Yamaha FJR13AG Service Manual
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Yamaha FJR13AG Service Manual

Yamaha FJR13AG Service Manual

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Table of Contents

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2016
SERVICE MANUAL
FJR13AG
FJR13ESG
B88-28197-70-E0

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Summary of Contents for Yamaha FJR13AG

  • Page 1 2016 SERVICE MANUAL FJR13AG FJR13ESG B88-28197-70-E0...
  • Page 2 EAS20002 FJR13AG/FJR13ESG SERVICE MANUAL ©2016 by Yamaha Motor Co., Ltd. First edition, January 2016 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • 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 EAS20004 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 EAS20005 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...

  • Page 7: Table Of Contents

    EAS10003 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 9: General Information

    IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE OF THE YCC-T (Yamaha Chip Controlled-Throttle)....1-2 OUTLINE OF THE CRUISE CONTROL SYSTEM........1-3 OUTLINE OF THE UNIFIED BRAKE SYSTEM ........1-11 OUTLINE OF THE TCS (Traction Control System).........1-12 MULTI-FUNCTION METER UNIT ............

  • Page 10: Identification

    IDENTIFICATION EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS30003 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.

  • Page 11: Features

    Yamaha developed the YCC-T system employing the most advanced electronic control technologies. Electronic control throttle systems have been used on automobiles, but Yamaha has developed a fast- er, more compact system specifically for the needs of a sports motorcycle. The Yamaha-developed system has a high-speed calculating capacity that produces computations of running conditions every 1/1000th of a second.

  • Page 12: Outline Of The Cruise Control System

    FEATURES YCC-T system outline 1. Throttle position sensor 6. Gear position switch 2. Throttle servo motor 7. Crankshaft position sensor 3. Accelerator position sensor 8. Rear wheel sensor 4. ECU (electronic control unit) 9. Coolant temperature sensor 5. Sensor input EAS30940 OUTLINE OF THE CRUISE CONTROL SYSTEM This model is equipped with a cruise control system designed to maintain a set cruising speed.
  • Page 13 FEATURES GEAR A.TEMP ˚C C.TEMP ˚C TIME TRIP 0:06 1. Battery 10. Grip cancel switch 2. Main switch 11. Accelerator position sensor 3. Meter assembly 12. Throttle servo motor 4. ECU (Engine Control Unit) 13. Throttle position sensor 5. Clutch switch 14.
  • Page 14 FEATURES Activating and setting the cruise control system 1. Push the cruise control power switch “ ” located on the left handlebar. The cruise control system indicator light “ ” will come on. 2. Push the “SET–” side of the cruise control setting switch to activate the cruise control system. Your current traveling speed will become the set cruising speed.
  • Page 15 FEATURES Traveling speed decreases as soon as the cruise control system is deactivated; unless the throttle grip is turned. a. Closed position b. Cruise control cancel direction Using the resume function Push the “RES+” side of the cruise control setting switch to reactivate the cruise control system. The traveling speed will return to the previously set cruising speed.
  • Page 16 FEATURES Operation chart A. Operation c. Push the “SET–” side of the cruise control setting switch B. Indication d. Currently set cruising speed increases C. Speed e. Currently set cruising speed decreases D. 160 km/h (100 mph) f. New cruising speed is set E.
  • Page 17 Because the automatic deactivation of the cruise control system is stored in the memory of the ECU, the deactivation can be checked using the Yamaha diagnostic tool. In some cases, the cruise control system may not be able to maintain the set cruising speed when the vehicle is traveling uphill or downhill.
  • Page 18 FEATURES Meter displays during cruise control system operation A. Cruise control system is activated (cruising b. 4 seconds elapse (during this time, input from speed is set) the cruise control power switch “ ” will not be received) B. Cruise control system is turned off (cruise control system indicator light “...
  • Page 19 ” goes off, cruise c. Cruise control power switch “ ” “ON” control system is deactivated, and cruise d. Delete the fault code on the yamaha control system indicator light “ ” flashes) diagnostic tool D. Cruise control system is turned off e.

  • Page 20: 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 21: Outline Of The Tcs (Traction Control System)

    FEATURES Brake pedal input force and braking force at each wheel a. Brake force e. Proportioning valve operation b. Brake pedal force f. Metering valve operation c. Rear brake force d. Front brake force (unified brake system) Metering valve This valve prevents the brake fluid pressure that is transmitted to the right front brake caliper from in- creasing until the pressure exceeds a set level.
  • Page 22 FEATURES TCS (Traction control system) layout 1. ECU (Engine Control Unit) 7. Throttle servo motor 2. “TCS” button 8. Spark plugs 3. Traction control system indicator/warning light 9. Ignition coils 4. Injectors 10. Front wheel sensor 5. ABS ECU 6. Rear wheel sensor TCS (Traction control system) block diagram The signals from the front and rear wheel sensors are sent to the ECU through the ABS ECU, and the ECU calculates the amount of slip according to the difference between the detected front and rear...
  • Page 23 FEATURES 1. Front wheel sensor D. Actuator control 2. Rear wheel sensor E. Fuel cut-off 3. ABS ECU F. Ignition timing (retarded) 4. “TCS” button G. Traction control system indicator/warning light (flashes) 5. ECU (Engine Control Unit) H. YCC-T motor throttle valve opening A.
  • Page 24 FEATURES Turn the traction control system off to help free the rear wheel if the motorcycle gets stuck in mud, sand, or other soft surfaces. ECA19650 NOTICE Use only the specified tires. Using different sized tires will prevent the traction control system from controlling tire rotation accurately.

  • Page 25: Multi-Function Meter Unit

    FEATURES • a clock EAS30982 MULTI-FUNCTION METER UNIT • a fuel meter • an eco indicator 9 10 • a transmission gear display • a drive mode display • a function display • an information display GEAR • a setting mode display A.TEMP ˚C C.TEMP...
  • Page 26 FEATURES Fuel meter • Select the transmission gear that is appropri- ate for the vehicle speed. Transmission gear display GEAR A.TEMP GEAR C.TEMP A.TEMP ˚C C.TEMP ˚C 1. Fuel meter TIME TRIP 0:06 The fuel meter indicates the amount of fuel in the fuel tank.
  • Page 27 High To increase the grip warmer temperature, push the “ ” side of the select switch. To de- crease the grip warmer temperature, push A. FJR13AG: the “ ” side of the select switch. 1. Windshield adjusting function ECA20750 2. Grip warmer adjusting function NOTICE 3.
  • Page 28 FEATURES • an odometer display • The tripmeters will reset and continue counting • tripmeter displays after 9999.9 is reached. • a fuel reserve tripmeter display When approximately 5.5 L (1.45 US gal, 1.21 • an estimated traveling range display Imp.gal) of fuel remains in the fuel tank, the last •...
  • Page 29 FEATURES Elapsed time display: Coolant temperature display: TIME TRIP C.TEMP ˚C 0:06 The time that has elapsed since the key was The coolant temperature display indicates the turned to “ON” is shown. The maximum time that temperature of the coolant. The coolant tem- can be shown is 99:59.
  • Page 30 FEATURES • The “L/100km” display shows the average Adjusting the windshield position amount of fuel necessary to travel 100 km. 1. To move the windshield up, push the “ ” • The “MPG” display shows the average dis- side of the select switch. To move the wind- tance that can be traveled on 1.0 Imp.gal of fu- shield down, push the “...
  • Page 31 FEATURES Adjusting the temperature levels of the grip This function allows warmer settings you to check and re- set the “TIME–2” and 1. Use the select switch to highlight “Grip “TIME–3” functions. Warmer”. These time trips show the total elapsed time that the MENU key has been in the Grip Warmer...
  • Page 32 FEATURES 4. Use the select switch to highlight “Middle” or Checking and resetting “TIME–2” and “TIME–3” “Low”, and then change the setting using the 1. Use the select switch to highlight “Time Trip”. same procedure that was used for the high setting.
  • Page 33 FEATURES 2. Push the “MENU” switch. The unit setting dis- Selecting the display items play will be shown and “km or mile” will flash 1. Use the select switch to highlight “Display”. in the display. MENU Grip Warmer Unit Maintenance Time Trip Km or mile Unit...
  • Page 34 FEATURES 5. When you are finished changing the settings, Setting the clock use the select switch to highlight “ ”, and then 1. Use the select switch to highlight “Clock”. push the “MENU” switch to return to the pre- vious display. MENU Grip Warmer Maintenance...
  • Page 35 FEATURES 2. Push the “MENU” switch. Drive mode switch “MODE” 3. Use the select switch to highlight “YES”, and EWA17660 WARNING then push the “MENU” switch. Do not change the D-mode while the vehicle is moving. All Reset Using this switch changes the drive mode to touring mode “T”...

  • Page 36: Important Information

    5. Keep all parts away from any source of fire. EAS30007 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 37: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS30010 EAS30012 BEARINGS AND OIL SEALS RUBBER PARTS Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in- manufacturer’s marks or numbers are visible. spection. Some of the rubber parts are sensitive When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc.

  • Page 38: Basic Service Information

    BASIC SERVICE INFORMATION EAS20010 BASIC SERVICE INFORMATION EAS30013 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. Screw type 1. Remove: • Quick fastener To remove the quick fastener, loosen the screw with a screwdriver, then pull the fastener out.

  • Page 39: Electrical System

    BASIC SERVICE INFORMATION ECA16760 EAS30014 NOTICE ELECTRICAL SYSTEM Be sure to connect the battery leads to the correct battery terminals. Reversing the bat- Electrical parts handling tery lead connections could damage the ECA16600 NOTICE electrical components. Never disconnect a battery lead while the en- gine is running;...
  • Page 40 BASIC SERVICE INFORMATION ECA16620 ECA23620 NOTICE NOTICE Handle electrical components with special • Do not perform angle adjustment of the IMU care, and do not subject them to strong and rear fender by pinching the washer and shocks. related parts. •...
  • Page 41 BASIC SERVICE INFORMATION Checking the electrical system 1. Disconnect: • Lead • Coupler Before checking the electrical system, make • Connector sure that the battery voltage is at least 12 V. ECA16780 NOTICE • When disconnecting a coupler, release the coupler lock, hold both sections of the cou- pler securely, and then disconnect the cou- pler.
  • Page 42 BASIC SERVICE INFORMATION • As a quick remedy, use a contact revitalizer available at most part stores. 3. Connect: • Lead • Coupler • Connector • When connecting a coupler or connector, push both sections of the coupler or connector to- gether until they are connected securely.

