Yamaha 2003 FJR1300 Service Manual
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Yamaha 2003 FJR1300 Service Manual

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2003
5JW1-AE4
SUPPLEMENTARY
SERVICE MANUAL

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Summary of Contents for Yamaha 2003 FJR1300

  • Page 1 2003 FJR1300(R) FJR1300A(R) 5JW1-AE4 SUPPLEMENTARY SERVICE MANUAL...
  • Page 3 FJR1300(N) 2001 SERVICE MANUAL: 5JW1-AE1 FJR1300(P) 2002 SUPPLEMENTARY SERVICE MANUAL: 5JW1-AE2 FJR1300(R)/FJR1300A(R) 2003 SUPPLEMENTARY SERVICE MANUAL © 2003 by Yamaha Motor Co., Ltd. First edition, February 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 SPECIAL TOOLS ..................1 SPECIFICATIONS ....................2 GENERAL SPECIFICATIONS ..............2 ENGINE SPECIFICATIONS ..............3 CHASSIS SPECIFICATIONS ..............5 ELECTRICAL SPECIFICATIONS .............8 TIGHTENING TORQUES ...............10 CHASSIS TIGHTENING TORQUES ..........10 CABLE ROUTING ...................11 FJR1300 ....................11 FJR1300A ...................23 PERIODIC CHECKS AND ADJUSTMENTS ..........42 INTRODUCTION ..................42 PERIODIC MAINTENANCE AND LUBRICATION CHART .....42 SEATS AND FUEL TANK ...............44...
  • Page 8 ELECTRICAL ....................131 ELECTRICAL COMPONENTS .............131 CHECKING THE SWITCHES ...............133 IMMOBILIZER SYSTEM ...............135 CIRCUIT DIAGRAM ................135 GENERAL INFORMATION ...............136 KEY CODES REGISTRATION METHOD..........137 SELF-DIAGNOSIS ERROR CODE INDICATION......140 TROUBLESHOOTING ..............141 CHECKING THE IMMOBILIZER SYSTEM ........142 ACCESSORY BOX SYSTEM ...............145 CIRCUIT DIAGRAM ................145 TROUBLESHOOTING ..............146 TROUBLESHOOTING ..................148 TROUBLESHOOTING WITH THE ABS WARNING LIGHT ....148...

  • Page 9: General Information

    SPECIAL TOOLS INFO GENERAL INFORMATION EB104000 SPECIAL TOOLS The following special tool is necessary for complete and accurate tune-up and assembly. Use only the appropriate special tool as this will help prevent damage caused by the use of inappro- priate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes.

  • Page 10: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code FJR1300: 5JWA (for Europe) ---- 5JWB (for F) ---- 5JWC (for Oceania) ---- FJR1300A: 5VS1 (for Europe) ---- 5VS2 (for F) ---- 5VS3 (for Oceania) ---- Dimensions Overall length 2,195 mm ---- Overall width...

  • Page 11: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, DOHC ---- Displacement 1,298 cm ---- Cylinder arrangement Forward-inclined parallel 4-cylinder ---- Bore × stroke 79.0 × 66.2 mm ---- Compression ratio 10.8 : 1 ---- Engine idling speed 1,000 ~ 1,100 r/min ---- Vacuum pressure at engine idling...
  • Page 12 SPEC ENGINE SPECIFICATIONS Item Standard Limit Cooling system Radiator capacity (including all 3.2 L ---- routes) Radiator capacity 1.03 L ---- Radiator cap opening pressure 93.3 ~ 122.7 kPa ---- (0.93 ~ 1.23 kg/cm 0.93 ~ 1.23 bar) Valve relief pressure 4.9 kPa (0.05 kg/cm 0.05 bar) ----...

  • Page 13: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Front tire Tire type Tubeless ---- Size 120/70 ZR17 M/C (58W) ---- Model (manufacturer) MEZ4J FRONT (METZELER)/ ---- BT020F N (BRIDGESTONE) Tire pressure (cold) 0 ~ 90 kg 250 kPa (2.5 kgf/cm , 2.5 bar) ---- 90 ~ 201 kg (FJR1300)
  • Page 14 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front suspension Suspension type Telescopic fork ---- Front fork type Coil spring/oil damper ---- Front fork travel 135 mm ---- Spring Free length 264 mm 259 mm Spacer length 149.5 mm ---- Installed length 249 mm ---- Spring rate (K1)
  • Page 15 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear suspension Suspension type Swingarm (link suspension) ---- Rear shock absorber assembly type Coil spring/gas-oil damper ---- Rear shock absorber assembly travel 60 mm ---- Upper spring Free length 156 mm 152.88 mm Installed length 138.1 mm ---- Lower spring...

  • Page 16: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V ---- 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 F8T927 (MITSUBISHI)
  • Page 17 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Coolant temperature sensor Model (manufacturer) 8CC (MITSUBISHI) ---- Resistance 5.21 ~ 6.37 kΩ at 0 °C ---- 0.290 ~ 0.354 kΩ at 80 °C ---- Fuses (amperage × quantity) 50 A × 1 Main fuse ---- Fuel injection system fuse 15 A...

