Page 1 FJR13AV(C) FJR13AEV(C) SERVICE MANUAL LIT-11616-19-83 3P6-28197-10...
Page 2 EAS20050 FJR13AV(C)/FJR13AEV(C) SERVICE MANUAL ©2006 by Yamaha Motor Corporation, U.S.A. First edition, April 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-19-83...
Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
Page 4 EAS20090 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. •...
Page 5 EAS20100 1. Serviceable with engine mounted SYMBOLS 2. Filling fluid The following symbols are used in this manual 3. Lubricant for easier understanding. 4. Special tool NOTE: 5. Tightening torque The following symbols are not relevant to every 6. Wear limit, clearance vehicle.
Page 7: Table Of Contents
EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
Page 9: General Information
ABS COMPONENT FUNCTIONS............1-10 ABS OPERATION ................... 1-16 ABS SELF-DIAGNOSIS FUNCTION ............1-20 ABS WARNING LIGHT AND OPERATION ..........1-22 OUTLINE OF THE YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE)....................1-23 INSTRUMENT FUNCTIONS..............1-26 IMPORTANT INFORMATION ............... 1-30 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-30 REPLACEMENT PARTS ................
Page 10: Identification
IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.
Page 11: Features
FEATURES EAS20170 FEATURES ET2C01025 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.
Page 12: Fi System
FEATURES ET3P61042 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm², 46.1 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
Page 13: Outline Of The Unified Brake System
OUTLINE OF THE UNIFIED BRAKE SYSTEM The Yamaha unified brake system is a system that operates one set of pistons in the front brakes to- gether with the rear brake when the brake pedal is depressed. Compared to conventional brake sys- tems, the ability to slow the vehicle using the simple operation of the brake pedal is improved.
Page 14: Outline Of The Abs
ET3P61019 OUTLINE OF THE ABS 1. The Yamaha ABS (anti-lock brake system) features an electronic control system, which acts on the front and rear brakes independently. However, one set of pistons in the right front brake caliper is operated together with the rear brake and this set of pistons is operated only if the force used to de- press the brake pedal exceeds a preset level.
Page 15 9. Rear wheel sensor rotor The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles, with a brake lever for operating the front brake and a brake pedal for operating the rear brake. However, part of the front brake is operated together with rear brake.
Page 16 FEATURES • Slip ratio: When the brakes are applied, slipping occurs between the tires and the road surface. 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 following formula. Chassis speed –...
Page 17 FEATURES The difference between the chassis speed and the wheel speed calculated in the slip ratio formula is equal to the wheel slip. When the wheel speed is suddenly reduced, the wheel has a tendency to lock. When the wheel slip and the wheel speed reduction rate exceed the preset values, the ABS ECU de- termines that the wheel has a tendency to lock.
Page 18 Slip ratio (%) b. Brake force 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 under various vehicle travel conditions. The ABS also includes a highly developed self-diagnosis function. The ABS detects any problem con- dition and allows normal braking even if the ABS is not operating properly.
Page 19: Abs Component Functions
FEATURES ABS block diagram 1. Rear brake master cylinder 10. Rear wheel sensor 2. Hydraulic unit 11. Metering valve 3. Front brake master cylinder 12. ABS ECU 4. ABS motor 13. Left front brake caliper 5. Hydraulic pump 14. Front wheel sensor 6.
Page 20 FEATURES 3. At high speed 6. Wheel sensor 4. At low speed 5. Wheel sensor rotor ABS warning light The ABS warning light “1” comes on to warn the rider if a malfunction in the ABS occurs. When the main switch is turned to “ON”, the ABS warning light comes on for 2 seconds, then goes off, so that the rider can check if the ABS warning light is disconnected and check if the ABS is operating properly.
Page 21 FEATURES When the ABS is activated, the flow control valve regulates the flow of brake fluid to the brake and the solenoid valve decreases and increases the brake fluid pressure. 1. When the brakes are operated normally, the solenoid valve “2” is closed, the spool “3” of the flow control valve does not move, and the hydraulic line between the brake master cylinder and brake caliper is open.
Page 22 FEATURES 1. Buffer chamber (pressurized) 3. Raised piston 2. Buffer chamber (depressurized) ABS ECU (electronic control unit) The ABS ECU “1” controls the ABS and is installed under the storage compartment. To protect the ABS ECU from water damage, it is protected by a cover “2”. As shown in the block following diagram, the ABS ECU receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits.
Page 23 FEATURES 1. Battery 16. Unified brake system solenoid 2. AC magneto 17. Rear brake solenoid 3. Rectifier/regulator 18. Front brake solenoid 4. Main fuse 19. Meter assembly 5. Main switch 20. ABS warning light 6. ABS fuse 21. Speedometer 7. ABS motor fuse 22.
Page 24 FEATURES 1. Software operation flow 2. Main switch “ON” 3. Initialize 4. Self-diagnosis (when static) 5. Self-diagnosis (when riding) 6. Receive signals 7. Control operation 8. Depressurize/pressurize A. 8/1000th of a second ABS motor relay The ABS motor relay “1” controls the power supply of the hydraulic unit and is located beside the hy- draulic unit.
Page 25: Abs Operation
FEATURES 1. ABS ECU 9. ABS warning light 2. Pump motor monitor 10. Battery 3. Power supply 11. ABS motor relay 4. Pump motor relay coil 12. Hydraulic unit 5. Power supply 13. ABS motor 6. Front brake solenoid 14. Solenoid valves 7.
Page 26 FEATURES Normal braking (ABS not activated) When the ABS is not activated, port D “11” of the solenoid valve is closed because a control signal has not been transmitted from the ABS ECU and port A “7” and port B “9” of the flow control valve are open. Therefore, when the brake lever is squeezed, the hydraulic pressure in the brake master cylinder in- creases and the brake fluid is sent to the brake caliper via port A and port B.
Page 27 FEATURES Emergency braking (ABS activated) 1. Depressurized state When the front wheel is about to lock, port D “11” of the solenoid valve is opened by the “depressur- ization” signal transmitted from the ABS ECU. When this occurs, the spool of the flow control valve compresses the return spring and closes port B “9”.
Page 28 FEATURES 2. Pressurized state Port D “11” is closed by the “pressurization” signal transmitted from the ABS ECU. Before this oc- curs, the spool of the flow control valve has compressed the return spring and closed port B “9”. Brake fluid that has entered through port A “7” is further restricted by the orifice “10” and the brake fluid is sent to the brake caliper via port A “7”...
Page 29: Abs Self-Diagnosis Function
FEATURES ET3P61053 ABS SELF-DIAGNOSIS FUNCTION ABS warning light The ABS warning light “1” comes on when a malfunction is detected by the ABS self-diagnosis. 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 is turned to “ON”. The ABS warning light comes on for 2 seconds while the ABS is performing a self-diagnosis, then goes off if there are no problems.
Page 30 FEATURES 3. The ABS warning light comes on while riding. If the ABS warning light comes on while riding, a malfunction has been detected in the ABS. The ABS hydraulic control will not be performed. The ABS will have recourse to manual braking if this occurs.
Page 31: Abs Warning Light And Operation
FEATURES ET3P61054 ABS WARNING LIGHT AND OPERATION ABS warning light • When the main switch is turned to “ON”, the ABS warning light comes on for 2 seconds, then goes off. • The ABS warning light comes on while the start switch is being pushed. •...
Page 32: Outline Of The Ycc-S (Yamaha Chip Controlled-Shift) System (Fjr13Ae)
* Wheel lock: A condition that occurs when the rotation of one or both of the wheels has stopped, but the vehicle continues to travel. ET3P66049 OUTLINE OF THE YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE) Concept YCC-S offers more enjoyable and easy riding by eliminating the need for the user to operate the clutch, which also reduces fatigue during long touring.
Page 33 FEATURES 1. YCC-S test coupler 8. MCU (motor control unit) 2. YCC-S control relay 9. Shift actuator 3. YCC-S indicator and warning light 10. Clutch actuator 4. YCC-S motor control fuse 11. Foot shift switch 5. Hand shift switch 12. YCC-S speed sensor 6.
Page 34 • If the YCC-S indicator and warning light come on while riding, stop the vehicle, park it in a safe place, and then contact a Yamaha dealer. Because the YCC-S system stops automatically when the YCC-S indicator and warning light come on, it is impossible to shift since clutch operation is stopped.
Page 35: Instrument Functions
FEATURES ET3P61043 Multi-function display INSTRUMENT FUNCTIONS Speedometer 1. Multi-function display 2. “SELECT” button 3. “RESET” button 1. Tachometer 2. Speedometer EW3P61020 WARNING 3. Multi-function display Be sure to stop the vehicle before making The speedometer shows the riding speed. any setting changes to the multi-function When the key is turned to “ON”, the speedome- display.
Page 36 FEATURES Odometer and tripmeter modes Clock 1. Odometer/tripmeter/fuel reserve tripmeter 1. Clock 2. “SELECT” button 2. “SELECT” button 3. “RESET” button 3. “RESET” button Pushing the “SELECT” button switches the dis- To set the clock: play between the odometer mode “ODO” and 1.
Page 37 FEATURES Coolant temperature meter Ambient temperature, instantaneous fuel consumption and average fuel consumption modes 1. Coolant temperature meter With the key in the “ON” position, the coolant 1. Ambient temperature/instantaneous fuel temperature meter indicates the temperature of consumption/average fuel consumption the coolant.
Page 38 FEATURES Instantaneous fuel consumption mode Self-diagnosis device 1. Instantaneous fuel consumption 1. Fault code display The display shows the distance that can be trav- This model is equipped with a self-diagnosis de- eled on 1.0 US.gal of fuel under the current vice for various electrical circuits.