  • Page 43: Special Tools

    8-250, 8-254, 8-256, 8-257, 8-258, 8-258, 8-259, 8-260, 8-261, 8-261, 8-263, 8-263, 8-264, 8-265, 8-266, 8-266 Valve lapper 90890-04101 90890-04101 Valve lapping tool YM-A8998 YM-A8998 Yamaha diagnostic tool USB 3-8, 8-62 90890-03250 Yamaha diagnostic tool (A/I) 3-8, 8-62 90890-03252 1-34...
  • Page 44 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Vacuum gauge 90890-03094 Vacuummate YU-44456 YU-44456 Carburetor angle driver 2 90890-03173 Steering nut wrench 3-18, 4-116 90890-01403 Exhaust flange nut wrench YU-A9472 Oil filter wrench 3-26 90890-01426 Oil filter wrench YU-38411 Oil pressure gauge set 3-27 90890-03120 Oil pressure adapter B...
  • Page 45 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Damper rod holder (ø32.5) 4-99, 4-100 90890-01513 Slide metal installer 4-100, 4-100, 90890-01508 4-101 Slide metal installer YM-01508 Fork seal driver 4-100, 4-100, 90890-01502 4-101, 4-101, Fork seal driver (48) 4-110, 4-111 YM-A0948 Fork spring compressor 4-107, 4-112...
  • Page 46 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod puller attachment (M10) 4-111 90890-01436 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Ring gear fix bolt (M14) 4-144 90890-01524 Ring gear fix bolt (M14) YM-01524 M14×P1.5 Final gear backlash band 4-145 90890-01511 Middle drive gear lash tool...
  • Page 47 Pivot shaft wrench adapter 5-9, 5-10 90890-01476 Rotor holding tool 5-15, 5-18 90890-01235 Universal magneto and rotor holder YU-01235 Yamaha bond No. 1215 5-20, 5-34, 5-37, 90890-85505 5-83, 6-13 (Three bond No.1215®) Valve spring compressor 5-25, 5-30 90890-04019 Valve spring compressor...
  • Page 48 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve spring compressor attachment 5-25, 5-30 90890-04114 Valve spring compressor adapter 19.5 mm YM-04114 Valve guide remover (ø5) 5-27 90890-04097 Valve guide remover (5.0 mm) YM-04097 Valve guide installer (ø5) 5-27 90890-04098 Valve guide installer (5.0 mm) YM-04098 Valve guide reamer (ø5)
  • Page 49 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Universal clutch holder 5-49, 5-53 90890-04086 Universal clutch holder YM-91042 Thickness gauge 5-50 90890-03180 Feeler gauge set YU-26900-9 Bearing retainer wrench 5-70, 5-72 90890-04137 Middle drive shaft bearing retainer wrench YM-04137 Damper spring compressor 5-70, 5-71 90890-04090 Middle drive gear damper spring compressor...
  • Page 50 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Piston ring compressor 5-92 90890-05158 Piston ring compressor YM-08037 Slide hammer bolt 5-100 90890-01083 Slide hammer bolt 6 mm YU-01083-1 Weight 5-100 90890-01084 Weight YU-01083-3 YU-01083-3 Radiator cap tester 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A 1-41...
  • Page 51 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester adapter 90890-01352 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 Middle drive bearing installer 40 & 50 mm YM-04058 Pressure gauge 7-10, 7-10...
  • Page 52 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Test harness– lean angle sensor (6P) 8-259 90890-03209 Test harness– lean angle sensor (6P) YU-03209 1-43...

  • Page 53: Specifications

    CHASSIS TIGHTENING TORQUES............2-15 LUBRICATION POINTS AND LUBRICANT TYPES ........2-16 ENGINE....................2-16 CHASSIS....................2-18 LUBRICATION SYSTEM CHART AND DIAGRAMS........2-19 ENGINE OIL LUBRICATION CHART .............2-19 LUBRICATION DIAGRAMS ..............2-21 COOLING SYSTEM DIAGRAMS ..............2-31 CABLE ROUTING (FJR13AG)..............2-35 CABLE ROUTING (FJR13ESG) ..............2-57...

  • Page 54: General Specifications

    1325/1455 mm (52.2/57.3 in) Seat height 805/825 mm (31.7/32.5 in) Wheelbase 1545 mm (60.8 in) Ground clearance 130 mm (5.12 in) (FJR13AG) 125 mm (4.92 in) (FJR13ESG) Minimum turning radius 3.1 m (10.17 ft) (FJR13AG) 3.2 m (10.50 ft) (FJR13ESG) Weight...

  • Page 55: Engine Specifications

    ENGINE SPECIFICATIONS EAS20014 ENGINE SPECIFICATIONS Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train DOHC Displacement 1298 cm³ Cylinder arrangement Inline Number of cylinders 4-cylinder Bore × stroke 79.0 × 66.2 mm (3.11 × 2.61 in) Compression ratio 10.8 : 1 Compression pressure 1392–1792 kPa/400 r/min (13.9–17.9 kgf/cm²/400 r/min, 198.0–254.9 psi/400 r/min)
  • Page 56 ENGINE SPECIFICATIONS Bypass valve opening pressure 78.4–117.6 kPa (0.78–1.18 kgf/cm², 11.4–17.1 psi) Relief valve operating pressure 480.0–560.0 kPa (4.80–5.60 kgf/cm², 69.6–81.2 psi) Cooling system Coolant quantity Radiator (including all routes) 2.60 L (2.75 US qt, 2.29 Imp.qt) Coolant reservoir (up to the maximum level mark) 0.25 L (0.26 US qt, 0.22 Imp.qt) Radiator cap valve opening pressure...
  • Page 57 ENGINE SPECIFICATIONS Valve guide inside diameter (exhaust) 5.000–5.012 mm (0.1969–0.1973 in) 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 0.100 mm (0.0039 in) Valve stem runout 0.010 mm (0.0004 in) Valve spring Free length (intake) 39.73 mm (1.56 in)
  • Page 58 ENGINE SPECIFICATIONS Journal oil clearance 0.027–0.045 mm (0.0011–0.0018 in) Bearing color code Code 2 Black Code 3 Brown Code 4 Green Code 5 Yellow Code 6 Pink Code 7 Code 8 White Clutch Clutch type Wet, multiple-disc Friction plate 1,2 thickness 2.92–3.08 mm (0.115–0.121 in) Wear limit 2.82 mm (0.111 in)
  • Page 59 ENGINE SPECIFICATIONS Fuel pump Pump type Electrical Throttle body ID mark 1MC1 00 Fuel injector 12.0 Ω Resistance Throttle position sensor Resistance 1.20–2.80 kΩ Accelerator position sensor Resistance 1.08–2.52 kΩ Fuel injection sensor 420–569 Ω Crankshaft position sensor resistance Idling condition Engine idling speed 950–1150 r/min Exhaust gas sampling point...

  • Page 60: Chassis Specifications

    1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) Front tire Type Tubeless Size 120/70 ZR17M/C (58W) Manufacturer/model BRIDGESTONE/BT023F F (FJR13AG) BRIDGESTONE/BT023F E (FJR13ESG) Rear tire Type Tubeless Size 180/55 ZR17M/C (73W) Manufacturer/model BRIDGESTONE/BT023R F (FJR13AG) BRIDGESTONE/BT023R E (FJR13ESG)
  • Page 61 Front fork travel 135.0 mm (5.31 in) Wheel travel 135 mm (5.3 in) Fork spring free length 314.0 mm (12.36 in) (FJR13AG) 273.8 mm (10.78 in) (FJR13ESG) Limit 307.7 mm (12.11 in) (FJR13AG) 268.3 mm (10.56 in) (FJR13ESG) Inner tube bending limit 0.2 mm (0.01 in)
  • Page 62 Type Swingarm (link suspension) Spring Coil spring Shock absorber Gas-hydraulic damper Rear shock absorber assembly travel 60.0 mm (2.36 in) (FJR13AG) 63.0 mm (2.48 in) (FJR13ESG) Wheel travel 125 mm (4.9 in) Spring preload Adjusting system Mechanical adjustable type (FJR13AG)

  • Page 63: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20016 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Engine control unit Model/manufacturer TBDFV4/DENSO (FJR13AG) TBDFV9/DENSO (FJR13ESG) Ignition system Ignition system Advancer type Digital Ignition timing (B.T.D.C.) 5.0 °/1050 r/min Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 1.19–1.61 Ω...
  • Page 64 310–325 Ω at 80 °C (310–325 Ω at 176 °F) Coolant temperature sensor resistance Lean angle sensor output voltage Operating angle 65 ° (FJR13AG) Output voltage up to operating angle 0.4–1.4 V (FJR13AG) Output voltage over operating angle 3.7–4.4 V (FJR13AG)
  • Page 65 ELECTRICAL SPECIFICATIONS Backup fuse 7.5 A Windshield motor fuse 20.0 A Electronic throttle valve fuse 7.5 A 2-12...

  • Page 66: Tightening Torques

    TIGHTENING TORQUES EAS20017 TIGHTENING TORQUES EAS30015 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 67: Engine Tightening Torques

    TIGHTENING TORQUES EAS30016 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf) Cylinder head cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Coolant drain bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Engine oil drain bolt 43 Nm (4.3 m·kgf, 31 ft·lbf) Oil filter cartridge bolt...

  • Page 68: Chassis Tightening Torques

    TIGHTENING TORQUES EAS30017 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Upper bracket pinch bolt 26 Nm (2.6 m·kgf, 19 ft·lbf) Lower bracket pinch bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) Front wheel axle bolt 91 Nm (9.1 m·kgf, 66 ft·lbf) Front wheel axle pinch bolt See TIP.

  • Page 69: Lubrication Points And Lubricant Types

    Damper drive cam and damper driven cam Middle driven gear Middle drive pinion gear Middle driven pinion gear Middle drive pinion gear nut Cylinder head cover mating surface Three Bond 1541C® Yamaha bond No.1215 Cylinder head cover gasket (Three Bond No.1215®) 2-16...
  • Page 70 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Yamaha bond No.1215 Crankcase mating surface (Three Bond No.1215®) Yamaha bond No.1215 Crankshaft position sensor lead grommet (Three Bond No.1215®) Yamaha bond No.1215 Stator coil assembly lead grommet (Three Bond No.1215®) 2-17...

  • Page 71: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES EAS30019 CHASSIS Lubrication point Lubricant Steering bearings and upper bearing cover lip Lower bearing dust seal lip Front wheel oil seal lip Rear wheel oil seal lip Rear wheel drive hub mating surface Rear brake pedal pivoting point Footrest assembly pivoting point Passenger footrest pivoting point Shift pedal pivoting point...

  • Page 72: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 2-19...
  • Page 73 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve assembly 4. Oil filter cartridge 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 74: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30021 LUBRICATION DIAGRAMS 2-21...
  • Page 75 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 2-22...
  • Page 76 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-23...
  • Page 77 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Drive axle 3. Oil delivery pipe 1 2-24...
  • Page 78 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25...
  • Page 79 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 2-26...
  • Page 80 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
  • Page 81 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 2-28...
  • Page 82 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • Page 83 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 2-30...

