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FJR13AV(C)
FJR13AEV(C)
SERVICE MANUAL
LIT-11616-19-83
3P6-28197-10

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   Summary of Contents for Yamaha FJR13AEV(C)

  • 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: Table Of Contents

    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: Outline Of The Fi System

    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 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 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 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 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 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 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

    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

    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 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

    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 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 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 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) 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) 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 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

    √ √ 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

    √ 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

    √ √ 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 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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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 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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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 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 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

    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 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

    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

    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

    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

    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 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

    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

    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 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

    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

    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

    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

    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

    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 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

    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

    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

    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

    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) 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

    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

    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

    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

    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 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

    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

    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 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

    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

    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

    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

    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 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

    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 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

    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

    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 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 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

    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

    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

    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

    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

    SHAFT DRIVE ® • Apply LOCTITE onto the stopper bolt. 3. Remove: • Bearing retainer 4. Measure: (with the bearing retainer wrench “1”) • Ring-gear-to-stopper-bolt clearance Bearing retainer wrench Ring-gear-to-stopper-bolt clear- 90890-04050 ance Pinion bearing retainer & remov- 0.30–0.60 mm (0.0118–0.0236 in) YM-04050 NOTE: ECA14330...

  • Page 291

    (with an appropriate press tool “4” and press) • Bearing “3” NOTE: (with an appropriate press tool “4” and an ap- The bearing can be reused, but Yamaha recom- propriate support for the final gear case) mends installing a new one. 3. Remove: •...

  • Page 292

    SHAFT DRIVE Final drive pinion gear shims Thickness (mm) 0.30 0.40 0.50 Since the final drive pinion gear shims are only available in 0.10 mm increments, round off to the hundredths digit. Hundredth Rounded value 0, 1, 2 3, 4, 5, 6, 7 8, 9 In the example above, the calculated final drive pinion gear shim thickness is 0.51 mm.

  • Page 293

    SHAFT DRIVE f = the ring gear bearing thickness constant. ECA14350 CAUTION: Ring gear bearing thickness The bearing retainer has left-hand threads. 13.00 mm (0.51 in) To tighten the bearing retainer, turn it coun- terclockwise. Example: If the final gear case is marked “51”, the ring Bearing retainer wrench gear bearing housing is marked “35”, the ring 90890-04050...

  • Page 294

    SHAFT DRIVE 4. Stake the coupling gear nut “1” at a cutout “a” in the final drive pinion gear. Ring-gear-to-thrust-washer clear- ance 5. Install: 0.10–0.20 mm (0.0039–0.0079 in) • Ring gear bearing housing (along with the ring gear, but without the f.

  • Page 295

    SHAFT DRIVE EAS23660 7. Install: INSTALLING THE DRIVE SHAFT AND FINAL • Sidestand DRIVE ASSEMBLY (FJR13A) • Left footrest assembly 1. Lubricate: • Drive shaft spline (final drive pinion gear side) Left footrest assembly/sidestand bolt Recommended lubricant 65 Nm (6.5 m·kg, 47 ft·lb) Molybdenum disulfide grease Left footrest assembly bolt (M8) 28 Nm (2.8 m·kg, 20 ft·lb)

  • Page 296

    SHAFT DRIVE 11.Check: Fork seal driver weight • Shift pedal position 90890-01184 Refer to “ADJUSTING THE SHIFT PEDAL Replacement hammer (FJR13A)” on page 3-32. YM-A9409-7 Oil seal installing tool ET3P66032 90890-01512 INSTALLING THE DRIVE SHAFT AND FINAL YM-01512 DRIVE ASSEMBLY (FJR13AE) 1.

  • Page 297

    SHAFT DRIVE 10.Fill: • Final gear case Refer to “CHECKING THE FINAL GEAR OIL LEVEL” on page 3-33. 4-110...

  • Page 298

    SHAFT DRIVE 4-111...

  • Page 299

    ENGINE ENGINE REMOVAL ..................5-1 REMOVING THE GEAR POSITION SENSOR (FJR13AE only)....5-8 REMOVING THE ENGINE (FJR13A) ............5-8 REMOVING THE ENGINE (FJR13AE) ............. 5-8 INSTALLING THE ENGINE ..............5-8 INSTALLING THE GEAR POSITION SENSOR (FJR13AE only) ... 5-11 ADJUSTING THE GEAR POSITION SENSOR (FJR13AE only).... 5-11 CAMSHAFTS ....................

  • Page 300

    CLUTCH ......................5-44 REMOVING THE CLUTCH ..............5-56 CHECKING THE FRICTION PLATES ............ 5-56 CHECKING THE CLUTCH PLATES............5-57 CHECKING THE CLUTCH SPRING PLATE .......... 5-57 CHECKING THE CLUTCH HOUSING............ 5-57 CHECKING THE CLUTCH BOSS............5-57 CHECKING THE PRESSURE PLATE ............ 5-58 CHECKING THE CLUTCH PUSH RODS ..........

  • Page 301

    MIDDLE GEAR....................5-81 REMOVING THE MIDDLE DRIVE SHAFT ASSEMBLY......5-87 DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY ....5-87 DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY .... 5-87 CHECKING THE MIDDLE DRIVE SHAFT ASSEMBLY ......5-88 CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY....... 5-88 ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY .....

  • Page 302

    ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the exhaust pipe assembly 17 Nm (1.7 m kg, 12 ft • • 25 Nm (2.5 m kg, 18 ft • • 20 Nm (2.0 m kg, 14 ft • • 12 Nm (1.2 m kg, 8.7 ft •...

  • Page 303

    ENGINE REMOVAL Disconnecting the leads and hoses (FJR13A) 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Front fender Refer to “FRONT WHEEL” on page 4-17. Refer to “GENERAL CHASSIS” on page Air filter case 4-1.

  • Page 304

    ENGINE REMOVAL Disconnecting the leads and hoses (FJR13A) 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Oil level switch coupler Disconnect. Crankshaft position sensor coupler Disconnect. Gear position switch coupler Disconnect. Ground lead Disconnect.

  • Page 305

    ENGINE REMOVAL Disconnecting the leads and hoses (FJR13AE) 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Front fender Refer to “FRONT WHEEL” on page 4-17. Refer to “GENERAL CHASSIS”...

  • Page 306

    ENGINE REMOVAL Disconnecting the leads and hoses (FJR13AE) 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Clutch release cylinder Dowel pin Crankcase breather hose Stator coil coupler Disconnect.

  • Page 307

    ENGINE REMOVAL Removing the engine 8 Nm (0.8 m kg, 5.8 ft 45 Nm (4.5 m kg, 32 ft • • 49 Nm (4.9 m kg, 35 ft • • • • 45 Nm (4.5 m kg, 32 ft • •...

  • Page 308

    ENGINE REMOVAL Removing the engine 8 Nm (0.8 m kg, 5.8 ft 45 Nm (4.5 m kg, 32 ft • • 49 Nm (4.9 m kg, 35 ft • • • • 45 Nm (4.5 m kg, 32 ft • •...

  • Page 309

    ENGINE REMOVAL ET3P66033 NOTE: REMOVING THE GEAR POSITION SENSOR Loosen the spacer bolt with the pivot shaft (FJR13AE only) wrench “1” and pivot shaft wrench adapter “2”. 1. Disconnect: • Gear position sensor coupler 2. Remove: Pivot shaft wrench 90890-01471 •...

  • Page 310

    ENGINE REMOVAL • Spacers “7” NOTE: • Engine mounting bolt (right front upper side) • Tighten the spacer bolt “1” to specification with “8” a pivot shaft wrench. • Engine mounting bolt (right front lower side) • When tightened, the spacer bolt should be flat “9”...

  • Page 311

    ENGINE REMOVAL 13.Install: NOTE: • Engine bracket (left rear side) “1” Tighten the pinch bolts (rear side) one at a time, • Engine bracket bolt (left rear side) “2” making sure to tighten the first bolt again after • Engine mounting bolts (left rear side) “3” tightening the second bolt.

  • Page 312

    ENGINE REMOVAL ET3P66035 2. Adjust: INSTALLING THE GEAR POSITION SENSOR • Gear position sensor angle (FJR13AE only) M MMM M MMM M MMM M MMM M MMM 1. Connect: a. Connect the gear position sensor coupler to • MCU coupler the gear position sensor.

  • Page 313

    CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover 10 Nm (1.0 m kg, 7.2 ft • • 13 Nm (1.3 m kg, 9.4 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Right side cowling 4-1.

  • Page 314

    CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Throttle bodies Refer to “THROTTLE BODIES” on page 7-5. Pickup rotor cover Refer to “PICKUP ROTOR” on page 5-37. Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap Exhaust camshaft cap Intake camshaft Exhaust camshaft Intake camshaft sprocket...

  • Page 315

    CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Align: • “T” mark on the pickup rotor (with the crankcase mating surface) M MMM M MMM M MMM M MMM M MMM a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the “T”...

  • Page 316

    CAMSHAFTS 3. Measure: EAS23850 • Camshaft runout CHECKING THE CAMSHAFTS Out of specification → Replace. 1. Check: • Camshaft lobes Camshaft runout limit Blue discoloration/pitting/scratches → Re- 0.030 mm (0.0012 in) place the camshaft. 2. Measure: • Camshaft lobe dimensions “a” and “b” Out of specification →...

  • Page 317

    CAMSHAFTS NOTE: • Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. • Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance ® with the Plastigauge Camshaft cap bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) a.

  • Page 318

    CAMSHAFTS L LLL L LLL L LLL L LLL L LLL 2. Install: • Timing chain “1” EAS24010 • Exhaust camshaft “2” INSTALLING THE CAMSHAFTS • Intake camshaft “3” 1. Install: (with the camshaft sprockets) • Exhaust camshaft sprocket ECA13740 •...

  • Page 319

    CAMSHAFTS ECA13730 CAUTION: The camshaft cap bolts must be tightened evenly or damage to the cylinder head, cam- shaft caps, and camshafts will result. NOTE: Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out.

  • Page 320

    L LLL L LLL L LLL L LLL L LLL • Apply Yamaha bond No.1215 “2” onto the mat- ing surfaces of the cylinder head cover gasket 7. Turn: and cylinder head. • Crankshaft • Tighten the cylinder head cover bolts in stages (several turns clockwise) and in a crisscross pattern.

  • Page 321

    CAMSHAFTS 5-20...

  • Page 322

    CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head (10) 25 Nm (2.5 m kg, 18 ft • • 2nd 25 Nm (2.5 m kg, 18 ft • • Final Specified angle 175–185˚ 12 Nm (1.2 m kg, 8.7 ft •...

  • Page 323

    CYLINDER HEAD EAS24120 M MMM M MMM M MMM M MMM M MMM REMOVING THE CYLINDER HEAD a. Place a straightedge “1” and a thickness 1. Remove: gauge “2” across the cylinder head. • Cylinder head bolts NOTE: • Loosen the bolts in the proper sequence as shown.

  • Page 324

    CYLINDER HEAD Cylinder head bolt (M10) 25 Nm (2.5 m·kg, 18 ft·lb) e. Tighten the cylinder head bolts further to reach the specified angle 175–185° in the proper tightening sequence as shown. Cylinder head bolt (M10) Final L LLL L LLL L LLL L LLL L LLL...

  • Page 325

    VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-21. Valve lifter Valve pad Valve cotter Upper spring seat Intake valve spring Exhaust valve spring Intake valve Exhaust valve...

  • Page 326

    VALVES AND VALVE SPRINGS EAS24280 NOTE: REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components. “1” and the valve spring compressor attachment NOTE: “2”.

  • Page 327

    VALVES AND VALVE SPRINGS 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide. • Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” - Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance (intake) b. Install the new valve guide with the valve 0.010–0.037 mm (0.0004–0.0015 guide installer “2”...

  • Page 328

    VALVES AND VALVE SPRINGS 3. Eliminate: EAS24300 CHECKING THE VALVE SEATS • Carbon deposits The following procedure applies to all of the (from the valve face and valve seat) valves and valve seats. 4. Check: 1. Eliminate: • Valve face •...

  • Page 329

    VALVES AND VALVE SPRINGS 4. Lap: • Valve face • Valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. M MMM M MMM M MMM M MMM M MMM a.

  • Page 330

    VALVES AND VALVE SPRINGS 2. Measure: EAS24320 • Compressed valve spring force “a” CHECKING THE VALVE LIFTERS Out of specification → Replace the valve The following procedure applies to all of the spring. valve lifters. 1. Check: Installed compression spring •...

  • Page 331

    VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019 YM-04019 Valve spring compressor attach- ment 90890-04114 Valve spring compressor adapt- er 19.5 mm YM-04114 4. Install: • Lower spring seat “1” • Valve stem seal “2” • Valve “3” • Valve spring “4” •...

  • Page 332

    GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Refer to “GENERAL CHASSIS” on page Air filter case 4-1.

  • Page 333

    GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch Order Job/Parts to remove Q’ty Remarks Starter clutch For installation, reverse the removal proce- dure. 5-32...

  • Page 334

    GENERATOR AND STARTER CLUTCH Removing the stator coil assembly Order Job/Parts to remove Q’ty Remarks Stator coil assembly lead holder Stator coil assembly For installation, reverse the removal proce- dure. 5-33...

  • Page 335

    GENERATOR AND STARTER CLUTCH EAS24490 EAS24560 REMOVING THE GENERATOR REMOVING THE STARTER CLUTCH 1. Remove: 1. Remove: • Generator rotor bolt “1” • Starter clutch bolts “1” • Washer NOTE: NOTE: While holding the generator rotor with the While holding the generator rotor “2” with the sheave holder, remove the starter clutch bolts.

  • Page 336

    Sheave holder 90890-01701 Primary clutch holder 3. Apply: YS-01880-A • Sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 90890-85505 ® (Three Bond No.1215 EAS24500 INSTALLING THE GENERATOR 1. Install: • Woodruff key •...

  • Page 337

    GENERATOR AND STARTER CLUTCH NOTE: Tighten the generator cover bolts in stages and in a crisscross pattern. 5-36...

  • Page 338

    PICKUP ROTOR EAS24520 PICKUP ROTOR Removing the pickup rotor 12 Nm (1.2 m kg, 8.7 ft • • 15 Nm (1.5 m kg, 11 ft • • 45 Nm (4.5 m kg, 32 ft • • 4 Nm (0.4 m kg, 2.9 ft •...

  • Page 339

    When installing the pickup rotor, align the groove “a” in the crankshaft sprocket with the projection “b” in the pickup rotor. 3. Apply: • Sealant (onto the crankshaft position sensor lead grommet) Yamaha bond No. 1215 90890-85505 ® (Three Bond No.1215 5-38...