  • Page 18: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening Thread torque Part to be tightened Remarks size m·kg Fuel tank and frame Fuel tank and fuel tank bracket Front wheel sensor and sensor housing FJR1300A Front brake pipe (hydraulic unit to front brake caliper) and FJR1300A lower bracket Front brake hose (hydraulic unit to front brake caliper)

  • Page 19: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING FJR1300 1 Throttle cable 9 Hazard switch 2 Brake hose 0 Rectifier/regulator 3 Clutch hose A Plate 4 Main switch lead/immobilizer lead B Plunger control unit hose 2 5 Headlight lead C Radiator 6 Fuse box D Radiator fan coupler 7 Thermostat assembly breather hose E Accessory box solenoid...
  • Page 20 SPEC CABLE ROUTING È Pass the right handlebar switch lead under the Ì After passing the coolant reservoir hose through handlebar. the two hose guides behind the plate, pass the É Pass the left handlebar switch lead under the hose through the right hole of the plate. Í...
  • Page 21 SPEC CABLE ROUTING 1 Brake hose B Front turn signal extension-lead M Ignition coil leads #2 and #3 2 Right handlebar switch lead C Ignition coils #1 and #4 N Starter relay 3 Throttle cable D Coolant reservoir O Negative battery lead 4 Starter relay lead E Coolant reservoir breather hose 5 Battery...
  • Page 22 SPEC CABLE ROUTING È Fasten the positive battery lead to the battery Í Pass the brake hose through the brake hose stay with a plastic locking tie. holder. É Fasten the positive battery lead and main fuse Î Pass the coolant reservoir hose through the hole lead with a plastic locking tie to the battery stay.
  • Page 23 SPEC CABLE ROUTING Ñ Support the coolant reservoir hose and coolant Õ Pass the starter motor lead, negative battery reservoir breather hose with the hose holder lead, wire harness, and spark plug leads #2 and located under the coolant reservoir. #3 through the battery stay.
  • Page 24 SPEC CABLE ROUTING 1 Immobilizer lead B Oil level switch lead 2 Main switch lead C Brake hose 3 Left handlebar switch lead D Coolant reservoir hose 4 Hazard switch E Thermostat assembly breather hose 5 Rectifier/regulator F Headlight lead 6 Clutch hose G Radiator fan lead 7 Fuel tank breather hose...
  • Page 25 SPEC CABLE ROUTING È To the radiator fan Î Fasten the clutch hose with the hose holder É Pass the wire harness, stator coil lead, coolant attached to the frame. Ï Insert the harness holder into the hole at the rear reservoir hose, thermostat...
  • Page 26 SPEC CABLE ROUTING 1 ECU É Fasten the wire harness to the Î Fasten the wire harness and 2 Tail/brake light wire harness (ECU) with the frame with a plastic locking tie. clamp attached to the clamp 3 Tail/brake light lead Ê...
  • Page 27 SPEC CABLE ROUTING 1 Air cut-off valve B Spark plug lead #1 2 Clutch hose C Spark plug lead #4 3 Left handlebar switch lead D Cable guide 4 Headlight lead E Throttle position sensor 5 Main switch lead F Sidestand switch lead 6 Immobilizer lead 7 Throttle cable 8 Right handlebar switch lead...
  • Page 28 SPEC CABLE ROUTING È Connect the wire harness and right handlebar Ì To the cylinder identification sensor Í To the fuel tank switch lead. É Pass the left handlebar switch lead, immobilizer Î Pass the cylinder identification sensor lead lead, main switch lead, headlight lead, and through the lead guide of throttle body.
  • Page 29 SPEC CABLE ROUTING Ò Support the throttle cables with the T-bar located Ô To the left slit of the plate behind the cable guide. Ó Pass the throttle cables under spark plug leads #1, #2, #3, and #4, and the wire harness, head- light lead, main switch lead, immobilizer lead, right handlebar switch lead, and left handlebar switch lead.
  • Page 30 SPEC CABLE ROUTING 1 Intake air temperature sensor È To the rear brake light switch 2 Lean angle circuit cut-off relay É Pass the rear brake light switch through the lead 3 Starting circuit cut-off relay guide attached to the frame. 4 Atmospheric pressure sensor Ê...

