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Yamaha FJR13AEV(C) Service Manual

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

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Table of Contents

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  Summary of Contents for Yamaha FJR13AEV(C)

  • Page 1 FJR13AV(C) FJR13AEV(C) SERVICE MANUAL LIT-11616-19-83 3P6-28197-10...
  • Page 2 EAS20050 FJR13AV(C)/FJR13AEV(C) SERVICE MANUAL ©2006 by Yamaha Motor Corporation, U.S.A. First edition, April 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-19-83...
  • Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
  • Page 4 EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
  • Page 5 EAS20100 1. Serviceable with engine mounted SYMBOLS 2. Filling fluid The following symbols are used in this manual 3. Lubricant for easier understanding. 4. Special tool NOTE: 5. Tightening torque The following symbols are not relevant to every 6. Wear limit, clearance vehicle.
  • Page 7: Table Of Contents

    EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
  • Page 9: 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