  • Page 340

    PICKUP ROTOR 4. Install: • Pickup rotor cover gasket • Pickup rotor cover Pickup rotor cover bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) NOTE: Tighten the pickup rotor cover bolts in stages and in a crisscross pattern. 5-39...

  • Page 341

    ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Throttle bodies Refer to “THROTTLE BODIES” on page 7-5. Starter motor lead Disconnect. Starter motor assembly For installation, reverse the removal proce- dure. 5-40...

  • Page 342

    ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Brush Brush seat (along with brushes) Washer Lock washer Oil seal Bearing Starter motor rear cover Collar O-ring Starter motor yoke Armature assembly For assembly, reverse the disassembly pro- cedure.

  • Page 343

    ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR Pocket tester 1. Check: 90890-03112 • Commutator Analog pocket tester Dirt → Clean with 600 grit sandpaper. YU-03112-C 2. Measure: • Commutator diameter “1” Armature coil Out of specification → Replace the starter Commutator resistance “1”...

  • Page 344

    ELECTRIC STARTER 7. Check: • Gear teeth Damage/wear → Replace the gear. 8. Check: • Bearing • Oil seal Damage/wear → Replace the defective part(s). EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: • Brush seat “1” NOTE: Align the slot “a” on the brush seat with the tab “b”...

  • Page 345

    CLUTCH EAS25060 CLUTCH Removing the clutch cover 12 Nm (1.2 m kg, 8.7 ft • • (10) 12 Nm (1.2 m kg, 8.7 ft 12 Nm (1.2 m kg, 8.7 ft • • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...

  • Page 346

    CLUTCH Removing the clutch 90 Nm (9.0 m kg, 65 ft • • 18 17 10 Nm (1.0 m kg, 7.2 ft • • 11 10 9,12 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Parts to remove Q’ty Remarks Rear balancer...

  • Page 347

    CLUTCH Removing the clutch 90 Nm (9.0 m kg, 65 ft • • 18 17 10 Nm (1.0 m kg, 7.2 ft • • 11 10 9,12 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Parts to remove Q’ty Remarks Thrust washer...

  • Page 348

    CLUTCH Removing the clutch master cylinder (FJR13A) Order Job/Parts to remove Q’ty Remarks Drain. Refer to “BLEEDING THE HYDRAULIC Clutch fluid CLUTCH SYSTEM (FJR13A)” on page 3-18. Clutch master cylinder reservoir cap Clutch master cylinder reservoir diaphragm holder Clutch master cylinder reservoir diaphragm Clutch lever Clutch master cylinder push rod pin Clutch switch coupler...

  • Page 349

    CLUTCH Removing the clutch master cylinder (FJR13A) Order Job/Parts to remove Q’ty Remarks Clutch master cylinder For installation, reverse the removal proce- dure. * Apply silicon grease 5-48...

  • Page 350

    CLUTCH Removing the clutch actuator and clutch master cylinder (FJR13AE) 7 Nm (0.7 m kg, 5.1 ft • • 19 Nm (1.9 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft •...

  • Page 351

    CLUTCH Removing the clutch actuator and clutch master cylinder (FJR13AE) 7 Nm (0.7 m kg, 5.1 ft • • 19 Nm (1.9 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft •...

  • Page 352

    CLUTCH Disassembling the clutch master cylinder (FJR13A) Order Job/Parts to remove Q’ty Remarks Clutch master cylinder push rod Dust boot Circlip Washer Clutch master cylinder kit Clutch master cylinder body For assembly, reverse the disassembly pro- cedure. * Apply silicon grease 5-51...

  • Page 353

    CLUTCH Disassembling the clutch master cylinder (FJR13AE) ∗ Order Job/Parts to remove Q’ty Remarks Clutch master cylinder kit Clutch master cylinder body For assembly, reverse the disassembly pro- cedure. * Apply silicon grease 5-52...

  • Page 354

    CLUTCH Removing the clutch release cylinder (FJR13A) Order Job/Parts to remove Q’ty Remarks Drain. Refer to “BLEEDING THE HYDRAULIC Clutch fluid CLUTCH SYSTEM (FJR13A)” on page 3-18. Clutch hose union bolt Copper washer Clutch hose Disconnect. Clutch release cylinder Dowel pin Plate For installation, reverse the removal proce- dure.

  • Page 355

    CLUTCH Removing the clutch release cylinder (FJR13AE) Order Job/Parts to remove Q’ty Remarks Drain. Refer to “BLEEDING THE HYDRAULIC Clutch fluid CLUTCH SYSTEM (FJR13AE)” on page 3-19. Clutch hose union bolt Copper washer Clutch hose Disconnect. Clutch release cylinder Dowel pin Plate For installation, reverse the removal proce- dure.

  • Page 356

    CLUTCH Disassembling the clutch release cylinder 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Clutch release cylinder piston Clutch release cylinder spring Clutch release cylinder piston seal Bleed screw Clutch release cylinder body For assembly, reverse the disassembly pro- cedure.

  • Page 357

    CLUTCH EAS25080 NOTE: REMOVING THE CLUTCH • Insert a cross-headed screwdriver into one of 1. Remove: the holes of the clutch housing and primary • Clutch cover “1” driven gear, and then rotate the inner primary NOTE: driven gear until both primary drive gears are Loosen each bolt 1/4 of a turn at a time, in stag- aligned.

  • Page 358

    CLUTCH EAS25130 CHECKING THE CLUTCH SPRING PLATE 1. Check: • Clutch spring plate Damage → Replace. 2. Check: • Clutch spring plate seat Damage → Replace. EAS25150 CHECKING THE CLUTCH HOUSING A. Friction plate 1, 3 1. Check: B. Friction plate 2 •...

  • Page 359

    CLUTCH EAS25250 INSTALLING THE CLUTCH 1. Install: • Clutch housing “1” NOTE: • Make sure that the projections “a” in the clutch housing align with the slots “b” in the oil pump drive sprocket. • Make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly.

  • Page 360

    CLUTCH • Lock washer “2” Recommended lubricant • Clutch boss nut “3” Engine oil Clutch boss nut 7. Install: 90 Nm (9.0 m·kg, 65 ft·lb) • Friction plates • Clutch plates NOTE: NOTE: • Install the clutch boss nut with its large inner di- First, install a friction plate and then alternate be- ameter side facing inward as shown in the illus- tween a clutch plate and a friction plate.

  • Page 361

    CLUTCH • Clutch fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt fluid immediately. • Avoid clutch fluid coming into contact with the eyes as it can cause serious injury. • First aid for clutch fluid entering the eyes: •...

  • Page 362

    CLUTCH • First, tighten the upper bolt, then the lower Recommended clutch component replace- bolt. ment schedule Every two years and Clutch fluid whenever the clutch is disassembled 1. Check: • Clutch master cylinder body Cracks/damage → Replace the clutch mas- ter cylinder.

  • Page 363

    CLUTCH EWA13370 ET3P66045 INSTALLING THE CLUTCH MASTER WARNING CYLINDER (FJR13AE) • Use only the designated clutch fluid. Other 1. Install: clutch fluids may cause the rubber seals to • Copper washers “1” deteriorate, causing leakage and poor clutch performance. • Clutch hose “2” •...

  • Page 364

    CLUTCH • Refill with the same type of clutch fluid that NOTE: is already in the system. Mixing clutch flu- The thickness of the new shim “1” is 1.5 mm ids may result in a harmful chemical reac- (0.06 in). tion, leading to poor clutch performance.

  • Page 365

    CLUTCH b. If the thickness of the shim installed on the 4. Adjust: vehicle is 1.5 mm (0.06 in), refer to the follow- • Clutch engagement point ing table. Refer to “Diagnostic code table (Diagnostic code No. Sh_ _66)”. Pressure plate Action NOTE: stroke...

  • Page 366

    CLUTCH • Never use solvents on internal clutch com- ponents as they will cause the piston seal to swell and distort. • Whenever a clutch release cylinder is dis- assembled, replace the piston seal. Recommended fluid DOT 4 EAS25350 INSTALLING THE CLUTCH RELEASE CYLINDER 1.

  • Page 367

    CLUTCH 2. Fill: • Clutch master cylinder reservoir (with the specified amount of the recom- mended clutch fluid) Recommended fluid DOT 4 EWA13370 WARNING • Use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance.

  • Page 368

    SHIFT ACTUATOR AND SHIFT ROD (FJR13AE only) ET3P66037 SHIFT ACTUATOR AND SHIFT ROD (FJR13AE only) Removing the shift actuator, shift rod and foot shift switch 4 Nm (0.4 m kg, 2.9 ft • • 20 Nm (2.0 m kg, 14 ft •...

  • Page 369

    SHIFT ACTUATOR AND SHIFT ROD (FJR13AE only) Removing the shift actuator, shift rod and foot shift switch 4 Nm (0.4 m kg, 2.9 ft • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 370

    SHIFT ACTUATOR AND SHIFT ROD (FJR13AE only) ET3P66038 REMOVING THE SHIFT ACTUATOR 1. Remove: • Shift actuator M MMM M MMM M MMM M MMM M MMM a. Pass a suitable 5 mm diameter rod “1” through the holes in the rear shift arm and shift actuator to secure the shift rod.

  • Page 371

    SHIFT ACTUATOR AND SHIFT ROD (FJR13AE only) 4. Adjust: Shift pedal pivot bolt • Foot shift switch 16 Nm (1.6 m·kg, 11 ft·lb) Refer to “ADJUSTING THE FOOT SHIFT ® LOCTITE SWITCH” on page 5-70. NOTE: ET3P66040 ADJUSTING THE FOOT SHIFT SWITCH •...

  • Page 372

    SHIFT ACTUATOR AND SHIFT ROD (FJR13AE only) Shift actuator rear bolt 20 Nm (2.0 m·kg, 14 ft·lb) Shift actuator front bolt 20 Nm (2.0 m·kg, 14 ft·lb) L LLL L LLL L LLL L LLL L LLL ET3P66041 INSTALLING THE LEFT FOOTREST ASSEMBLY 1.

  • Page 373

    SHIFT ACTUATOR AND SHIFT ROD (FJR13AE only) Shift rod front locknut 7 Nm (0.7 m·kg, 5.1 ft·lb) Shift rod rear locknut 10 Nm (1.0 m·kg, 7.2 ft·lb) h. Pull out the rod from the holes. L LLL L LLL L LLL L LLL L LLL 5-72...

  • Page 374

    SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Clutch housing Refer to “CLUTCH” on page 5-44. FJR13AE Shift rod Refer to “SHIFT ACTUATOR AND SHIFT ROD (FJR13AE only)” on page 5-67. Oil baffle plate 1 Shift arm Circlip...

  • Page 375

    SHIFT SHAFT EAS25420 3. Install: CHECKING THE SHIFT SHAFT • Shift arm “1” 1. Check: • Shift shaft Shift arm bolt Bends/damage/wear → Replace. 10 Nm (1.0 m·kg, 7.2 ft·lb) • Shift shaft spring Damage/wear → Replace. NOTE: Align the punch mark “a” in the shift shaft with EAS25430 the slot in the shift arm.

  • Page 376

    SHIFT SHAFT 3. Install: • Front shift arm “1” Front shift arm bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) NOTE: Align the punch mark “a” on the front shift arm with the punch mark “b” on the shift shaft. 5-75...

  • Page 377

    OIL PUMP EAS24920 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-15. Throttle bodies Refer to “THROTTLE BODIES” on page 7-5. Exhaust pipe assembly Refer to “ENGINE REMOVAL”...

  • Page 378

    OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Relief valve assembly For installation, reverse the removal proce- dure. 5-77...

  • Page 379

    OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil pump housing cover Oil pump inner rotor Oil pump outer rotor Washer Oil pump driven sprocket Oil pump housing For assembly, reverse the disassembly pro- cedure. 5-78...

  • Page 380

    OIL PUMP EAS24960 CHECKING THE OIL PUMP Inner-rotor-to-outer-rotor-tip 1. Check: clearance • Oil pump driven sprocket Less than 0.12 mm (0.0047 in) Limit • Oil pump housing 0.20 mm (0.0079 in) • Oil pump housing cover Cracks/damage/wear → Replace the defec- Outer-rotor-to-oil-pump-housing clearance tive part(s).

  • Page 381

    OIL PUMP EAS24980 EAS25050 CHECKING THE OIL DELIVERY PIPES INSTALLING THE OIL PAN The following procedure applies to all of the oil 1. Install: delivery pipes. • Oil pan gasket 1. Check: • Oil pan • Oil delivery pipes Damage → Replace. Oil pan bolt Obstruction →...

  • Page 382

    MIDDLE GEAR EAS25710 MIDDLE GEAR Removing the middle gear (FJR13A) Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Oil pan/Oil pump Refer to “OIL PUMP” on page 5-76. Middle gear case cover Middle gear case cover gasket Dowel pin Damper cover Damper...

  • Page 383

    MIDDLE GEAR Removing the middle gear (FJR13A) Order Job/Parts to remove Q’ty Remarks Spacer Middle driven gear Bearing retainer Bearing Middle drive pinion gear shim Bearing For installation, reverse the removal proce- dure. 5-82...

  • Page 384

    MIDDLE GEAR Removing the middle gear (FJR13AE) Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Oil pan/Oil pump Refer to “OIL PUMP” on page 5-76. Middle gear case cover Middle gear case cover gasket Dowel pin Damper cover Damper...

  • Page 385

    MIDDLE GEAR Removing the middle gear (FJR13AE) Order Job/Parts to remove Q’ty Remarks Middle driven gear Bearing retainer Bearing Middle drive pinion gear shim Bearing For installation, reverse the removal proce- dure. 5-84...

  • Page 386

    MIDDLE GEAR Disassembling the middle drive shaft assembly Order Job/Parts to remove Q’ty Remarks Spring retainer Spring seat Damper spring Damper driven cam Damper drive cam Middle drive shaft For assembly, reverse the disassembly pro- cedure. 5-85...

  • Page 387

    MIDDLE GEAR Disassembling the middle driven shaft assembly Order Job/Parts to remove Q’ty Remarks Oil seal Middle driven pinion gear nut Middle driven shaft Middle driven pinion gear Bearing retainer Bearing Middle driven shaft bearing housing For assembly, reverse the disassembly pro- cedure.

  • Page 388

    MIDDLE GEAR EAS25730 REMOVING THE MIDDLE DRIVE SHAFT ASSEMBLY 1. Remove: • Middle drive pinion gear nut “1” • Lock washer “2” M MMM M MMM M MMM M MMM M MMM a. Straighten the lock washer tab. b. Loosen the middle drive pinion gear nut. NOTE: While holding the middle drive shaft.