Page 39: Important Information
5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
Page 40: Bearings And Oil Seals
IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.
Page 41: Checking The Connections
CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: • Lead NOTE: • Coupler • If there is no continuity, clean the terminals. •...
Page 42: Special Tools
SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
Page 43 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Compression gauge 3-13 90890-03081 Engine compression tester YU-33223 Oil filter wrench 3-15 90890-01426 YU-38411 Oil pressure gauge set 3-16 90890-03120 Oil pressure adapter B 3-16 90890-03124 Vacuum/pressure pump gauge set 3-19 90890-06756 Mityvac brake bleeding tool YS-42423 Magnet base B...
Page 44 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Slide metal installer 4-79 90890-01508 YM-01508 Fork seal driver 4-79, 4-80 90890-01502 YM-A0948 Final gear backlash band 4-101 90890-01511 YM-01230 Coupling gear/middle shaft tool 4-103, 4-106 90890-01229 Gear holder YM-01229 Bearing retainer wrench 4-103, 4-106 90890-04050 Pinion bearing retainer &...
Page 45 5-11, 5-70, 7-9 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Rotor holding tool 5-14, 5-17 90890-01235 Universal magneto & rotor holder YU-01235 Yamaha bond No. 1215 5-19, 5-35, 90890-85505 5-38, 5-101, ® 6-13 (Three Bond No.1215 Valve spring compressor 5-25, 5-30...
Page 46 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide reamer (ø5) 5-26 90890-04099 Valve guide reamer (5.0 mm) YM-04099 Sheave holder 5-34, 5-35, 90890-01701 5-38 Primary clutch holder YS-01880-A Flywheel puller 5-34 90890-01362 Heavy duty puller YU-33270-B Universal clutch holder 5-56, 5-59 90890-04086 YM-91042...
Page 47 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Gear lash measurement tool 5-91 90890-01467 YM-01467 Piston pin puller set 5-105 90890-01304 Piston pin puller YU-01304 YU-01304 Piston ring compressor 5-110 90890-05158 YM-08037 Slide hammer bolt 5-123 90890-01083 Slide hammer bolt 6 mm YU-01083-1 Weight 5-123...
Page 48 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984 YU-33984 Mechanical seal installer 6-13 90890-04078 Water pump seal installer YM-33221-A Middle driven shaft bearing driver 6-13 90890-04058 Bearing driver 40 mm YM-04058 Pressure gauge 90890-03153...
Page 49: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................ 2-10 ELECTRICAL SPECIFICATIONS..............2-13 TIGHTENING TORQUES................2-16 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-16 ENGINE TIGHTENING TORQUES............2-17 CHASSIS TIGHTENING TORQUES............2-22 LUBRICATION POINTS AND LUBRICANT TYPES ........2-27 ENGINE ....................2-27 CHASSIS ....................
Page 50: General Specifications
GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model FJR13A 3P64 (USA) FJR13A 3P65 (California) FJR13AE 2D24 (USA) FJR13AE 2D25 (California) Dimensions Overall length 2230 mm (87.8 in) Overall width 750 mm (29.5 in) Overall height 1450 mm (57.1 in) Seat height 800 mm (31.5 in) Wheelbase 1545 mm (60.8 in)
Page 51: Engine Specifications
ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 1298.0 cm³ (79.20 cu.in) Cylinder arrangement Forward-inclined parallel 4-cylinder Bore × stroke 79.0 × 66.2 mm (3.11 × 2.61 in) Compression ratio 10.80 :1 Standard compression pressure (at sea level) 1600 kPa/400 r/min (228 psi/400 r/min) (16.0 kgf/cm²/400 r/min) Minimum–maximum...
Page 52 ENGINE SPECIFICATIONS Coolant reservoir capacity (up to the maximum level mark) 0.25 L (0.26 US qt) (0.22 Imp.qt) Radiator cap opening pressure 93.3–122.7 kPa (13.5–17.8 psi) (0.93–1.23 kgf/cm²) Valve relief pressure 4.9 kPa (0.7 psi) (0.05 kgf/cm²) Thermostat Model/manufacturer 4FM/NIPPON THERMOSTAT Valve opening temperature 69.0–73.0 °C (156.20–163.40 °F) Valve full open temperature...
Page 53 ENGINE SPECIFICATIONS Limit 24.897 mm (0.9802 in) Camshaft runout limit 0.030 mm (0.0012 in) Timing chain Model/number of links 92RH2015/136 Tensioning system Automatic Valve, valve seat, valve guide Valve clearance (cold) Intake 0.15–0.22 mm (0.0059–0.0087 in) Exhaust 0.18–0.25 mm (0.0071–0.0098 in) Valve dimensions Valve head diameter A (intake) 29.90–30.10 mm (1.1772–1.1850 in)
Page 54 ENGINE SPECIFICATIONS Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clearance (exhaust) 0.020–0.047 mm (0.0008–0.0019 in) Limit 0.105 mm (0.0041 in) Valve stem runout 0.010 mm (0.0004 in) Cylinder head valve seat width (intake) 0.90–1.10 mm (0.0354–0.0433 in) Cylinder head valve seat width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Valve spring...
Page 55 ENGINE SPECIFICATIONS Height H 5.0 mm (0.20 in) Offset 0.50 mm (0.0197 in) Offset direction Intake side Piston pin bore inside diameter 19.004–19.015 mm (0.7482–0.7486 in) Limit 19.045 mm (0.7498 in) Piston pin outside diameter 18.991–19.000 mm (0.7477–0.7480 in) Limit 18.971 mm (0.7469 in) Piston-pin-to-piston-pin-bore clearance 0.004–0.024 mm (0.00016–0.00094 in)
Page 56 ENGINE SPECIFICATIONS Connecting rod ® Oil clearance (using plastigauge 0.031–0.048 mm (0.0012–0.0019 in) Bearing color code 1.Blue 2.Black 3.Brown 4.Green 5.Yellow 6.Pink Small end inside diameter 19.005–19.018 mm (0.7482–0.7487 in) Crankshaft Width A 61.60–63.20 mm (2.425–2.488 in) Width B 325.10–326.30 mm (12.80–12.85 in) Runout limit C 0.030 mm (0.0012 in) Big end side clearance D...
Page 57 ENGINE SPECIFICATIONS 39/22 (1.773) 31/23 (1.348) 28/26 (1.077) 26/28 (0.929) Main axle runout limit 0.08 mm (0.0032 in) Drive axle runout limit 0.08 mm (0.0032 in) Shifting mechanism Shift mechanism type Shift drum and guide bar Shift fork guide bar bending limit 0.100 mm (0.0039 in) Air filter Air filter element...
Page 58 ENGINE SPECIFICATIONS Ring-gear-to-stopper-bolt clearance 0.30–0.60 mm (0.0118–0.0236 in) Ring-gear-to-thrust-washer clearance 0.10–0.20 mm (0.0039–0.0079 in) Final gear backlash 0.22–0.45 mm (0.0087–0.0177 in)
Page 59: Chassis Specifications
CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 26.00° Trail 109.0 mm (4.29 in) Front wheel Wheel type Cast wheel 17M/C × MT3.50 Rim size Rim material Aluminum Wheel travel 135.0 mm (5.31 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
Page 60 CHASSIS SPECIFICATIONS Front brake Type Dual disc brake Operation Right hand operation Front disc brake Disc outside diameter × thickness 320.0 × 4.5 mm (12.60 × 0.18 in) Brake disc thickness limit 4.0 mm (0.16 in) Brake disc deflection limit 0.10 mm (0.0039 in) Brake pad lining thickness (inner) 5.5 mm (0.22 in)
Page 61 CHASSIS SPECIFICATIONS Spring rate K1 8.30 N/mm (47.39 lb/in) (0.85 kgf/mm) Spring stroke K1 0.0–135.0 mm (0.00–5.31 in) Inner tube outer diameter 48.0 mm (1.89 in) Inner tube bending limit 0.2 mm (0.01 in) Optional spring available Recommended oil Ohlins R & T43 (ACC-RT43F-00-00) Quantity 696.0 cm³...
Page 62: Electrical Specifications
ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Transistorized coil ignition (digital) Ignition timing (B.T.D.C.) 5.0°/1050 r/min Engine control unit Model/manufacturer FUA0010/MITSUBISHI Ignition coil Model/manufacturer JO383/DENSO Minimum ignition spark gap 6.0 mm (0.24 in) 1.53–2.07 Ω...
Page 63 Engine trouble warning light ABS warning light Electric starting system System type Constant mesh Starter motor Model/manufacturer 3P6/YAMAHA Power output 0.80 kW 0.024–0.030 Ω at 20 °C (68 °F) Armature coil resistance Brush overall length 10.8 mm (0.43 in) Limit 3.65 mm (0.14 in)
Page 64 ELECTRICAL SPECIFICATIONS Headlight relay Model/manufacturer ACM33211 M05/MATSUSHITA 96.0 Ω Coil resistance Radiator fan Model/manufacturer 3P6/DENSO Running rpm 4250 r/min Fan motor relay Model/manufacturer ACM33211 M05/MATSUSHITA 96.0 Ω Coil resistance Thermo unit Model/manufacturer 25978/MITSUBISHI 290.0–390.0 Ω Resistance at 80°C Gear position sensor Output voltage (at neutral position) FJR13AE 0.71–0.91 V Resistance...
Page 65: Tightening Torques
TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.
Page 66: Engine Tightening Torques
TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Spark plug 13 Nm (1.3 m·kg, 9.4 ft·lb) Cylinder head bolt See NOTE. Cylinder head bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Camshaft cap bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Cylinder head cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Engine oil check bolt...
Page 67 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Oil pump housing cover bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Oil level switch bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Throttle body joint clamp screw 3 Nm (0.3 m·kg, 2.2 ft·lb) Air filter case joint clamp screw 4 Nm (0.4 m·kg, 2.9 ft·lb) Air filter case and rear lower fuel...
Page 68 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Starter clutch bolt 32 Nm (3.2 m·kg, 23 ft·lb) Use a Clutch boss nut 90 Nm (9.0 m·kg, 65 ft·lb) lock washer. Clutch spring bolt 8 Nm (0.8 m·kg, 5.8 ft·lb) Clutch release cylinder bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Clutch hose union bolt...
Page 69 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Coolant reservoir bracket bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Clutch fluid reservoir bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) (FJR13AE) Clutch actuator bracket bolt 19 Nm (1.9 m·kg, 13 ft·lb) (FJR13AE) Clutch actuator bracket bolt 10 Nm (1.0 m·kg, 7.2 ft·lb)
Page 70 TIGHTENING TORQUES Cylinder head tightening sequence: Crankcase tightening sequence: 19 22 2-21...
Page 71: Chassis Tightening Torques
TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolts (right front 49 Nm (4.9 m·kg, 35 ft·lb) lower side) Engine mounting bolts (right front 49 Nm (4.9 m·kg, 35 ft·lb) upper side) Engine mounting bolts (left front 49 Nm (4.9 m·kg, 35 ft·lb) lower side) Engine mounting bolts (left front...
Page 72 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Lower ring nut (initial tightening 52 Nm (5.2 m·kg, 37 ft·lb) torque) NOTE. Lower ring nut (final tightening 18 Nm (1.8 m·kg, 13 ft·lb) torque) NOTE. Handlebar bolt 23 Nm (2.3 m·kg, 17 ft·lb) Handlebar nut 65 Nm (6.5 m·kg, 47 ft·lb) Clutch master cylinder holder bolt...
