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

Yamaha FJR13AEV(C) Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Periodic Maintenance

Engine

Chassis

Electrical System

Chassis

General Chassis

Front Wheel

Rear Wheel

Front Brake

Rear Brake

Abs (Anti-Lock Brake System)

Handlebars

Front Fork

Steering Head

Rear Shock Absorber Assembly

Swingarm

Shaft Drive

Engine

Engine Removal

Camshafts

Cylinder Head

Valves and Valve Springs

Generator and Starter Clutch

Pickup Rotor

Electric Starter

Clutch

SHIFT ACTUATOR and SHIFT ROD (FJR13AE Only)

Shift Shaft

Oil Pump

Middle Gear

Crankcase

Connecting Rods and Pistons

Crankshaft

Transmission

Balancers

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Yamaha FJR13AEV(C)