  • Page 31: Fjr1300A

    SPEC CABLE ROUTING FJR1300A 1 Throttle cable 0 Thermostat assembly breather hose 2 Brake hose (front brake master cylinder to A Coolant reservoir hose B Hazard switch hydraulic unit) 3 Clutch hose C Rectifier/regulator 4 Main switch/immobilizer lead D Plate 5 Front wheel sensor lead E Plunger control unit hose 2 6 Headlight lead...
  • Page 32 SPEC CABLE ROUTING È Pass the right handlebar switch lead under the Í Pass the wire harness, stator coil lead, coolant handlebar. reservoir hose, thermostat assembly É Pass the left handlebar switch lead under the breather hose through the left slit of the plate. Î...
  • Page 33 SPEC CABLE ROUTING Ò Pass the radiator fan lead on the outside of the plate. Ó Fasten the brake hoses to the frame. Ô Tighten the brake hose joint bolt, union bolt, and brake hose holder bolt in the proper tightening sequence as shown.
  • Page 34 SPEC CABLE ROUTING 1 Brake hose (front brake master A Spark plug lead #1 K Starter motor lead B Ignition coils #1 and #4 L Spark plug lead #2 cylinder to hydraulic unit) 2 Right handlebar switch lead C Front turn signal extension lead M Spark plug lead #3 3 Throttle cable N Ignition coils #2 and #3...
  • Page 35 SPEC CABLE ROUTING È Fasten the positive battery lead Ë Install the connector so that Î Pass the coolant reservoir hose to the battery stay with a plastic ignition coil leads #1 and #4 can through the hole of the plate. Ï...
  • Page 36 SPEC CABLE ROUTING Ñ Support the coolant reservoir hose and coolant Ô Pass the wire harness and spark plug leads #1, reservoir breather hose with the hose holder #2, #3, and #4 through the right slit of the plate. Õ Pass the starter motor lead, negative battery located under the coolant reservoir.
  • Page 37 SPEC CABLE ROUTING 1 Tail/brake light lead È Pass the tail/brake light lead under the rear 2 Hydraulic unit wheel sensor lead. 3 Brake hose (front brake master cylinder to É Fasten the rear wheel sensor lead to the rear hydraulic unit) brake hose (hydraulic unit to rear brake caliper) 4 Brake hose (hydraulic unit to rear brake caliper)
  • Page 38 SPEC CABLE ROUTING 1 Immobilizer lead B Oil level switch lead 2 Main switch lead C Front wheel sensor 3 Left handlebar switch lead D Brake hose (hydraulic unit to front brake caliper) 4 Hazard switch E Coolant reservoir hose 5 Rectifier/regulator F Thermostat assembly breather hose 6 Clutch hose...
  • Page 39 SPEC CABLE ROUTING È Pass the wire harness, stator coil lead, coolant Î Pass the front wheel sensor lead through the reservoir hose, thermostat assembly holder. Ï Pass the front wheel sensor lead outside of the breather hose through the left slit of the plate. É...
  • Page 40 SPEC CABLE ROUTING Ò Pass the brake hose (hydraulic unit to front Ø To the wire harness Ù Contact the clutch hose to the turn stopper. brake caliper) and front wheel sensor through the brake hose holder. Ó 60 ~ 70 mm Ô...
  • Page 41 SPEC CABLE ROUTING 1 Air filter case breather hose È To the intake air temperature sensor 2 ECU (engine) É Fasten the wire harness to the frame with a plas- 3 ECU (ABS) tic locking tie. 4 Tail/brake light Ê To the inside of the U-lock storage box 5 Tail/brake light lead Ë...
  • Page 42 SPEC CABLE ROUTING Î Fasten the wire harness and wire harness (ECU) with the clamp attached to the clamp bracket, which is attached to the seat lock bracket. Ï Pass the air filter case breather hose, fuel tank breather hose, and fuel tank over flow hose through the hose guide.
  • Page 43 SPEC CABLE ROUTING 1 ECU (engine) 0 Hydraulic unit breather hose 2 Wire harness 3 ECU (ABS) È Be sure to install the ECU (ABS) so that the sub- 4 Sub-wire harness (ABS) wire harness (ABS) and leads do not get 5 Rear wheel sensor lead pinched between the ECU (ABS) and rear 6 Brake hose (rear brake master cylinder to...
  • Page 44 SPEC CABLE ROUTING 1 Air cut-off valve A T-bar 2 Clutch hose B Spark plug lead #3 3 Front wheel sensor lead C Spark plug lead #2 4 Left handlebar switch lead D Spark plug lead #1 5 Headlight lead E Spark plug lead #4 6 Main switch lead F Cable guide...
  • Page 45 SPEC CABLE ROUTING È Connect the wire harness and right handlebar Ì To the cylinder identification sensor Í To the fuel tank switch lead. É Pass the left handlebar switch lead, front wheel Î Pass the cylinder identification sensor lead sensor lead, immobilizer lead, main switch lead, through the lead guide of the throttle body.
  • Page 46 SPEC CABLE ROUTING Ò Support the throttle cables with the T-bar located Ô To the left slit of the plate behind the cable guide. Ó Pass the throttle cables under spark plug leads #1, #2, #3, and #4, and the wire harness, head- light lead, main switch lead, immobilizer lead, right handlebar switch lead, and left handlebar switch lead.
  • Page 47 SPEC CABLE ROUTING 1 Intake air temperature sensor A Seat lock cable 2 Rear brake light switch coupler 3 Brake hose (hydraulic unit to front brake caliper) È Fasten the brake hoses with the hose holder 4 Hydraulic unit attached to the frame. 5 Brake hose (front brake master cylinder to É...
  • Page 48 SPEC CABLE ROUTING Í Pass the CYCLELOCK coupler through the inside of the storage box of the U-lock. Î Pass the CYCLELOCK coupler through the lead guide. Ï Pass the wire harnesses under the tray bracket. É Ê È È Ë...
  • Page 49 SPEC CABLE ROUTING 1 Brake hose (front brake master 8 Sub-wire harness (ABS) Ì Contact the bracket claw to the 9 Hydraulic unit cylinder to hydraulic unit) hydraulic unit. 2 Brake hose (rear brake master 0 Hydraulic unit drain plug Í...

  • Page 50: 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 51: Periodic Maintenance And Lubrication Chart

    PERIODIC MAINTENANCE AND LUBRICATION CHART ODOMETER READING (× 1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK • Make sure that all nuts, bolts and screws are √ √ √ √ √ 14 * Chassis fasteners properly tightened. Sidestand/center- • Check operation. √...

  • Page 52: 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 53 SEATS AND FUEL TANK Order Job/Part Q’ty Remarks Bolt Fuel tank Refer to “REMOVING THE FUEL TANK” in chapter 3. (Manual No.: 5JW1-AE1) For installation, reverse the removal procedure. – 45 –...

  • Page 54: Installing The Fuel Pump

    SEATS AND FUEL TANK INSTALLING THE FUEL PUMP 1. Install: • fuel pump 4 Nm (0.4 m · kg) NOTE: • Do not damage the installation surfaces of the fuel tank when installing the fuel pump. • Always use a new fuel pump gasket. •...

  • Page 55: Cowlings And Covers

    COWLINGS AND COVERS EAS00041 COWLINGS AND COVERS COWLINGS 10 Nm (1.0 m • Order Job/Part Q’ty Remarks Removing the cowlings Remove the parts in the order listed. Rider seat Refer to “SEATS AND FUEL TANK” in chapter 3. (Manual No.: 5JW1-AE1) Fuel tank Refer to “SEATS AND FUEL TANK”.
  • Page 56 COWLINGS AND COVERS 10 Nm (1.0 m • Order Job/Part Q’ty Remarks Front left inner panel (front cowling) Accessory box solenoid coupler Clamp Sub-wire harness coupler Front cowling assembly For installation, reverse the removal procedure. – 48 –...
  • Page 57 COWLINGS AND COVERS ( 7 ) Order Job/Part Q’ty Remarks Disassembling the front cowling Remove the parts in the order listed. assembly Windshield outer bracket Windshield Grommet Windshield inner bracket Rear view mirror (left and right) Panel Front cowling Accessory box Accessory box lock assembly Auxiliary light coupler Headlight coupler...