  • Page 84: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20020 COOLING SYSTEM DIAGRAMS 2-31...
  • Page 85 COOLING SYSTEM DIAGRAMS 1. Thermostat inlet pipe 1 2. Thermostat inlet hose 1 3. Oil cooler outlet hose 4. Radiator 5. Coolant reservoir breather hose 6. Thermostat inlet pipe 2 7. Coolant reservoir hose 8. Radiator inlet hose 9. Thermostat inlet hose 2 10.
  • Page 86 COOLING SYSTEM DIAGRAMS 2-33...
  • Page 87 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 88: Cable Routing (Fjr13Ag)

    CABLE ROUTING (FJR13AG) EAS20246 CABLE ROUTING (FJR13AG) Handlebar (front view) 2-35...
  • Page 89 CABLE ROUTING (FJR13AG) 1. Grip warmer lead (right) 2. Brake hose (front brake master cylinder to brake pipe/lower joint assembly) 3. Handlebar switch lead (right) 4. Clutch hose 5. Handlebar switch lead (left) 6. Clutch switch lead 7. Main switch lead 8.
  • Page 90 CABLE ROUTING (FJR13AG) Radiator and battery (right side view) 2-37...
  • Page 91 CABLE ROUTING (FJR13AG) 1. Starter motor lead N. Fasten the leads with the plastic band so that they are positioned in a straight line as shown in the 2. ECU (engine control unit) coupler illustration. Face the end of the plastic band 3.
  • Page 92 CABLE ROUTING (FJR13AG) Rear brake hose (right side view) 5 6 7 8 9 10 11 1 12 13 2-39...
  • Page 93 CABLE ROUTING (FJR13AG) 1. Rear wheel sensor lead 2. Brake hose (rear brake master cylinder to brake pipe/middle joint assembly) 3. Rear brake fluid reservoir hose 4. Rear brake fluid reservoir 5. Brake pipe (hydraulic unit to metering valve) 6. Hydraulic unit assembly 7.
  • Page 94 CABLE ROUTING (FJR13AG) Horn and radiator (left side view) 2-41...
  • Page 95 CABLE ROUTING (FJR13AG) 1. Radiator inlet hose 2. Radiator fan motor (left) 3. Radiator 4. Coolant reservoir breather hose 5. Horn 6. Radiator fan motor coupler (left) 7. Radiator fan motor lead (left) 8. Coolant reservoir hose A. After connecting the left radiator fan motor coupler, position the coupler between the left side cowling and the left lower inner panel.
  • Page 96 CABLE ROUTING (FJR13AG) Front brake hose and engine (left side view) 2-43...
  • Page 97 CABLE ROUTING (FJR13AG) 1. Clutch hose N. Fasten the grommets on the front wheel sensor lead and the brake hose (brake pipe/upper joint 2. AC magneto lead assembly to front brake calipers) with the holder. 3. Rectifier/regulator lead O. Pass the front wheel sensor lead through the 4.
  • Page 98 CABLE ROUTING (FJR13AG) Rear fender (left side view) 2-45...
  • Page 99 CABLE ROUTING (FJR13AG) 1. Wire harness 2. Tail/brake light assembly coupler 3. Tail/brake light assembly 4. Rear turn signal light lead 5. License plate light lead 6. Seat lock cable 7. Option parts (air bag coupler) 8. Rear wheel sensor lead 9.
  • Page 100 CABLE ROUTING (FJR13AG) Throttle bodies (top view) 2-47...
  • Page 101 CABLE ROUTING (FJR13AG) 1. Ignition coil #1 coupler F. Install the positive battery lead terminal so that it is not positioned to the outside of the starter relay. 2. Clutch hose G. Install the starter motor lead terminal so that it is 3.
  • Page 102 CABLE ROUTING (FJR13AG) Rear fender (top view) 2-49...
  • Page 103 4. License plate light coupler 5. Tail/brake light assembly lead 6. Seat lock cable A. Route the Yamaha diagnostic tool lead to the rear of the positioning ribs on the storage compartment as shown in the illustration. B. Install the protective cap onto the Yamaha diagnostic tool coupler, and then install the coupler onto the projection on the storage compartment.
  • Page 104 CABLE ROUTING (FJR13AG) Front cowling assembly and electrical components board 2-51...
  • Page 105 CABLE ROUTING (FJR13AG) 1. Headlight beam adjusting knob shaft L. Secure the holder by inserting the projection on the holder into the hole in the electrical 2. Headlight sub-wire harness components board, and then fasten the handlebar 3. Relay unit lead switch leads, grip warmer leads, front brake light 4.
  • Page 106 CABLE ROUTING (FJR13AG) Hydraulic unit assembly (top and side view) 2-53...
  • Page 107 CABLE ROUTING (FJR13AG) 1. Hydraulic unit assembly 2. Brake pipe/middle joint assembly 3. Brake pipe (hydraulic unit to metering valve) 4. Brake pipe (hydraulic unit to proportioning valve) 5. Brake pipe/upper joint assembly 6. Brake pipe/lower joint assembly 7. Brake pipe (proportioning valve to rear brake hose) 8.
  • Page 108 CABLE ROUTING (FJR13AG) Fuel tank and canister 2-55...
  • Page 109 CABLE ROUTING (FJR13AG) 1. Fuel tank overflow hose (fuel tank to 3-way joint) 2. Fuel tank breather/overflow hose 3. Fuel tank breather hose (fuel tank to 3-way joint) A. Install each hose onto the hose fitting of the fuel tank up to the wide portion at the base of the fitting.

  • Page 110: Cable Routing (Fjr13Esg)

    CABLE ROUTING (FJR13ESG) EAS20235 CABLE ROUTING (FJR13ESG) Handlebar (front view) 2-57...
  • Page 111 CABLE ROUTING (FJR13ESG) 1. Grip warmer lead (right) 2. Coupler rubber cover 3. Brake hose (front brake master cylinder to brake pipe/lower joint assembly) 4. Handlebar switch lead (right) 5. Front brake light switch lead 6. Clutch hose 7. Handlebar switch lead (left) 8.
  • Page 112 CABLE ROUTING (FJR13ESG) Radiator and battery (right side view) 2-59...
  • Page 113 CABLE ROUTING (FJR13ESG) 1. Starter motor lead N. Fasten the leads with the plastic band so that they are positioned in a straight line as shown in the 2. ECU (engine control unit) coupler illustration. Face the end of the plastic band 3.
  • Page 114 CABLE ROUTING (FJR13ESG) Rear brake hose (right side view) 5 6 7 8 9 10 11 1 12 13 2-61...
  • Page 115 CABLE ROUTING (FJR13ESG) 1. Rear wheel sensor lead 2. Brake hose (rear brake master cylinder to brake pipe/middle joint assembly) 3. Rear brake fluid reservoir hose 4. Rear brake fluid reservoir 5. Brake pipe (hydraulic unit to metering valve) 6. Hydraulic unit assembly 7.
  • Page 116 CABLE ROUTING (FJR13ESG) Horn and radiator (left side view) 2-63...
  • Page 117 CABLE ROUTING (FJR13ESG) 1. Radiator inlet hose 2. Radiator fan motor (left) 3. Radiator 4. Coolant reservoir breather hose 5. Horn 6. Radiator fan motor coupler (left) 7. Radiator fan motor lead (left) 8. Coolant reservoir hose A. After connecting the left radiator fan motor coupler, position the coupler between the left side cowling and the left lower inner panel.
  • Page 118 CABLE ROUTING (FJR13ESG) Front brake hose and engine (left side view) 2-65...
  • Page 119 CABLE ROUTING (FJR13ESG) 1. Clutch hose N. Fasten the front wheel sensor lead and brake hose (brake pipe/upper joint assembly to front brake 2. AC magneto lead calipers) with the holder. Make sure that the front 3. Rectifier/regulator lead wheel sensor lead is positioned to the rear of the 4.
  • Page 120 CABLE ROUTING (FJR13ESG) Rear fender (left side view) 2-67...
  • Page 121 CABLE ROUTING (FJR13ESG) 1. Wire harness 2. Option parts (air bag coupler) 3. Tail/brake light assembly coupler 4. IMU sub-wire harness coupler 5. Tail/brake light assembly 6. Rear turn signal light lead 7. License plate light lead 8. Seat lock cable 9.
  • Page 122 CABLE ROUTING (FJR13ESG) Throttle bodies (top view) 5 6 7 2-69...
  • Page 123 CABLE ROUTING (FJR13ESG) 1. Ignition coil #1 coupler D. Route the throttle cables and brake hoses through the right opening in the frame. 2. Clutch hose E. Install the immobilizer unit coupler holder so that 3. Front wheel sensor lead the end with the bolt is facing forward.
  • Page 124 CABLE ROUTING (FJR13ESG) Rear fender (top view) 2-71...
  • Page 125 8. Tail/brake light assembly lead 9. Seat lock cable 10. SCU lead A. Route the Yamaha diagnostic tool lead to the rear of the positioning ribs and under the band that is used to secure the SCU (suspension control unit).
  • Page 126 CABLE ROUTING (FJR13ESG) Front cowling assembly and electrical components board 2-73...
  • Page 127 CABLE ROUTING (FJR13ESG) 1. Headlight beam adjusting knob shaft L. Secure the holder by inserting the projection on the holder into the hole in the electrical 2. Headlight sub-wire harness components board, and then fasten the handlebar 3. Relay unit lead switch leads, grip warmer leads, front brake light 4.
  • Page 128 CABLE ROUTING (FJR13ESG) Hydraulic unit assembly (top and side view) 2-75...
  • Page 129 CABLE ROUTING (FJR13ESG) 1. Hydraulic unit assembly 2. Brake pipe/middle joint assembly 3. Brake pipe (hydraulic unit to metering valve) 4. Brake pipe (hydraulic unit to proportioning valve) 5. Brake pipe/upper joint assembly 6. Brake pipe/lower joint assembly 7. Brake pipe (proportioning valve to rear brake hose) 8.
  • Page 130 CABLE ROUTING (FJR13ESG) Fuel tank and canister 2-77...
  • Page 131 CABLE ROUTING (FJR13ESG) 1. Fuel tank overflow hose (fuel tank to 3-way joint) 2. Fuel tank breather/overflow hose 3. Fuel tank breather hose (fuel tank to 3-way joint) A. Install each hose onto the hose fitting of the fuel tank up to the wide portion at the base of the fitting. B.
  • Page 132 CABLE ROUTING (FJR13ESG) 2-79...

  • Page 133: Periodic Checks And Adjustments

    CHECKING THE CENTERSTAND ............3-19 LUBRICATING THE CENTERSTAND ............3-19 CHECKING THE SIDESTAND SWITCH..........3-19 CHECKING THE FRONT FORK ............. 3-19 ADJUSTING THE FRONT FORK LEGS (FJR13AG)......3-20 ADJUSTING THE DAMPING FORCE (FJR13ESG) .......3-21 CHECKING THE REAR SUSPENSION..........3-22 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY...
  • Page 134 ADJUSTING THE PRELOAD OF THE REAR SHOCK ABSORBER ASSEMBLY (FJR13ESG)............... 3-23 LUBRICATING THE REAR SUSPENSION..........3-25 CHECKING THE ENGINE OIL LEVEL............3-25 CHANGING THE ENGINE OIL ...............3-25 MEASURING THE ENGINE OIL PRESSURE ........3-27 CHECKING THE COOLANT LEVEL............3-27 CHECKING THE COOLING SYSTEM ............3-28 CHANGING THE COOLANT..............

  • Page 136: Periodic Maintenance

    • From 37000 km (24000 mi) or 36 months, repeat the maintenance intervals starting from 13000 km (8000 mi) or 12 months. • Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer perform the service.
  • Page 137 PERIODIC MAINTENANCE ROUTINE INITIAL ODOMETER READINGS × 1000 km ITEM × 1000 mi month • Check operation, fluid level, √ √ √ √ √ √ 2 * Clutch and for fluid leakage. • Correct if necessary. • Check operation, fluid level, and for fluid leakage.
  • Page 138 Front and rear √ √ √ √ √ √ 26 * • Check operation. brake switches • Apply Yamaha cable lubricant √ √ √ √ √ √ 27 * Control cables or other suitable cable lubricant thoroughly. • Check operation.

  • Page 139: Checking The Fuel Line

    PERIODIC MAINTENANCE • T–bar EAS30619 CHECKING THE FUEL LINE Refer to “GENERAL CHASSIS (6)” on page 1. Remove: 4-22. • Rider seat 2. Remove: Refer to “GENERAL CHASSIS (1)” on page • Ignition coil 4-1. 3. Remove: • Fuel tank •...