Page 73 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear lower fuel tank bracket and 8 Nm (0.8 m·kg, 5.8 ft·lb) frame bolt Fuel tank cap bolt 6 Nm (0.6 m·kg, 4.3 ft·lb) Canister bolt (for California only) 7 Nm (0.7 m·kg, 5.1 ft·lb) Canister bracket bolt (for Califor- 10 Nm (1.0 m·kg, 7.2 ft·lb) nia only)
Page 74 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear brake master cylinder bolt 18 Nm (1.8 m·kg, 13 ft·lb) Rear brake master cylinder lock- 16 Nm (1.6 m·kg, 11 ft·lb) Left footrest assembly bolt 28 Nm (2.8 m·kg, 20 ft·lb) Left footrest assembly bolt 49 Nm (4.9 m·kg, 35 ft·lb) Left footrest assembly/sidestand...
Page 75 TIGHTENING TORQUES 3. Check that the right end of the front axle is flush with the front fork. If necessary, manually push the front axle or lightly tap it with a soft hammer until its end is flush with the front fork. However, if the surface of the front axle end is not parallel to the surface of the front fork, align a point on the outer edge of the axle with the fork, making sure that the axle does not protrude past the fork.
Page 76: Lubrication Points And Lubricant Types
LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Crankshaft pins Piston surfaces Piston pins Connecting rod bolts and nuts Crankshaft journals Camshaft lobes Camshaft journals Balancer absorbers, weights, gears and shafts Valve stems (intake and exhaust) Valve stem ends (intake and exhaust) Water pump impeller shaft...
Page 77 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant ® Cylinder head cover mating surface Three Bond 1541 Yamaha bond No.1215 Cylinder head cover gasket (Three Bond ® No.1215 Yamaha bond No.1215 Crankcase mating surface (Three Bond ® No.1215 Yamaha bond No.1215...
Page 78: Chassis
LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and upper bearing cover lip Lower bearing dust seal lip Front wheel oil seal lips (right and left) Rear wheel oil seal lips Rear wheel drive hub oil seal Rear wheel drive hub mating surface Rear brake pedal pivoting point Footrest assembly pivoting point...
Page 79 LUBRICATION POINTS AND LUBRICANT TYPES 2-30...
Page 80: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-31...
Page 81 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve assembly 4. Oil filter 5. Oil cooler 6. Main gallery 7. Front balancer shaft 8. Rear balancer shaft 9. Oil nozzle 10. Intake camshaft 11. Exhaust camshaft 12.
Page 82: Lubrication Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-33...
Page 83 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Cylinder head 3. Exhaust camshaft 4. Oil check bolt 5. Main gallery bolt 6. Crankshaft 7. Oil nozzle 2-34...
Page 84 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
Page 85 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Drive axle 3. Oil delivery pipe 1 2-36...
Page 86 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-37...
Page 87 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil check bolt 2. Crankshaft 3. Oil cooler 4. Oil strainer 5. Oil delivery pipe 3 6. Oil pump 2-38...
Page 88 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-39...
Page 89 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Rear balancer 2. Oil delivery pipe 2 3. Engine oil drain bolt 4. Oil level switch 5. Crankshaft 6. Front balancer 7. Crank pin 8. Oil delivery pipe 3 9. Relief valve assembly 2-40...
Page 90 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-41...
Page 91 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil delivery pipe 2 3. Oil cooler 4. Engine oil drain bolt 5. Oil level switch 6. Oil filter cartridge 7. Oil delivery pipe 3 8. Oil pan 9. Oil pump 2-42...
Page 92: Cooling System Diagrams
COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-43...
Page 93 COOLING SYSTEM DIAGRAMS 1. Thermostat inlet pipe 1 2. Thermostat inlet hose 1 3. Plunger control unit hose 1 4. Plunger control unit hose 2 5. Oil cooler outlet hose 6. Radiator 7. Coolant reservoir breather hose 8. Thermostat inlet pipe 2 9.
Page 94 COOLING SYSTEM DIAGRAMS 2-45...
Page 95 COOLING SYSTEM DIAGRAMS 1. Thermostat inlet pipe 1 2. Thermostat inlet hose 2 3. Radiator inlet hose 4. Radiator 5. Radiator outlet hose 6. Oil cooler outlet hose 7. Water jacket joint inlet hose 8. Water pump outlet pipe 9. Water pump outlet hose 10.
Page 96: Cable Routing (Fjr13A)
CABLE ROUTING (FJR13A) EAS20430 CABLE ROUTING (FJR13A) 2-47...
Page 97 CABLE ROUTING (FJR13A) 1. Brake hose (front brake master cylinder to hydraulic unit) 2. Right handlebar switch lead 3. Clutch hose 4. Left handlebar switch lead 5. Main switch lead 6. Left horn (low) 7. Brake hose (hydraulic unit to left front brake caliper) 8.
Page 98 CABLE ROUTING (FJR13A) 14 15 2-49...
Page 99 CABLE ROUTING (FJR13A) 1. O sensor lead F. Route the positive battery lead between the battery stay and the battery box. 2. Engine idling speed adjusting cable G. To front cowling wire harness 3. Starter motor lead H. Align the rear end of the right radiator fan motor 4.
Page 100 CABLE ROUTING (FJR13A) 2-51...
Page 101 CABLE ROUTING (FJR13A) 1. Rear wheel sensor lead 2. Rear brake fluid reservoir 3. Rear brake light switch lead 4. Hydraulic unit 5. Brake hose (front brake master cylinder to hydraulic unit) 6. Brake hose (hydraulic unit to proportioning valve) 7.
Page 102 CABLE ROUTING (FJR13A) 2-53...
Page 103 CABLE ROUTING (FJR13A) 1. Auxiliary DC jack 2. Left radiator fan motor lead 3. Accessory box solenoid 4. Wire harness 5. Front cowling wire harness 6. Radiator inlet hose 7. Left radiator fan 8. Coolant reservoir breather hose 9. Left horn (low) 10.
Page 104 CABLE ROUTING (FJR13A) 34 30 2-55...
Page 105 CABLE ROUTING (FJR13A) 1. Grip warmer couplers (for optional grip warmers) F. Fasten the leads (to oil level switch and crankshaft position sensor) that branch off from the wire 2. Handlebar switch couplers harness to the guide on the holder with a plastic 3.
Page 106 CABLE ROUTING (FJR13A) 2-57...
Page 107 CABLE ROUTING (FJR13A) 1. Wire harness 2. ECU (engine control unit) 3. ABS ECU (electronic control unit) 4. Tail/brake light 5. Rear turn signal light 6. Tail/brake light assembly lead 7. License plate light lead 8. Seat lock cable 9. Hydraulic unit breather hose 10.
Page 108 CABLE ROUTING (FJR13A) 5 6 7 8 9 2-59...
Page 109 CABLE ROUTING (FJR13A) 1. Spark plug lead #1 L. Route the fuel tank breather hose (joint to rollover valve) next to the wire harness and pass it through 2. Spark plug lead #2 the guide. (for California only) 3. Clutch hose M.
Page 110 CABLE ROUTING (FJR13A) 2-61...
Page 111 CABLE ROUTING (FJR13A) 1. License plate light lead 2. Tail/brake light assembly lead 3. Seat lock cable 4. Intake air temperature sensor A. Route the tail/brake light assembly lead and license plate light lead between the rib and the U- lock holder on the rear fender, making sure that the leads are not routed on top of the holder.
Page 112 CABLE ROUTING (FJR13A) 2-63...
Page 113 CABLE ROUTING (FJR13A) 1. Windshield drive unit O. Route the right headlight beam adjusting cable between the right headlight lead and the thermistor 2. Relay unit lead. 3. Thermistor P. Position the plastic locking tie 25 mm (0.98 in) to 4.
Page 114 CABLE ROUTING (FJR13A) 2-65...
Page 115 CABLE ROUTING (FJR13A) 1. Hydraulic unit 2. Proportioning valve 3. Brake hose (proportioning valve to rear brake caliper) 4. Brake hose (rear brake master cylinder to hydraulic unit) 5. Brake hose (hydraulic unit to metering valve) 6. Brake hose (hydraulic unit to front brake calipers) 7.
Page 116: Cable Routing (Fjr13Ae)
CABLE ROUTING (FJR13AE) ET3P66048 CABLE ROUTING (FJR13AE) 11 10 2-67...
Page 117 CABLE ROUTING (FJR13AE) 1. Brake hose (front brake master cylinder to M. Fasten the right handlebar switch lead, right grip hydraulic unit) warmer lead, and main switch lead with a plastic locking tie at the location shown in the illustration. 2.
Page 118 CABLE ROUTING (FJR13AE) 41 42 14 15 2-69...
Page 119 CABLE ROUTING (FJR13AE) 1. O sensor lead F. Route the positive battery lead between the battery stay and the battery box. 2. Engine idling speed adjusting cable G. To front cowling wire harness 3. Starter motor lead H. Align the rear end of the right radiator fan motor 4.
Page 120 CABLE ROUTING (FJR13AE) 2-71...
Page 121 CABLE ROUTING (FJR13AE) 1. Rear wheel sensor lead 2. Rear brake fluid reservoir 3. Rear brake light switch lead 4. Clutch actuator motor lead 5. Clutch actuator sensor lead 6. Hydraulic unit 7. Brake hose (front brake master cylinder to hydraulic unit) 8.
Page 122 CABLE ROUTING (FJR13AE) 2-73...
Page 123 CABLE ROUTING (FJR13AE) 1. Auxiliary DC jack 2. Left radiator fan motor lead 3. Accessory box solenoid 4. Wire harness 5. Front cowling wire harness 6. Radiator inlet hose 7. Grip warmer control unit leads 8. Left radiator fan 9. Coolant reservoir breather hose 10.
Page 124 CABLE ROUTING (FJR13AE) 37 38 2-75...
Page 125 CABLE ROUTING (FJR13AE) 1. Grip warmer couplers C. To oil level switch 2. Hand shift switch coupler D. Fasten the leads (to oil level switch and crankshaft position sensor) that branch off from the wire 3. Handlebar switch couplers harness to the guide on the holder with a plastic 4.
Page 126 CABLE ROUTING (FJR13AE) 2-77...
Page 127 CABLE ROUTING (FJR13AE) 1. Wire harness L. Route the leads between the left tail/brake light bulb socket and the rear left turn signal light bulb 2. ECU (engine control unit) socket. 3. ABS ECU (electronic control unit) M. Route the tail/brake light assembly lead between 4.
Page 128 CABLE ROUTING (FJR13AE) 5 6 7 8 2-79...
Page 129 CABLE ROUTING (FJR13AE) 1. Spark plug lead #1 L. Route the fuel tank breather hose (joint to rollover valve) next to the wire harness and pass it through 2. Spark plug lead #2 the guide. (for California only) 3. Front wheel sensor lead M.
Page 130 CABLE ROUTING (FJR13AE) 2-81...
Page 131 CABLE ROUTING (FJR13AE) 1. Clutch actuator motor lead 2. Clutch actuator sensor lead 3. License plate light lead 4. Tail/brake light assembly lead 5. Seat lock cable 6. Intake air temperature sensor A. Connect the clutch actuator motor lead and clutch actuator sensor lead, install the rubber cover around the leads, and then place the cover between the hydraulic unit and the frame.
Page 132 CABLE ROUTING (FJR13AE) 2-83...