  • Page 58: Electrical System

    ADJUSTING THE HEADLIGHT BEAMS ELECTRICAL SYSTEM EAS00185 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights. 1. Adjust: • headlight beam (vertically) M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting knob 1 in direction a or Headlight beam is Direction a raised.

  • Page 59: Chassis

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed. discs NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. Reflector For AUS only Brake caliper (left and right)

  • Page 60: Rear Wheel And Brake Disc

    CHAS REAR WHEEL AND BRAKE DISC REAR WHEEL AND BRAKE DISC EAS00560 Order Job/Part Q’ty Remarks Disassembling the rear wheel Remove the parts in the order listed. Dust cover Rear wheel drive hub Dust seal Wheel bearing Rear wheel drive hub damper Oil seal Circlip Wheel bearing...

  • Page 61: Installing The Bearing

    CHAS REAR WHEEL AND BRAKE DISC INSTALLING THE BEARING 1. Install: • bearing 1 a 3.5 ~ 4.5 mm b rear wheel – 53 –...

  • Page 62: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER È FJR1300A Order Job/Part Q’ty Remarks Removing the rear brake master cyl- Remove the parts in the order listed. inder Side cover (right) Refer to “COWLINGS AND COVERS” in chapter 3.
  • Page 63 CHAS FRONT AND REAR BRAKES È FJR1300A Order Job/Part Q’ty Remarks Union bolt Refer to “DISASSEMBLING/ Copper washer ASSEMBLING THE Brake hose Disconnect. REAR BRAKE MASTER CYLINDER” in chapter 4. (Manual No.: 5JW1-AE1) Cotter pin Brake master cylinder For installation, reverse the removal procedure.
  • Page 64 CHAS FRONT AND REAR BRAKES EAS00587 Order Job/Part Q’ty Remarks Disassembling the rear brake mas- Remove the parts in the order listed. ter cylinder Dust boot Circlip Push rod Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly procedure.

  • Page 65: Handlebars

    CHAS HANDLEBARS HANDLEBARS RIGHT HANDLEBAR Order Job/Part Q’ty Remarks Removing the right handlebar Remove the parts in the order listed. Front brake light switch connector Disconnect. Brake master cylinder holder Brake master cylinder Refer to “REMOVING/ Grip end INSTALLING THE Throttle cable housing HANDLEBARS”...

  • Page 66: Anti-Lock Brake System (Fjr1300A)

    ABS OUTLINE Yamaha ABS features 1. The Yamaha ABS (Anti-Lock Brake System) features a dual electronic control system, which acts on the front and rear brakes independently. 2. The ABS features a compact and lightweight design to help maintain the basic maneuverability of the motorcycle.
  • Page 67 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) EAS00872 The operation of the Yamaha ABS brakes is the same as conventional motorcycles, with a brake lever for operating the front wheel brake and a brake pedal for operating the rear wheel brake. When wheel lockup is detected during emer- gency braking, hydraulic control is performed by the hydraulic system independently.
  • Page 68 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • Slip ratio: When the brakes are applied, slipping occurs between the tires and the road sur- face. 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 follow- ing formula.
  • Page 69 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) EAS00875 Wheel slip and hydraulic control The ECU (ABS) calculates the wheel speed of each wheel according to the rotation signal Motorcycle speed received from the front and rear wheel sen- sors. In addition, the ECU (ABS) calculates the motorcycle chassis speed and the rate of speed reduction based on the wheel speed Wheel speed...
  • Page 70 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) The higher the cornering force on a tire, the Brake force less traction there is available for braking. This is true whether the motorcycle is equipped with an ABS or not. Therefore, sudden braking while cornering is not recommended. Exces- Side force sive cornering force, which an ABS cannot pre- vent, could cause the tire to slip sideways.
  • Page 71 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) EAS00877 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 providing various travel conditions for motorcy- cles. The ABS also includes a highly developed self-diagnostic function. The ABS detects any problem conditions and allows normal braking even if the ABS is not operating properly.
  • Page 72 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) EAS00878 ABS component functions • Wheel sensors and sensor rotors Wheel sensors 1 detect the wheel rotation speed and transmit the wheel rotation signal to the ECU (ABS). Each wheel sensor is composed of a perma- nent magnet and a coil.
  • Page 73 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) EAS00879 • Hydraulic unit The hydraulic unit 1 is composed of a hydrau- lic control valve (solenoid valve, flow control valve), a buffer chamber, and a hydraulic pump for each brake and an ABS motor. The hydraulic unit adjusts the front and rear wheel brake fluid pressure to control the wheel rota- tion speed according to signals transmitted...
  • Page 74 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • Hydraulic control valve The hydraulic control valve is composed of a flow control valve and solenoid valve. When the ABS is activated, the flow control valve regulates the flow of brake fluid to each brake and the solenoid valve decreases and increases the brake fluid pressure.
  • Page 75 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • Buffer chamber The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating. 1 Buffer chamber (pressurized) 2 Buffer chamber (depressurized) 3 Raised piston • Electronic control unit (ECU) The ECU (ABS) 1 controls the ABS and is installed under the tray bracket.
  • Page 76 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) As shown in the block diagram below, the ECU (ABS) receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits. Both a main microcomputer and a sub microcomputer are installed in the ECU (ABS) to provide mutual monitoring. 1 Battery A Main switch K Meter assembly...
  • Page 77 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • ABS control operation The ABS control operation performed in the ECU (ABS) is divided into the following two parts. • Hydraulic control • Self-diagnosis These operations are performed once every 8/1,000 of a second. When a failure is detected in the ABS, a malfunction code is stored in the memory of the ECU (ABS) for easy problem identification and troubleshoot-...
  • Page 78 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • Fail-safe relay The fail-safe relay controls the power supply of the hydraulic unit and is located beside the hydraulic unit. 1 Fail-safe relay Composition and operation The fail-safe relay is composed of the solenoid relay 1 and ABS motor relay 2. The solenoid relay is activated (continuous) by signals transmitted from the ECU (ABS).
  • Page 79 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) ABS operation The ABS hydraulic circuit consists of two systems: the front wheel and rear wheel. The following describes the front system only. • Normal braking (ABS not activated) When the ABS is not activated port D A of the solenoid valve is closed because a control signal has not been transmitted from the ECU (ABS) and port A 7 and port B 9 of the flow control valve are open.
  • Page 80 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • Emergency braking (ABS activated) 1) Depressurized state When the front wheel is about to lockup, port D A of the solenoid valve is opened by the “depres- surization” signal transmitted from the ECU (ABS). When this occurs, the spool of the flow control valve compresses the return spring to close port B 9.
  • Page 81 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) 2) Pressurized state Port D A is closed by the “pressurization” signal transmitted from the ECU (ABS). Before this occurs, the spool of the flow control valve has compressed the return spring to close port B 9. Brake fluid that has entered through port A 7 is further restricted by the orifice 0 and the brake fluid is sent to the brake calipers via port A 7 and port C C.
  • Page 82 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) EAS00880 Self-diagnosis function • ABS warning light The ABS warning light 1 comes on when a malfunction is detected by the ABS self-diag- nosis. It is located in the meter assembly. • Instances when the ABS warning light comes on 1) The ABS warning light comes on when the Main switch Main switch...
  • Page 83 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) 4) The ABS warning light 4 flashes and mal- function code 3 is indicated on the multi- function display when a test coupler adaptor 2 is connected to the 4-pin test coupler 1 for troubleshooting the ABS. The 4-pin test coupler can be accessed by removing the right inner panel (front cowl- ing).
  • Page 84 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) Cautions for operation ABS warning light: • When the main switch is set to “ON”, the ABS warning light comes on for 2 seconds, then goes off. • If the ABS warning light comes on while riding, stop the motorcycle, and then set the main switch to “OFF”, then set the main switch to “ON”.