  • Page 140: Adjusting The Valve Clearance

    PERIODIC MAINTENANCE Before installing the spark plug, clean the spark plug and gasket surface. 9. Install: • Ignition coil 10.Install: • T–bar Refer to “GENERAL CHASSIS (6)” on page 4-22. • Fuel tank 4. Measure: Refer to “FUEL TANK” on page 7-1. •...
  • Page 141 PERIODIC MAINTENANCE Cylinder #2 180° Cylinder #4 360° Cylinder #3 540° ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5. Remove: • Camshafts • Refer to “CAMSHAFTS” on page 5-12. •...
  • Page 142 PERIODIC MAINTENANCE b. Calculate the difference between the speci- 25 thicknesses in 0.05 fied valve clearance and the measured valve Available valve pads mm (0.002 in) incre- ments clearance. Example: Example: Specified valve clearance = 0.15–0.22 mm Valve pad number = 158 (0.0059–0.0087 in) Rounded value = 160 Measured valve clearance = 0.25 mm...

  • Page 143: Checking The Engine Idling Speed

    ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the Yamaha diagnostic tool. Use the diagnostic code number “67”. Refer to “SELF-DIAGNOSTIC FUNCTION 4. Install: AND DIAGNOSTIC CODE TABLE (ECU)” on • Vacuum gauge “1” page 9-5.
  • Page 144 PERIODIC MAINTENANCE Engine idling speed • Turn the bypass air screw using the carburetor 950–1150 r/min angle driver. • After each step, rev the engine two or three b. Check the vacuum pressure. times, each time for less than a second, and The difference in vacuum pres- check the synchronization again.

  • Page 145: Checking The Exhaust System

    PERIODIC MAINTENANCE 4. Install: EAS30625 CHECKING THE EXHAUST SYSTEM • Side cowlings The following procedure applies to all of the ex- Refer to “GENERAL CHASSIS (2)” on page haust pipes and gaskets. 4-5. 1. Remove: • Side cowlings EAS30800 CHECKING THE CRANKCASE BREATHER Refer to “GENERAL CHASSIS (2)”...

  • Page 146: Checking The Air Induction System

    PERIODIC MAINTENANCE EAS30627 EAS30889 CHECKING THE AIR INDUCTION SYSTEM ADJUSTING THE CLUTCH LEVER Refer to “CHECKING THE AIR INDUCTION 1. Adjust: SYSTEM” on page 7-17. • Clutch lever position (distance “a” from the handlebar grip to the EAS31490 clutch lever) CLEANING THE AIR FILTER ELEMENT ▼...

  • Page 147: Bleeding The Hydraulic Clutch System

    PERIODIC MAINTENANCE 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. Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared.

  • Page 148: Adjusting The Front Disc Brake

    PERIODIC MAINTENANCE k. Fill the clutch master cylinder reservoir to the EAS30632 CHECKING THE BRAKE FLUID LEVEL proper level with the specified brake and 1. Stand the vehicle on a level surface. clutch fluid. Refer to “CHECKING THE CLUTCH FLUID •...

  • Page 149: Bleeding The Hydraulic Brake System (Abs)

    PERIODIC MAINTENANCE • When refilling, be careful that water does • When bleeding the ABS, make sure that there not enter the brake master cylinder reser- is always enough brake fluid before applying voir or brake fluid reservoir. Water will sig- the brake.

  • Page 150: Checking The Front Brake Pads

    PERIODIC MAINTENANCE EWA14020 WARNING After bleeding the ABS, check the brake op- eration. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • Side cover (right) Refer to “GENERAL CHASSIS (1)” on page 4-1.

  • Page 151: Checking The Brake Hoses

    Damage/out-of-round → Replace. 290 kPa (2.90 kgf/cm², 42 psi) Maximum load EWA13260 WARNING 216 kg (476 lb) (FJR13AG) 213 kg (470 lb) (FJR13ESG) Never attempt to make any repairs to the * Total weight of rider, passenger, cargo wheel. and accessories...
  • Page 152 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 Front tire 2. Side wall Size 3.

  • Page 153: Checking The Wheel Bearings

    PERIODIC MAINTENANCE EAS30106 CHECKING THE WHEEL BEARINGS The following procedure applies to all of the wheel bearings. 1. Check: • Wheel bearings Refer to “CHECKING THE FRONT WHEEL” on page 4-32 and “CHECKING THE REAR WHEEL” on page 4-42. EAS30642 CHECKING THE SWINGARM PIVOT b.

  • Page 154: Lubricating The Steering Head

    PERIODIC MAINTENANCE f. Install the upper ring nut “2”. Recommended lubricant g. Finger tighten the upper ring nut, then align Lithium-soap-based grease the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the upper ring EAS30111 nut until their slots are aligned.

  • Page 155: Adjusting The Front Fork Legs (Fjr13Ag)

    • Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement → Repair. Refer to “FRONT FORK (FJR13AG)” on page 4-93 and “FRONT FORK (FJR13ESG)” on page 4-105. ▼ ▼▼▼...

  • Page 156: Adjusting The Damping Force (Fjr13Esg)

    PERIODIC MAINTENANCE Compression damping Direction “a” Adjustment value from the start Rebound damping is increased (sus- position (Soft) pension is harder). 32 click (s) out* Direction “b” Adjustment value from the start Rebound damping is decreased (sus- position (STD) pension is softer). 11 click (s) out* Adjustment value from the start position (Hard)

  • Page 157: Checking The Rear Suspension

    2. Check: • Rear shock absorber assembly HARD Gas leaks/oil leaks → Replace the rear shock absorber assembly. Refer to “REAR SHOCK ABSORBER AS- SEMBLY (FJR13AG)” on page 4-118 and “REAR SHOCK ABSORBER ASSEMBLY ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲...

  • Page 158: Adjusting The Preload Of The Rear Shock Absorber Assembly (Fjr13Esg)

    PERIODIC MAINTENANCE Spring preload Rebound damping ECA13590 NOTICE Adjustment value from the start position (Soft) Never go beyond the maximum or minimum 20 click (s) out* adjustment positions. Adjustment value from the start 1. Adjust: position (STD) • Spring preload 12 click (s) out* Adjustment value from the start ▼...
  • Page 159 PERIODIC MAINTENANCE (Refer to “ELECTRONICALLY ADJUST- While the preload is being adjusted, the infor- ABLE SUSPENSION SYSTEM mation display will show a group of dots mov- (FJR13ESG)” on page 8-227.) ing in a circle. Once the selected pictogram returns, the preload adjustment is complete. 1.

  • Page 160: Lubricating The Rear Suspension

    PERIODIC MAINTENANCE imately 6 minutes for the preload adjusting Recommended brand function motor to cool down, and then try ad- YAMALUBE justing the preload again. SAE viscosity grades 10W-40, 10W-50, 15W-40, 20W- 40 or 20W-50 GEAR GEAR Recommended engine oil grade API service SG type or higher, JASO standard MA 10 30 50 70 90 110...
  • Page 161 PERIODIC MAINTENANCE Oil filter cartridge 17 Nm (1.7 m·kgf, 12 ft·lbf) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 6. Install: • Engine oil drain bolt (along with the gasket Engine oil drain bolt 43 Nm (4.3 m·kgf, 31 ft·lbf) 4.

  • Page 162: Measuring The Engine Oil Pressure

    PERIODIC MAINTENANCE c. Start the engine and keep it idling until engine Oil pressure gauge set oil starts to seep from the engine oil check 90890-03120 bolt. If no engine oil comes out after one min- Oil pressure adapter B ute, turn the engine off so that it will not seize.

  • Page 163: Checking The Cooling System

    PERIODIC MAINTENANCE 2. Remove: • Oil cooler outlet hose “2” • Side panel (left) • Radiator inlet hose “3” Refer to “GENERAL CHASSIS (2)” on page • Radiator outlet hose “4” 4-5. • Oil cooler inlet hose “5” 3. Check: •...

  • Page 164: Changing The Coolant

    PERIODIC MAINTENANCE Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter- clockwise toward the detent to allow any re- sidual pressure to escape. When the hissing sound has stopped, press down on the radi- ator cap and turn it counterclockwise to re- move.

  • Page 165: Checking The Final Gear Oil Level

    PERIODIC MAINTENANCE 11.Fill: • Cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol anti- freeze containing corrosion in- hibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) 14.Install: Radiator (including all routes) • Coolant reservoir cap 2.60 L (2.75 US qt, 2.29 Imp.qt) 15.Start the engine, warm it up for several min- Coolant reservoir (up to the...

  • Page 166: Changing The Final Gear Oil

    PERIODIC MAINTENANCE EAS31574 CHECKING THE BRAKE LIGHT SWITCHES Type 1. Check: Shaft gear oil (Part No.:ACC- • Front brake light switch operation SHFTD-EX-00) • Rear brake light switch operation 4. Install: When operating the brake lever and brake • Final gear oil filler bolt pedal, confirm that the brake light turns on.

  • Page 167: Checking And Lubricating The Cables

    ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the Yamaha diagnostic tool. Use the diagnostic code number “82”. With the engine stopped, turn the throttle grip Refer to “SELF-DIAGNOSTIC FUNCTION slowly and release it. Make sure that the throttle AND DIAGNOSTIC CODE TABLE (ECU)”...

  • Page 168: Checking The Switches, Lights And Signals

    PERIODIC MAINTENANCE Direction “a” Throttle grip free play is increased. Direction “b” Throttle grip free play is decreased. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Adjust: • Headlight beam (horizontally) ▼...

  • Page 169: Chassis

    CHASSIS GENERAL CHASSIS (1) ................. 4-1 REMOVING THE CENTER REAR COWLING.......... 4-2 INSTALLING THE CENTER REAR COWLING ........4-2 REMOVING THE REAR COWLINGS ............4-2 INSTALLING THE REAR COWLINGS............4-2 REMOVING THE SIDE COVERS ............. 4-2 INSTALLING THE SIDE COVERS............4-3 INSTALLING THE SEATS................. 4-3 GENERAL CHASSIS (2) .................
  • Page 170 REAR WHEEL ....................4-39 REMOVING THE REAR WHEEL ............4-41 DISASSEMBLING THE REAR WHEEL ..........4-41 CHECKING THE REAR WHEEL............. 4-42 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR .................. 4-42 ASSEMBLING THE REAR WHEEL ............4-42 ADJUSTING THE REAR WHEEL STATIC BALANCE......4-43 INSTALLING THE REAR WHEEL (REAR BRAKE DISC) ......4-44 FRONT BRAKE .....................
  • Page 171 STEERING HEAD..................4-114 REMOVING THE LOWER BRACKET...........4-116 CHECKING THE STEERING HEAD .............4-116 INSTALLING THE STEERING HEAD ...........4-116 REAR SHOCK ABSORBER ASSEMBLY (FJR13AG).......4-118 HANDLING THE REAR SHOCK ABSORBER ........4-120 DISPOSING OF A REAR SHOCK ABSORBER ........4-120 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY....4-120 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ....4-120...
  • Page 172 SWINGARM....................4-133 REMOVING THE SWINGARM..............4-135 CHECKING THE SWINGARM ..............4-135 INSTALLING THE SWINGARM ............4-135 SHAFT DRIVE .....................4-137 TROUBLESHOOTING ................4-142 CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND CHECKING THE SHAFT DRIVE FOR LEAKS........4-144 MEASURING THE FINAL GEAR BACKLASH ........4-144 ADJUSTING THE FINAL GEAR BACKLASH ........4-145 MEASURING THE RING-GEAR-TO-STOPPER-BOLT CLEARANCE..................4-146 ADJUSTING THE RING-GEAR-TO-STOPPER-BOLT...

