diagnostic code No. 20 (sidestand switch) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective sidestand switch...
  • Page 29: Throttle Bodies

    FUEL INJECTION SYSTEM THROTTLE BODIES Order Job/Part Q’ty Remarks Removing the throttle bodies Remove the parts in the order listed. Seats/T-bar/rubber sheet Refer to “SEATS AND FUEL TANK” in chapter 3. (Manual No.: 5JW1-AE1) Fuel tank Refer to “SEATS AND FUEL TANK”. Air filter case Refer to “AIR FILTER CASE”.
  • Page 30 FUEL INJECTION SYSTEM Order Job/Part Q’ty Remarks Throttle cable Disconnect. Plunger control unit hose 1 Disconnect. Plunger control unit hose 2 Disconnect. Throttle body joint For installation, reverse the removal procedure. – 22 –...
  • Page 31 FUEL INJECTION SYSTEM Order Job/Part Q’ty Remarks Removing the injectors Remove the parts in the order listed. Throttle position sensor coupler Disconnect. Intake air pressure sensor coupler Disconnect. Cylinder #1-injector coupler Disconnect. Cylinder #2-injector coupler Disconnect. Cylinder #3-injector coupler Disconnect. Cylinder #4-injector coupler Disconnect.
  • Page 32 FUEL INJECTION SYSTEM Order Job/Part Q’ty Remarks Intake air pressure sensor Fuel injection pipe Injector Throttle position sensor For installation, reverse the removal procedure. – 24 –...
  • Page 33: Air Induction System

    AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM INSTALLING THE REED VALVES 1. Install: • plate 1 NOTE: Align the notch a in each plate with the pro- jection b of each reed valve seat on the cylin- der head cover. – 25 –...
  • Page 34: Electrical

    – ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL ELECTRICAL COMPONENTS 1 Windshield drive unit 8 Radiator fan motor E Ignition coil 2 Battery 9 Wire harness F Main fuse 3 Starter relay 0 Neutral switch G ABS motor fuse (FJR1300A) 4 Fuel injection system fuse A Sidestand switch 5 Front brake light switch B Oil level switch...
  • Page 35 – ELEC ELECTRICAL COMPONENTS 1 Coolant temperature sensor 8 ECU (engine) D Accessory box solenoid 2 Intake air pressure sensor 9 ECU (ABS) (FJR1300A) E Accessory box relay 3 Intake air temperature sensor 0 Speed sensor F Headlight relay 1 4 Relay unit A Cylinder identification sensor G Radiator fan motor relay...
  • Page 36: Fuel Injection System

    – ELEC FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM CIRCUIT DIAGRAM (FJR1300) – 28 –...
  • Page 37: Circuit Diagram (Fjr1300A)

    – ELEC FUEL INJECTION SYSTEM CIRCUIT DIAGRAM (FJR1300A) – 29 –...
  • Page 38: Checking The Fuel Pump

    – ELEC FUEL INJECTION SYSTEM EAS00819 CHECKING THE FUEL PUMP WARNING Gasoline is extremely flammable and under certain circumstances there can be a dan- ger of an explosion or fire. Be extremely careful and note the following points: • Stop the engine before refueling. •...
  • Page 39: Fjr1300 Wiring Diagram

    FJR1300 WIRING DIAGRAM 1 Immobilizer unit § Headlight fuse 2 Main switch • Signaling system fuse ¶ Radiator fan motor fuse 3 Rectifier/regulator 4 Generator ß Windshield motor fuse 5 Backup fuse (odometer, clock and windshield) ® CYCLELOCK 6 Main fuse ©...
  • Page 40 FJR1300A WIRING DIAGRAM 1 Immobilizer unit § Rear turn signal light (left) 2 Main switch • Rear turn signal light (right) ¶ Rear brake light switch 3 Rectifier/regulator 4 Generator ß Turn signal relay 5 ABS fuse ® Windshield drive unit 6 Backup fuse (odometer, clock and windshield) ©...
  • Page 42 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
  • Page 43 FJR1300 WIRING DIAGRAM W/B Y Gy/G Gy/G Y W/B R/L R/B G/B G/B R/B R/L W Y/L Y/L W Sb/W Br/Y Br/Y Sb/W Y Lg Y/B Br/B Br/B Br/G Br/G B/L P/W L/B O/B L Sb Ch Br/W Br/G Br/G Br/W (BLACK) (BLACK)
  • Page 44 FJR1300A WIRING DIAGRAM G/L R/W Br/L Br/W W/B Y Gy/G Gy/G Y W/B R/L R/B G/B G/B R/B R/L W Y/L Y/L W Sb/W Br/Y Br/Y Sb/W Y Lg Y/B Br/B Br/B B/L P/W L/B O/B L Br/W Br/G Sb Ch Br/G Br/W (BLACK)

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