  • Page 85: Abs Components

    CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) EAS00882 ABS COMPONENTS 1 Front brake hose (front brake master cylinder to 8 Electronic control unit (ECU) 9 Rear brake hose (rear brake master cylinder to hydraulic unit) 2 ABS warning light hydraulic unit) 3 Fuse box 0 Fail-safe relay 4 Front brake hose (hydraulic unit to front brake A Hydraulic unit...

  • Page 86: Abs Couplers

    CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) EAS00883 ABS COUPLERS Gy W W1 B1 Wire har- ness end Front wheel sensor coupler Wire har- ness end B R/W Br/W B R/W Wire har- Wire harness end Wire har- ness end ness end Fail-safe relay cou- ABS test coupler Hydraulic unit coupler...

  • Page 87: Circuit Diagram

    CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) EAS00884 CIRCUIT DIAGRAM – 79 –...
  • Page 88 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) 2 Main switch 5 ABS fuse 7 Main fuse 8 ABS motor fuse 9 Battery [ Sub-wire harness (ABS) \ ECU (ABS) ] Rear wheel sensor _ Fail-safe relay a Hydraulic unit b ABS test coupler c Front wheel sensor k ABS warning light l Multifunction meter...

  • Page 89: Troubleshooting

    CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) TROUBLESHOOTING EAS00881 ABS troubleshooting outline Use this section to troubleshoot the ABS. Read this service manual carefully and make sure you understand the information provided before repairing any malfunctions or performing service. The electronic control unit (ECU) has an ABS self-diagnostic function. When failures occur in the ABS, the ABS warning light on the meter assembly indicates a malfunction.
  • Page 90 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) ABS self-diagnosis by the ECU (ABS) The ECU (ABS) performs a static check on the ABS when the main switch is set to “ON”. The ECU (ABS) also monitors the ABS while riding the motorcycle and checks for malfunctions. If malfunctions occur, the malfunction codes are stored in the memory of the ECU (ABS).
  • Page 91 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) EAS00886 Basic troubleshooting process Does not come on. Comes on for 2 seconds, then goes off. Check the ABS warning light. Flashing Remains on. [B-1] [B-3] [B-2] [B-5] [B-4] Warning light does Warning light Warning light Present Past not come on.
  • Page 92 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) EAS00887 ABS troubleshooting • [A] ABS malfunction check using the ABS warning light Set the main switch to “ON”. (Do not start the engine.) → [B-1] 1) Warning light does not come on. → [B-2] 2) Warning light remains on.
  • Page 93 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • [B-4] ABS malfunction check using the ABS self-diagnosis (past malfunction) Remove the right inner panel (front cowling) and the front right inner panel (front cowling) to access the test coupler 1. Remove the protective cap and connect the test coupler adaptor 2 to the test coupler.
  • Page 94 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • [B-5] ABS malfunction check using the ABS self-diagnosis (present malfunction) NOTE: Before proceeding, read [B-3], “Function of the test coupler terminals”. Remove the right inner panel (front cowling) and the front right inner panel to access the test cou- pler.
  • Page 95 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • [C] Determining the cause and location of the malfunction • [C-1] Only the ABS warning light does not come on when the main switch is set to “ON” NOTE: Check following the steps in sequence. 1.
  • Page 96 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • [C-3] ABS warning light flashes With the engine off, check the front and rear brake switches. Check if the brake light comes on when the front or rear brake is applied. 1) The light does not come on for only one brake. →...
  • Page 97 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • [C-5] Diagnosis by the malfunction code Malfunction codes are used to determine the malfunctions that have occurred. (Refer to “[B-4] ABS malfunction check using the ABS self-diagnosis (past malfunction)” and “[B-5] ABS malfunction check using the ABS self-diagnosis (present malfunction)”.) The malfunction codes are explained in the following table.
  • Page 98 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) Malfunction Problem Check point Reference code Defective operation of the ABS motor is • Fail-safe relay [C-5-9] Mal- detected. (ABS motor keeps running and will • ABS wire harness circuit function code not stop.) • ABS motor circuit 34 (page 94) Front wheel will not recover from the locking •...
  • Page 99 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • [C-5-1] Malfunction code 11 (Front wheel sensor signal is not received correctly.) Set the main switch to “OFF”, then back to “ON” after removing the test coupler adaptor. 1) ABS warning light remains on. →...
  • Page 100 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • [C-5-3] Malfunction codes 13 (front wheel) and 14 (rear wheel) (Incorrect signal is detected from either the front or rear wheel.) 1) The wheel sensors or sensor rotors are not properly installed. 1 Installation of the front or rear wheel sensor →...
  • Page 101 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • [C-5-6] Malfunction code 31 (Disconnection is detected between the fail-safe relay and the hydraulic unit solenoid.) Check the following: 1) ABS motor fuse • Check if the ABS motor fuse beside the battery is blown. 2) Hydraulic unit solenoid coupler •...
  • Page 102 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • [C-5-8] Malfunction code 33 (ABS motor operation malfunction is detected. [ABS motor stops and does not rotate.]) Check the following: 1) ABS motor fuse • Check if the ABS motor fuse beside the battery is blown. 2) Fail-safe relay →...
  • Page 103 • Check the brake hose lines for kinks and deterioration. WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake hose lines. • Check that the connections of the brake hose lines from the brake master cylinder to the hydrau- lic unit and to the front brake caliper from the hydraulic unit are correct.
  • Page 104 • Check the brake hose lines for kinks and deterioration (particularly between the hydraulic unit and the rear brake caliper). WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake hose lines. – 96 –...
  • Page 105 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • Check that the connections of the brake hose lines from the brake master cylinder to the hydrau- lic unit and to the rear brake caliper from the hydraulic unit are correct. WARNING The rear brake will not function properly if the connections are reversed. •...
  • Page 106 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • [C-5-12] Malfunction code 51 (Front wheel does not recover from the locking tendency even though the signal is continuously transmitted from the ECU (ABS) to release the hydraulic pressure [when the battery voltage is low].) Check the following: 1) Rotation of the front wheel Refer to “[C-5-10] Malfunction code 41”.
  • Page 107 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • [C-5-13] Malfunction code 52 (Rear wheel does not recover from the locking tendency even though the signal is continuously transmitted from the ECU (ABS) to release the hydraulic pressure [when the battery voltage is low].) Check the following: 1) Rotation of the rear wheel Refer to “[C-5-11] Malfunction code 42”.

