Yamaha FJR1300A(D) Manuals

Yamaha FJR1300A(D) Manuals

Manuals and User Guides for Yamaha FJR1300A(D). We have 1 Yamaha FJR1300A(D) manual available for free PDF download: Service Manual

Yamaha FJR1300A(D) Service Manual

Yamaha FJR1300A(D) Service Manual (662 pages)

Brand: Yamaha | Category: Motorcycle | Size: 20.86 MB

Table of Contents

Table of Contents

7
- How to Use this Manual
  4
- Symbols
  5
- General Information
  9
  - Identification
    10
    
    Model Label
    10
    
    Vehicle Identification Number
    10
    
    Outline of the Fi System
    11
    
    Fi System
    12
    
    YCC-T (Yamaha Chip Controlled Throttle)
    13
    
    Outline of the Cruise Control System
    15
    
    Outline of the Unified Brake System
    22
    
    Outline of the Abs
    24
    
    Abs Component Functions
    28
    
    Abs Operation
    34
    
    Abs Self-Diagnosis Function
    37
    
    Abs Warning Light and Operation
    40
    
    OUTLINE of the TCS (Traction Control System)
    41
    
    Multi-Function Meter Unit
    44
  - Important Information
    55
    
    Gaskets, Oil Seals and O-Rings
    55
    
    Lock Washers/Plates and Cotter Pins
    55
    
    Preparation for Removal and Disassembly
    55
    
    Replacement Parts
    55
    
    Bearings and Oil Seals
    56
    
    Circlips
    56
    
    Rubber Parts
    56
  - Basic Service Information
    57
    
    Quick Fasteners
    57
    
    Electrical System
    58
  - Special Tools
    62
Specifications

71
- General Specifications
  72
- Engine Specifications
  73
- Chassis Specifications
  81
- Electrical Specifications
  84
- Tightening Torques
  87
- Lubrication Points and Lubricant Types
  98
  - Engine
    98
  - Chassis
    100
- Lubrication System Chart and Diagrams
  102
  - Engine Oil Lubrication Chart
    102
  - Lubrication Diagrams
    104
- Cooling System Diagrams
  114
- Cable Routing
  118
Periodic Checks and Adjustments

139
- General Maintenance and Lubrication Chart
  142
- Introduction
  142
- Periodic Maintenance
  142
- Periodic Maintenance Chart for the Emission Control System
  142
- Checking the Fuel Line
  145
- Checking the Spark Plugs
  145
- Adjusting the Valve Clearance
  146
- Checking the Engine Idling Speed
  148
- Synchronizing the Throttle Bodies
  149
- Checking the Exhaust System
  150
- Adjusting the Exhaust Gas Volume
  151
- Checking the Air Induction System
  152
- Checking the Crankcase Breather Hose
  152
- Cleaning the Air Filter Element
  152
- Adjusting the Clutch Lever
  153
- Bleeding the Hydraulic Clutch System
  153
- Checking the Clutch Fluid Level
  153
- Adjusting the Front Disc Brake
  154
- Bleeding the Hydraulic Brake System (Abs)
  155
- Checking the Brake Fluid Level
  155
- Adjusting the Rear Disc Brake
  157
- Checking the Front Brake Pads
  157
- Checking the Brake Hoses
  158
- Checking the Rear Brake Pads
  158
- Checking the Tires
  158
- Checking the Wheels
  158
- Checking and Adjusting the Steering Head
  160
- Checking the Swingarm Pivot
  160
- Checking the Wheel Bearings
  160
- Lubricating the Swingarm Pivot
  160
- Checking the Chassis Fasteners
  161
- Checking the Sidestand
  161
- Lubricating the Levers
  161
- Lubricating the Pedals
  161
- Lubricating the Sidestand
  161
- Lubricating the Steering Head
  161
- Adjusting the Front Fork Legs
  162
- Checking the Centerstand
  162
- Checking the Front Fork
  162
- Checking the Sidestand Switch
  162
- Lubricating the Centerstand
  162
- Adjusting the Rear Shock Absorber Assembly
  164
- Checking the Rear Suspension
  164
- Changing the Engine Oil
  165
- Checking the Engine Oil Level
  165
- Lubricating the Rear Suspension
  165
- Checking the Coolant Level
  167
- Measuring the Engine Oil Pressure
  167
- Changing the Coolant
  168
- Checking the Cooling System
  168
- Changing the Final Gear Oil
  170
- Checking the Final Gear Oil Level
  170
- Adjusting the Rear Brake Light Switch
  171
- Checking and Lubricating the Cables
  171
- Checking the Brake Light Switches
  171
- Checking the Throttle Grip Operation
  172
- Adjusting the Headlight Beams
  173
- Checking the Switches, Lights and Signals
  173
- Replacing the Headlight Bulbs
  173
Chassis