  • Page 389

    MIDDLE GEAR 4. Check: • Bearings Damage/pitting → Replace. EAS25790 CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1. Check: • Middle driven pinion gear Galling/pitting/wear → Replace. 2. Check: c. Remove the middle driven pinion gear nut. • Bearings L LLL L LLL L LLL L LLL...

  • Page 390

    MIDDLE GEAR Bearing retainer 110 Nm (11.0 m·kg, 80 ft·lb) L LLL L LLL L LLL L LLL L LLL EAS25860 INSTALLING THE MIDDLE DRIVE SHAFT ASSEMBLY d. Lock the threads with a drift punch. 1. Tighten: • Bearing retainer “1” M MMM M MMM M MMM...

  • Page 391

    MIDDLE GEAR M MMM M MMM M MMM M MMM M MMM NOTE: a. Tighten the middle drive pinion gear nut to Finger tighten the middle driven shaft bearing specification. housing bolts. Middle drive pinion gear nut 110 Nm (11.0 m·kg, 80 ft·lb) NOTE: •...

  • Page 392

    MIDDLE GEAR EAS25880 EAS25900 MEASURING THE MIDDLE GEAR ADJUSTING THE MIDDLE GEAR BACKLASH BACKLASH 1. Loosen: 1. Measure: • Middle driven shaft bearing housing bolts • Middle gear backlash 2. Remove: Out of specification → Refer to “ADJUSTING • Middle driven pinion gear shim(s) THE MIDDLE GEAR BACKLASH”...

  • Page 393

    MIDDLE GEAR 6. Measure: 11.Measure: • Crankcase-to-middle-driven-shaft-bearing- • Middle gear backlash Out of specification → Refer to “MEASUR- housing clearance (with a thickness gauge) ING THE MIDDLE GEAR BACKLASH” on 7. Select: page 5-91. • Middle driven pinion gear shim(s) “1” EAS25930 ALIGNING THE MIDDLE GEAR NOTE:...

  • Page 394

    MIDDLE GEAR Middle drive pinion gear shim thickness “A” = “c” - “a” - “b” “a”= 65.00 “b”= 18.94 “c”= a numeral on the lower crankcase, to be divided by 100 and added to “84” “e” = Measured value “f” = a numeral on the lower crankcase, to be divided by 100 and added to “87”.

  • Page 395

    CRANKCASE EAS25540 CRANKCASE Separating the crankcase (FJR13A) 10 Nm (1.0 m kg, 7.2 ft 20 Nm (2.0 m kg, 14 ft • • • • 2nd 20 Nm (2.0 m kg, 14 ft • • (10) 24 Nm (2.4 m kg, 17 ft •...

  • Page 396

    CRANKCASE Separating the crankcase (FJR13A) 10 Nm (1.0 m kg, 7.2 ft 20 Nm (2.0 m kg, 14 ft • • • • 2nd 20 Nm (2.0 m kg, 14 ft • • (10) 24 Nm (2.4 m kg, 17 ft •...

  • Page 397

    CRANKCASE Separating the crankcase (FJR13AE) 10 Nm (1.0 m kg, 7.2 ft 20 Nm (2.0 m kg, 14 ft • • • • 2nd 20 Nm (2.0 m kg, 14 ft (10) • • 24 Nm (2.4 m kg, 17 ft •...

  • Page 398

    CRANKCASE Separating the crankcase (FJR13AE) 10 Nm (1.0 m kg, 7.2 ft 20 Nm (2.0 m kg, 14 ft • • • • 2nd 20 Nm (2.0 m kg, 14 ft (10) • • 24 Nm (2.4 m kg, 17 ft •...

  • Page 399

    CRANKCASE Removing the oil baffle plate and bearings 10 Nm (1.0 m kg, 7.2 ft • • 70 Nm (7.0 m kg, 50 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 400

    CRANKCASE Removing the oil baffle plate and bearings 10 Nm (1.0 m kg, 7.2 ft • • 70 Nm (7.0 m kg, 50 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 401

    CRANKCASE EAS25550 EAS25580 DISASSEMBLING THE CRANKCASE CHECKING THE CRANKCASE 1. Place the engine upside down. 1. Thoroughly wash the crankcase halves in a 2. Remove: mild solvent. • Crankcase bolts 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. NOTE: 3.

  • Page 402

    CRANKCASE Recommended lubricant Engine oil 2. Apply: • Sealant (onto the crankcase mating surfaces and oil baffle plate 2) Yamaha bond No. 1215 90890-85505 ECA13980 ® (Three Bond No.1215 CAUTION: Before tightening the crankcase bolts, make NOTE: sure the transmission gears shift correctly...

  • Page 403

    CRANKCASE EW3P61014 WARNING If the bolt is tightened more than the speci- fied angle, do not loosen the bolt and then re- tighten it. Instead, replace the bolt with a new one and perform the procedure again. 13 21 19 22 EC3P61033 CAUTION: •...

  • Page 404

    CRANKCASE Crankcase bolt “11”, “12” 24 Nm (2.4 m·kg, 17 ft·lb) Crankcase bolt “13”, “14” 12 Nm (1.2 m·kg, 8.7 ft·lb) Crankcase bolt “15”–“31” 10 Nm (1.0 m·kg, 7.2 ft·lb) NOTE: Tighten the crankcase bolts in the proper tight- ening sequence as shown. 13 21 19 22 5-103...

  • Page 405

    CONNECTING RODS AND PISTONS ET3P61027 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-94. Connecting rod cap Big end lower bearing Piston pin clip Piston pin Piston Connecting rod Big end upper bearing...

  • Page 406

    CONNECTING RODS AND PISTONS EAS26030 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the con- necting rods and pistons. 1. Remove: • Connecting rod cap “1” NOTE: Identify the position of each connecting rod so that it can be reinstalled in its original place.

  • Page 407

    CONNECTING RODS AND PISTONS d. If out of specification, replace the piston and NOTE: piston rings as a set. Measure cylinder bore “C” by taking side-to-side e. Calculate the piston-to-cylinder clearance and front-to-back measurements of the cylinder. with the following formula. Then, find the average of the measurements.

  • Page 408

    CONNECTING RODS AND PISTONS 2. Install: 2. Measure: • Piston ring • Piston pin outside diameter “a” Out of specification → Replace the piston pin. (into the cylinder) NOTE: Piston pin outside diameter Level the piston ring into the cylinder with the 18.991–19.000 mm (0.7477–...

  • Page 409

    CONNECTING RODS AND PISTONS ET3P61028 CHECKING THE CONNECTING RODS 1. Measure: • Crankshaft-pin-to-big-end-bearing clearance Out of specification → Replace the big end bearings. Oil clearance (using plasti- ® gauge 0.031–0.048 mm (0.0012–0.0019 d. Assemble the connecting rod halves. NOTE: M MMM M MMM M MMM M MMM...

  • Page 410

    CONNECTING RODS AND PISTONS For example, if the connecting rod P and the crankshaft web P numbers are 6 and 1 re- spectively, then the bearing size for P (connecting rod) - P (crankshaft) 6 - 1 = 5 (yellow) Bearing color code 1.Blue 2.Black 3.Brown 4.Green L LLL...

  • Page 411

    CONNECTING RODS AND PISTONS • Reinstall each piston into its original cylinder Recommended lubricant (numbering order starting from the left: #1 to Molybdenum disulfide oil #4). 6. Lubricate: • Crankshaft pins • Big end bearings • Connecting rod inner surface (with the recommended lubricant) Recommended lubricant Engine oil...

  • Page 412

    CONNECTING RODS AND PISTONS EWA13400 WARNING If the connecting rod nut is tightened more than the specified angle, do not loosen the nut and then retighten it. Instead, replace the connecting rod bolt and nut with a new one and perform the procedure again. ECA13950 CAUTION: Do not use a torque wrench to tighten the...

  • Page 413

    CRANKSHAFT EAS25950 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-94. Front balancer weight Refer to “BALANCERS” on page 5-127. Refer to “CONNECTING RODS AND PIS- Connecting rod caps TONS” on page 5-104. Crankshaft Crankshaft journal upper bearing Crankshaft journal lower bearing...

  • Page 414

    CRANKSHAFT EAS26040 REMOVING THE CRANKSHAFT JOURNAL Journal oil clearance (using plas- BEARINGS ® tigauge 1. Remove: 0.027–0.045 mm (0.0011–0.0018 • Crankshaft journal upper bearings (from the upper crankcase) • Crankshaft journal lower bearings ECA13920 CAUTION: (from the lower crankcase) Do not interchange the crankshaft journal NOTE: bearings.

  • Page 415

    CRANKSHAFT e. Install the crankshaft journal lower bearings • If J –J are the same, use the same size for all “3” into the lower crankcase and assemble of the bearings. the crankcase halves. NOTE: • Align the projections “c” of the crankshaft jour- nal lower bearings with the notches “d”...

  • Page 416

    CRANKSHAFT NOTE: • Align the projections “a” on the crankshaft jour- nal bearings “1” with the notches “b” in the crankcases. • Be sure to install each crankshaft journal bear- ing in its original place. 5-115...

  • Page 417

    TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks (FJR13A) Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-94. Stopper lever Refer to “SHIFT SHAFT” on page 5-73. Drive axle assembly Bearing Washer Bearing Shift drum retainer...

  • Page 418

    TRANSMISSION Removing the transmission, shift drum assembly, and shift forks (FJR13A) Order Job/Parts to remove Q’ty Remarks Main axle assembly For installation, reverse the removal proce- dure. 5-117...

  • Page 419

    TRANSMISSION Removing the transmission, shift drum assembly, and shift forks (FJR13AE) Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-94. Stopper lever Refer to “SHIFT SHAFT” on page 5-73. Gear position sensor bracket Oil seal Drive axle assembly Bearing Washer...

  • Page 420

    TRANSMISSION Removing the transmission, shift drum assembly, and shift forks (FJR13AE) Order Job/Parts to remove Q’ty Remarks Main axle assembly For installation, reverse the removal proce- dure. 5-119...

  • Page 421

    TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks 2nd pinion gear Toothed lock washer Toothed lock washer retainer 5th pinion gear Toothed spacer Toothed washer Circlip 3rd pinion gear 4th pinion gear Collar Main axle/1st pinion gear Bearing Main axle bearing housing For assembly, reverse the disassembly pro-...

  • Page 422

    TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Middle drive gear Washer 2nd wheel gear Collar Washer 5th wheel gear Circlip Toothed washer 3rd wheel gear Toothed spacer Toothed lock washer Toothed lock washer retainer 4th wheel gear Washer 1st wheel gear Bearing...

  • Page 423

    TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Drive axle For assembly, reverse the disassembly pro- cedure. 5-122...

  • Page 424

    TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Main axle assembly NOTE: Remove the main axle assembly with the slide hammer bolts “1” and weight. Slide hammer bolt 90890-01083 3. Check: Slide hammer bolt 6 mm • Shift fork movement YU-01083-1 (along the shift fork guide bar) Weight...

  • Page 425

    TRANSMISSION 5. Check: Main axle runout limit • Transmission gear movement 0.08 mm (0.0032 in) Rough movement → Replace the defective part(s). 6. Check: • Circlips Bends/damage/looseness → Replace. ET3P61030 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1. Install: • Toothed washer “1” •...

  • Page 426

    TRANSMISSION • Stake the main axle bearing housing bolts at a cutout “a” in the main axle bearing housing. A. Main axle B. Drive axle 3. Install: 2. Install: • 2nd pinion gear “1” • Shift fork-C • Shift drum assembly NOTE: •...

  • Page 427

    TRANSMISSION NOTE: • The bearing pin “1” must face towards the rear of the upper crankcase. • Make sure the bearing circlip “2” is inserted into the groove in the upper crankcase. 5. Check: • Transmission Rough movement → Repair. NOTE: Oil each gear, shaft, and bearing thoroughly.

  • Page 428

    BALANCERS ET3P61031 BALANCERS Removing the front balancer Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-94. Front balancer lever Front balancer shaft Washer Bearing Front balancer gear Damper Front balancer weight For installation, reverse the removal proce- dure.

  • Page 429

    BALANCERS Removing the rear balancer Order Job/Parts to remove Q’ty Remarks Throttle bodies Refer to “THROTTLE BODIES” on page 7-5. Pickup rotor cover Refer to “PICKUP ROTOR” on page 5-37. Clutch cover Refer to “CLUTCH” on page 5-44. Rear balancer cover Rear balancer cover gasket Rear balancer lever Rear balancer shaft...

  • Page 430

    BALANCERS EAS26120 2. Align: CHECKING THE BALANCERS • “T” mark on the pickup rotor 1. Check: (with the crankcase mating surface) • Front balancer gear M MMM M MMM M MMM M MMM M MMM Damage/wear → Replace the front balancer a.

  • Page 431

    BALANCERS Front balancer lever bolt 14 Nm (1.4 m·kg, 10 ft·lb) Front balancer shaft pinch bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) NOTE: Make sure that the balancer shaft does not ro- tate. L LLL L LLL L LLL L LLL L LLL 4.

  • Page 432

    BALANCERS b. Align the balancer gear punch mark “c” with the primary driven gear point “d” as shown. NOTE: • Make sure that the rear balancer gear teeth and the primary driven gear teeth mesh cor- rectly. • Make sure that the balancer gear punch mark “c”...

  • Page 433

    BALANCERS Rear balancer lever bolt 14 Nm (1.4 m·kg, 10 ft·lb) Rear balancer shaft pinch bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) NOTE: Make sure that the balancer shaft does not ro- tate. L LLL L LLL L LLL L LLL L LLL 4.

  • Page 434

    BALANCERS 5-133...

  • Page 435

    COOLING SYSTEM RADIATOR...................... 6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR..............6-3 OIL COOLER ....................6-4 CHECKING THE OIL COOLER ..............6-5 INSTALLING THE OIL COOLER .............. 6-5 THERMOSTAT....................6-6 CHECKING THE THERMOSTAT ............. 6-8 INSTALLING THE THERMOSTAT ASSEMBLY ........6-8 WATER PUMP ....................

  • Page 436

    RADIATOR EAS26380 RADIATOR Removing the radiator 7 Nm (0.7 m kg, 5.1 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 437

    RADIATOR Removing the radiator 7 Nm (0.7 m kg, 5.1 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 438

    RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat-head b. Apply the specified pressure for ten seconds screwdriver.

  • Page 439

    OIL COOLER EAS26410 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-15. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-25. Radiator Refer to “RADIATOR” on page 6-1. Exhaust pipe assembly Refer to “ENGINE REMOVAL”...