  • Page 174: General Chassis (1)

    GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the seats and covers 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) 21 Nm (2.1 m kgf, 15 ft Ibf)

  • Page 175: Removing The Center Rear Cowling

    GENERAL CHASSIS (1) EAS31839 REMOVING THE CENTER REAR COWLING 1. Remove: • Center rear cowling “1” Slide the center rear cowling rearward and re- move it. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...

  • Page 176: Installing The Side Covers

    GENERAL CHASSIS (1) b. Install the rider seat height position adjuster EAS31196 INSTALLING THE SIDE COVERS “2” so that the “H” mark “a” is aligned with the The following procedure applies to both of the match mark “b”. side covers. 1.

  • Page 177: General Chassis (2)

    GENERAL CHASSIS (1) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ To install the rider seat in the low position a. Install the rider seat height position adjuster “1” so that the “L” mark “a” is aligned with the match mark “b”.
  • Page 178 GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) Removing the side cowlings 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • • • • •...
  • Page 179 GENERAL CHASSIS (2) Removing the side cowlings 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • • • • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) •...

  • Page 180: Adjusting The Side Panels

    GENERAL CHASSIS (2) EAS31843 ADJUSTING THE SIDE PANELS The following procedure applies to both of the side panels. 1. Adjust: • Side panel position The side panel “1” can be opened 20 mm (0.79 in) for added ventilation to suit the riding condi- tions.

  • Page 181: Installing The Front Cowling Inner Panel

    GENERAL CHASSIS (2) 2. Remove: EAS31845 INSTALLING THE FRONT COWLING INNER • Front cowling inner panel “1” PANEL ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Unhook the tabs “a” on the top of the front 1.

  • Page 182: Removing The Side Cowlings

    GENERAL CHASSIS (2) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the front left turn signal/position light coupler, auxiliary DC jack coupler, and ac- cessory box solenoid coupler, and then fas- ten the front left turn signal/position light lead “a”, auxiliary DC jack lead “b”, and accessory box solenoid lead “c”...

  • Page 183: General Chassis (3)

    GENERAL CHASSIS (3) EAS20156 GENERAL CHASSIS (3) Removing the front cowling assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • ’ Order Job/Parts to remove Remarks “ ” Side cowlings Refer to Removing the side cowlings...
  • Page 184 GENERAL CHASSIS (3) Removing the front cowling assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • ’ Order Job/Parts to remove Remarks Headlight coupler Disconnect. Auxiliary light coupler Disconnect.

  • Page 185: Removing The Windshield Bracket Covers

    GENERAL CHASSIS (3) EAS31847 REMOVING THE WINDSHIELD BRACKET COVERS The following procedure applies to both of the windshield bracket covers. 1. Remove: • Windshield bracket outer cover “1” Slide the windshield bracket outer cover upward, and then remove it. EAS31094 REMOVING THE CENTER COVERS 1.

  • Page 186: Installing The Front Cowling Assembly

    GENERAL CHASSIS (3) Face the projection “a” on the headlight beam adjusting knob joint forward. 2. Install: • Center cover assembly “1” Fit the projections on the lower center cover into the holes in the front cowling. EAS31279 INSTALLING THE FRONT COWLING ASSEMBLY 1.

  • Page 187: General Chassis (4)

    GENERAL CHASSIS (4) EAS20157 GENERAL CHASSIS (4) Removing the meter assembly and electrical components board (FJR13AG) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • ’ Order Job/Parts to remove Remarks “ ” Side cowlings Refer to Removing the side cowlings “...
  • Page 188 GENERAL CHASSIS (4) Removing the meter assembly and electrical components board (FJR13AG) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • ’ Order Job/Parts to remove Remarks Disconnect. Grip warmer coupler (left) Black coupler. Clutch switch coupler Disconnect. Lean angle sensor...
  • Page 189 GENERAL CHASSIS (4) Removing the meter assembly and electrical components board (FJR13ESG) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • ’ Order Job/Parts to remove Remarks “ ” Side cowlings Refer to Removing the side cowlings “ Refer to Removing the front cowling assem- Front cowling assembly ”...
  • Page 190 GENERAL CHASSIS (4) Removing the windshield drive unit 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 32 Nm (3.2 m kgf, 23 ft Ibf) •...

  • Page 191: Installing The Windshield Drive Unit

    GENERAL CHASSIS (4) EAS31850 INSTALLING THE WINDSHIELD DRIVE UNIT 1. Check: • Windshield drive unit operation After installing the windshield drive unit to the windshield drive unit bracket, check the opera- tion of the drive unit. ▼ ▼▼▼ ▼ ▼▼▼ ▼...

  • Page 192: General Chassis (5)

    GENERAL CHASSIS (5) EAS20158 GENERAL CHASSIS (5) Removing the electrical components tray 1/2 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • ’ Order Job/Parts to remove Remarks “ ”...

  • Page 193: General Chassis (7)

    GENERAL CHASSIS (5) Removing the electrical components tray 2/2 (FJR13AG) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • •...
  • Page 194 GENERAL CHASSIS (5) Removing the electrical components tray 2/2 (FJR13ESG) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf)
  • Page 195 GENERAL CHASSIS (6) EAS20159 GENERAL CHASSIS (6) Removing the T-bar 37 Nm (3.7 m kgf, 27 ft Ibf) • • 37 Nm (3.7 m kgf, 27 ft Ibf) • • ’ Order Job/Parts to remove Remarks Rider seat “ ” Refer to Removing the seats and covers Fuel tank...
  • Page 196 GENERAL CHASSIS (7) EAS20193 GENERAL CHASSIS (7) Removing the air filter case (FJR13AG) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • (11) 8 Nm (0.8 m kgf, 5.8 ft Ibf) •...
  • Page 197 GENERAL CHASSIS (7) Removing the air filter case (FJR13AG) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • (11) 8 Nm (0.8 m kgf, 5.8 ft Ibf) • •...
  • Page 198 Air filter case cover Air filter element ’ Owner s tool kit SCU (Suspension Control Unit) Yamaha diagnostic tool coupler Rear lower fuel tank bracket Storage compartment Crankcase breather hose Disconnect. Air induction system hose (air filter case joint Disconnect.
  • Page 199 GENERAL CHASSIS (7) Removing the air filter case (FJR13ESG) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • (11) 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf)

  • Page 200: Front Wheel

    FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel, brake discs, wheel sensor, and sensor housing (FJR13AG) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 6 Nm (0.6 m kgf, 4.3 ft...
  • Page 201 FRONT WHEEL Removing the front wheel, brake discs, wheel sensor, and sensor housing (FJR13AG) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) •...
  • Page 202 FRONT WHEEL Removing the front wheel, brake discs, wheel sensor, and sensor housing (FJR13ESG) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) •...
  • Page 203 FRONT WHEEL Removing the front wheel, brake discs, wheel sensor, and sensor housing (FJR13ESG) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) •...
  • Page 204 FRONT WHEEL Disassembling the front wheel 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • ’ Order Job/Parts to remove Remarks Oil seal Front wheel sensor rotor Wheel bearing Spacer 4-31...

  • Page 205: Removing The Front Wheel

    FRONT WHEEL EAS30145 ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ REMOVING THE FRONT WHEEL a. Clean the surface of the front wheel hub. ECA23420 b. Remove the oil seals “1” with a flathead NOTICE screwdriver.

  • Page 206: Maintenance Of The Front Wheel Sensor And Sensor Rotor

    FRONT WHEEL 2. Check: • The front wheel sensor cannot be disas- • Tire sembled. Do not attempt to disassemble it. • Front wheel If faulty, replace with a new one. Damage/wear → Replace. • Keep magnets (including magnetic pick-up Refer to “CHECKING THE TIRES”...

  • Page 207: Assembling The Front Wheel

    FRONT WHEEL EAS30151 ASSEMBLING THE FRONT WHEEL Wheel sensor rotor deflection ECA18080 limit NOTICE 0.14 mm (0.0055 in) • Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...

  • Page 208: Adjusting The Front Wheel Static Balance

    FRONT WHEEL b. When the front wheel stops, put an “X ” mark at the bottom of the wheel. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Install: c. Turn the front wheel 90° so that the “X ”...

  • 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 Foreign materials cause dam- age to the inner sensor rotor and wheel sen- sor. To route the front wheel sensor lead, refer to “CABLE ROUTING (FJR13AG)” on page 2-35 and “CABLE ROUTING (FJR13ESG)” on page 2-57. ▲...
  • Page 211 FRONT WHEEL When installing the front fender, make sure that there is no dirt between the front fender and front fork legs. 4-38...

  • Page 212: Rear Wheel

    REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel, brake disc, wheel sensor, and sensor housing 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 125 Nm (12.5 m kgf, 90 ft lbf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...
  • Page 213 REAR WHEEL Disassembling the rear wheel 4.5 Nm (0.45 m kgf, 3.3 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 80 Nm (8.0 m kgf, 58 ft Ibf) • • ’ Order Job/Parts to remove Remarks Dust cover Rear wheel drive hub...

  • Page 214: Removing The Rear Wheel

    REAR WHEEL EAS30156 EAS30158 REMOVING THE REAR WHEEL DISASSEMBLING THE REAR WHEEL ECA23440 ECA18080 NOTICE NOTICE Keep magnets (including magnetic pick-up • Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away tools, magnetic screwdrivers, etc.) away from the rear wheel hub “1”, otherwise the from the wheel sensor rotor.

  • Page 215: Checking The Rear Wheel

    REAR WHEEL EAS30167 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR ECA18170 NOTICE • Handle the ABS components with care since they have been accurately adjusted. Keep them away from dirt and do not sub- ject them to shocks. •...

  • Page 216: Adjusting The Rear Wheel Static Balance

    REAR WHEEL Hexagon wrench (41) 90890-01525 Hexagon wrench (41) YM-01525 Bearing retainer 80 Nm (8.0 m·kgf, 58 ft·lbf) LOCTITE® ECA18180 2. Rear wheel NOTICE 2. Install: The bearing retainer has left-handed threads. To tighten the retainer, turn it coun- • Wheel bearings terclockwise.

  • Page 217: Installing The Rear Wheel (Rear Brake Disc)

    REAR WHEEL EAS30165 ECA14470 INSTALLING THE REAR WHEEL (REAR NOTICE BRAKE DISC) Make sure there are no foreign materials in 1. Install: the wheel hub. Foreign materials cause dam- • Rear brake disc age to the inner sensor rotor and wheel sen- sor.
  • Page 218 Rear wheel sensor bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) • To route the rear wheel sensor lead, refer to “CABLE ROUTING (FJR13AG)” on page 2-35 and “CABLE ROUTING (FJR13ESG)” on page 2-57. • When installing the rear wheel sensor, check the rear wheel sensor lead for twists and the sensor electrode for foreign materials.

