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.
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.
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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...
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...
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.
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.
• 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)
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.
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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.
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.
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”.
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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 –...
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-...
FUEL INJECTION SYSTEM WIRING DIAGRAM (FJR1300A) – 14 –...
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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...
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.
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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. •...
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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.
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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).
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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...
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”.
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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 –...
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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.
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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 –...
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 –...
– 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...
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– 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...
– 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. •...