175
- General Chassis
  
  178
  - Installing the Center Rear Cowling
    179
  - Installing the Rear Cowlings
    179
  - Removing the Center Rear Cowling
    179
  - Removing the Rear Cowlings
    179
  - Installing the Seats
    180
  - Installing the Side Covers
    180
  - Removing the Side Covers
    180
  - Adjusting the Side Panels
    184
  - Removing the Front Cowling Inner Panel
    184
  - Installing the Front Cowling Inner Panel
    185
  - Installing the Side Cowlings
    186
  - Removing the Side Cowlings
    186
  - Installing the Center Covers
    189
  - Installing the Windshield Bracket Covers
    189
  - Removing the Center Covers
    189
  - Removing the Windshield Bracket Covers
    189
  - Installing the Front Cowling Assembly
    190
  - Installing the Headlight Beam Adjusting Knob Joints
    190
  - Installing the Windshield Drive Unit
    193
- Front Wheel
  
  199
- Rear Wheel
  
  208
- Front Brake
  
  215
- Rear Brake
  
  227
  - Introduction
    233
  - Checking the Rear Brake Disc
    233
  - Replacing the Rear Brake Pads
    233
  - Removing the Rear Brake Caliper
    234
  - Disassembling the Rear Brake Caliper
    235
  - Checking the Rear Brake Caliper
    235
  - Assembling the Rear Brake Caliper
    235
  - Installing the Rear Brake Caliper
    236
  - Removing the Rear Brake Master Cylinder
    237
  - Checking the Rear Brake Master Cylinder
    237
  - Assembling the Rear Brake Master Cylinder
    238
  - Installing the Rear Brake Master Cylinder
    238
- Abs (Anti-Lock Brake System)
  
  240
- Handlebars
  
  253
  - Adjusting the Handlebar Position
    255
  - Removing the Handlebars
    255
  - Checking the Handlebars
    256
  - Installing the Handlebars
    256
- Front Fork
  
  259
  - Removing the Front Fork Legs
    264
  - Disassembling the Front Fork Legs
    264
  - Checking the Front Fork Legs
    265
  - Assembling the Front Fork Legs
    266
  - Installing the Front Fork Legs
    269
- Steering Head
  
  271
  - Removing the Lower Bracket
    273
  - Checking the Steering Head
    273
  - Installing the Steering Head
    273
- Rear Shock Absorber Assembly
  
  275
- Swingarm
  
  279
  - Removing the Swingarm
    281
  - Checking the Swingarm
    281
  - Installing the Swingarm
    281
- Shaft Drive
  
  283
Engine

299
- Engine Inspection
  
  302
  - Measuring the Compression Pressure
    302
- Engine Removal
  
  304
  - Engine
    308
    
    Installing the Engine
    309
    
    Removing the Engine
    309
- Camshafts
  
  312
  - Removing the Camshafts
    314
  - Checking the Camshafts
    315
  - Checking the Camshaft Sprockets
    316
  - Checking the Timing Chain Guides
    316
  - Checking the Timing Chain Tensioner
    316
  - Installing the Camshafts
    317
- Cylinder Head
  
  321
  - Removing the Cylinder Head
    322
  - Checking the Cylinder Head
    322
  - Installing the Cylinder Head
    322
- Valves and Valve Springs
  
  325
  - Removing the Valves
    325
  - Checking the Valves and Valve Guides
    325
  - Checking the Valve Seats
    327
  - Checking the Valve Springs
    329
  - Checking the Valve Lifters
    329
  - Installing the Valves
    329
- Generator and Starter Clutch
  
  332
  - Removing the Generator
    334
  - Removing the Starter Clutch
    334
  - Checking the Starter Clutch
    334
  - Installing the Starter Clutch
    335
  - Installing the Generator
    335
- Pickup Rotor
  
  337
  - Removing the Pickup Rotor
    338
  - Installing the Pickup Rotor
    338
- Electric Starter
  
  340
  - Checking the Starter Motor
    342
  - Assembling the Starter Motor
    343
- Clutch
  