Page 133 CABLE ROUTING (FJR13AE) 1. Windshield drive unit O. Route the right headlight beam adjusting cable between the right headlight lead and the thermistor 2. Relay unit lead. 3. Thermistor P. Position the plastic locking tie 25 mm (0.98 in) to 4.
Page 134 CABLE ROUTING (FJR13AE) 2-85...
Page 135 CABLE ROUTING (FJR13AE) 1. Hydraulic unit 2. Proportioning valve 3. Brake hose (proportioning valve to rear brake caliper) 4. Brake hose (rear brake master cylinder to hydraulic unit) 5. Brake hose (hydraulic unit to metering valve) 6. Brake hose (hydraulic unit to front brake calipers) 7.
Page 136 CABLE ROUTING (FJR13AE) 2-87...
Page 137: Periodic Checks And Adjustments
PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE................3-1 INTRODUCTION..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM (FJR13A) .................. 3-1 GENERAL MAINTENANCE AND LUBRICATION CHART (FJR13A) ..3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM (FJR13AE)................3-3 GENERAL MAINTENANCE AND LUBRICATION CHART (FJR13AE) ..3-4 ENGINE ......................
Page 138 CHASSIS....................... 3-28 ADJUSTING THE FRONT DISC BRAKE..........3-28 ADJUSTING THE REAR DISC BRAKE ..........3-28 CHECKING THE BRAKE FLUID LEVEL ..........3-29 CHECKING THE FRONT BRAKE PADS..........3-29 CHECKING THE REAR BRAKE PADS ..........3-30 CHECKING THE BRAKE HOSES ............3-30 ADJUSTING THE REAR BRAKE LIGHT SWITCH.........
Page 140: Periodic Maintenance
√ √ age. • Replace any damaged parts. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. EAU32183 GENERAL MAINTENANCE AND LUBRICATION CHART (FJR13A) INITIAL...
Page 141 23 * Front and rear √ √ √ √ √ √ • Check operation. brake switches • Apply Yamaha chain and ca- √ √ √ √ √ √ 24 * Control cables ble lube or engine oil SAE 10W-30 thoroughly.
Page 142: Periodic Maintenance Chart For The Emission Control System (Fjr13Ae)
√ and switches • Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.
Page 143: General Maintenance And Lubrication Chart (Fjr13Ae)
√ √ age. • Replace any damaged parts. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. ET3P66052 GENERAL MAINTENANCE AND LUBRICATION CHART (FJR13AE) INITIAL...
Page 144 26 * and switches • Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.
Page 145: Engine
ENGINE EAS20470 ENGINE Valve clearance (cold) Intake 0.15–0.22 mm (0.0059–0.0087 in) EAS20490 ADJUSTING THE VALVE CLEARANCE Exhaust The following procedure applies to all of the 0.18–0.25 mm (0.0071–0.0098 in) valves. M MMM M MMM M MMM M MMM M MMM NOTE: a.
Page 146 ENGINE • Measure the valve clearance in the following M MMM M MMM M MMM M MMM M MMM a. Remove the valve lifter “1” and the valve pad sequence. “2” with a valve lapper “3”. Valve clearance measuring sequence Valve lapper Cylinder #1 →...
Page 147: Synchronizing The Throttle Bodies
ENGINE Example: • Install the valve lifter and the valve pad in the If the valve pad is marked “155”, the pad correct place. thickness is 1.55 mm (0.061 in). g. Install the exhaust and intake camshafts, tim- d. Calculate the sum of the values obtained in ing chain and camshaft caps.
Page 148 ENGINE 2. Remove: M MMM M MMM M MMM M MMM M MMM a. With throttle body #3 as standard, adjust • Rider seat throttle bodies #1, #2, and #4 using the air Refer to “GENERAL CHASSIS” on page 4-1. screw “1”.
Page 149: Adjusting The Engine Idling Speed
ENGINE 9. Measure: 6. Adjust: • Engine idling speed • Engine idling speed Out of specification → Adjust. M MMM M MMM M MMM M MMM M MMM a. Turn the engine idle speed adjustment screw Make sure that the vacuum pressure is within “1”...
Page 150: Checking The Spark Plugs
ENGINE M MMM M MMM M MMM M MMM M MMM Handlebar side a. Slide back the rubber covers “1”. b. Loosen the locknut “2”. c. Turn the adjusting nut “3” in direction “a” or “b” until the specified throttle cable free play is obtained.
Page 151: Checking The Ignition Timing
ENGINE ECA13320 10.Install: CAUTION: • T-bar Before removing the spark plugs, blow away Refer to “GENERAL CHASSIS” on page 4-1. any dirt accumulated in the spark plug wells • Fuel tank with compressed air to prevent it from falling Refer to “FUEL TANK” on page 7-1. into the cylinders.
Page 152: Measuring The Compression Pressure
ENGINE EAS20710 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cyl- inders. NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: • Valve clearance 5. Install: Out of specification → Adjust. • Fuel tank Refer to “ADJUSTING THE VALVE CLEAR- Refer to “FUEL TANK”...
Page 153: Checking The Engine Oil Level
ENGINE • Rider seat Standard compression pressure Refer to “GENERAL CHASSIS” on page 4-1. (at sea level) 1600 kPa/400 r/min (228 psi/400 EAS20750 CHECKING THE ENGINE OIL LEVEL r/min) (16.0 kgf/cm²/400 r/min) Minimum–maximum 1. Stand the vehicle on a level surface. 1390–1790 kPa (197.7–254.6 psi) NOTE: (13.9–17.9 kgf/cm²)
Page 154: Changing The Engine Oil
ENGINE 4. Start the engine, warm it up for several min- ECA13390 CAUTION: utes, and then turn it off. Make sure the O-ring “3” is positioned cor- 5. Check the engine oil level again. rectly in the groove of the oil filter cartridge. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled.
Page 155: Measuring The Engine Oil Pressure
ENGINE 12.Check: EWA12980 WARNING • Engine oil pressure The engine, muffler and engine oil are ex- M MMM M MMM M MMM M MMM M MMM a. Remove the right side cowling. Refer to tremely hot. “GENERAL CHASSIS” on page 4-1. 5.
Page 156: Adjusting The Clutch Lever (Fjr13A Only)
ENGINE EAS20860 ADJUSTING THE CLUTCH LEVER (FJR13A only) 1. Adjust: • Clutch lever position (distance “a” from the handlebar grip to the clutch lever) M MMM M MMM M MMM M MMM M MMM a. While pushing the clutch lever forward, turn the adjusting dial “1”...
Page 157: Bleeding The Hydraulic Clutch System (Fjr13A)
ENGINE • When bleeding the hydraulic clutch system, make sure there is always enough clutch fluid before applying the clutch lever. Ignoring this precaution could allow air to enter the hydraulic clutch system, considerably lengthening the bleeding procedure. • If bleeding is difficult, it may be necessary to let the clutch fluid settle for a few hours.
Page 158: Bleeding The Hydraulic Clutch System (Fjr13Ae)
ENGINE EWA13010 WARNING After bleeding the hydraulic clutch system, check the clutch operation. L LLL L LLL L LLL L LLL L LLL ET3P66027 BLEEDING THE HYDRAULIC CLUTCH SYSTEM (FJR13AE) EWA13000 WARNING b. Turn the main switch to “ON” and check that Bleed the hydraulic clutch system whenever: the transmission is in neutral.
Page 159 ENGINE l. Repeat steps (i) to (k) until all of the air bub- d. Install a suitable bracket “4”, the magnet base bles have disappeared from the clutch fluid in B “5” and the dial gauge & stand set “6”. the plastic hose of the vacuum/pressure Magnet base B pump gauge set.
Page 160: Checking The Vehicle After Bleeding The Hydraulic Clutch System (Fjr13Ae Only)
ENGINE g. If the pressure plate stroke is out of specifica- b. Start the engine. tion, repeat steps (j) to (l) in the procedure for c. Shift the transmission from neutral to 1st gear step “2. Bleed” until clutch pressure plate and back to neutral ten times.
Page 161: Cleaning The Air Filter Element (Fjr13A)
ENGINE EAS20920 • Shift actuator CLEANING THE AIR FILTER ELEMENT Refer to “SHIFT ACTUATOR AND SHIFT (FJR13A) ROD (FJR13AE only)” on page 5-67. 1. Remove: • Air filter case cover • Rider seat • Air filter element • Left side cover Refer to “GENERAL CHASSIS”...
Page 162: Checking The Fuel Line
ENGINE 1. Remove: • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. • Fuel tank Refer to “FUEL TANK” on page 7-1. • Air filter case Refer to “GENERAL CHASSIS” on page 4-1. • Throttle body Refer to “THROTTLE BODIES” on page 7-5. 2.
Page 163: Checking The Exhaust System
ENGINE • Rider seat 4. Install: Refer to “GENERAL CHASSIS” on page 4-1. • Side cowlings Refer to “GENERAL CHASSIS” on page 4-1. EAS21080 CHECKING THE EXHAUST SYSTEM EAS21090 The following procedure applies to all of the ex- CHECKING THE CANISTER (for California haust pipes and gaskets.
Page 164: Checking The Cooling System
ENGINE • Use only distilled water. However, if dis- tilled water is not available, soft water may be used. 4. Start the engine, warm it up for several min- utes, and then turn it off. 5. Check: • Coolant level NOTE: Before checking the coolant level, wait a few minutes until it settles.
Page 165 ENGINE 7. Drain: EWA13030 WARNING • Coolant A hot radiator is under pressure. Therefore, (from the coolant reservoir) do not remove the radiator cap when the en- 8. Install: gine is hot. Scalding hot fluid and steam may • Coolant reservoir be blown out, which could cause serious in- 9.
Page 166 ENGINE • If coolant is swallowed, induce vomiting and get immediate medical attention. ECA13480 CAUTION: • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if nec- essary, correct the antifreeze concentra- tion of the coolant.
Page 167: Chassis
CHASSIS EAS21140 CHASSIS Brake pedal position 42.0 mm (1.65 in) (below the top of the rider footrest) EAS21160 ADJUSTING THE FRONT DISC BRAKE 1. Adjust: • Brake lever position (distance “a” from the throttle grip to the brake lever) M MMM M MMM M MMM M MMM...
Page 168: Checking The Brake Fluid Level
CHASSIS air must be removed by bleeding the brake system. Air in the brake system will consid- erably reduce braking performance. ECA13510 CAUTION: After adjusting the brake pedal position, make sure there is no brake drag. L LLL L LLL L LLL L LLL L LLL...
Page 169: Checking The Rear Brake Pads
CHASSIS EC3P61037 2. Check: CAUTION: • Brake hose holders Loose → Tighten the holder bolts. The amount of wear may differ for the brake pads of the right front brake caliper between 3. Hold the vehicle upright and apply the brake the brake pads operated by the brake lever several times.
Page 170: Bleeding The Hydraulic Brake System (Abs)
CHASSIS EAS22780 BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS) EWA14000 WARNING Always bleed the brake system when the brake related parts are removed. EC3P61012 CAUTION: • Bleed the brake system in the following or- der. • 1st step: Front brake calipers •...
Page 171: Adjusting The Shift Pedal (Fjr13A)
CHASSIS EC3P61029 CAUTION: Direction “a” Shift pedal is raised. Make sure that the main switch is turned to Direction “b” “OFF” before checking the operation of the Shift pedal is lowered. hydraulic unit. k. After operating the ABS, repeat steps (e) to NOTE: (i), and then fill the brake master cylinder res- Check that the groove “c”...