  • Page 108: Ecu (Abs) And Fail-Safe Relay

    CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) EAS00888 ECU (ABS) AND FAIL-SAFE RELAY Order Job/Part Q’ty Remarks Removing the ECU (ABS) and fail- Remove the parts in the order listed. safe relay Air filter case Refer to “AIR FILTER CASE” in chapter 3.
  • Page 109 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) [D-1] Maintenance of the ECU (ABS) • Removing the ECU (ABS) 1. Remove: • ECU (ABS) 1 NOTE: When removing the ECU (ABS), take care not to damage the ECU (ABS) or ECU (ABS) cou- plers.
  • Page 110 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • Checking the fail-safe relay 1. Check: • solenoid relay for continuity Connect the pocket tester (Ω × 1) to the ter- minals. Check for continuity between terminals 3 and 4 of the solenoid relay. Tester positive probe →...
  • Page 111 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) 2. Check: • ABS motor relay for continuity Connect the pocket tester (Ω × 1) to the ter- minals of the ABS motor relay. Check for continuity between terminals 1 and 6 of the ABS motor relay. Tester positive probe →...

  • Page 112: Front Wheel Sensor And Sensor Rotor

    CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) EAS00889 FRONT WHEEL SENSOR AND SENSOR ROTOR 72 Nm (7.2 m • 23 Nm (2.3 m • 7 Nm (0.7 m • 40 Nm (4.0 m • 30 Nm (3.0 m • Order Job/Part Q’ty Remarks Removing the front wheel sensor Remove the parts in the order listed.
  • Page 113 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) 72 Nm (7.2 m • 23 Nm (2.3 m • 7 Nm (0.7 m • 40 Nm (4.0 m • 30 Nm (3.0 m • Order Job/Part Q’ty Remarks Collar (right) Brake disc (left and right) For installation, reverse the removal procedure.
  • Page 114 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) [D-3] Maintenance of the front wheel sensor and sensor rotor • ABS wheel sensor and sensor rotor CAUTION: • 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 115 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) 2. Measure: • front wheel sensor resistance Connect the pocket tester (Ω × 1k) to the terminals of the front wheel sensor coupler. Tester positive probe → Terminal 1 Tester negative probe → Terminal 2 Regulated resistance 1.12 ~ 1.68 kΩ...
  • Page 116 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) 2. Install: • front wheel sensor 1 30 Nm (3.0 m · kg) • front wheel sensor lead holder 2 • brake caliper 3 40 Nm (4.0 m · kg) • brake hose holder 4 NOTE: When installing the front wheel sensor, check the wheel sensor lead for twists and the sensor...

  • Page 117: Rear Wheel Sensor And Sensor Rotor

    CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) EAS00890 REAR WHEEL SENSOR AND SENSOR ROTOR Order Job/Part Q’ty Remarks Removing the rear wheel sensor and Remove the parts in the order listed. sensor rotor NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. ECU (ABS) Refer to “ECU (ABS) AND FAIL-SAFE RELAY”.
  • Page 118 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) Order Job/Part Q’ty Remarks Sensor housing Brake disc For installation, reverse the removal procedure. – 110 –...
  • Page 119 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) [D-4] Maintenance of the rear wheel sensor and sensor rotor CAUTION: • Be sure not to contact the sensor elec- trode to any metal part when removing the front wheel sensor from the sensor housing. •...
  • Page 120 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • Installing the rear wheel sensor 1. Install: • rear wheel NOTE: • Align the slot a of the sensor housing 1 with the projection b of the rear brake cali- per assembly 2, and then assemble them. •...