  • Page 440

    OIL COOLER EAS26420 CHECKING THE OIL COOLER 1. Check: • Oil cooler Cracks/damage → Replace. 2. Check: • Oil cooler inlet hose • Oil cooler outlet hose • Water pump outlet hose • Water pump outlet pipe • Water jacket joint inlet hose Cracks/damage/wear →...

  • Page 441

    THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat assembly 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 442

    THERMOSTAT Removing the thermostat assembly 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • •...

  • Page 443

    THERMOSTAT EAS26450 2. Check: CHECKING THE THERMOSTAT • Thermostat housing 1. Check: Cracks/damage → Replace. • Thermostat 3. Check: Does not open at 71–85 °C (159.8–185.0 °F) • Thermostat hoses → Replace. • Thermostat pipes • Radiator inlet hose • Thermostat cover/radiator filler pipe •...

  • Page 444

    THERMOSTAT 5. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-3.

  • Page 445

    WATER PUMP EAS26500 WATER PUMP Removing the water pump Order Job/Parts to remove Q’ty Remarks It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil. Refer to “GENERAL CHASSIS” on page Right side cowling 4-1.

  • Page 446

    WATER PUMP Disassembling the water pump Order Job/Parts to remove Q’ty Remarks Water pump housing cover O-ring Circlip Impeller shaft Rubber damper holder Rubber damper Water pump seal Oil seal Bearing Water pump housing For assembly, reverse the disassembly pro- cedure.

  • Page 447

    NOTE: • Install the water pump seal with the special tools. • Before installing the water pump seal, apply Yamaha bond No.1215 (Three Bond ® No.1215 ) “2” to the water pump housing “3”. 6-12...

  • Page 448

    90890-04078 0.15 mm (0.006 in) Water pump seal installer YM-33221-A Middle driven shaft bearing driv- 90890-04058 Bearing driver 40 mm YM-04058 Yamaha bond No. 1215 90890-85505 ® (Three Bond No.1215 1. Straightedge 2. Impeller 5. Install: • Impeller “1” • Circlip...

  • Page 449

    WATER PUMP 2. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-25. 3. Check: • Cooling system Leaks → Repair or replace any faulty part. 4. Measure: • Radiator cap opening pressure Below the specified pressure →...

  • Page 450

    WATER PUMP 6-15...

  • Page 451

    FUEL SYSTEM FUEL TANK ....................7-1 REMOVING THE FUEL TANK..............7-3 REMOVING THE FUEL PUMP ..............7-3 CHECKING THE FUEL PUMP BODY ............7-3 CHECKING THE ROLLOVER VALVES (for California only) ....7-3 INSTALLING THE FUEL PUMP..............7-3 INSTALLING THE FUEL TANK ..............7-4 THROTTLE BODIES..................

  • Page 452

    FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 10 Nm (1.0 m kg, 7.2 ft 16 Nm (1.6 m kg, 11 ft • • • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...

  • Page 453

    FUEL TANK Removing the rollover valve and canister (for California only) Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Side cowlings 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Canister purge hose (throttle body-#1 to 3-way joint) 3-way joint Canister purge hose (throttle body-#4 to 3-way...

  • Page 454

    FUEL TANK EAS26630 EAS26670 REMOVING THE FUEL TANK CHECKING THE FUEL PUMP BODY 1. Extract the fuel in the fuel tank through the 1. Check: fuel tank cap with a pump. • Fuel pump body Obstruction → Clean. 2. Remove: Cracks/damage →...

  • Page 455

    FUEL TANK • After installing the fuel hose holder “1”, make sure that the sections “a”, “b”, and “c” of the holder are installed securely. ET3P61018 INSTALLING THE FUEL TANK 1. Install: • Fuel hose (fuel rail side) EC3P61007 CAUTION: When installing the fuel hose, make sure that it is securely connected, and that the fuel hose connector cover on the fuel hose is in...

  • Page 456

    THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle bodies 3 Nm (0.3 m kg, 2.2 ft • • 3 Nm (0.3 m kg, 2.2 ft • • Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Refer to “GENERAL CHASSIS”...

  • Page 457

    THROTTLE BODIES Removing the throttle bodies 3 Nm (0.3 m kg, 2.2 ft • • 3 Nm (0.3 m kg, 2.2 ft • • Order Job/Parts to remove Q’ty Remarks Plunger control unit hose 2 Disconnect. Throttle body joint For installation, reverse the removal proce- dure.

  • Page 458

    THROTTLE BODIES Removing the injectors 4 Nm (0.4 m kg, 2.9 ft • • 3.5 Nm (0.35 m kg, 2.53 ft • • Order Job/Parts to remove Q’ty Remarks Throttle position sensor coupler Disconnect. Intake air pressure sensor coupler Disconnect. Cylinder-#1 injector coupler Disconnect.

  • Page 459

    THROTTLE BODIES EAS26980 CHECKING THE INJECTORS Pressure gauge 1. Check: 90890-03153 • Injectors YU-03153 Damage → Replace. Fuel pressure adapter 90890-03176 YM-03176 EAS26990 CHECKING THE THROTTLE BODIES 1. Check: • Throttle bodies Cracks/damage → Replace the throttle bod- ies as a set. 2.

  • Page 460

    THROTTLE BODIES Digital circuit tester 90890-03174 Model 88 Multimeter with ta- chometer YU-A1927 c. Turn the main switch to “ON”. d. Measure the throttle position sensor voltage. e. Adjust the throttle position sensor angle so that the voltage is within the specified range. Output voltage (at idle) 0.63–0.73 V f.

  • Page 461

    THROTTLE BODIES 7-10...

  • Page 462

    AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM 7-11...

  • Page 463

    AIR INDUCTION SYSTEM 1. Reed valve assembly 2. Air induction system hose (3-way joint to reed valve cover) 3. Air induction system hose (air cut-off valve to 3-way joint) 4. Air induction system hose (3-way joint to air cut-off valve) 5.

  • Page 464

    AIR INDUCTION SYSTEM Removing the air cut-off valve Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Refer to “GENERAL CHASSIS” on page T-bar 4-1. Air induction system solenoid coupler Disconnect. Air induction system hose (air filter case joint assembly to 3-way joint) Air induction system hose (3-way joint to hose plug)

  • Page 465

    AIR INDUCTION SYSTEM Removing the reed valves 14 Nm (1.4 m kg, 10 ft • • Order Job/Parts to remove Q’ty Remarks Thermostat inlet pipe 1 Refer to “THERMOSTAT” on page 6-6. Reed valve cover (cylinder-#1) Reed valve cover (cylinders-#2/#3) Reed valve cover (cylinder-#4) Reed valve assembly Reed valve plate...

  • Page 466

    AIR INDUCTION SYSTEM EAS27050 1. Check: CHECKING THE PRESSURE REGULATOR • Hoses 1. Check: Loose connections → Connect properly. • Pressure regulator Cracks/damage → Replace. Damage → Replace. • Pipes Cracks/damage → Replace. EAS27060 CHECKING THE AIR INDUCTION SYSTEM 2. Check: •...

  • Page 467

    ELECTRICAL SYSTEM IGNITION SYSTEM ..................8-1 CIRCUIT DIAGRAM (1/2) (FJR13A) ............8-1 CIRCUIT DIAGRAM (2/2) (FJR13A) ............8-3 CIRCUIT DIAGRAM (1/2) (FJR13AE)............8-5 CIRCUIT DIAGRAM (2/2) (FJR13AE)............8-7 ENGINE STOPPING DUE TO SIDESTAND OPERATION....... 8-9 TROUBLESHOOTING ................8-10 ELECTRIC STARTING SYSTEM..............8-13 CIRCUIT DIAGRAM (1/2) (FJR13A) ............

  • Page 468

    FUEL INJECTION SYSTEM ................. 8-57 CIRCUIT DIAGRAM (1/2) (FJR13A) ............8-57 CIRCUIT DIAGRAM (2/2) (FJR13A) ............8-59 CIRCUIT DIAGRAM (1/2) (FJR13AE)............. 8-61 CIRCUIT DIAGRAM (2/2) (FJR13AE)............. 8-63 ECU SELF-DIAGNOSTIC FUNCTION............ 8-65 SELF-DIAGNOSTIC FUNCTION TABLE..........8-66 TROUBLESHOOTING METHOD............8-68 DIAGNOSTIC MODE ................8-69 TROUBLESHOOTING DETAILS ............

  • Page 469

    GRIP WARMER SYSTEM (FJR13AE only) ..........8-159 CIRCUIT DIAGRAM (1/2)..............8-159 CIRCUIT DIAGRAM (2/2)..............8-161 TROUBLESHOOTING ................8-163 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only)..8-165 CIRCUIT DIAGRAM (1/2)..............8-165 CIRCUIT DIAGRAM (2/2)..............8-167 TROUBLESHOOTING ................8-169 MAINTENANCE OF THE MCU............. 8-170 MCU (motor control unit) SELF-DIAGNOSTIC FUNCTION....

  • Page 470

    CHECKING THE AIR INDUCTION SYSTEM SOLENOID....8-232 CHECKING THE CYLINDER IDENTIFICATION SENSOR ....8-232 CHECKING THE INTAKE AIR PRESSURE SENSOR ......8-233 CHECKING THE INTAKE AIR TEMPERATURE SENSOR....8-233 CHECKING THE ACCESSORY BOX SOLENOID ....... 8-234 CHECKING THE YCC-S SPEED SENSOR (FJR13AE only) ....8-234 CHECKING THE GEAR POSITION SENSOR (FJR13AE only) ...

  • Page 472

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM (1/2) (FJR13A)

  • Page 473

    IGNITION SYSTEM 1. Main switch 7. Main fuse 8. Battery 12.Gear position switch 13.Coupler 1 (wire harness–front cowling wire harness) 16.Coupler 2 (wire harness–front cowling wire harness) 30.Coupler 3 (wire harness–front cowling wire harness) 31.Sidestand switch 32.Cylinders-#1/#4 ignition coil 33.Spark plug 34.Cylinders-#2/#3 ignition coil 40.ECU (engine control unit) 41.Crankshaft position sensor...

  • Page 474

    IGNITION SYSTEM ET3P61001 CIRCUIT DIAGRAM (2/2) (FJR13A) Front cowling wire harness...

  • Page 475

    IGNITION SYSTEM 13.Coupler 1 (front cowling wire harness–wire harness) 16.Coupler 2 (front cowling wire harness–wire harness) 30.Coupler 3 (front cowling wire harness–wire harness) 50.Coupler 5 (front cowling wire harness–wire harness) 67.Engine stop switch 76.Relay unit 91.Lean angle sensor...

  • Page 476

    IGNITION SYSTEM ET3P66001 CIRCUIT DIAGRAM (1/2) (FJR13AE)

  • Page 477

    IGNITION SYSTEM 1. Main switch 7. Main fuse 8. Battery 13.Coupler 1 (wire harness–front cowling wire harness) 16.Coupler 2 (wire harness–front cowling wire harness) 17.Neutral switch 32.Coupler 3 (wire harness–front cowling wire harness) 33.Sidestand switch 34.Cylinders-#1/#4 ignition coil 35.Spark plug 36.Cylinders-#2/#3 ignition coil 42.ECU (engine control unit) 43.Crankshaft position sensor...

  • Page 478

    IGNITION SYSTEM ET3P66002 CIRCUIT DIAGRAM (2/2) (FJR13AE) Front cowling wire harness...

  • Page 479

    IGNITION SYSTEM 13.Coupler 1 (front cowling wire harness–wire harness) 16.Coupler 2 (front cowling wire harness–wire harness) 32.Coupler 3 (front cowling wire harness–wire harness) 63.Coupler 5 (front cowling wire harness–wire harness) 81.Engine stop switch 89.Relay unit 103.Lean angle sensor...

  • Page 480

    IGNITION SYSTEM ET3P61002 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the gear position switch (neutral circuit) and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark.

  • Page 481

    IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar 4. Throttle bodies NG → 1. Check the fuses. (Main and ignition) Replace the fuse(s).

  • Page 482

    IGNITION SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-211. OK ↓ NG → 9. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES”...

  • Page 483

    IGNITION SYSTEM 8-12...

  • Page 484

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM (1/2) (FJR13A) 8-13...

  • Page 485

    ELECTRIC STARTING SYSTEM 1. Main switch 7. Main fuse 8. Battery 10.Starter relay 11.Starter motor 12.Gear position switch 16.Coupler 2 (wire harness–front cowling wire harness) 30.Coupler 3 (wire harness–front cowling wire harness) 31.Sidestand switch 50.Coupler 5 (wire harness–front cowling wire harness) 55.Ignition fuse 8-14...

  • Page 486

    ELECTRIC STARTING SYSTEM ET3P61003 CIRCUIT DIAGRAM (2/2) (FJR13A) Front cowling wire harness 8-15...

  • Page 487

    ELECTRIC STARTING SYSTEM 16.Coupler 2 (front cowling wire harness–wire harness) 30.Coupler 3 (front cowling wire harness–wire harness) 50.Coupler 5 (front cowling wire harness–wire harness) 67.Engine stop switch 68.Start switch 71.Clutch switch 76.Relay unit 77.Starting circuit cut-off relay 8-16...

  • Page 488

    ELECTRIC STARTING SYSTEM ET3P66005 CIRCUIT DIAGRAM (1/2) (FJR13AE) 8-17...

  • Page 489

    ELECTRIC STARTING SYSTEM 1. Main switch 7. Main fuse 8. Battery 10.Starter relay 11.Starter motor 12.Diode 1 16.Coupler 2 (wire harness–front cowling wire harness) 17.Neutral switch 24.Rear brake light switch 26.Brake light relay 32.Coupler 3 (wire harness–front cowling wire harness) 33.Sidestand switch 55.MCU (motor control unit) 62.YCC-S control relay...

  • Page 490

    ELECTRIC STARTING SYSTEM ET3P66006 CIRCUIT DIAGRAM (2/2) (FJR13AE) Front cowling wire harness 8-19...

  • Page 491

    ELECTRIC STARTING SYSTEM 16.Coupler 2 (front cowling wire harness–wire harness) 32.Coupler 3 (front cowling wire harness–wire harness) 63.Coupler 5 (front cowling wire harness–wire harness) 80.Front brake light switch 81.Engine stop switch 82.Start switch 89.Relay unit 90.Starting circuit cut-off relay 8-20...

  • Page 492

    ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION (FJR13A) If the engine stop switch is set to “ ” and the main switch is turned “ON” (both switch circuits are closed), the starter motor can only operate if at least one of the following conditions is met: •...