Page 172: Checking The Final Gear Oil Level
CHASSIS Final gear oil filler bolt 23 Nm (2.3 m·kg, 17 ft·lb) EAS21470 CHANGING THE FINAL GEAR OIL 1. Place a container under the final gear case. 2. Remove: • Final gear oil filler bolt “1” • Final gear oil drain bolt “2” Completely drain the final gear case of its oil.
Page 173: Adjusting The Handlebar Position
CHASSIS 2. Check: EWA13140 WARNING • Steering head Do not overtighten the lower ring nut. Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness → Adjust the steering Lower ring nut (final tightening torque) head.
Page 174: Checking The Front Fork
CHASSIS e. Install the handlebar bolts “3” and nuts “2” temporarily. 2. Adjust: • Handlebar position M MMM M MMM M MMM M MMM M MMM f. Tighten the handlebar bolts and nuts. a. Remove the plates “1”. Handlebar bolt 23 Nm (2.3 m·kg, 17 ft·lb) Handlebar nut 65 Nm (6.5 m·kg, 47 ft·lb)
Page 175: Adjusting The Front Fork Legs
CHASSIS EAS21580 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. EWA13150 WARNING • Always adjust both front fork legs evenly. Uneven adjustment can result in poor han- dling and loss of stability. •...
Page 176: Adjusting The Rear Shock Absorber Assembly
CHASSIS Compression damping 1. Adjust: ECA13590 • Spring preload CAUTION: M MMM M MMM M MMM M MMM M MMM a. Move the adjusting lever “1” in direction “a” or Never go beyond the maximum or minimum “b”. adjustment positions. b.
Page 177: Adjusting The Side Panels
CHASSIS L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL ET3P61035 M MMM M MMM M MMM M MMM M MMM ADJUSTING THE SIDE PANELS To close a side panel 1.
Page 178 CHASSIS c. Insert the projection “c” on the front of the rid- a. Low position er seat into seat holder (for high position) “3” b. High position as shown. 2. Remove: • Passenger seat • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. 3.
Page 179: Checking The Tires
CHASSIS b. Install the rider seat height position adjuster “2” so that the “L” mark “a” is aligned with the match mark “b”. EWA13180 WARNING • The tire pressure should only be checked and regulated when the tire temperature c. Insert the projection “c” on the front of the rid- equals the ambient air temperature.
Page 180 No guarantee con- cerning handling characteristics can be giv- en if a tire combination other than one approved by Yamaha is used on this vehicle. 1. Tire tread depth 3-41...
Page 181: Checking The Wheels
CHASSIS EAS21690 CHECKING AND LUBRICATING THE Front tire CABLES Size The following procedure applies to all of the in- 120/70 ZR17M/C (58W) Manufacturer/model ner and outer cables. METZELER/Roadtec Z6G EWA13270 WARNING Manufacturer/model BRIDGESTONE/BT020F Damaged outer cable may cause the cable to corrode and interfere with its movement.
Page 182: Lubricating The Rear Suspension
CHASSIS Recommended lubricant Lithium-soap-based grease EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension. Recommended lubricant Lithium-soap-based grease 3-43...
Page 183: Electrical System
ELECTRICAL SYSTEM EAS21750 EWA13320 ELECTRICAL SYSTEM WARNING Since the headlight bulb gets extremely hot, EAS21760 keep flammable products and your hands CHECKING AND CHARGING THE BATTERY away from the bulb until it has cooled down. Refer to “ELECTRICAL COMPONENTS” on 6.
Page 184 ELECTRICAL SYSTEM L LLL L LLL L LLL L LLL L LLL 2. Adjust: • Headlight beam (horizontally) M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting screws “1” in direction “a” or “b”. Left headlight Direction “a”...
Page 185 CHASSIS GENERAL CHASSIS ..................4-1 REMOVING THE SIDE PANELS .............. 4-9 INSTALLING THE FRONT COWLING LEFT INNER PANEL 2....4-9 INSTALLING THE FRONT COWLING RIGHT INNER PANEL 2 ... 4-10 INSTALLING THE SIDE PANELS ............4-10 FRONT WHEEL .................... 4-17 REMOVING THE FRONT WHEEL ............
Page 186 REAR BRAKE....................4-41 INTRODUCTION..................4-47 CHECKING THE REAR BRAKE DISC ........... 4-47 REPLACING THE REAR BRAKE PADS ..........4-47 REMOVING THE REAR BRAKE CALIPER ..........4-48 DISASSEMBLING THE REAR BRAKE CALIPER ........4-49 CHECKING THE REAR BRAKE CALIPER..........4-49 ASSEMBLING THE REAR BRAKE CALIPER ........4-49 INSTALLING THE REAR BRAKE CALIPER...........
Page 187 SWINGARM ....................4-91 REMOVING THE SWINGARM ............... 4-93 CHECKING THE SWINGARM ..............4-93 INSTALLING THE SWINGARM .............. 4-93 SHAFT DRIVE....................4-95 TROUBLESHOOTING ................4-99 CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND CHECKING THE SHAFT DRIVE FOR LEAKS ........4-100 MEASURING THE FINAL GEAR BACKLASH........
Page 188 GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seats and covers 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 21 Nm (2.1 m kg, 15 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 189 GENERAL CHASSIS Removing the front cowling assembly (FJR13A) 10 Nm (1.0 m kg, 7.2 ft • • 32 Nm (3.2 m kg, 23 ft • • 17 19 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft •...
Page 190 GENERAL CHASSIS Removing the front cowling assembly (FJR13A) 10 Nm (1.0 m kg, 7.2 ft • • 32 Nm (3.2 m kg, 23 ft • • 17 19 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft •...
Page 191 GENERAL CHASSIS Removing the front cowling assembly (FJR13AE) 10 Nm (1.0 m kg, 7.2 ft • • 32 Nm (3.2 m kg, 23 ft • • 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft •...
Page 192 GENERAL CHASSIS Removing the front cowling assembly (FJR13AE) 10 Nm (1.0 m kg, 7.2 ft • • 32 Nm (3.2 m kg, 23 ft • • 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft •...
Page 193 GENERAL CHASSIS Disassembling the front cowling assembly 10 Nm (1.0 m kg, 7.2 ft 7 Nm (0.7 m kg, 5.1 ft • • • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 194 GENERAL CHASSIS Removing the headlight assembly Order Job/Parts to remove Q’ty Remarks Refer to “Disassembling the front cowling Front cowling assembly”. Headlight assembly For installation, reverse the removal proce- dure.
Page 195 GENERAL CHASSIS Removing the windshield drive unit, meter assembly, and relays 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 196: General Chassis
GENERAL CHASSIS ET3P61037 REMOVING THE SIDE PANELS 1. Remove: • Side panel “1” NOTE: To release a pin on the side panel “1” from its corresponding hinge on the side cowling “2”, push the end “a” of the hinge with a flathead screwdriver.
Page 197: Installing The Front Cowling Right Inner Panel 2
GENERAL CHASSIS e. Fit the lower right corner of inner panel 2 into the front cowling assembly, making sure to align the bolt hole in the panel with the bolt hole in the cowling. i. Insert the adjusting knob shaft into the hole in inner panel 2, making sure to align the projec- tion “a”...
Page 198 GENERAL CHASSIS 4-11...
Page 199 GENERAL CHASSIS Removing the T-bar 37 Nm (3.7 m kg, 27 ft • • 37 Nm (3.7 m kg, 27 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rider seat 4-1. Fuel tank Refer to “FUEL TANK”...
Page 200 GENERAL CHASSIS Removing the air filter case (FJR13A) 18 Nm (1.8 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft • • (11) 8 Nm (0.8 m kg, 5.8 ft • • 4 Nm (0.4 m kg, 2.9 ft •...
Page 201 GENERAL CHASSIS Removing the air filter case (FJR13A) 18 Nm (1.8 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft • • (11) 8 Nm (0.8 m kg, 5.8 ft • • 4 Nm (0.4 m kg, 2.9 ft •...
Page 202 GENERAL CHASSIS Removing the air filter case (FJR13AE) 18 Nm (1.8 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft • • (11) 8 Nm (0.8 m kg, 5.8 ft • • 4 Nm (0.4 m kg, 2.9 ft •...
Page 203 GENERAL CHASSIS Removing the air filter case (FJR13AE) 18 Nm (1.8 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft • • (11) 8 Nm (0.8 m kg, 5.8 ft • • 4 Nm (0.4 m kg, 2.9 ft •...
Page 204: Front Wheel
FRONT WHEEL EAS21880 FRONT WHEEL Removing the front wheel, brake discs, wheel sensor, and sensor housing 7 Nm (0.7 m kg, 5.1 ft 7 Nm (0.7 m kg, 5.1 ft • • • • 6 Nm (0.6 m kg, 4.3 ft •...
Page 205 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-18...
Page 206: Removing The Front Wheel
FRONT WHEEL EAS21900 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Front wheel sensor • Front brake calipers L LLL L LLL L LLL...
Page 207: Maintenance Of The Front Wheel Sensor And Sensor Rotor
FRONT WHEEL 2. Measure: • Front wheel sensor resistance Out of specification → Replace. Regulated resistance 1.2–1.6 kΩ at 20 °C (68 °F) M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (Ω × 1k) to the front wheel sensor coupler terminals as shown.
Page 208: Assembling The Front Wheel
FRONT WHEEL EAS21960 ASSEMBLING THE FRONT WHEEL 1. Install: • Wheel bearings • Oil seals M MMM M MMM M MMM M MMM M MMM a. Install the new wheel bearings and oil seals in the reverse order of disassembly. EC3P61021 CAUTION: c.
Page 209: Installing The Front Wheel (Front Brake Discs)
FRONT WHEEL c. If the heavy spot does not stay in that posi- 2. Check: tion, install a heavier weight. • Front brake discs d. Repeat steps (b) and (c) until the front wheel Refer to “CHECKING THE FRONT BRAKE is balanced.
Page 210 FRONT WHEEL M MMM M MMM M MMM M MMM M MMM • To route the front wheel sensor lead, refer a. Insert the front wheel axle from the right side to “CABLE ROUTING (FJR13A)” on page and tighten it with the front wheel axle bolt 2-47 and “CABLE ROUTING (FJR13AE)”...
Page 211: Rear Wheel
REAR WHEEL EAS22030 REAR WHEEL Removing the rear wheel, brake disc, wheel sensor, and sensor housing 7 Nm (0.7 m kg, 5.1 ft • • 125 Nm (12.5 m kg, 90 ft • • 30 Nm (3.0 m kg, 22 ft •...
Page 212 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Dust cover Rear wheel drive hub Dust seal Wheel bearing Rear wheel drive hub damper Oil seal Circlip Wheel bearing Spacer Spacer Oil seal Bearing For assembly, reverse the disassembly pro- cedure.
Page 213: Removing The Rear Wheel
REAR WHEEL EAS22050 Refer to “CHECKING THE TIRES” on page REMOVING THE REAR WHEEL 3-40 and “CHECKING THE WHEELS” on 1. Stand the vehicle on a level surface. page 3-42. EWA13120 3. Measure: WARNING • Radial wheel runout Securely support the vehicle so that there is •...
Page 214: Adjusting The Rear Wheel Static Balance