  • Page 121: Hydraulic Unit

    CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) EAS00891 HYDRAULIC UNIT 30 Nm (3.0 m • 30 Nm (3.0 m • 16 Nm (1.6 m • 16 Nm (1.6 m • Order Job/Part Q’ty Remarks Removing the hydraulic unit Remove the parts in the order listed. Air filter case Refer to “AIR FILTER CASE”...
  • Page 122 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) 30 Nm (3.0 m • 30 Nm (3.0 m • 16 Nm (1.6 m • 16 Nm (1.6 m • Order Job/Part Q’ty Remarks Rear brake hose (rear brake master cylinder to hydraulic unit) Union bolt/copper washers Rear brake hose (hydraulic unit to rear brake caliper) Breather hose...
  • Page 123 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) [D-5] Maintenance of the hydraulic unit CAUTION: Do not remove the hydraulic unit to check the resistance of the solenoid valves and the ABS motor for continuity. WARNING Refill with the same type of brake fluid that is already in the system.
  • Page 124 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • Checking the resistance of the solenoid valves and ABS motor for continuity CAUTION: When check the hydraulic unit solenoid relay and ABS motor, do not remove the brake hoses. 1. Measure: • resistance of the solenoid valve (front) Connect a pocket tester (Ω...
  • Page 125 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • Removing the hydraulic unit 1. Remove: • brake hose 1 (from the front brake master cylinder) • brake hose 2 (to the front brake caliper) • brake hose 3 (from the rear brake master cylinder) •...
  • Page 126 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • Installing the hydraulic unit Proceed in the reverse order of disassembly. Pay attention to the following items. 1. Install: • hydraulic unit bracket 1 1 16 Nm (1.6 m · kg) NOTE: Tighten the nuts in the proper sequence. 2.
  • Page 127 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) 5. Fill: • brake master cylinder reservoirs Recommended brake fluid DOT 4 6. Bleed the brake system. 7. Check the operation of the hydraulic unit according to the brake lever and the brake pedal response. (Refer “[D-6-3-1] Hydraulic unit operation test 1”.)

  • Page 128: Hydraulic Abs

    CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) HYDRAULIC ABS EAS00892 Bleeding the brake system (ABS) WARNING Always bleed the brake system when the brake related parts are removed. CAUTION: Bleed the brake system in the following order. 1st: Front brake caliper a 2nd: Rear brake caliper b •...
  • Page 129 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) Bleeding the ABS for FJR1300A 1 Hydraulic unit 4 Buffer chamber 7 Hydraulic pump pressure 2 Brake caliper 5 Hydraulic pump 3 Solenoid valve 6 Brake master cylinder pressure EAS00134 Bleeding the ABS brake WARNING Bleed the ABS whenever: •...
  • Page 130 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) 1. Remove: • right side cover È Refer to “COWLINGS AND COVERS” in chapter 3. (Manual No.: 5JW1-AE1) 2. Bleed: • ABS M MMM M MMM M MMM M MMM M MMM a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid.
  • Page 131 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) l. Tighten the bleed screw to the specified torque. Bleed screw 6 Nm (0.6 m · kg) m. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. Refer to “CHECKING THE BRAKE FLUID LEVEL”...
  • Page 132 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) 2. Check: • installation of the wheel sensors to the sen- sor housings (Refer to “[D-3] Maintenance of the front wheel sensor and sensor rotor” and “[D-4] Maintenance of the rear wheel sensor and sensor rotor”.) Wheel sensor 30 Nm (3.0 m·kg) Hydraulic unit operation test...
  • Page 133 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) 4. Check: • battery voltage Battery voltage Higher than 12.8 V Lower than 12.8 V → Charge or replace the battery. NOTE: • If the battery voltage is lower than 12.8 V, charge the battery and perform hydraulic unit operation test 1.
  • Page 134 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) 9. After releasing the start switch, operate the brake lever and the brake pedal simulta- neously. NOTE: • A reaction-force pulsating action is gener- ated in the brake lever 1 0.5 second after the brake lever and the brake pedal are oper- ated simultaneously continues...
  • Page 135 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) 12.Set the main switch to “OFF”. 13.Remove the test coupler adaptor from the test coupler. 14.Set the main switch to “ON”. 15.Set the engine stop switch to “ ”. • [D-6-3-2] Hydraulic unit operation test 2 WARNING Securely support the motorcycle so that there is no danger of it falling over.
  • Page 136 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) 6. Set the main switch to “ON” while operating the brake lever and the brake pedal simulta- neously. CAUTION: When the main switch is set to “ON”, be sure to operate both the brake levers and the brake pedal simultaneously.
  • Page 137 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) 3. Set the engine stop switch 1 to “ ”. CAUTION: Be sure to set the engine stop switch to “ ”. If the start switch is pushed without setting the engine stop switch to “ ”, the starter motor gears or other parts may be damaged.
  • Page 138 CHAS ANTI-LOCK BRAKE SYSTEM (FJR1300A) • [D-6-6] Delete function test 1. Place the motorcycle on the centerstand. 2. Set the main switch to “OFF”. 3. Connect the test coupler adapter to the test coupler. 4. Set the main switch to “ON”. 5.

  • Page 139: 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 switch B Oil level switch...

  • Page 140: Electrical Components

    – ELEC ELECTRICAL COMPONENTS 1 Coolant temperature sensor 8 ECU (engine) E Accessory box solenoid 2 Intake air pressure sensor 9 ECU (ABS) (FJR1300A) F Headlight relay 1 3 Intake air temperature sensor 0 Starting circuit cut-off relay G Headlight relay 2 4 Atmospheric pressure sensor H Fuel injection system relay A Speed sensor...