  • Page 493

    ELECTRIC STARTING SYSTEM ET3P66007 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION (FJR13AE) If the engine stop switch is set to “ ” (the switch circuit is closed), the main switch is turned “ON” (the switch circuit is closed), and the brake lever is squeezed (the front brake light switch circuit is open) or the brake pedal is depressed (the rear brake light switch circuit is open), the starter motor can only op- erate if at least one of the following conditions is met: •...

  • Page 494

    ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING (FJR13A) The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar 4. Throttle bodies NG → 1. Check the fuses. (Main and ignition) Replace the fuse(s).

  • Page 495

    ELECTRIC STARTING SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-211. OK ↓ NG → 9. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES”...

  • Page 496

    ELECTRIC STARTING SYSTEM ET3P66008 TROUBLESHOOTING (FJR13AE) The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar 4. Throttle bodies NG → 1. Check the fuses. (Main, signaling system, and igni- tion) Replace the fuse(s).

  • Page 497

    ELECTRIC STARTING SYSTEM NG → 8. Check the brake light relay. Refer to “CHECKING THE RE- Replace the brake light relay. LAYS” on page 8-221. OK ↓ NG → 9. Check the YCC-S control relay. Refer to “CHECKING THE RE- Replace the YCC-S control relay.

  • Page 498

    ELECTRIC STARTING SYSTEM NG → 17.Check the entire starting system wiring. Refer to “CIRCUIT DIAGRAM (1/2) Properly connect or repair the starting sys- (FJR13AE)” on page 8-17 and tem wiring. “CIRCUIT DIAGRAM (2/2) (FJR13AE)” on page 8-19. OK ↓ Replace the MCU or diode 1. 8-27...

  • Page 499

    ELECTRIC STARTING SYSTEM 8-28...

  • Page 500

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM Br/W Br/L Br/L Br/R R R/L Br/L L/B L/Y ( RED ) ( RED ) Br/L (GRAY) (BLACK) Br/B Br/R Br/B R/L B (DARK GREEN) Br/B Br/B G/W B Br/L Br/R Br/L (BLACK) (BLACK) Br/L...

  • Page 501

    CHARGING SYSTEM 2. Rectifier/regulator 3. AC magneto 7. Main fuse 8. Battery 8-30...

  • Page 502

    CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. NOTE: • Before troubleshooting, remove the following part(s): 1. Front cowling right inner panel 1 NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES”...

  • Page 503

    CHARGING SYSTEM 8-32...

  • Page 504

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM (1/2) 8-33...

  • Page 505

    LIGHTING SYSTEM 1. Main switch 7. Main fuse 8. Battery 25.License plate light 27.Tail/brake light 30.Coupler 3 (wire harness–front cowling wire harness) 40.ECU (engine control unit) 50.Coupler 5 (wire harness–front cowling wire harness) 51.Headlight relay (on/off) 52.Hazard lighting fuse 54.Headlight fuse 55.Ignition fuse 8-34...

  • Page 506

    LIGHTING SYSTEM ET3P61004 CIRCUIT DIAGRAM (2/2) Front cowling wire harness 8-35...

  • Page 507

    LIGHTING SYSTEM 30.Coupler 3 (front cowling wire harness–wire harness) 50.Coupler 5 (front cowling wire harness–wire harness) 72.Dimmer switch 86.Meter light 87.High beam indicator light 93.Front left turn signal light 94.Front right turn signal light 95.Headlight relay (dimmer) 97.Headlight 8-36...

  • Page 508

    LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlights, high beam indicator light, taillight, license plate light, front turn signal lights or meter light. NOTE: • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3.

  • Page 509

    LIGHTING SYSTEM NG → 8. Check the entire lighting system wiring. Properly connect or repair the lighting sys- Refer to “CIRCUIT DIAGRAM (1/2)” tem wiring. on page 8-33 and “CIRCUIT DIA- GRAM (2/2)” on page 8-35. OK ↓ Replace the ECU. 8-38...

  • Page 510

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM (1/2) (FJR13A) 8-39...

  • Page 511

    SIGNALING SYSTEM 1. Main switch 4. ABS ECU fuse 7. Main fuse 8. Battery 12.Gear position switch 13.Coupler 1 (wire harness–front cowling wire harness) 15.Fuel sender 16.Coupler 2 (wire harness–front cowling wire harness) 18.ABS ECU (electronic control unit) 20.Rear wheel sensor 23.Rear brake light switch 24.Brake light relay 27.Tail/brake light...

  • Page 512

    SIGNALING SYSTEM ET3P61005 CIRCUIT DIAGRAM (2/2) (FJR13A) Front cowling wire harness 8-41...

  • Page 513

    SIGNALING SYSTEM 13.Coupler 1 (front cowling wire harness–wire harness) 16.Coupler 2 (front cowling wire harness–wire harness) 30.Coupler 3 (front cowling wire harness–wire harness) 48.Coupler 4 (front cowling wire harness–wire harness) 50.Coupler 5 (front cowling wire harness–wire harness) 63.Turn signal/hazard relay 66.Front brake light switch 69.Hazard switch 74.Turn signal switch...

  • Page 514

    SIGNALING SYSTEM ET3P66009 CIRCUIT DIAGRAM (1/2) (FJR13AE) 8-43...

  • Page 515

    SIGNALING SYSTEM 1. Main switch 4. ABS ECU fuse 7. Main fuse 8. Battery 13.Coupler 1 (wire harness–front cowling wire harness) 15.Fuel sender 16.Coupler 2 (wire harness–front cowling wire harness) 17.Neutral switch 19.ABS ECU (electronic control unit) 21.Rear wheel sensor 24.Rear brake light switch 25.Diode 2 26.Brake light relay...

  • Page 516

    SIGNALING SYSTEM ET3P66010 CIRCUIT DIAGRAM (2/2) (FJR13AE) Front cowling wire harness 8-45...

  • Page 517

    SIGNALING SYSTEM 13.Coupler 1 (front cowling wire harness–wire harness) 16.Coupler 2 (front cowling wire harness–wire harness) 32.Coupler 3 (front cowling wire harness–wire harness) 57.Coupler 4 (front cowling wire harness–wire harness) 63.Coupler 5 (front cowling wire harness–wire harness) 78.Turn signal/hazard relay 80.Front brake light switch 83.Hazard switch 87.Turn signal switch...

  • Page 518

    SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or indicator light. • The horn fails to sound. • The fuel meter fails to come on. • The speedometer fails to operate. NOTE: •...

  • Page 519

    SIGNALING SYSTEM Checking the signaling system The horn fails to sound. NG → 1. Check the horn switch. Refer to “CHECKING THE Replace the left handlebar switch. SWITCHES” on page 8-211. OK ↓ NG → 2. Check the horns. Refer to “CHECKING THE Replace the horn(s).

  • Page 520

    SIGNALING SYSTEM NG → 5. Check the diode 2. (FJR13AE) Refer to “CHECKING THE DIODE Replace the diode 2. 2 (FJR13AE only)” on page 8-236. OK ↓ NG → 6. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM (1/2) (FJR13A)”...

  • Page 521

    SIGNALING SYSTEM NG → 5. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM (1/2) (FJR13A)” on page 8-39, “CIRCUIT Properly connect or repair the signaling DIAGRAM (2/2) (FJR13A)” on page system wiring. 8-41, “CIRCUIT DIAGRAM (1/2) (FJR13AE)” on page 8-43, and “CIRCUIT DIAGRAM (2/2) (FJR13AE)”...

  • Page 522

    SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM (1/2) Properly connect or repair the signaling (FJR13A)” on page 8-39 and “CIR- system wiring. CUIT DIAGRAM (2/2) (FJR13A)” on page 8-41. OK ↓ Replace the meter assembly. The oil level warning light fails to come on.

  • Page 523

    SIGNALING SYSTEM The speedometer fails to operate. NG → 1. Check the rear wheel sensor. Refer to “MAINTENANCE OF THE Replace the rear wheel sensor. REAR WHEEL SENSOR AND SENSOR ROTOR” on page 4-26. OK ↓ NG → 2. Check the entire speed sensor wir- Properly connect or repair the speed sen- ing.

  • Page 524

    COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-53...

  • Page 525

    COOLING SYSTEM 1. Main switch 7. Main fuse 8. Battery 40.ECU (engine control unit) 43.Coolant temperature sensor 55.Ignition fuse 58.Radiator fan motor relay 59.Left radiator fan motor fuse 60.Left radiator fan motor 61.Right radiator fan motor fuse 62.Right radiator fan motor 8-54...

  • Page 526

    COOLING SYSTEM EAS27320 TROUBLESHOOTING The radiator fan motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar NG → 1. Check the fuses. (Main, ignition, left radiator fan mo- tor, and right radiator fan motor) Replace the fuse(s).

  • Page 527

    COOLING SYSTEM 8-56...

  • Page 528

    FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM (1/2) (FJR13A) 8-57...

  • Page 529

    FUEL INJECTION SYSTEM 1. Main switch 4. ABS ECU fuse 5. Fuel injection system fuse 7. Main fuse 8. Battery 12.Gear position switch 13.Coupler 1 (wire harness–front cowling wire harness) 14.Fuel pump 16.Coupler 2 (wire harness–front cowling wire harness) 18.ABS ECU (electronic control unit) 20.Rear wheel sensor 30.Coupler 3 (wire harness–front cowling wire harness)

  • Page 530

    FUEL INJECTION SYSTEM ET3P61006 CIRCUIT DIAGRAM (2/2) (FJR13A) Front cowling wire harness 8-59...

  • Page 531

    FUEL INJECTION SYSTEM 13.Coupler 1 (front cowling wire harness–wire harness) 16.Coupler 2 (front cowling wire harness–wire harness) 30.Coupler 3 (front cowling wire harness–wire harness) 50.Coupler 5 (front cowling wire harness–wire harness) 67.Engine stop switch 72.Dimmer switch 76.Relay unit 78.Fuel pump relay 83.Multi-function meter 85.Engine trouble warning light 91.Lean angle sensor...

  • Page 532

    FUEL INJECTION SYSTEM ET3P66012 CIRCUIT DIAGRAM (1/2) (FJR13AE) 8-61...

  • Page 533

    FUEL INJECTION SYSTEM 1. Main switch 4. ABS ECU fuse 5. Fuel injection system fuse 7. Main fuse 8. Battery 13.Coupler 1 (wire harness–front cowling wire harness) 14.Fuel pump 16.Coupler 2 (wire harness–front cowling wire harness) 17.Neutral switch 19.ABS ECU (electronic control unit) 21.Rear wheel sensor 32.Coupler 3 (wire harness–front cowling wire harness)

  • Page 534

    FUEL INJECTION SYSTEM ET3P66013 CIRCUIT DIAGRAM (2/2) (FJR13AE) Front cowling wire harness 8-63...

  • Page 535

    FUEL INJECTION SYSTEM 13.Coupler 1 (front cowling wire harness–wire harness) 16.Coupler 2 (front cowling wire harness–wire harness) 32.Coupler 3 (front cowling wire harness–wire harness) 63.Coupler 5 (front cowling wire harness–wire harness) 81.Engine stop switch 85.Dimmer switch 89.Relay unit 91.Fuel pump relay 96.Multi-function meter 98.Engine trouble warning light 103.Lean angle sensor...

  • Page 536

    FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 537

    FUEL INJECTION SYSTEM a. Main switch “OFF” d. Engine trouble warning light on for 1.4 seconds b. Main switch “ON” c. Engine trouble warning light off EAS27380 SELF-DIAGNOSTIC FUNCTION TABLE If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.

  • Page 538

    FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive Intake air tempera- Intake air temperature sensor: ture sensor Able Able open or short circuit detected. (open or short circuit) sensor No normal signal is received from Able...

  • Page 539

    FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive Faulty ECU memory. (When this ECU internal malfunc- malfunction is detected in the Unable Unable tion ECU, the fault code number might not appear on the meter.) Communication error with the meter Able / un-...

  • Page 540

    FUEL INJECTION SYSTEM 5. Erase the malfunction history in the diagnos- The engine operation is not normal but the tic mode. Refer to “Sensor operation table engine trouble warning light does not come (Diagnostic code No. 62)”. 1. Check the operation of following sensors and NOTE: actuators in the Diagnostic mode.

  • Page 541

    FUEL INJECTION SYSTEM “d:01 d:70” “d:70 d:01” 7. Verify the operation of the sensor or actuator. • Sensor operation The data representing the operating conditions of the sensor appears on the trip LCD. • Actuator operation Set the engine stop switch to “ ”...

  • Page 542

    FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in front cowling wire A break or disconnection of harness. the black/red lead of the • Open or short circuit in wire harness. ECU is detected.

  • Page 543

    FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in front cowling wire Malfunction detected in the harness. primary wire of the cylin- • Open or short circuit in wire harness. ders-#1/#4 ignition coil.

  • Page 544

    FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in front cowling wire harness. • Open or short circuit in wire harness. No signals are received Er-1 • Malfunction in meter assembly. —...

  • Page 545

    FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Vehicle speed pulse 0–999 Check that the number in- creases when the rear wheel is rotated. The num- ber is cumulative and does not reset each time the wheel is stopped. Lean angle sensor Remove the lean angle sensor and incline it more...

  • Page 546

    FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Malfunction history code — display • No history • History exists Fault codes 11-50 • (If more than one code number is detected, the dis- play alternates every two seconds to show all the de- tected code numbers.

  • Page 547

    FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the injector #2 five times at one-second inter- Check the operating sound Injector #2 vals. of the injector #2 five times. Illuminates the engine trou- ble warning light. Actuates the injector #3 five times at one-second inter- Check the operating sound Injector #3...

  • Page 548

    FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Disconnect the grip warmer control unit coupler from the control unit, if equipped, and then con- Illuminates the engine trou- Grip warmer nect a pocket tester to the ble warning light. terminals (light green/white–black) of the coupler (wire harness side)

  • Page 549

    FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the crankshaft posi- tion sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of crankshaft posi- Check for looseness or pinching. Cranking the tion sensor engine.

  • Page 550

    FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor: open or short circuit detected. Diagnostic code No. Intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...

  • Page 551

    FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor: open or short circuit detected. Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle position Check for looseness or pinching. Turning the sensor.

  • Page 552

    FUEL INJECTION SYSTEM Fault code No. Symptom Stuck throttle position sensor is detected. Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle position Check for looseness or pinching. Starting the en- sensor.

  • Page 553

    FUEL INJECTION SYSTEM Fault code No. Symptom A break or disconnection of the black/red lead of the ECU is detected. Diagnostic code No. Sidestand switch Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Execute the diagnostic mode. If the transmis- •...