REAR WHEEL 2. Check: 2. Rear wheel • Rear brake disc 2. Install: Refer to “CHECKING THE REAR BRAKE • Wheel bearings DISC” on page 4-47. 3. Lubricate: • Oil seals • Oil seal lips Refer to “ASSEMBLING THE FRONT WHEEL”...
Page 215 REAR WHEEL 5. Tighten: • Brake torque rod nuts • Rear wheel axle nut • Rear wheel axle pinch bolt Brake torque rod nut 30 Nm (3.0 m·kg, 22 ft·lb) Rear wheel axle nut 125 Nm (12.5 m·kg, 90 ft·lb) Rear wheel axle pinch bolt 23 Nm (2.3 m·kg, 17 ft·lb) 6.
Page 216: Front Brake
FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 6 Nm (0.6 m kg, 4.3 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 40 Nm (4.0 m kg, 29 ft •...
Page 217 FRONT BRAKE Removing the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-31. Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm hold- Brake master cylinder reservoir diaphragm Brake lever Front brake light switch connector Disconnect.
Page 218 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder push rod Dust boot Circlip Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. * Apply silicon grease 4-31...
Page 219 FRONT BRAKE Removing the front brake calipers 7 Nm (0.7 m kg, 5.1 ft • • 40 Nm (4.0 m kg, 29 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
Page 220 FRONT BRAKE Disassembling the front brake calipers 6 Nm (0.6 m kg, 4.3 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 17 Nm (1.7 m kg, 12 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
Page 221: Introduction
FRONT BRAKE EAS22220 e. Measure the deflection 1.5 mm (0.06 in) be- INTRODUCTION low the edge of the brake disc. EWA14100 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary.
Page 222: Replacing The Front Brake Pads
FRONT BRAKE d. Measure the brake disc deflection. 2. Install: e. If out of specification, repeat the adjustment • Brake pads steps until the brake disc deflection is within • Brake pad spring specification. NOTE: f. If the brake disc deflection cannot be brought Always install new brake pads and a new brake within specification, replace the brake disc.
Page 223: Removing The Front Brake Calipers
FRONT BRAKE 3. Lubricate: EAS22300 REMOVING THE FRONT BRAKE CALIPERS • Brake pad bolts The following procedure applies to both of the brake calipers. Recommended lubricant Lithium-soap-based grease NOTE: Before removing the brake caliper, drain the ECA14150 brake fluid from the entire brake system. CAUTION: 1.
Page 224: Checking The Front Brake Calipers
FRONT BRAKE EWA13560 WARNING EAS22410 ASSEMBLING THE FRONT BRAKE • Cover the brake caliper pistons with a rag. CALIPERS Be careful not to get injured when the pis- EWA13620 tons are expelled from the brake caliper. WARNING • Never try to pry out the brake caliper pis- •...
Page 225 FRONT BRAKE ECA14170 • When refilling, be careful that water does CAUTION: not enter the brake master cylinder reser- When installing the brake hose onto the voir and brake fluid reservoir. Water will brake caliper “1”, make sure the brake pipe significantly lower the boiling point of the “a”...
Page 226: Removing The Front Brake Master Cylinder
FRONT BRAKE EAS22490 EAS22520 REMOVING THE FRONT BRAKE MASTER ASSEMBLING THE FRONT BRAKE MASTER CYLINDER CYLINDER EWA13520 NOTE: WARNING Before removing the front brake master cylinder, • Before installation, all internal brake com- drain the brake fluid from the entire brake sys- ponents should be cleaned and lubricated tem.
Page 227 FRONT BRAKE EW3P66002 ECA13540 CAUTION: WARNING Proper brake hose routing is essential to in- Brake fluid may damage painted surfaces sure safe vehicle operation. Refer to “CABLE and plastic parts. Therefore, always clean up ROUTING (FJR13A)” on page 2-47 and “CA- any spilt brake fluid immediately.
Page 228 REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Rear brake caliper bolt Rear brake caliper Brake pad shim Rear brake pad Brake pad spring For installation, reverse the removal proce- dure. 4-41...
Page 229 REAR BRAKE Removing the rear brake master cylinder 30 Nm (3.0 m kg, 22 ft • • 28 Nm (2.8 m kg, 20 ft • • 28 Nm (2.8 m kg, 20 ft • • 18 Nm (1.8 m kg, 13 ft •...
Page 230 REAR BRAKE Removing the rear brake master cylinder 30 Nm (3.0 m kg, 22 ft • • 28 Nm (2.8 m kg, 20 ft • • 28 Nm (2.8 m kg, 20 ft • • 18 Nm (1.8 m kg, 13 ft •...
Page 231 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Brake master cylinder push rod Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. * Apply silicon grease 4-44...
Page 232 REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-31. Brake hose union bolt Copper washer Brake hose (proportioning valve to rear brake caliper) Rear brake caliper bolt Loosen.
Page 233 REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Rear brake caliper bolt Brake pad shim Rear brake pad Brake pad spring Rear brake caliper bracket Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.
Page 234: Rear Brake
REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA14100 4.5 mm (0.18 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc deflection ventive measures: Refer to “CHECKING THE FRONT BRAKE •...
Page 235: Removing The Rear Brake Caliper
REAR BRAKE NOTE: Rear brake caliper bolt Always install new brake pads, brake pad shims, 27 Nm (2.7 m·kg, 19 ft·lb) and brake pad springs as a set. 4. Check: M MMM M MMM M MMM M MMM M MMM •...
Page 236: Disassembling The Rear Brake Caliper
REAR BRAKE EAS22600 1. Check: DISASSEMBLING THE REAR BRAKE • Brake caliper piston “1” CALIPER Rust/scratches/wear → Replace the brake 1. Remove: caliper pistons. • Brake caliper piston “1” • Brake caliper cylinder “2” • Brake caliper piston seals “2” Scratches/wear →...
Page 237 REAR BRAKE • Rear wheel axle nut 3. Install: NOTE: • Copper washers • Do not install the brake pads, brake pad shims, • Brake hose (proportioning valve to rear brake and brake pad springs. caliper) “1” • Align the slot “a” of the rear wheel sensor hous- •...
Page 238: Removing The Rear Brake Master Cylinder
REAR BRAKE EWA13090 1. Remove: WARNING • Brake hose union bolt “1” • Use only the designated brake fluid. Other • Copper washers “2” brake fluids may cause the rubber seals to • Brake hose (rear brake master cylinder to hy- deteriorate, causing leakage and poor draulic unit) “3”...
Page 239: Installing The Rear Brake Master Cylinder
REAR BRAKE 3. Fill: Recommended fluid • Brake fluid reservoir DOT 4 (with the specified amount of the recom- mended brake fluid) EAS22740 INSTALLING THE REAR BRAKE MASTER Recommended fluid CYLINDER DOT 4 1. Install: EWA13090 • Copper washers WARNING •...
Page 240 REAR BRAKE 7. Adjust: • Brake pedal position Refer to “ADJUSTING THE REAR DISC BRAKE” on page 3-28. 8. Adjust: • Rear brake light operation timing Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH” on page 3-30. 4-53...
Page 241: Abs (Anti-Lock Brake System)
ABS (ANTI-LOCK BRAKE SYSTEM) EAS22760 ABS (ANTI-LOCK BRAKE SYSTEM) ET3P61060 ABS COMPONENTS CHART 15 2 9,10 1. Brake hose (metering valve to right front brake caliper) 2. Brake hose (hydraulic unit to front brake calipers) 3. Brake hose (front brake master cylinder to hydraulic unit) 4.
Page 242 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the rear fender assembly 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
Page 243 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit 7 Nm (0.7 m kg, 5.1 ft • • 16 Nm (1.6 m kg, 11 ft • • 30 Nm (3.0 m kg, 22 ft • • 30 Nm (3.0 m kg, 22 ft •...
Page 244 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit 7 Nm (0.7 m kg, 5.1 ft • • 16 Nm (1.6 m kg, 11 ft • • 30 Nm (3.0 m kg, 22 ft • • 30 Nm (3.0 m kg, 22 ft •...
Page 245: Removing The Hydraulic Unit
ABS (ANTI-LOCK BRAKE SYSTEM) ET3P61055 • Brake hose “3” (hydraulic unit to front brake REMOVING THE HYDRAULIC UNIT calipers) ECA14510 • Brake hose “4” (hydraulic unit to proportion- CAUTION: ing valve) Do not remove the hydraulic unit to check • Brake hose “5” (hydraulic unit to metering the resistance of the solenoid valves and the valve) ABS motor for continuity.
Page 246: Checking The Proportioning Valve And Metering Valve
ABS (ANTI-LOCK BRAKE SYSTEM) 4. Install: ET3P61057 • Copper washers CHECKING THE PROPORTIONING VALVE • Brake hose “1” (hydraulic unit to metering AND METERING VALVE valve) 1. Check: • Brake hose “2” (hydraulic unit to proportion- • Proportioning valve Cracks/damage → Replace the proportioning ing valve) •...
Page 247: Hydraulic Unit Operation Tests
ABS (ANTI-LOCK BRAKE SYSTEM) 5. Fill: The hydraulic unit operation can be tested using • Brake master cylinder reservoir the following two methods. • Brake fluid reservoir • Hydraulic unit operation test 1: this test checks (with the specified amount of the recom- the function of the ABS after the system was mended brake fluid) disassembled, adjusted, or serviced.
Page 248 ABS (ANTI-LOCK BRAKE SYSTEM) 5. Connect the test coupler adapter “1” to the force is released during the second pulse in the ABS test coupler “2”. brake pedal, the second person will be able to rotate the rear wheel for 0.1 second. Test coupler adapter 90890-03149 a.
Page 249 ABS (ANTI-LOCK BRAKE SYSTEM) the first pulse in the brake pedal, check that the brake hoses are connected correctly to the hydraulic unit. • If the pulse is hardly felt in either the brake lever or brake pedal, check that the brake hoses are connected correctly to the hy- draulic unit.
Page 250: Trial Run
ABS (ANTI-LOCK BRAKE SYSTEM) 9. After releasing the start switch, operate the brake lever and the brake pedal simulta- neously. 12.After the pulsating action has stopped in the brake pedal, it is generated in the brake lever 0.5 second later and continues for approxi- 10.A reaction-force pulsating action is generated mately 2 seconds.
Page 251: Handlebars
HANDLEBARS EAS22850 HANDLEBARS Removing the left handlebar (FJR13A) Order Job/Parts to remove Q’ty Remarks Clutch switch coupler Disconnect. Clutch master cylinder holder Clutch master cylinder assembly Left handlebar Left handlebar switch lead Lead holder Left handlebar switch Grip end Handlebar grip For installation, reverse the removal proce- dure.
Page 252 HANDLEBARS Removing the left handlebar (FJR13AE) Order Job/Parts to remove Q’ty Remarks Left handlebar Left grip warmer lead Hand shift switch lead Left handlebar switch lead Lead holder 1 Hand shift switch Lead holder 2 Left handlebar switch Grip end Handlebar grip For installation, reverse the removal proce- dure.