  • Page 141: Checking The Switches

    – ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the ter- minals. Refer to “CHECKING SWITCH CONTINUITY” in chapter 8. (Manual No.: 5JW1-AE1) Damage/wear → Repair or replace. Improperly connected →...
  • Page 142 – ELEC CHECKING THE SWITCHES 1 Main fuse 2 Main switch 3 Clutch switch 4 Pass switch 5 Dimmer switch 6 Horn switch 7 Windshield position switch 8 Turn signal switch 9 Front brake light switch 0 Engine stop switch A Start switch B Rear brake light switch C Neutral switch...

  • Page 143: Immobilizer System

    – ELEC IMMOBILIZER SYSTEM EB805000 IMMOBILIZER SYSTEM CIRCUIT DIAGRAM 1 Immobilizer unit 2 Main switch 6 Backup fuse 7 Main fuse 9 Battery T ECU (engine) h Immobilizer system indicator light æ Ignition fuse – 135 –...
  • Page 144 – ELEC IMMOBILIZER SYSTEM GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following. • a code re-registering key (with a red bow) •...

  • Page 145: Key Codes Registration Method

    – ELEC IMMOBILIZER SYSTEM KEY CODES REGISTRATION METHOD In the course of use, you may encounter the following case where replace these parts and registra- tion of code re-registering/standard key is required. NOTE: Each standard key is registered during production, therefore re-registering at purchase is not neces- sary.
  • Page 146 – ELEC IMMOBILIZER SYSTEM Standard key registration: When you lose a standard key and need a new one. Or when the code re-registering key is re-reg- istered after the immobilizer unit or ECU, are replaced. NOTE: It is prohibited to start the engine with the standard key that is not registered. If the main switch is turned “ON”...
  • Page 147 – ELEC IMMOBILIZER SYSTEM 6. Check that the engine can be started with the two registered standard keys. NOTE: The flashing stops when 5 seconds elapse and the registration mode is finished. In this case, the second standard key cannot be registered and only the first standard key is registered. Registration of the second unregis- less than 5.0 s...

  • Page 148: Self-Diagnosis Error Code Indication

    – ELEC IMMOBILIZER SYSTEM SELF-DIAGNOSIS ERROR CODE INDICATION When the system failure occurred, the error code number is indicated in the immobilizer system indicator light blinks at the same time. The pattern of blinking also shows the error code. Error code Detection Symptoms Trouble...
  • Page 149 – ELEC IMMOBILIZER SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. The immobilizer system fails to operate. Refer to “CHECKING AND CHARGING (The immobilizer system indicator light THE BATTERY” in chapter 3. starts to blink in the self-diagnosis code (Manual No.: 5JW1-AE1) sequence.) Open-circuit voltage...

  • Page 150: Checking The Immobilizer System

    – ELEC IMMOBILIZER SYSTEM CHECKING THE IMMOBILIZER SYSTEM • Set the main switch to “ON”. 1. Immobilizer system indicator light does not • Measure the voltage (12 V) between red/ go on when the main switch is set to “ON”. green and black on the immobilizer unit coupler.
  • Page 151 – ELEC IMMOBILIZER SYSTEM 4. Voltage • Connect the pocket tester (DC 20 V) to the immobilizer unit coupler as shown. Tester positive probe → green/blue 1 Tester negative probe → black 2 B BB R/G B2 Y/L G/L R/W R/W Lg Y/L •...
  • Page 152 – ELEC IMMOBILIZER SYSTEM 2. When the main switch is set to “ON”, the immobilizer system indicator light flashes after 1 sec- ond. • Check if metal or other immobilizer system keys exists near the immobilizer unit. If found, remove the metal or keys, and then check the condition again.

  • Page 153: Accessory Box System

    – ELEC ACCESSORY BOX SYSTEM ACCESSORY BOX SYSTEM CIRCUIT DIAGRAM 2 Main switch 7 Main fuse 9 Battery F Neutral switch H Accessory box solenoid I Accessory box relay ¡ Signaling system fuse – 145 –...
  • Page 154 – ELEC ACCESSORY BOX SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. The accessory box system fails to oper- Refer to “CHECKING AND CHARGING ate. THE BATTERY” in chapter 3. (Manual No.: 5JW1-AE1) CAUTION: Before troubleshooting, make sure that the Minimum open-circuit voltage 12.8 V or more at 20 °C transmission is in neutral.
  • Page 155 – ELEC ACCESSORY BOX SYSTEM EAS00759 5. Accessory box relay 6. Accessory box solenoid • Disconnect the accessory box relay from • Remove the accessory box solenoid cou- the wire harness. pler from the wire harness. • Connect the pocket tester (Ω × 1) and bat- •...
  • Page 156 TRBL TROUBLESHOOTING WITH THE ABS WARNING LIGHT SHTG TROUBLESHOOTING TROUBLESHOOTING WITH THE ABS WARNING LIGHT When the main switch is set to “ON”. (Engine does not start.) ONLY THE ABS WARNING LIGHT DOES NOT COME ON • Blown, damaged, or incorrect fuse (ABS fuse) •...
  • Page 157 FJR1300A WIRING DIAGRAM 1 Immobilizer unit § Tail/brake light 2 Main switch • Rear turn signal light (left) ¶ Rear turn signal light (right) 3 Rectifier/regulator 4 Generator ß Rear brake light switch 5 ABS fuse ® Turn signal relay 6 Backup fuse (odometer, clock and windshield) ©...
  • Page 158 FJR1300 WIRING DIAGRAM 1 Immobilizer unit § Ignition fuse 2 Main switch • Headlight fuse ¶ Signaling system fuse 3 Rectifier/regulator 4 Generator ß Radiator fan motor fuse 5 Backup fuse (odometer, clock and windshield) ® Windshield motor fuse 6 Main fuse ©...
  • Page 160 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
  • Page 161 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)
  • Page 162 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)

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