  • Page 219: Front Brake

    FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads (FJR13AG) 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 220 FRONT BRAKE Removing the front brake pads (FJR13ESG) 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) •...
  • Page 221 FRONT BRAKE Removing the front brake master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 1.0 Nm (0.10 m kgf, 0.72 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) •...
  • Page 222 FRONT BRAKE Disassembling the front brake master cylinder ’ Order Job/Parts to remove Remarks Brake master cylinder push rod Dust boot Circlip Brake master cylinder kit Brake master cylinder body 4-49...
  • Page 223 FRONT BRAKE Removing the front brake calipers (FJR13AG) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • ’ Order...
  • Page 224 FRONT BRAKE Removing the front brake calipers (FJR13ESG) 40 Nm (4.0 m kgf, 29 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • ’ Order Job/Parts to remove Remarks The following procedure applies to both of...
  • Page 225 FRONT BRAKE Disassembling the front brake calipers 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • ’ Order Job/Parts to remove Remarks The following procedure applies to both of the front brake calipers.

  • Page 226: Introduction

    FRONT BRAKE d. Hold the dial gauge at a right angle against EAS30168 INTRODUCTION the brake disc surface. EWA14101 e. Measure the deflection 1.5 mm (0.06 in) be- WARNING low the edge of the brake disc. Disc brake components rarely require disas- sembly.

  • Page 227: Replacing The Front Brake Pads

    FRONT BRAKE Always install new brake pads and new brake pad springs as a set. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”.

  • Page 228: Removing The Front Brake Calipers

    FRONT BRAKE Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-13. EAS30172 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. 1. Remove: • Brake caliper pistons “1” • Brake caliper piston dust seals “2” •...

  • Page 229: Checking The Front Brake Calipers

    FRONT BRAKE • Whenever a brake caliper is disassembled, EAS30173 CHECKING THE FRONT BRAKE CALIPERS replace the brake caliper piston dust seals Recommended brake component replacement and brake caliper piston seals. schedule Brake pads If necessary Specified brake fluid DOT 4 Piston dust seals Every two years Piston seals...

  • Page 230: Removing The Front Brake Master Cylinder

    FRONT BRAKE • Brake hose holder Refer to “REPLACING THE FRONT BRAKE PADS” on page 4-54. Brake pad bolt 17 Nm (1.7 m·kgf, 12 ft·lbf) Brake caliper bolt 40 Nm (4.0 m·kgf, 29 ft·lbf) Brake hose holder bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 4.

  • Page 231: Checking The Front Brake Master Cylinder

    FRONT BRAKE • Install the brake master cylinder holder with the “UP” mark facing up. • Fit the projection “a” on the brake master cylin- der holder into the hole “b” in the right handle- bar. • First, tighten the upper bolt, then the lower bolt. EAS30725 CHECKING THE FRONT BRAKE MASTER CYLINDER...
  • Page 232 FRONT BRAKE 3. Fill: • Brake master cylinder reservoir • Brake fluid reservoir (with the specified amount of the specified brake fluid) Specified brake fluid DOT 4 EWA17280 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Page 233: Rear Brake

    REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake pads 27 Nm (2.7 m kgf, 20 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • ’...
  • Page 234 REAR BRAKE Removing the rear brake master cylinder 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) 30 Nm (3.0 m kgf, 22 ft Ibf) • • • • 18 Nm (1.8 m kgf, 13 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) •...
  • Page 235 REAR BRAKE Removing the rear brake master cylinder 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) 30 Nm (3.0 m kgf, 22 ft Ibf) • • • • 18 Nm (1.8 m kgf, 13 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) •...
  • Page 236 REAR BRAKE Disassembling the rear brake master cylinder 16 Nm (1.6 m kgf, 12 ft Ibf) • • ’ Order Job/Parts to remove Remarks Dust boot Circlip Brake master cylinder push rod Brake master cylinder kit Brake master cylinder body 4-63...
  • Page 237 REAR BRAKE Removing the rear brake caliper 125 Nm (12.5 m kgf, 90 ft lbf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...
  • Page 238 REAR BRAKE Disassembling the rear brake caliper 27 Nm (2.7 m kgf, 20 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • ’ Order Job/Parts to remove Remarks Rear brake caliper bolt Brake pad shim Rear brake pad Brake pad spring Rear brake caliper bracket...

  • Page 239: Introduction

    REAR BRAKE EAS30183 INTRODUCTION Brake disc thickness limit EWA14101 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 240: Removing The Rear Brake Caliper

    REAR BRAKE ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ ECA18210 NOTICE a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose •...

  • Page 241: Disassembling The Rear Brake Caliper

    REAR BRAKE EAS30188 CHECKING THE REAR BRAKE CALIPER Recommended brake component replacement schedule Brake pads If necessary Piston dust seal Every two years Piston seal Every two years Brake hoses Every four years Every two years and Brake fluid whenever the brake is EAS30187 disassembled DISASSEMBLING THE REAR BRAKE...

  • Page 242: Installing The Rear Brake Caliper

    REAR BRAKE • Never use solvents on internal brake com- ponents as they will cause the brake caliper piston dust seal and brake caliper piston seal to swell and distort. • Whenever a brake caliper is disassembled, replace the brake caliper piston dust seal and brake caliper piston seal.

  • Page 243: Removing The Rear Brake Master Cylinder

    REAR BRAKE • Rear brake caliper 5. Install: • Brake pad springs • Rear brake pads • Brake pad shims • Rear brake caliper bolts • Rear brake caliper Refer to “REPLACING THE REAR BRAKE PADS” on page 4-66. Rear brake caliper bolt 9.

  • Page 244: Assembling The Rear Brake Master Cylinder

    REAR BRAKE 2. Check: • Brake master cylinder kit Damage/scratches/wear → Replace. 3. Check: • Brake fluid reservoir Cracks/damage → Replace. • Brake fluid reservoir diaphragm Cracks/damage → Replace. 4. Check: • Brake hose Cracks/damage/wear → Replace. 2. Install: • Rear brake light switch “1” EAS30195 ASSEMBLING THE REAR BRAKE MASTER CYLINDER...
  • Page 245 REAR BRAKE 4. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-14. 5. Check: • Brake fluid level Below the minimum level mark “a” → Add the specified brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”...

  • Page 246: Abs (Anti-Lock Brake System)

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS20032 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the rear fender assembly (FJR13AG) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (1)”...
  • Page 247 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the metering valve, proportioning valve, and brake pipes 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) •...
  • Page 248 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the metering valve, proportioning valve, and brake pipes 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) •...
  • Page 249 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly (FJR13AG) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 16 Nm (1.6 m kgf, 12 ft Ibf) • •...
  • Page 250 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly (FJR13ESG) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf)

  • Page 251: Abs Components Chart

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS30728 ABS COMPONENTS CHART 12,13 1. Brake hose (metering valve to right front brake caliper) 2. Brake hose (brake pipe/upper joint assembly to front brake calipers) 3. Brake hose (front brake master cylinder to brake pipe/lower joint assembly) 4.

  • Page 252: Removing The Hydraulic Unit Assembly

    ABS (ANTI-LOCK BRAKE SYSTEM) 3. Slide the rear fender assembly “1” down. EAS30197 REMOVING THE HYDRAULIC UNIT (FJR13ESG) ASSEMBLY ECA18230 NOTICE Unless necessary, avoid removing and in- stalling the brake pipes of the hydraulic unit assembly. EWA13930 WARNING Refill with the same type of brake fluid that is already in the system.

  • Page 253: Checking The Hydraulic Unit Assembly

    ABS (ANTI-LOCK BRAKE SYSTEM) • When using a bolt, do not tighten the bolt until EAS30200 INSTALLING THE HYDRAULIC UNIT the bolt head touches the hydraulic unit. Other- ASSEMBLY wise, the brake pipe seating surface could be 1. Install: deformed. •...
  • Page 254 ABS (ANTI-LOCK BRAKE SYSTEM) • Brake pipe (hydraulic unit to proportioning ECA19290 NOTICE valve) “2” If the brake pipe flare nut does not turn easi- Proportioning valve bolt ly, replace the hydraulic unit, brake pipes, 7 Nm (0.7 m·kgf, 5.1 ft·lbf) and related parts as a set.
  • Page 255 ABS (ANTI-LOCK BRAKE SYSTEM) ECA19290 NOTICE Brake pipe flare nut 16 Nm (1.6 m·kgf, 12 ft·lbf) If the brake pipe flare nut does not turn easi- Metering valve bolt ly, replace the hydraulic unit, brake pipes, 7 Nm (0.7 m·kgf, 5.1 ft·lbf) and related parts as a set.

  • Page 256: Hydraulic Unit Operation Tests

    ABS (ANTI-LOCK BRAKE SYSTEM) 1. Place the vehicle on the centerstand. ECA13540 NOTICE 2. Turn the main switch to “OFF”. Brake fluid may damage painted surfaces 3. Remove: and plastic parts. Therefore, always clean up • Upper inner panel (right) any spilt brake fluid immediately.
  • Page 257 ABS (ANTI-LOCK BRAKE SYSTEM) 6. Turn the main switch to “ON” while operating the brake lever and the brake pedal simulta- neously. • This check cannot be performed unless both the brake lever and the brake pedal are oper- ated simultaneously when the main switch is turned to “ON”.
  • Page 258 ABS (ANTI-LOCK BRAKE SYSTEM) e. Retract the sidestand. 6. Extend the sidestand. 7. Turn the main switch to “ON”. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 8. Push the “ ” side of the start/engine stop 3.

  • Page 259: Checking The Abs Warning Light

    ABS (ANTI-LOCK BRAKE SYSTEM) 11.After the pulsating action has stopped in the 13.Turn the main switch to “OFF”. brake lever, it is generated in the brake pedal 14.Remove the test coupler adapter from the “1” 0.5 second later and continues for approx- ABS test coupler.

  • Page 260: Handlebars

    HANDLEBARS EAS20033 HANDLEBARS Removing the left handlebar 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 65 Nm (6.5 m kgf, 47 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...
  • Page 261 HANDLEBARS Removing the right handlebar 23 Nm (2.3 m kgf, 17 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • 65 Nm (6.5 m kgf, 47 ft Ibf) •...

  • Page 262: Adjusting The Handlebar Position

    HANDLEBARS EAS31396 ADJUSTING THE HANDLEBAR POSITION 1. Check: • Handlebar position The handlebar position can be adjusted to one of three positions to suit the rider’s preference. a. Front position b. Standard position c. Rear position e. Install the handlebar bolts “3” and nuts “2” temporarily.

  • Page 263: Checking The Handlebars

    HANDLEBARS ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS30204 CHECKING THE HANDLEBARS 3. Install: 1. Check: • Handlebar switch (right) “1” • Handlebar (left) • Handlebar (right) Align the projection “a” on the right handlebar Bends/cracks/damage →...
  • Page 264 HANDLEBARS • When installing the throttle cable housing, align the projection “a” on the housing with the hole “b” in the right handlebar and be sure not to pinch the right grip warmer lead. • There should be 1–3 mm (0.04–0.12 in) of clearance “c”...
  • Page 265 HANDLEBARS 10.Install: • Clutch master cylinder assembly • Clutch master cylinder holder “1” Clutch master cylinder holder bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Install the clutch master cylinder holder with the “UP” mark facing up. • Align the mating surfaces of the clutch master cylinder holder with the punch mark “a”...