Page 253 HANDLEBARS Removing the right handlebar (FJR13A) Order Job/Parts to remove Q’ty Remarks Front brake light switch connector Disconnect. Front brake master cylinder holder Front brake master cylinder assembly Grip end Throttle cable housing Throttle cable Disconnect. Throttle grip Right handlebar Right handlebar switch lead Lead holder Right handlebar switch...
Page 254 HANDLEBARS Removing the right handlebar (FJR13AE) Order Job/Parts to remove Q’ty Remarks Front brake light switch connector Disconnect. Front brake master cylinder holder Front brake master cylinder assembly Grip end Throttle cable housing Throttle cable Disconnect. Throttle grip Right handlebar Right grip warmer lead Right handlebar switch lead Lead holder...
Page 255: Removing The Handlebars
HANDLEBARS EAS22870 EWA13700 REMOVING THE HANDLEBARS WARNING 1. Stand the vehicle on a level surface. Do not touch the handlebar grip until the rub- EWA13120 ber adhesive has fully dried. WARNING Securely support the vehicle so that there is NOTE: no danger of it falling over.
Page 256 HANDLEBARS • Left handlebar • There should be 1–3 mm (0.04–0.12 in) of clearance “c” between the throttle grip and the NOTE: grip end. Fit the projections on each handlebar into the holes in the upper bracket, making sure that the handlebars are installed in the same position.
Page 257: Installing The Handlebars (Fjr13Ae)
HANDLEBARS EWA13700 Clutch master cylinder holder WARNING bolt Do not touch the handlebar grip until the rub- 10 Nm (1.0 m·kg, 7.2 ft·lb) ber adhesive has fully dried. NOTE: NOTE: There should be 1–3 mm (0.04–0.12 in) of clear- • Install the clutch master cylinder holder with ance “a”...
Page 258 HANDLEBARS • Lead holder 2 “2” NOTE: • Align the projection “a” on the hand shift switch with hole “b” on the left handlebar. • When installing the hand shift switch, route the left grip warmer lead “3” and left handlebar switch lead “4”...
Page 259 HANDLEBARS 10.Install: • Front brake master cylinder assembly • Front brake master cylinder holder “1” Front brake master cylinder hold- er bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) NOTE: • Install the brake master cylinder holder with the “UP” mark facing up. •...
Page 260: Front Fork
FRONT FORK EAS22950 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Refer to “GENERAL CHASSIS” on page Front cowling assembly 4-1. Front wheel Refer to “FRONT WHEEL” on page 4-17. Battery holder Negative battery lead Disconnect.
Page 261 FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Cap bolt O-ring Damper adjusting rod Spacer Washer Fork spring Dust seal Oil seal clip Oil seal Washer Damper rod assembly bolt Copper washer...
Page 262 FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks Inner tube Outer tube bushing 1 D = 52 mm (2.05 in), l = 12 mm (0.47 in) Outer tube bushing 2 D = 51 mm (2.01 in), l = 15 mm (0.59 in) Inner tube bushing Outer tube For assembly, reverse the disassembly pro-...
Page 263: Removing The Front Fork Legs
FRONT FORK EAS22960 1. Hold the nut “1” and loosen the cap bolt “2”. REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over.
Page 264: Checking The Front Fork Legs
FRONT FORK M MMM M MMM M MMM M MMM M MMM a. Pull up the inner tube completely, fill it with oil up to the top, and then install the cap bolt. NOTE: Do not install the fork spring. b.
Page 265: Assembling The Front Fork Legs
FRONT FORK • Before assembling the front fork leg, make Fork spring free length sure all of the components are clean. 262.0 mm (10.31 in) 1. Install: Limit 257.0 mm (10.12 in) • Inner tube bushing “1” • Oil flow stopper “2” •...
Page 266 FRONT FORK 6. Install: • Oil seal “1” (with the fork seal driver “2”) Fork seal driver 90890-01502 YM-A0948 ECA14220 CAUTION: 4. Install: Make sure the numbered side of the oil seal • Outer tube bushing 2 (D = 51 mm (2.01 in), l faces up.
Page 267 FRONT FORK 8. Install: 11.Slowly stroke the inner tube “1” up and down. • Dust seal “1” (with the fork seal driver “2”) Fork seal driver 90890-01502 YM-A0948 12.Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed.
Page 268: Installing The Front Fork Legs
FRONT FORK 16.Install: NOTE: • Cap bolt Install the fork spring so that the end “A” shown (to the outer tube) in the illustration is facing up. NOTE: Temporarily tighten the cap bolt. EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.
Page 269 FRONT FORK 3. Adjust: • Spring preload • Rebound damping • Compression damping Refer to “ADJUSTING THE FRONT FORK LEGS” on page 3-36. 4-82...
Page 270: Steering Head
STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 115 Nm (11.5 m kg, 85 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • 2nd 18 Nm (1.8 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 271 STEERING HEAD Removing the lower bracket 115 Nm (11.5 m kg, 85 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • 2nd 18 Nm (1.8 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 272: Removing The Lower Bracket
STEERING HEAD EAS23110 b. Remove the bearing race from the lower REMOVING THE LOWER BRACKET bracket “3” with a floor chisel “4” and ham- 1. Stand the vehicle on a level surface. mer. EWA13120 c. Install new bearing races. WARNING ECA14270 Securely support the vehicle so that there is CAUTION:...
Page 273 STEERING HEAD • Lock washer “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 3-33. 3. Install: • Upper bracket • Steering stem nut NOTE: Temporarily tighten the steering stem nut. 4. Install: • Front fork legs Refer to “FRONT FORK” on page 4-73. NOTE: Temporarily tighten the upper and lower bracket pinch bolts.
Page 274: Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 7 Nm (0.7 m kg, 5.1 ft • • 64 Nm (6.4 m kg, 46 ft • • 40 Nm (4.0 m kg, 29 ft •...
Page 275 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 7 Nm (0.7 m kg, 5.1 ft • • 64 Nm (6.4 m kg, 46 ft • • 40 Nm (4.0 m kg, 29 ft • • 15 12 16 16 15 14 40 Nm (4.0 m kg, 29 ft...
Page 276: Handling The Rear Shock Absorber
REAR SHOCK ABSORBER ASSEMBLY EAS23180 NOTE: HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that the EWA13740 WARNING rear wheel is elevated. This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling •...
Page 277: Checking The Connecting Arm And Relay Arm
REAR SHOCK ABSORBER ASSEMBLY • Rear shock absorber Gas leaks/oil leaks → Replace the rear shock absorber assembly. • Spring Damage/wear → Replace the rear shock ab- sorber assembly. • Bushing Damage/wear → Replace the rear shock ab- sorber assembly. •...
Page 278 SWINGARM EAS23330 SWINGARM Removing the swingarm 23 Nm (2.3 m kg, 17 ft • • 125 Nm (12.5 m kg, 90 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 115 Nm (11.5 m kg, 85 ft •...
Page 279 SWINGARM Removing the swingarm 23 Nm (2.3 m kg, 17 ft • • 125 Nm (12.5 m kg, 90 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 115 Nm (11.5 m kg, 85 ft • • 28 Nm (2.8 m kg, 20 ft •...
Page 280: Swingarm
SWINGARM EAS23350 EAS23360 REMOVING THE SWINGARM CHECKING THE SWINGARM 1. Stand the vehicle on a level surface. 1. Check: • Swingarm EWA13120 WARNING Bends/cracks/damage → Replace. Securely support the vehicle so that there is 2. Check: no danger of it falling over. •...
Page 281 SWINGARM 3. Swingarm 4. Connecting arm A. Left side B. Right side 3. Tighten: • Pivot shaft Pivot shaft 23 Nm (2.3 m·kg, 17 ft·lb) • Pivot shaft locknut Pivot shaft locknut 115 Nm (11.5 m·kg, 85 ft·lb) • Pivot shaft nut Pivot shaft nut 125 Nm (12.5 m·kg, 90 ft·lb) 4-94...
Page 282: Shaft Drive
SHAFT DRIVE EAS23550 SHAFT DRIVE Removing the final drive assembly Order Job/Parts to remove Q’ty Remarks Drain. Final gear oil Refer to “CHANGING THE ENGINE OIL” on page 3-15. Rear wheel Refer to “REAR WHEEL” on page 4-24. Final drive assembly For installation, reverse the removal proce- dure.
Page 283 SHAFT DRIVE Removing the universal joint Order Job/Parts to remove Q’ty Remarks FJR13AE Left footrest assembly/Sidestand Refer to “SHIFT ACTUATOR AND SHIFT ROD (FJR13AE only)” on page 5-67. Shift arm FJR13A Left footrest assembly FJR13A FJR13A Sidestand switch coupler Disconnect. Sidestand FJR13A Drive shaft dust cover...
Page 284 SHAFT DRIVE Disassembling the final drive assembly Order Job/Parts to remove Q’ty Remarks Circlip Oil seal Drive shaft Spring Ring gear bearing housing Dust cover Oil seal Stopper bolt Left-hand threads Stopper bolt shim(s) Ring gear shim(s) Ring gear Bearing Thrust washer Coupling gear nut Coupling gear...
Page 285 SHAFT DRIVE Disassembling the final drive assembly Order Job/Parts to remove Q’ty Remarks Final drive pinion gear Bearing Final drive pinion gear shim(s) Final drive pinion gear bearing Ring gear bearing Oil seal Collar Final gear case For assembly, reverse the disassembly pro- cedure.
Page 286: Troubleshooting
SHAFT DRIVE EAS23560 TROUBLESHOOTING Symptom Possible cause 1. A pronounced hesitation or jerky movement A. Bearing damage during acceleration, deceleration or sus- B. Improper gear backlash tained speeds (not to be confused with en- C. Damaged gear teeth gine surging or transmission-related D.
Page 287: Checking The Final Drive Oil For Contamination And Checking The Shaft Drive For Leaks
SHAFT DRIVE NO → 2. Place the vehicle on a suitable Rear wheel bearings and shaft drive bear- stand so that the rear wheel is ele- ings are probably not damaged. Repeat vated and then spin the rear wheel. the test or remove and check the compo- Is the wheel bearing damaged? nents.
Page 288: Adjusting The Final Gear Backlash
SHAFT DRIVE e. Record the reading on the dial gauge. Final gear backlash f. Remove the dial gauge, final gear backlash 0.22–0.45 mm (0.0087–0.0177 in) band, and bolt. g. Rotate the final drive pinion gear 90°. M MMM M MMM M MMM M MMM M MMM...
Page 289: Measuring The Ring-Gear-To-Stopper-Bolt Clearance
SHAFT DRIVE Final gear backlash is in- Thinner shim creased. Final gear backlash is de- Thicker shim creased. b. If it is necessary to increase the final gear backlash by more than 0.2 mm, reduce the thrust washer thickness by 0.2 mm for every 0.2 mm increase of ring gear shim thickness.
Page 290: Disassembling The Final Drive Assembly
SHAFT DRIVE ® • Apply LOCTITE onto the stopper bolt. 3. Remove: • Bearing retainer 4. Measure: (with the bearing retainer wrench “