  • Page 554

    FUEL INJECTION SYSTEM Fault code No. Symptom Coolant temperature sensor: open or short circuit detect- Diagnostic code No. Coolant temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of coolant tempera- Check for looseness or pinching. Turning the ture sensor main switch to “ON”.

  • Page 555

    FUEL INJECTION SYSTEM Fault code No. Symptom Intake air temperature sensor: open or short circuit de- tected. Diagnostic code No. Intake air temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of intake air tem- Check for looseness or pinching.

  • Page 556

    FUEL INJECTION SYSTEM Fault code No. Symptom No normal signal is received from the O sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of O sensor Check for looseness or pinching. Starting the en- gine, warming it Connections •...

  • Page 557

    FUEL INJECTION SYSTEM Fault code No. Symptom Latch up detected. No normal signal is received from the lean angle sensor. Diagnostic code No. Lean angle sensor Order Item/components and probable Check or maintenance job Reinstatement cause method The vehicle has overturned. Raise the vehicle upright.

  • Page 558

    FUEL INJECTION SYSTEM Fault code No. Symptom The amount of air-fuel ratio feedback compensation is maintained continuously in the vicinity of the upper limit (lean air-fuel ratio). Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method...

  • Page 559

    FUEL INJECTION SYSTEM Fault code No. Symptom The amount of air-fuel ratio feedback compensation is maintained continuously in the vicinity of the upper limit (lean air-fuel ratio). Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method...

  • Page 560

    FUEL INJECTION SYSTEM Fault code No. Symptom The amount of air-fuel ratio feedback compensation is maintained continuously in the vicinity of the lower limit (rich air-fuel ratio). Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method...

  • Page 561

    FUEL INJECTION SYSTEM Fault code No. Symptom The amount of air-fuel ratio feedback compensation is maintained continuously in the vicinity of the lower limit (rich air-fuel ratio). Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method...

  • Page 562

    FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinders- #1/#4 ignition coil. Diagnostic code No. Cylinders-#1/#4 ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the en- •...

  • Page 563

    FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinders- #2/#3 ignition coil. Diagnostic code No. Cylinders-#2/#3 ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the en- •...

  • Page 564

    FUEL INJECTION SYSTEM Fault code No. Symptom Lean angle sensor: open or short circuit detected. Diagnostic code No. Lean angle sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...

  • Page 565

    FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the rear wheel sensor. B. Open or short circuit is detected in the neutral circuit of the gear position switch. (FJR13A) Open or short circuit is detected in the neutral switch. (FJR13AE) Diagnostic code No.

  • Page 566

    FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the rear wheel sensor. B. Open or short circuit is detected in the neutral circuit of the gear position switch. (FJR13A) Open or short circuit is detected in the neutral switch. (FJR13AE) Diagnostic code No.

  • Page 567

    FUEL INJECTION SYSTEM Fault code No. Symptom The ECU is unable to monitor the battery voltage (an open or short circuit in the line to the ECU). Diagnostic code No. Fuel system voltage Order Item/components and probable Check or maintenance job Reinstatement cause method...

  • Page 568

    FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to the fuel injection system is not normal. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the en- •...

  • Page 569

    FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signals are received from the ECU. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...

  • Page 570

    FUEL INJECTION SYSTEM Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...

  • Page 571

    FUEL INJECTION SYSTEM 8-100...

  • Page 572

    FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM (1/2) 8-101...

  • Page 573

    FUEL PUMP SYSTEM 1. Main switch 5. Fuel injection system fuse 7. Main fuse 8. Battery 14.Fuel pump 16.Coupler 2 (wire harness–front cowling wire harness) 40.ECU (engine control unit) 50.Coupler 5 (wire harness–front cowling wire harness) 55.Ignition fuse 8-102...

  • Page 574

    FUEL PUMP SYSTEM ET3P61007 CIRCUIT DIAGRAM (2/2) Front cowling wire harness 8-103...

  • Page 575

    FUEL PUMP SYSTEM 16.Coupler 2 (front cowling wire harness–wire harness) 50.Coupler 5 (front cowling wire harness–wire harness) 67.Engine stop switch 76.Relay unit 78.Fuel pump relay 8-104...

  • Page 576

    FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar NG → 1. Check the fuses. (Main, ignition, and fuel injection system) Replace the fuse(s).

  • Page 577

    FUEL PUMP SYSTEM 8-106...

  • Page 578

    WINDSHIELD DRIVE SYSTEM EAS27610 WINDSHIELD DRIVE SYSTEM EAS27620 CIRCUIT DIAGRAM (1/2) 8-107...

  • Page 579

    WINDSHIELD DRIVE SYSTEM 1. Main switch 6. Backup fuse (odometer, clock, and windshield drive system) 7. Main fuse 8. Battery 16.Coupler 2 (wire harness–front cowling wire harness) 50.Coupler 5 (wire harness–front cowling wire harness) 53.Signaling system fuse 8-108...

  • Page 580

    WINDSHIELD DRIVE SYSTEM ET3P61008 CIRCUIT DIAGRAM (2/2) Front cowling wire harness 8-109...

  • Page 581

    WINDSHIELD DRIVE SYSTEM 16.Coupler 2 (front cowling wire harness–wire harness) 50.Coupler 5 (front cowling wire harness–wire harness) 73.Windshield position switch 100.Windshield drive unit 8-110...

  • Page 582

    WINDSHIELD DRIVE SYSTEM EAS27630 TROUBLESHOOTING The windshield fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar NG → 1. Check the fuses. (Main, signaling system, and back- Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...

  • Page 583

    WINDSHIELD DRIVE SYSTEM 8-112...

  • Page 584

    ACCESSORY BOX SYSTEM ET3P61009 ACCESSORY BOX SYSTEM ET3P61010 CIRCUIT DIAGRAM (1/2) Br/W Br/L Br/L Br/R R R/L Br/L L/B L/Y ( RED ) ( RED ) Br/L (GRAY) (BLACK) Br/B Br/B Br/R Br/B Br/B Br/L Br/R Br/L (BLACK) (BLACK) Br/L Br/B (BLACK) (BLACK)

  • Page 585

    ACCESSORY BOX SYSTEM 1. Main switch 7. Main fuse 8. Battery 50.Coupler 5 (wire harness–front cowling wire harness) 53.Signaling system fuse 8-114...

  • Page 586

    ACCESSORY BOX SYSTEM ET3P61011 CIRCUIT DIAGRAM (2/2) Front cowling wire harness 8-115...

  • Page 587

    ACCESSORY BOX SYSTEM 50.Coupler 5 (front cowling wire harness–wire harness) 79.Accessory box solenoid 8-116...

  • Page 588

    ACCESSORY BOX SYSTEM ET3P61012 TROUBLESHOOTING The accessory box fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1. Front cowling assembly NG → 1. Check the fuses. (Main and signaling system) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...

  • Page 589

    ACCESSORY BOX SYSTEM 8-118...

  • Page 590

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS28790 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27730 CIRCUIT DIAGRAM (1/2) (FJR13A) 8-119...

  • Page 591

    ABS (ANTI-LOCK BRAKE SYSTEM) 1. Main switch 4. ABS ECU fuse 7. Main fuse 8. Battery 9. ABS motor fuse 10.Starter relay 13.Coupler 1 (wire harness–front cowling wire harness) 16.Coupler 2 (wire harness–front cowling wire harness) 17.ABS test coupler 18.ABS ECU (electronic control unit) 19.Front wheel sensor 20.Rear wheel sensor 21.ABS motor relay...

  • Page 592

    ABS (ANTI-LOCK BRAKE SYSTEM) ET3P61021 CIRCUIT DIAGRAM (2/2) (FJR13A) Front cowling wire harness 8-121...

  • Page 593

    ABS (ANTI-LOCK BRAKE SYSTEM) 13.Coupler 1 (front cowling wire harness–wire harness) 16.Coupler 2 (front cowling wire harness–wire harness) 30.Coupler 3 (front cowling wire harness–wire harness) 50.Coupler 5 (front cowling wire harness–wire harness) 66.Front brake light switch 67.Engine stop switch 68.Start switch 76.Relay unit 77.Starting circuit cut-off relay 82.ABS warning light...

  • Page 594

    ABS (ANTI-LOCK BRAKE SYSTEM) ET3P66014 CIRCUIT DIAGRAM (1/2) (FJR13AE) 8-123...

  • Page 595

    ABS (ANTI-LOCK BRAKE SYSTEM) 1. Main switch 4. ABS ECU fuse 7. Main fuse 8. Battery 9. ABS motor fuse 10.Starter relay 12.Diode 1 13.Coupler 1 (wire harness–front cowling wire harness) 16.Coupler 2 (wire harness–front cowling wire harness) 18.ABS test coupler 19.ABS ECU (electronic control unit) 20.Front wheel sensor 21.Rear wheel sensor...

  • Page 596

    ABS (ANTI-LOCK BRAKE SYSTEM) ET3P66015 CIRCUIT DIAGRAM (2/2) (FJR13AE) Front cowling wire harness 8-125...

  • Page 597

    ABS (ANTI-LOCK BRAKE SYSTEM) 13.Coupler 1 (front cowling wire harness–wire harness) 16.Coupler 2 (front cowling wire harness–wire harness) 32.Coupler 3 (front cowling wire harness–wire harness) 63.Coupler 5 (front cowling wire harness–wire harness) 80.Front brake light switch 81.Engine stop switch 82.Start switch 89.Relay unit 90.Starting circuit cut-off relay 95.ABS warning light...

  • Page 598

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS27740 ABS COMPONENTS CHART 11,12 1. ABS test coupler 2. ABS warning light 3. ABS ECU fuse 4. ABS motor fuse 5. ABS motor relay 6. ABS ECU (electronic control unit) 7. Hydraulic unit (HU) 8. Rear wheel sensor 9.

  • Page 599

    ABS (ANTI-LOCK BRAKE SYSTEM) 8-128...

  • Page 600

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS27750 ABS COUPLER LOCATION CHART B/Y Y/W Y/L L L Y/L Y/W B/Y L/W Y/G W/L G/W G/W W/L Y/G L/W Ch Dg R/G B/W G/R Sb B/L B/W W G/B G/R G/B B/R P B/R G/B G/R B/R L/W Y/W P B/Y R/W G/W Y/L Sb/W Y R/G R/L B/R L/Y L/Y B/R R/L R/G...

  • Page 601

    ABS (ANTI-LOCK BRAKE SYSTEM) 1. Meter assembly coupler 2. ABS test coupler 3. ABS motor relay coupler 4. Hydraulic unit solenoid coupler 5. ABS motor coupler 6. Rear wheel sensor coupler 7. ABS ECU coupler 8. Wire harness–ABS wire harness coupler 9.

  • Page 602

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS27760 ABS ECU AND ABS MOTOR RELAY Removing the ABS ECU and ABS motor relay Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rear side cover 4-1. Refer to “GENERAL CHASSIS” on page Storage compartment 4-1.

  • Page 603

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS27770 NOTE: MAINTENANCE OF THE ABS ECU Measure the resistance of the front brake, rear brake, and unified brake system solenoid Checking the ABS ECU valves. 1. Check: • Terminals “1” of the ABS ECU M MMM M MMM M MMM M MMM...

  • Page 604

    ABS (ANTI-LOCK BRAKE SYSTEM) • Positive tester probe → Pocket tester terminals “1”, “2”, “3”, “4”, “5”, and “6” 90890-03112 • Negative tester probe → Analog pocket tester negative battery terminal YU-03112-C • Positive tester probe → terminal “1” • Negative tester probe → terminal “2”...

  • Page 605

    ABS (ANTI-LOCK BRAKE SYSTEM) Self-diagnosis and servicing The ABS ECU has a self-diagnosis function. By utilizing this function, quick problem identification and service are possible. Previous malfunctions can be checked since the ABS ECU also stores the mal- function history. In case malfunctions are detected: The light cannot be used to recall the malfunction codes from the memory of the ABS ECU if the ABS warning light is already on.

  • Page 606

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS27810 BASIC PROCESS FOR TROUBLESHOOTING Does not come on. Comes on for 2 seconds, then goes off. Check the ABS warning light. Flashing. Remains on. [B-1] [B-3] [B-2] [B-5] [B-4] The ABS warning light The ABS warning The ABS warning Present Past...

  • Page 607

    ABS (ANTI-LOCK BRAKE SYSTEM) NOTE: Do not delete the malfunction codes during the troubleshooting procedures. Be sure to delete the codes when the service is finished. EW3P61011 WARNING When maintenance or checks have been performed on components related to the ABS, be sure to perform a final check before delivering the vehicle to the customer.

  • Page 608

    ABS (ANTI-LOCK BRAKE SYSTEM) 1. The malfunction code “1” is displayed on the multi-function display (example: malfunction code 11). 2. The ABS warning light flashes every 0.5 second for more than 6 seconds. The ABS warning light flashes every 0.5 second if a malfunction code for a past malfunction is not stored in the memory of the ABS ECU.

  • Page 609

    ABS (ANTI-LOCK BRAKE SYSTEM) 1. ABS test coupler 7. ABS warning light terminal (green/red) 2. Lock plate 8. Test coupler adapter 3. Protective cap 9. Light green lead 4. Ground terminal (black) 10. Black lead 5. T/C terminal (sky blue) 11.

  • Page 610

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS27840 [C-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON WHEN THE MAIN SWITCH IS TURNED TO “ON” Disconnect the ABS ECU couplers and meter assembly coupler, and then connect the test coupler adapter to the ABS test coupler. 1.

  • Page 611

    ABS (ANTI-LOCK BRAKE SYSTEM) W/B Br/B Br/W B B/W G/R G/Y W/Y Lg R/B B W/G W/L W/Y Y/G Sb B2 W/L R/W Br/G B R/B 5. ABS ECU 8. Starter relay 6. Start switch 9. Starter motor 7. Relay unit (starting circuit cut-off relay) ET3P61066 [C-4] THE ABS WARNING LIGHT FLASHES With the engine off, check the front and rear brake light switches.

  • Page 612

    ABS (ANTI-LOCK BRAKE SYSTEM) • The vehicle was continuously ridden on extremely uneven roads. The system is normal. • The front or rear brake light switch is defective or improperly adjusted. Replace or adjust. ET3P61068 [C-6] THE ABS WARNING LIGHT REMAINS ON 1.

  • Page 613

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS27880 [C-7] DIAGNOSIS BY THE MALFUNCTION CODE Connect the test coupler adapter to the ABS test coupler, and then connect a pocket tester to the light green terminal of the adapter and the positive battery terminal to determine the malfunction code by the movement of the pocket tester needle.