  344
  - Removing the Clutch
    350
  - Checking the Friction Plates
    351
  - Checking the Clutch Plates
    351
  - Checking the Clutch Spring Plate
    351
  - Checking the Clutch Housing
    352
  - Checking the Clutch Boss
    352
  - Checking the Pressure Plate
    352
  - Checking the Clutch Push Rods
    352
  - Checking the Primary Driven Gear
    352
  - Installing the Clutch
    353
  - Disassembling the Clutch Master Cylinder
    354
  - Checking the Clutch Master Cylinder
    355
  - Assembling the Clutch Master Cylinder
    355
  - Installing the Clutch Master Cylinder
    355
  - Removing the Clutch Release Cylinder
    356
  - Checking the Clutch Release Cylinder
    356
  - Assembling the Clutch Release Cylinder
    356
  - Installing the Clutch Release Cylinder
    357
- Shift Shaft
  
  358
  - Checking the Shift Shaft
    359
  - Checking the Stopper Lever
    359
  - Installing the Shift Shaft
    359
  - Adjusting the Shift Pedal
    359
- Oil Pump
  
  361
  - Checking the Oil Pump
    364
  - Checking the Relief Valve
    364
  - Checking the Oil Delivery Pipes
    364
  - Checking the Oil Strainer
    365
  - Assembling the Oil Pump
    365
  - Installing the Oil Pan
    365
- Middle Gear
  
  366
- Crankcase
  
  378
  - Disassembling the Crankcase
    382
  - Checking the Crankcase
    382
  - Checking the Oil Delivery Pipes
    382
  - Checking the Bearings and Oil Seal
    382
  - Checking the Timing Chain and Oil Pump Drive Chain
    382
  - Assembling the Crankcase
    383
- Connecting Rods and Pistons
  
  387
  - Removing the Connecting Rods and Pistons
    387
  - Checking the Cylinders and Pistons
    387
  - Checking the Piston Rings
    388
  - Checking the Piston Pin
    389
  - Checking the Connecting Rods
    390
  - Installing the Connecting Rods and Pistons
    391
- Crankshaft
  
  394
  - Removing the Crankshaft Journal Bearings
    395
  - Checking the Oil Nozzles
    395
  - Checking the Crankshaft
    395
  - Installing the Crankshaft
    396
- Transmission
  
  398
  - Removing the Transmission
    403
  - Checking the Shift Forks
    403
  - Checking the Shift Drum Assembly
    403
  - Checking the Transmission
    403
  - Assembling the Main Axle and Drive Axle
    404
  - Installing the Transmission
    405
- Balancers
  
  409
  - Checking the Balancers
    409
  - Installing the Front Balancer
    409
  - Installing the Rear Balancer
    410
Cooling System

413
- Radiator
  
  414
  - Checking the Radiator
    416
  - Installing the Radiator
    416
  - Removing the Radiator
    416
- Oil Cooler
  
  417
  - Checking the Oil Cooler
    418
  - Installing the Oil Cooler
    418
- Thermostat
  
  419
  - Checking the Thermostat
    421
  - Installing the Thermostat Assembly
    421
- Water Pump
  
  423
  - Disassembling the Water Pump
    425
  - Checking the Water Pump
    425
  - Assembling the Water Pump
    425
  - Installing the Water Pump
    426
Fuel System

429
- Fuel Tank
  
  430
  - Removing the Fuel Tank
    431
  - Removing the Fuel Pump
    431
  - Checking the Fuel Pump Body
    431
  - Installing the Fuel Pump
    431
  - Installing the Fuel Tank
    431
- Throttle Bodies
  
  433
  - Checking the Injectors (before Removing)
    436
  - Removing the Injectors
    436
  - Checking the Injectors
    436
  - Checking and Cleaning the Throttle Bodies
    436
  - Checking the Throttle Body Joints
    438
  - Replacing the Throttle Bodies
    438
  - Installing the Injectors
    438
  - Checking the Injector Pressure
    438
  - Checking the Fuel Pressure
    439
  - Adjusting the Throttle Position Sensor
    440
  - Adjusting the Accelerator Position Sensor
    440
- Air Induction System
  
  442
  - Checking the Air Induction System
    446
  - Installing the Air Induction System
    446
  - Electrical System
    447
  - General Information
    448
    
    Electric Starting System
    456
    
    Checking the Switches
    618
  - Troubleshooting
    643
    
    Wiring Diagram
    656

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