Yamaha FJR13AEV(C) Service Manual

Quick Links

7 Table of Contents

49 Specifications

137 Periodic Checks and Adjustments

140 Periodic Maintenance

145 Engine

167 Chassis

183 Electrical System

185 Chassis

196 General Chassis

204 Front Wheel

211 Rear Wheel

216 Front Brake

234 Rear Brake

241 Abs (Anti-Lock Brake System)

251 Handlebars

260 Front Fork

270 Steering Head

274 Rear Shock Absorber Assembly

280 Swingarm

282 Shaft Drive

299 Engine

302 Engine Removal

313 Camshafts

322 Cylinder Head

326 Valves and Valve Springs

332 Generator and Starter Clutch

338 Pickup Rotor

341 Electric Starter

357 Clutch

368 SHIFT ACTUATOR and SHIFT ROD (FJR13AE Only)

374 Shift Shaft

377 Oil Pump

382 Middle Gear

395 Crankcase

405 Connecting Rods and Pistons

413 Crankshaft

417 Transmission

428 Balancers

Chapters

7 Table of Contents

49 Specifications

137 Periodic Checks and Adjustments

140 Periodic Maintenance

145 Engine

167 Chassis

183 Electrical System

185 Chassis

196 General Chassis

204 Front Wheel

211 Rear Wheel

216 Front Brake

234 Rear Brake

241 Abs (Anti-Lock Brake System)

251 Handlebars

260 Front Fork

270 Steering Head

274 Rear Shock Absorber Assembly

280 Swingarm

282 Shaft Drive

299 Engine

302 Engine Removal

313 Camshafts

322 Cylinder Head

326 Valves and Valve Springs

332 Generator and Starter Clutch

338 Pickup Rotor

341 Electric Starter

357 Clutch

368 SHIFT ACTUATOR and SHIFT ROD (FJR13AE Only)

374 Shift Shaft

377 Oil Pump

382 Middle Gear

395 Crankcase

405 Connecting Rods and Pistons

413 Crankshaft

417 Transmission

428 Balancers

Troubleshooting

7
Table of Contents

49
Specifications

137
Periodic Checks and Adjustments

140
Periodic Maintenance

145
Engine

167
Chassis

183
Electrical System

185
Chassis

196
General Chassis

204
Front Wheel

211
Rear Wheel

216
Front Brake

234
Rear Brake

241
Abs (Anti-Lock Brake System)

251
Handlebars

260
Front Fork

270
Steering Head

274
Rear Shock Absorber Assembly

280
Swingarm

282
Shaft Drive

299
Engine

302
Engine Removal

313
Camshafts

322
Cylinder Head

326
Valves and Valve Springs

332
Generator and Starter Clutch

338
Pickup Rotor

341
Electric Starter

357
Clutch

368
SHIFT ACTUATOR and SHIFT ROD (FJR13AE Only)

374
Shift Shaft

377
Oil Pump

382
Middle Gear

395
Crankcase

405
Connecting Rods and Pistons

413
Crankshaft

417
Transmission

428
Balancers

7
Table of Contents

49
Specifications

137
Periodic Checks and Adjustments

140
Periodic Maintenance

145
Engine

167
Chassis

183
Electrical System

185
Chassis

196
General Chassis

204
Front Wheel

211
Rear Wheel

216
Front Brake

234
Rear Brake

241
Abs (Anti-Lock Brake System)

251
Handlebars

260
Front Fork

270
Steering Head

274
Rear Shock Absorber Assembly

280
Swingarm

282
Shaft Drive

299
Engine

302
Engine Removal

313
Camshafts

322
Cylinder Head

326
Valves and Valve Springs

332
Generator and Starter Clutch

338
Pickup Rotor

341
Electric Starter

357
Clutch

368
SHIFT ACTUATOR and SHIFT ROD (FJR13AE Only)

374
Shift Shaft

377
Oil Pump

382
Middle Gear

395
Crankcase

405
Connecting Rods and Pistons

413
Crankshaft

417
Transmission

428
Balancers