  • Page 266: Front Fork (Fjr13Ag)

    FRONT FORK (FJR13AG) EAS20247 FRONT FORK (FJR13AG) Removing the front fork legs 26 Nm (2.6 m kgf, 19 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...
  • Page 267 FRONT FORK (FJR13AG) Disassembling the left front fork leg 23 Nm (2.3 m kgf, 17 ft Ibf) • • ’ Order Job/Parts to remove Remarks Cap bolt O-ring Washer Spacer Fork spring Dust seal Oil seal clip Oil seal Washer...
  • Page 268 FRONT FORK (FJR13AG) Disassembling the left front fork leg 23 Nm (2.3 m kgf, 17 ft Ibf) • • ’ Order Job/Parts to remove Remarks Outer tube bushing 1 D = 52 mm (2.05 in), l = 15 mm (0.59 in) Outer tube bushing 2 D = 51 mm (2.01 in), l = 15 mm (0.59 in)
  • Page 269 FRONT FORK (FJR13AG) Disassembling the right front fork leg 15 Nm (1.5 m kgf, 11 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • ’ Order Job/Parts to remove Remarks Cap bolt O-ring Damper adjusting rod...
  • Page 270 FRONT FORK (FJR13AG) Disassembling the right front fork leg 15 Nm (1.5 m kgf, 11 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • ’ Order Job/Parts to remove Remarks Oil flow stopper Outer tube bushing 1 D = 52 mm (2.05 in), l = 15 mm (0.59 in)

  • Page 271: Removing The Front Fork Legs

    FRONT FORK (FJR13AG) 1. Hold the nut “1” and loosen the cap bolt “2”. EAS31648 REMOVING THE FRONT FORK LEGS (Right side only) The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface.

  • Page 272: Checking The Front Fork Legs

    FRONT FORK (FJR13AG) 2. Measure: Damper rod holder (ø32.5) • Spring free length “a” 90890-01513 Out of specification → Replace. Fork spring free length 314.0 mm (12.36 in) Limit 307.7 mm (12.11 in) 5. Remove: • Inner tube ▼ ▼▼▼...
  • Page 273 FRONT FORK (FJR13AG) • Before assembling the front fork leg, make Slide metal installer sure all of the components are clean. 90890-01508 1. Install: Slide metal installer YM-01508 • Inner tube bushing Fork seal driver • Damper rod assembly 90890-01502...
  • Page 274 FRONT FORK (FJR13AG) Slide metal installer 90890-01508 Slide metal installer YM-01508 Fork seal driver 90890-01502 Fork seal driver (48) YM-A0948 ECA14220 NOTICE 9. Install: Make sure the numbered side of the oil seal • Dust seal “1” faces up. (with the fork seal driver “2”) Fork seal driver •...
  • Page 275 FRONT FORK (FJR13AG) 15.Measure: Recommended oil • Front fork leg oil level “a” Yamaha Suspension Oil 01 (from the top of the inner tube, with the outer Quantity (left) tube fully compressed and without the fork 753.0 cm³ (25.46 US oz, 26.56 spring) Imp.oz)

  • Page 276: Installing The Front Fork Legs

    FRONT FORK (FJR13AG) EAS31652 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: • Front fork leg Temporarily tighten the upper and lower bracket pinch bolts. Make sure the inner tube is flush with the top of the upper bracket.
  • Page 277 FRONT FORK (FJR13AG) • Compression damping (right side only) Refer to “ADJUSTING THE FRONT FORK LEGS (FJR13AG)” on page 3-20. 4-104...

  • Page 278: Front Fork (Fjr13Esg)

    FRONT FORK (FJR13ESG) EAS20248 FRONT FORK (FJR13ESG) Removing the front fork legs 26 Nm (2.6 m kgf, 19 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...
  • Page 279 FRONT FORK (FJR13ESG) Disassembling the front fork legs 15 Nm (1.5 m kgf, 11 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • ’ Order Job/Parts to remove Remarks The following procedure applies to both of the front fork legs.

  • Page 280: Removing The Front Fork Legs

    FRONT FORK (FJR13ESG) EAS30206 ECA20260 REMOVING THE FRONT FORK LEGS NOTICE The following procedure applies to both of the Because the left and right damper rod as- front fork legs. semblies are different, be sure to install them 1. Stand the vehicle on a level surface. in the correct positions.

  • Page 281: Checking The Front Fork Legs

    FRONT FORK (FJR13ESG) Stroke the damper rod “1” several times while draining the fork oil. 3. Remove: • Dust seal • Oil seal clip (with a flat-head screwdriver) ECA19100 NOTICE Do not scratch the outer tube. A. Left side B. Right side 4.

  • Page 282: Assembling The Front Fork Legs

    FRONT FORK (FJR13ESG) 1. Install: • Damper rod assembly “1” (onto the inner tube “2”) • Damper rod assembly bolt • Copper washer ECA17401 NOTICE For the damper rod assembly, the right side is used for the rebound operation and left side for the compression.
  • Page 283 FRONT FORK (FJR13ESG) While holding the damper rod assembly with the damper rod holder “1”, tighten the damper rod assembly bolt. Damper rod holder (ø27) 90890-01423 Damping rod holder YM-01423 5. Install: 3. Lubricate: • Outer tube • Inner tube outer surface (onto the inner tube) Recommended oil 6.
  • Page 284 FRONT FORK (FJR13ESG) 10.Fill: • Front fork leg (with the specified amount of the recom- mended fork oil) Recommended oil Yamaha Suspension Oil 01 Quantity (left) 580.0 cm³ (19.61 US oz, 20.46 Imp.oz) Quantity (right) 8. Install: 570.0 cm³ (19.27 US oz, 20.10 •...
  • Page 285 FRONT FORK (FJR13ESG) Level (left) 123 mm (4.8 in) Level (right) 123 mm (4.8 in) d. Reinstall the rod puller and rod puller attach- ment. e. Press down in the spacer with the fork spring compressor “1”. f. Pull up the rod puller and install the rod holder “2”...

  • Page 286: Installing The Front Fork Legs

    FRONT FORK (FJR13ESG) i. Hold the cap bolt (with front fork stepping mo- tor) and tighten the cap bolt (with front fork When installing the front fork legs, make sure stepping motor) locknut to specification. that the front fork stepping motor couplers are positioned at the angles shown in the illustration.

  • Page 287: Steering Head

    Refer to “FUEL TANK” on page 7-1. Handlebars Refer to “HANDLEBARS” on page 4-87. Front wheel Refer to “FRONT WHEEL” on page 4-27. Refer to “FRONT FORK (FJR13AG)” on Front fork legs page 4-93 and “FRONT FORK (FJR13ESG)” on page 4-105. Immobilizer unit coupler cover holder...
  • Page 288 STEERING HEAD Removing the lower bracket 7 Nm (0.7 m kgf, 5.1 ft Ibf) 115 Nm (11.5 m kgf, 83 ft lbf) • • • • 1st 52 Nm (5.2 m kgf, 38 ft Ibf) • • 2nd 18 Nm (1.8 m kgf, 13 ft Ibf) •...

  • Page 289: Removing The Lower Bracket

    STEERING HEAD b. Remove the bearing race from the lower EAS30213 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 NOTICE...
  • Page 290 • Steering stem nut Temporarily tighten the steering stem nut. 4. Install: • Front fork legs Refer to “FRONT FORK (FJR13AG)” on page 4-93 and “FRONT FORK (FJR13ESG)” on page 4-105. Temporarily tighten the upper and lower bracket pinch bolts.

  • Page 291: Rear Shock Absorber Assembly (Fjr13Ag)

    REAR SHOCK ABSORBER ASSEMBLY (FJR13AG) EAS20233 REAR SHOCK ABSORBER ASSEMBLY (FJR13AG) Removing the rear shock absorber assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 64 Nm (6.4 m kgf, 46 ft Ibf) • • 40 Nm (4.0 m...
  • Page 292 REAR SHOCK ABSORBER ASSEMBLY (FJR13AG) Removing the rear shock absorber assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 64 Nm (6.4 m kgf, 46 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) •...

  • Page 293: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY (FJR13AG) EAS31912 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 294: Checking The Connecting Arm And Relay Arm

    REAR SHOCK ABSORBER ASSEMBLY (FJR13AG) • Rear shock absorber assembly Gas leaks/oil leaks → Replace the rear shock • Make sure that the oil seals do not protrude absorber assembly. past the edges of the relay arm. • Spring • When installing the oil seals to the relay arm, Damage/wear →...
  • Page 295 REAR SHOCK ABSORBER ASSEMBLY (FJR13AG) • Make sure that the warning label on the rear shock absorber assembly faces to the right. • When installing the rear shock absorber as- sembly, lift up the swingarm. 4-122...

  • Page 296: Rear Shock Absorber Assembly (Fjr13Esg)

    REAR SHOCK ABSORBER ASSEMBLY (FJR13ESG) EAS20254 REAR SHOCK ABSORBER ASSEMBLY (FJR13ESG) Removing the rear fender assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (1)”...
  • Page 297 REAR SHOCK ABSORBER ASSEMBLY (FJR13ESG) Removing the rear fender assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • ’ Order Job/Parts to remove Remarks Brake switch relay Plastic band Rear fender assembly Rear shock absorber assembly stepping motor Disconnect.
  • Page 298 REAR SHOCK ABSORBER ASSEMBLY (FJR13ESG) Removing the rear shock absorber assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) 64 Nm (6.4 m kgf, 46 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • •...
  • Page 299 REAR SHOCK ABSORBER ASSEMBLY (FJR13ESG) Removing the rear shock absorber assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) 64 Nm (6.4 m kgf, 46 ft Ibf) • • • • 11 9 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 300 REAR SHOCK ABSORBER ASSEMBLY (FJR13ESG) Removing the stepping motor and DC motor 0.7 Nm (0.07 m kgf, 0.51 ft Ibf) • • 0.7 Nm (0.07 m kgf, 0.51 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) •...

  • Page 301: Removing The Rear Fender Assembly

    REAR SHOCK ABSORBER ASSEMBLY (FJR13ESG) then pull the couplers out through the holes in EAS31852 REMOVING THE REAR FENDER ASSEMBLY the DC motor upper cover and rear fender as- 1. Remove the rear fender bolts “1” and quick sembly. fasteners “2”. Move the rear shock absorber assembly, and then pull the couplers out through the holes in the DC motor upper cover and rear fender as-...

  • Page 302: Disposing Of A Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY (FJR13ESG) • Rear shock absorber assembly EAS30729 DISPOSING OF A REAR SHOCK ABSORBER 1. Gas pressure must be released before dis- Partially pull out the rear shock absorber assem- posing of a rear shock absorber. To release bly upper bolt, slide the spacer “2”...

  • Page 303: Replacing The Stepping Motor

    REAR SHOCK ABSORBER ASSEMBLY (FJR13ESG) 3. Check: • Spacers • Make sure that the warning label on the rear Damage/scratches → Replace. shock absorber assembly faces to the right. • When installing the rear shock absorber as- EAS31042 REPLACING THE STEPPING MOTOR sembly, lift up the swingarm.

  • Page 304: Installing The Rear Fender Assembly

    REAR SHOCK ABSORBER ASSEMBLY (FJR13ESG) EAS31853 INSTALLING THE REAR FENDER • Make sure that the oil seals do not protrude ASSEMBLY past the edges of the relay arm. 1. Install the rear fender assembly temporarily. • When installing the oil seals to the relay arm, 2.
  • Page 305 REAR SHOCK ABSORBER ASSEMBLY (FJR13ESG) 5. Install the rear fender bolts “1” and quick fas- teners “2”. 4-132...