  • Page 614

    ABS (ANTI-LOCK BRAKE SYSTEM) Malfunc- Problem Check point Reference tion code No continuity in the front or rear wheel sensor circuits. • Continuity of the sensor cir- Malfunction cuits codes 15 and • Wire harness and ABS wire 15/16 harness (ABS circuit) (See page •...

  • Page 615

    ABS (ANTI-LOCK BRAKE SYSTEM) Malfunc- Problem Check point Reference tion code Rear wheel will not recover from the locking tendency even though the sig- nal is continuously transmitted from the ABS ECU to release the hydraulic • Brake dragging Malfunction pressure (when the battery voltage is •...

  • Page 616

    ABS (ANTI-LOCK BRAKE SYSTEM) Malfunc- Problem Check point Reference tion code Rear wheel will not recover from the locking tendency even though the sig- nal is continuously transmitted from the • Brake dragging Malfunction ABS ECU to release the hydraulic •...

  • Page 617

    ABS (ANTI-LOCK BRAKE SYSTEM) c. Front wheel sensor circuit is short-circuited. • Front wheel sensor or lead is short-circuited. Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4-20 and “INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS)” on page 4-22. •...

  • Page 618

    ABS (ANTI-LOCK BRAKE SYSTEM) NOTE: If the vehicle is continuously ridden on extremely uneven roads, the ABS warning light may flash and malfunction code 11 or 12 may be recorded depending on the condition. Malfunction codes 13/26 (front wheel) and 14/27 (rear wheel) (Incorrect signal from the front (13/26) or rear (14/27) wheel sensor is detected.) 1.

  • Page 619

    ABS (ANTI-LOCK BRAKE SYSTEM) • Front or rear wheel sensor or lead is broken. Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4-20, “INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS)” on page 4-22, “MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR” on page 4-26, and “INSTALLING THE REAR WHEEL (REAR BRAKE DISC)”...

  • Page 620

    ABS (ANTI-LOCK BRAKE SYSTEM) Malfunction code 23 (Front or rear brake light switch is defective.) 1. Wire harness, ABS wire harness, and front cowling wire harness • Check the entire anti-lock brake system wiring. Refer to “CIRCUIT DIAGRAM (1/2) (FJR13A)” on page 8-119, “CIRCUIT DIAGRAM (2/2) (FJR13A)” on page 8-121, “CIRCUIT DIAGRAM (1/2) (FJR13AE)”...

  • Page 621

    ABS (ANTI-LOCK BRAKE SYSTEM) W/B Br/B Br/W B B/W G/R G/Y W/Y Lg G/Y Br Br/B R/B B W/G W/L W/Y Y/G Sb B2 3. ABS ECU 6. Rear brake light switch 4. Front brake light switch 7. Tail/brake light 5.

  • Page 622

    ABS (ANTI-LOCK BRAKE SYSTEM) EW3P61005 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake hose lines. • Check that the connections of the brake hose lines from the brake master cylinder to the hydraulic unit and from the hydraulic unit to the front brake calipers and the metering valve are correct.

  • Page 623

    EW3P61005 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake hose lines. • Check that the connections of the brake hose lines from the brake master cylinder to the hydraulic unit and from the hydraulic unit to the proportioning valve are correct.

  • Page 624

    ABS (ANTI-LOCK BRAKE SYSTEM) Terminal color Solenoid ABS wire harness Front brake white, white red/white, white/blue Rear brake green, green red/white, white/green Unified brake system red, red red/white, white/yellow 6. Hydraulic unit If the malfunction is not corrected after checking items (1) to (5), replace the hydraulic unit. Be sure to connect the brake hoses and couplers correctly and securely.

  • Page 625

    ABS (ANTI-LOCK BRAKE SYSTEM) 3. Wire harness and ABS wire harness • Remove the ABS motor relay and ABS motor fuse, and then check for continuity between the red/blue terminal of ABS wire harness and the starter relay ABS motor fuse terminal “1” (ABS wire harness side) shown in the illustration.

  • Page 626

    ABS (ANTI-LOCK BRAKE SYSTEM) W/B Br/B Br/W B B/W G/R G/Y W/Y Lg R/W R/W R/B B W/G W/L W/Y Y/G Sb B2 5. ABS ECU 8. Rear brake solenoid 6. Hydraulic unit 9. Unified brake system solenoid 7. Front brake solenoid 3.

  • Page 627

    ABS (ANTI-LOCK BRAKE SYSTEM) 5. The multi-function display switches to the ET3P61020 [D-2] DELETE FUNCTION TEST odometer/tripmeter/fuel reserve tripmeter 1. Place the vehicle on the centerstand. display and the ABS warning light flashes in 2. Turn the main switch to “OFF”. 0.5 second-intervals while the malfunction 3.

  • Page 628

    ABS (ANTI-LOCK BRAKE SYSTEM) M MMM M MMM M MMM M MMM M MMM Pocket tester a. Connect the pocket tester (DC 12 V) to the 90890-03112 ABS ECU couplers. Analog pocket tester YU-03112-C Pocket tester 90890-03112 Analog pocket tester •...

  • Page 629

    ABS (ANTI-LOCK BRAKE SYSTEM) 8-158...

  • Page 630

    GRIP WARMER SYSTEM (FJR13AE only) ET3P66016 GRIP WARMER SYSTEM (FJR13AE only) ET3P66017 CIRCUIT DIAGRAM (1/2) 8-159...

  • Page 631

    GRIP WARMER SYSTEM (FJR13AE only) 1. Main switch 7. Main fuse 8. Battery 42.ECU (engine control unit) 63.Coupler 5 (wire harness–front cowling wire harness) 64.Headlight (on/off)/grip warmer relay 66.Signaling system fuse 67.Headlight fuse 70.Grip warmer control unit 8-160...

  • Page 632

    GRIP WARMER SYSTEM (FJR13AE only) ET3P66018 CIRCUIT DIAGRAM (2/2) Front cowling wire harness W/L R/W R/W L/W Br/G B R/B R/B B Br/W Ch G/Y G/L R/W R/W G/L R/B L/R Br/B Br/B L/R R/B L/Y Br/R Br/B Br/G Br/B Br/Y B Br/G Br/G...

  • Page 633

    GRIP WARMER SYSTEM (FJR13AE only) 63.Coupler 5 (front cowling wire harness–wire harness) 117.Right grip warmer 118.Left grip warmer 8-162...

  • Page 634

    GRIP WARMER SYSTEM (FJR13AE only) ET3P66019 TROUBLESHOOTING • The grip warmers do not become warm at all. • The grip warmers are abnormally hot while the engine is idling. • The grip warmers do not become very warm while the vehicle is traveling. NOTE: •...

  • Page 635

    GRIP WARMER SYSTEM (FJR13AE only) NG → 2. Disconnect the grip warmer control unit coupler (white/yellow and black/green) and check that the Replace the ECU. temperature does not drop while the engine is running. OK ↓ Replace the grip warmer control unit. The grip warmers do not become very warm while the vehicle is traveling.

  • Page 636

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) ET3P66056 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) ET3P66057 CIRCUIT DIAGRAM (1/2) 8-165...

  • Page 637

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) 1. Main switch 7. Main fuse 8. Battery 13.Coupler 1 (wire harness–front cowling wire harness) 16.Coupler 2 (wire harness–front cowling wire harness) 19.ABS ECU (electronic control unit) 24.Rear brake light switch 26.Brake light relay 32.Coupler 3 (wire harness–front cowling wire...

  • Page 638

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) ET3P66058 CIRCUIT DIAGRAM (2/2) Front cowling wire harness 8-167...

  • Page 639

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) 13.Coupler 1 (front cowling wire harness–wire harness) 16.Coupler 2 (front cowling wire harness–wire harness) 32.Coupler 3 (front cowling wire harness–wire harness) 57.Coupler 4 (front cowling wire harness–wire harness) 58.Coupler 6 (front cowling wire harness–wire harness) 63.Coupler 5 (front cowling wire harness–wire...

  • Page 640

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) ET3P66059 TROUBLESHOOTING • The hand shift select indicator light fails to come on. • The transmission gear display on the multi-function meter fails to indicate the selected gear. NOTE: • Before troubleshooting, remove the following part(s): 1.

  • Page 641

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) The transmission gear display on the multi-function meter fails to indicate the selected gear. NG → 1. Check the gear position sensor. Refer to “CHECKING THE GEAR POSITION SENSOR (FJR13AE only)” on page 8-235 and “AD- Replace the gear position sensor.

  • Page 642

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) SHIFT Checking the YCC-S indicator and warning light The YCC-S indicator and warning light come on for 1.4 seconds after the main switch has been turned to “ON” and they come on while the start switch is being pushed. If the YCC-S indicator and warning light does not come on under these conditions, the warning light (LED) may be defective.

  • Page 643

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Able/un- Fault Able/un- able to Symptom Malfunction detecting condition code No. able to start change the shift Overcurrent to clutch Detected current in shift actuator Sh_ _13* Unable Unable actuator motor motor is too high.

  • Page 644

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Able/un- Fault Able/un- able to Symptom Malfunction detecting condition code No. able to start change the shift Engine speed signal from ECU Engine speed signal Sh_ _31 does not match multi-function Unable Unable is abnormal.

  • Page 645

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Able/un- Fault Able/un- able to Symptom Malfunction detecting condition code No. able to start change the shift Braking signal is not No braking signal is received by Sh_ _47 detected while brak- MCU (motor control unit) when ve-...

  • Page 646

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) 5. Erase the malfunction history in the diagnos- tic mode. Refer to “Diagnostic code table (Di- agnostic code No. Sh_ _62)”. NOTE: Turning the main switch to “OFF” will not erase the malfunction history.

  • Page 647

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Diagnostic code table Diagnos- Data displayed on tic code Item meter (reference Checking method value) Sh_ _61 Malfunction history code display • No history Sh_ _61 — • History exists Fault code numbers If fault codes are stored in the malfunction Sh_ _11–Sh_ _52...

  • Page 648

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Diagnos- Data displayed on tic code Item meter (reference Checking method value) Sh_ _63 Clutch actuation op- Sh_ _63 The clutch actuator can be operated in this eration mode. 1. The hand shift select indicator light NOTE: comes on when the clutch is engaged.

  • Page 649

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Diagnos- Data displayed on tic code Item meter (reference Checking method value) Sh_ _65 Gear position setting Sh_ _65 The gear position can be set in this mode. 1. Make sure that the transmission is in neutral.

  • Page 650

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Diagnos- Data displayed on tic code Item meter (reference Checking method value) Sh_ _66 Adjust the clutch en- Sh_ _66 This mode adjust the clutch engagement gagement position point manually. The clutch engagement point while the ve-...

  • Page 651

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Fault code No. Sh_ _11 Symptom Too low or too high voltage is supplied to the YCC-S system. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •...

  • Page 652

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Fault code No. Sh_ _13 Symptom Over current to clutch actuator motor. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...

  • Page 653

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Fault code No. Sh_ _14 Symptom Over current to shift actuator motor. Order Item/components and probable Check or maintenance job Reinstatement cause method • Connections • Check the coupler for any pins Turning the •...

  • Page 654

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Fault code No. Sh_ _15 Symptom Abnormal current is detected in clutch or shift actuator motor drive circuit. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...

  • Page 655

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Fault code No. Sh_ _16 Symptom Malfunction of clutch or shift actuator motor drive circuit in the MCU (motor control unit). Order Item/components and probable Check or maintenance job Reinstatement cause method Connections •...

  • Page 656

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Fault code No. Sh_ _17 Symptom Detected clutch actuator position is incorrect. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...

  • Page 657

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Fault code No. Sh_ _18 Symptom Detected shift actuator position is incorrect. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...

  • Page 658

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Fault code No. Sh_ _19 Symptom Output signal of shift actuator sensor is abnor- mal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...

  • Page 659

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Fault code No. Sh_ _21 Symptom Output signal of gear position sensor is abnor- mal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •...

  • Page 660

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Fault code No. Sh_ _22 Symptom Output signal of foot shift switch is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •...

  • Page 661

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Fault code No. Sh_ _25 Symptom Error has occurred in the actuator drive circuit in MCU (motor control unit) when main switch is turned to “ON”. Order Item/components and probable Check or maintenance job...

  • Page 662

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Fault code No. Sh_ _27 Symptom Diagnosis mode is activated at engine start-up. Order Item/components and probable Check or maintenance job Reinstatement cause method YCC-S test coupler • Check that the test coupler Turning the adapter is not connected.

  • Page 663

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Fault code No. Sh_ _32 Symptom YCC-S speed sensor signal is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...

  • Page 664

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Fault code No. Sh_ _35 Symptom Start switch signal is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the • Wire harness MCU (motor control that may be pulled out.

  • Page 665

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Fault code No. Sh_ _37 Symptom Power supply to clutch or shift actuator motor is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...

  • Page 666

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Fault code No. Sh_ _38 Symptom Malfunction of hand shift lever switch (shift up or shift down). Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •...

  • Page 667

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Fault code No. Sh_ _41 Symptom Coolant temperature sensor signal is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •...

  • Page 668

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Fault code No. Sh_ _43 Symptom Communication between MCU (motor control unit) and ABS ECU is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •...

  • Page 669

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Fault code No. Sh_ _45 Symptom Shift operation and gear position do not match. Order Item/components and probable Check or maintenance job Reinstatement cause method Shift rod • Check the shift rod pin hole lo- Turning the cation.

  • Page 670

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Fault code No. Sh_ _47 Symptom Braking signal is not detected while braking. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •...

  • Page 671

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Fault code No. Sh_ _49 Symptom Engine idling speed is too high when vehicle is started. Order Item/components and probable Check or maintenance job Reinstatement cause method Clutch operation. • Check the clutch stroke.

  • Page 672

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) Fault code No. Sh_ _52 Symptom Main switch signal is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the • Wire harness MCU (motor control that may be pulled out.

  • Page 673

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE only) 8-202...

  • Page 674

    ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS FJR13A 8-203...

  • Page 675

    ELECTRICAL COMPONENTS 1. Windshield drive unit 2. Battery 3. Starter relay 4. ABS motor fuse 5. Front brake light switch 6. Clutch switch 7. Fuse box 2 8. Fuse box 1 9. Right radiator fan motor 10. Left radiator fan motor 11.

  • Page 676

    ELECTRICAL COMPONENTS FJR13A 8-205...

  • Page 677

    ELECTRICAL COMPONENTS 1. Coolant temperature sensor 2. Throttle position sensor 3. Intake air pressure sensor 4. Intake air temperature sensor 5. ABS motor relay 6. Hydraulic unit 7. ECU (engine control unit) 8. ABS (ECU) 9. Cylinder identification sensor 10. O sensor 11.

  • Page 678

    ELECTRICAL COMPONENTS FJR13AE 8-207...

  • Page 679

    ELECTRICAL COMPONENTS 1. Windshield drive unit 2. Battery 3. Starter relay 4. ABS motor fuse 5. Front brake light switch 6. Fuse box 2 7. Fuse box 1 8. Right radiator fan motor 9. Left radiator fan motor 10. Neutral switch 11.

  • Page 680

    ELECTRICAL COMPONENTS FJR13AE 8-209...

  • Page 681

    ELECTRICAL COMPONENTS 1. Coolant temperature sensor 2. Throttle position sensor 3. Intake air pressure sensor 4. Intake air temperature sensor 5. ABS motor relay 6. Hydraulic unit 7. MCU (motor control unit) 8. ECU (engine control unit) 9. ABS (ECU) 10.

  • Page 682

    ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES FJR13A Br/W Lg B Sb R/Y L/B DOWN Dg Br/W Ch B Br/W Ch Br L/B L/Y L/B L/Y R/W R/B (RED) L/W B Br/W (BROWN) (BLACK) (BLUE) 8-211...

  • Page 683

    ELECTRICAL COMPONENTS 1. Front brake light switch 2. Main switch 3. Rear brake light switch 4. Gear position switch 5. Sidestand switch 6. Clutch switch 7. Hazard switch 8. Start switch 9. Engine stop switch 10. Horn switch 11. Dimmer switch 12.

  • Page 684

    ELECTRICAL COMPONENTS FJR13AE Br/W Lg B Sb R/Y L/B DOWN Dg Br/W Ch O/W Br/L O/B B R/B G/R B/L G/B Shift up Shift down Br/L PUSH Br L/B L/Y L/B L/Y (RED) B Br/W Ch R/W R/B (BROWN) L/W B Br/W (BLUE) 8-213...

  • Page 685

    ELECTRICAL COMPONENTS 1. Front brake light switch 2. Main switch 3. Rear brake light switch 4. Neutral switch 5. Sidestand switch 6. Hazard switch 7. Start switch 8. Engine stop switch 9. Hand shift select button 10. Hand shift lever switch (shift up) 11.

  • Page 686

    ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 CAUTION: Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

  • Page 687

    ELECTRICAL COMPONENTS EAS27990 1. Remove: CHECKING THE BULBS AND BULB • Bulb SOCKETS EW3P61001 WARNING NOTE: Do not check any of the lights that use LEDs. Since headlight bulbs get extremely hot, keep flammable products and your hands Check each bulb and bulb socket for damage or away from them until they have cooled wear, proper connections, and also for continuity down.

  • Page 688

    ELECTRICAL COMPONENTS NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. If the pocket tester indicates “∞”, replace the fuse. L LLL L LLL L LLL L LLL L LLL Checking the condition of the bulb sockets 3.

  • Page 689

    ELECTRICAL COMPONENTS EWA13310 • Charging time, charging amperage and WARNING charging voltage for an MF battery are dif- Never use a fuse with an amperage rating ferent from those of conventional batteries. other than that specified. Improvising or us- The MF battery should be charged accord- ing a fuse with the wrong amperage rating ing to the appropriate charging method.

  • Page 690

    ELECTRICAL COMPONENTS ECA13670 NOTE: CAUTION: • The charge state of an MF battery can be • Never remove the MF battery sealing caps. checked by measuring its open-circuit voltage • Do not use a high-rate battery charger (i.e., the voltage when the positive battery ter- since it forces a high-amperage current minal is disconnected).

  • Page 691

    ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM NOTE: Charging method using a variable-current Voltage should be measured 30 minutes after (voltage) charger the engine is stopped. a. Measure the open-circuit voltage prior to charging. b. Connect a charger and ammeter to the bat- tery and start charging.

  • Page 692

    ELECTRICAL COMPONENTS Relay unit (starting circuit cut-off relay) Recommended lubricant Dielectric grease 10.Install: • Front cowling right inner panel 1 Refer to “GENERAL CHASSIS” on page 4-1. EAS28040 CHECKING THE RELAYS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, re- 1.

  • Page 693

    ELECTRICAL COMPONENTS Headlight relay (on/off) Second step: 1. Positive battery terminal 1. Positive battery terminal 2. Negative battery terminal 2. Negative battery terminal 3. Positive tester probe 3. Positive tester probe 4. Negative tester probe 4. Negative tester probe 5. Negative tester probe Result Result Continuity...

  • Page 694

    ELECTRICAL COMPONENTS Second step: Result Continuity (between “3” and “4”) Radiator fan motor relay Y /G 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe Br/B 4. Negative tester probe Result 1. Positive battery terminal No continuity 2.

  • Page 695

    ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe → blue/red “1” • Negative tester probe → ground L LLL L LLL L LLL L LLL L LLL 3. Check: • ABS motor relay continuity No continuity → Replace. M MMM M MMM M MMM...

  • Page 696

    ELECTRICAL COMPONENTS Continuity Positive tester probe → sky blue “1” Negative tester probe → black/yellow “2” No continuity Positive tester probe → black/yellow “2” Negative tester probe → sky blue “1” b. Turn the main switch to “ON”. Continuity c. Measure the turn signal/hazard relay output Positive tester probe →...

  • Page 697

    ELECTRICAL COMPONENTS c. Check the relay unit (diode) for continuity. Pocket tester d. Check the relay unit (diode) for no continuity. 90890-03112 L LLL L LLL L LLL L LLL L LLL Analog pocket tester YU-03112-C EAS28070 CHECKING THE SPARK PLUG CAPS The following procedure applies to all of the •...

  • Page 698

    ELECTRICAL COMPONENTS c. Measure the secondary coil resistance. 2. Check: • Crankshaft position sensor resistance L LLL L LLL L LLL L LLL L LLL Out of specification → Replace the crank- ET3P61015 shaft position sensor. CHECKING THE IGNITION SPARK GAP 1.

  • Page 699

    ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe → yellow/green “1” • Negative tester probe → black/blue “2” b. Check the starter motor operation. L LLL L LLL L LLL L LLL L LLL EAS28150 CHECKING THE STATOR COIL 1.

  • Page 700

    ELECTRICAL COMPONENTS EAS28180 CHECKING THE HORNS The following procedure applies to both of the horns. 1. Check: • Horn resistance Out of specification → Replace. Coil resistance 1.01–1.11 Ω at 20 °C (68 °F) b. Measure the stator coil resistance. M MMM M MMM M MMM...

  • Page 701

    ELECTRICAL COMPONENTS b. Measure the oil level switch resistance. L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL EAS28190 CHECKING THE OIL LEVEL SWITCH EAS28220 1. Drain: CHECKING THE FUEL SENDER •...

  • Page 702

    ELECTRICAL COMPONENTS EAS28260 CHECKING THE COOLANT TEMPERATURE SENSOR 1. Remove: • Coolant temperature sensor EWA14130 WARNING • Handle the coolant temperature sensor with special care. • Never subject the coolant temperature sen- sor to strong shocks. If the coolant temper- b.

  • Page 703

    ELECTRICAL COMPONENTS EAS28370 CHECKING THE AIR INDUCTION SYSTEM Coolant temperature sensor SOLENOID 18 Nm (1.8 m·kg, 13 ft·lb) 1. Check: • Air induction system solenoid resistance EAS28300 Out of specification → Replace. CHECKING THE THROTTLE POSITION SENSOR Solenoid resistance 1. Remove: 19–25 Ω...

  • Page 704

    ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM • Positive tester probe → a. Connect the pocket tester (DC 20 V) to the pink/white “1” cylinder identification sensor coupler (wire • Negative tester probe → harness side) as shown. black/blue “2”...

  • Page 705

    ELECTRICAL COMPONENTS c. Measure the accessory box solenoid resis- b. Immerse the intake air temperature sensor tance. “1” in a container filled with water “2”. L LLL L LLL L LLL L LLL L LLL NOTE: Make sure that the intake air temperature sensor ET3P66020 CHECKING THE YCC-S SPEED SENSOR terminals do not get wet.

  • Page 706: Specifications

    ELECTRICAL COMPONENTS ET3P66021 3. Install: CHECKING THE GEAR POSITION SENSOR • Gear position sensor (FJR13AE only) Refer to “INSTALLING THE GEAR POSI- 1. Remove: TION SENSOR (FJR13AE only)” on page • Gear position sensor 5-11. NOTE: Remove only the screws “1” when removing the ET3P66022 CHECKING THE FOOT SHIFT SWITCH gear position sensor.

  • Page 707

    ELECTRICAL COMPONENTS 1. Check: Pocket tester • Grip warmer resistance 90890-03112 Out of specification → Replace the grip Analog pocket tester warmer. YU-03112-C Grip warmer resistance • Positive tester probe → FJR13AE 1.21–1.48 Ω at 20 °C brown “1” (68 °F) •...

  • Page 708

    ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM a. Remove the diode 2 from the wire harness. b. Connect the pocket tester (Ω × 1) to the diode 2 terminals as shown. c. Check the diode 2 for continuity. d.

  • Page 709: General Information

    TROUBLESHOOTING TROUBLESHOOTING ..................9-1 GENERAL INFORMATION ............... 9-1 STARTING FAILURES ................9-1 INCORRECT ENGINE IDLING SPEED ............ 9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE......9-2 FAULTY GEAR SHIFTING ............... 9-2 SHIFT PEDAL DOES NOT MOVE............9-2 JUMPS OUT OF GEAR ................9-2 FAULTY CLUTCH ..................9-2 OVERHEATING ..................

  • Page 710

    TROUBLESHOOTING EAS28450 Electrical system TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) NOTE: • Blown, damaged or incorrect fuse The following guide for troubleshooting does not • Improperly installed fuse cover all the possible causes of trouble. It should 3.

  • Page 711: Fuel System

    TROUBLESHOOTING Fuel system • Bent shift shaft 1. Throttle body(-ies) Shift drum and shift forks • Damaged or loose throttle body joint • Foreign object in a shift drum groove • Improperly synchronized throttle bodies • Seized shift fork • Improperly adjusted engine idling speed •...

  • Page 712: Chassis

    TROUBLESHOOTING • Bent clutch push rod • Incorrect spark plug heat range • Damaged clutch boss 2. Ignition system • Burnt primary driven gear bushing • Faulty ECU • Damaged clutch release cylinder EAS28610 • Match marks not aligned OVERCOOLING 2.

  • Page 713: Troubleshooting

    TROUBLESHOOTING • Improperly installed lower bracket • Headlight bulb life expired (improperly tightened ring nut) Tail/brake light does not come on • Bent steering stem • Wrong tail/brake light bulb • Damaged ball bearing or bearing race • Too many electrical accessories 2.

  • Page 714

    EAS28740 51. Headlight relay (on/off) EAS28750 WIRING DIAGRAM COLOR CODE 52. Hazard lighting fuse Black 53. Signaling system fuse FJR13AV(C) 2006 Brown 54. Headlight fuse 1. Main switch Chocolate 55. Ignition fuse 2. Rectifier/regulator Dark green 56. Auxiliary DC jack fuse 3.

  • Page 715

    ET3P66050 53. Clutch actuator sensor 107.Hand shift lever switch (shift WIRING DIAGRAM 54. Clutch actuator motor down) 55. MCU (motor control unit) 108.Hand shift select button FJR13AEV(C) 2006 56. YCC-S test coupler 109.Hand shift select indicator light 1. Main switch 57.

  • Page 716

    Sb/W Sky blue/White White/Black White/Green White/Blue White/Yellow Yellow/Black Yellow/Green Yellow/Blue Yellow/Red Yellow/White...

  • Page 718

    YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...

  • Page 719

    FJR13AV(C) 2006 WIRING DIAGRAM (1/2) L R/L R/B G/B G/B R/B R/L L W/Y W Sb W L/W W/L Y/G Br/W Br/W Y/G W/L L/W Y Gy/W L/B O/B O/B L/B Gy/W Y B/W Br/B B Br/B B/W G/Y P/W B/L B W/B W/B B B/L (GRAY) (GRAY)

  • Page 720

    FJR13AV(C) 2006 WIRING DIAGRAM (2/2) Sb/W R L/W R/B W/L R/L L/W L/Y R/W L/G B/R Sb B/Y Sb/W Sb B/R L/G W/L R/W R/W L/W Br/G B R/B R/B B Br/W Ch G/Y Br/G B/R R/L R/G Br/G G/Y Sb B/Y Br/G R/G R/L B/R L/Y R/W G/L...

  • Page 721

    FJR13AV(C) 2006 WIRING DIAGRAM (1/2) (GRAY) (GRAY) WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS SUB-WIRE HARNESS (GRAY) ( RED ) ( RED ) (GRAY) (GRAY) (BLACK) (DARK GREEN) (GRAY) (GRAY) (BLACK) (BLACK) (GRAY)

  • Page 722

    FJR13AV(C) 2006 WIRING DIAGRAM (2/2) (BLACK) (BLACK) (BLACK) DOWN (GRAY) (BLACK) (BLACK) (GRAY) (BLACK) (GRAY) (GRAY) (GRAY) (BLACK) (GRAY)

  • Page 723

    FJR13AEV(C) 2006 WIRING DIAGRAM (1/2) L R/L R/B G/B G/B R/B R/L L W/Y W Sb W Br/W Y/G W/L L/W Y Gy/W L/B O/B L/W W/L Y Br/W O/B L/B Gy/W Y Br/B Br/B P/W B/L B W/B B Br/B B/W G/Y B/W Br/B W/B B B/L (BLACK)

  • Page 724

    FJR13AEV(C) 2006 WIRING DIAGRAM (2/2) Sb/W R L/W R/B W/L R/L L/W L/Y R/W L/G B/R Sb B/R Sb/W Sb B/R B/R R/L R/G R/G R/L B/R L/Y G/Y Sb Sb G/Y R/B W/L R/W R/W L/W Br/G B R/B R/B B Br/W Ch G/Y Br/G...

  • Page 725

    FJR13AEV(C) 2006 WIRING DIAGRAM (1/2) (BLACK) (BLACK) (GRAY) (GRAY) WIRE HARNESS SUB-LEAD 1 WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS SUB-WIRE HARNESS 1 WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS SUB-LEAD 2 (BLACK) (BLACK)

  • Page 726

    FJR13AEV(C) 2006 WIRING DIAGRAM (2/2) (BLACK) ( BLACK ) DOWN ( BLACK ) ( GRAY ) (BLACK) (GRAY) (BLACK) (GRAY) ( GRAY ) ( GRAY ) ( GRAY ) (BLACK) PUSH Shift up Shift down...

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