  • Page 306: Swingarm

    4-23. Rear wheel Refer to “REAR WHEEL” on page 4-39. Refer to “REAR SHOCK ABSORBER AS- Rear shock absorber assembly/Connecting SEMBLY (FJR13AG)” on page 4-118 and arms “REAR SHOCK ABSORBER ASSEMBLY (FJR13ESG)” on page 4-123. Final drive assembly/Universal joint Refer to “SHAFT DRIVE” on page 4-137.
  • Page 307 SWINGARM Removing the swingarm 23 Nm (2.3 m kgf, 17 ft Ibf) • • 125 Nm (12.5 m kgf, 90 ft lbf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 308: Removing The Swingarm

    SWINGARM 2. Check: EAS30226 REMOVING THE SWINGARM • Pivot shaft 1. Stand the vehicle on a level surface. Roll the pivot shaft on a flat surface. EWA13120 Bends → Replace. WARNING EWA13770 Securely support the vehicle so that there is WARNING no danger of it falling over.
  • Page 309 SWINGARM • When installing the oil seals “3” to the swing- arm, face the character stamp of the oil seals outside. 4. Swingarm 5. Connecting arm A. Left side B. Right side 3. Tighten: • Pivot shaft Pivot shaft 23 Nm (2.3 m·kgf, 17 ft·lbf) •...

  • Page 310: Shaft Drive

    SHAFT DRIVE EAS20040 SHAFT DRIVE Removing the final drive assembly 23 Nm (2.3 m kgf, 17 ft Ibf) • • 42 Nm (4.2 m kgf, 30 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • ’...
  • Page 311 SHAFT DRIVE Removing the universal joint 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...
  • Page 312 SHAFT DRIVE Disassembling the final drive assembly 23 Nm (2.3 m kgf, 17 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) •...
  • Page 313 SHAFT DRIVE Disassembling the final drive assembly 23 Nm (2.3 m kgf, 17 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) •...
  • Page 314 SHAFT DRIVE Disassembling the final drive assembly 23 Nm (2.3 m kgf, 17 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) •...

  • Page 315: Troubleshooting

    SHAFT DRIVE EAS30238 TROUBLESHOOTING Symptom Possible cause 1. A pronounced hesitation or jerky movement A. Bearing damage during acceleration, deceleration or sustained B. Improper gear backlash speeds (not to be confused with engine surging C. Damaged gear teeth or transmission-related movements). D.
  • Page 316 SHAFT DRIVE Troubleshooting chart When causes (A) or (B) shown in the table at the beginning of the “TROUBLESHOOTING” section ex- ist, check the following points. YES → 1. Place the vehicle on a suitable stand so that the front wheel is ele- •...

  • Page 317: Checking The Final Drive Oil For Contamination And Checking The Shaft Drive For Leaks

    SHAFT DRIVE EAS31901 CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND CHECKING THE SHAFT DRIVE FOR LEAKS 1. Drain: • Final gear oil (from the final gear case) Refer to “CHANGING THE FINAL GEAR OIL” on page 3-31. 2. Check: •...

  • Page 318: Adjusting The Final Gear Backlash

    SHAFT DRIVE EAS30241 ADJUSTING THE FINAL GEAR BACKLASH 1. Remove: • Ring gear bearing housing bolts “1” • Ring gear bearing housing nuts “2” Working in a crisscross pattern, loosen each bolt and nut 1/4 of a turn. After all of the bolts and nuts are fully loosened, remove them.

  • Page 319: Measuring The Ring-Gear-To-Stopper-Bolt Clearance

    SHAFT DRIVE EAS30243 ADJUSTING THE RING-GEAR-TO- Ring gear shims STOPPER-BOLT CLEARANCE Thickness (mm) 1. Remove: 0.25 0.30 0.40 0.50 • Ring gear “1” • Stopper bolt “2” Thrust washers • Stopper bolt shim(s) “3” Thickness (mm) • Ring gear bearing housing “4” 1.2 1.4 1.6 1.8 2.0 ▲...

  • Page 320: Disassembling The Final Drive Assembly

    SHAFT DRIVE Ring-gear-to-stopper-bolt clear- Bearing retainer wrench ance 90890-04050 0.30–0.60 mm (0.0118–0.0236 in) Pinion bearing retainer & remov- YM-04050 If the ring-gear-to-stopper-bolt clearance is out ECA14330 of specification, repeat the above procedure. NOTICE The bearing retainer has left-hand threads. EAS30244 To loosen the bearing retainer, turn it clock- DISASSEMBLING THE FINAL DRIVE wise.

  • Page 321: Aligning The Final Drive Pinion Gear And Ring Gear

    SHAFT DRIVE The bearing can be reused, but Yamaha recom- mends installing a new one. 3. Remove: • Bearing “1” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Heat the final gear case to approximately 150 °C (302 °F).
  • Page 322 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 323 SHAFT DRIVE Ring gear bearing thickness 13.00 mm (0.51 in) Example: If the final gear case is marked “51”, the ring gear bearing housing is marked “35”, the ring gear is marked “+ 05”, and “f” is 13.00: 45.51 + 3.35 - 35.45 - 13 0.41 3.

  • Page 324: Checking The Drive Shaft

    SHAFT DRIVE 6. Adjust: Thrust washers • Final gear backlash Thickness (mm) Refer to “MEASURING THE FINAL GEAR 1.2 1.4 1.6 1.8 2.0 BACKLASH” on page 4-144 and “ADJUST- ING THE FINAL GEAR BACKLASH” on i. Repeat the measurement steps until the ring- page 4-145.
  • Page 325 SHAFT DRIVE Fork seal driver weight 90890-01184 Replacement hammer YM-A9409-7 Fork seal driver attachment 90890-01186 Replacement 27 mm YM-A9409-1 6. Install: • Universal joint • Final drive assembly Align the drive shaft splines with the driven yoke of the universal joint. 7.
  • Page 326 SHAFT DRIVE 9. Connect: • Sidestand switch coupler Wrap the lead cover around the sidestand switch coupler and oil level switch coupler ac- cording to the procedure indicated by the num- bers in the illustration. 10.Install: • Shift arm “1” Align the punch mark “a”...
  • Page 327 ENGINE ENGINE INSPECTION ..................5-1 MEASURING THE COMPRESSION PRESSURE........5-1 ENGINE REMOVAL ..................5-3 REMOVING THE ENGINE ................ 5-9 INSTALLING THE ENGINE............... 5-9 CAMSHAFTS....................5-12 REMOVING THE CAMSHAFTS..............5-15 CHECKING THE CAMSHAFTS ..............5-16 CHECKING THE CAMSHAFT SPROCKETS .........5-17 CHECKING THE TIMING CHAIN GUIDES..........5-17 CHECKING THE TIMING CHAIN TENSIONER........
  • Page 328 CLUTCH ......................5-43 REMOVING THE CLUTCH ..............5-49 CHECKING THE FRICTION PLATES.............5-50 CHECKING THE CLUTCH PLATES ............5-50 CHECKING THE CLUTCH SPRINGS.............5-51 CHECKING THE CLUTCH HOUSING ............5-51 CHECKING THE CLUTCH BOSS............5-51 CHECKING THE PRESSURE PLATE ............5-51 CHECKING THE CLUTCH PUSH RODS ..........5-51 CHECKING THE PRIMARY DRIVEN GEAR ..........5-52 INSTALLING THE CLUTCH..............
  • Page 329 CRANKCASE ....................5-78 DISASSEMBLING THE CRANKCASE............5-82 CHECKING THE CRANKCASE ..............5-82 CHECKING THE OIL DELIVERY PIPES ..........5-82 CHECKING THE BEARINGS AND OIL SEAL ........5-82 CHECKING THE TIMING CHAIN AND OIL PUMP DRIVE CHAIN..5-82 ASSEMBLING THE CRANKCASE............5-82 INSTALLING THE OIL PUMP DRIVE SPROCKET ........5-85 CONNECTING RODS AND PISTONS ............

  • Page 330: Engine Inspection

    ENGINE INSPECTION EAS20041 ENGINE INSPECTION EAS30249 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cyl- inders. Insufficient compression pressure will result in a loss of performance. 1. Measure: • Valve clearance 8. Measure: Out of specification → Adjust. •...
  • Page 331 ENGINE INSPECTION Compression pressure (with oil applied into the cylinder) Reading Diagnosis Piston ring(s) wear or Higher than without oil damage → Repair. Pistons, valves, cylinder head gasket or piston Same as without oil ring(s) possibly defec- tive → Repair. ▲...

  • Page 332: Engine Removal

    ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the exhaust pipe assembly and muffler 17 Nm (1.7 m kgf, 12 ft Ibf) • • 25 Nm (2.5 m kgf, 18 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 333 ENGINE REMOVAL Removing the exhaust pipe assembly and muffler 17 Nm (1.7 m kgf, 12 ft Ibf) • • 25 Nm (2.5 m kgf, 18 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) •...
  • Page 334 ENGINE REMOVAL Disconnecting the leads and hose 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Front fender Refer to “FRONT WHEEL” on page 4-27. Refer to “GENERAL CHASSIS (7)”...
  • Page 335 ENGINE REMOVAL Disconnecting the leads and hose 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Dowel pin Crankcase breather hose Stator coil coupler Disconnect.
  • Page 336 ENGINE REMOVAL Removing the engine 8 Nm (0.8 m kgf, 5.8 ft Ibf) 45 Nm (4.5 m kgf, 33 ft Ibf) • • • • 49 Nm (4.9 m kgf, 35 ft Ibf) • • 45 Nm (4.5 m kgf, 33 ft Ibf) •...

  • Page 337: Engine

    ENGINE REMOVAL Removing the engine 8 Nm (0.8 m kgf, 5.8 ft Ibf) 45 Nm (4.5 m kgf, 33 ft Ibf) • • • • 49 Nm (4.9 m kgf, 35 ft Ibf) • • 45 Nm (4.5 m kgf, 33 ft Ibf) •...

  • Page 338: Removing The Engine

    ENGINE REMOVAL EAS30250 REMOVING THE ENGINE 1. Loosen: • Spacer bolt Loosen the spacer bolt with the pivot shaft wrench “1” and pivot shaft wrench adapter “2”. Pivot shaft wrench 90890-01471 Frame spanner socket YM-01471 Pivot shaft wrench adapter 90890-01476 3.
  • Page 339 ENGINE REMOVAL 11.Tighten: Pivot shaft wrench • Engine bracket and engine bolts (top) “13” 90890-01471 (temporarily tighten) Frame spanner socket • Engine bracket bolts (top) “14” YM-01471 (temporarily tighten) Pivot shaft wrench adapter 90890-01476 When temporarily tightened, the bolts “13” and 6.
  • Page 340 ENGINE REMOVAL • Engine bracket and frame bolt (left rear side) “2” • Engine bracket and engine bolts (left rear side) “3” Do not fully tighten the bolts. 14.Tighten: • Engine bracket and frame bolt (left rear side) “2” Engine bracket and frame bolt (left rear side) 32 Nm (3.2 m·kgf, 23 ft·lbf) 15.Tighten:...

  • Page 341: Camshafts

    CAMSHAFTS EAS20043 CAMSHAFTS Removing the cylinder head cover 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (6)”...
  • Page 342 CAMSHAFTS Removing the cylinder head cover 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Cylinder head cover gasket Dowel pin...
  • Page 343 CAMSHAFTS Removing the camshafts 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 24 Nm (2.4 m kgf, 17 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 344: Removing The Camshafts

    CAMSHAFTS EAS30256 REMOVING THE CAMSHAFTS 1. Align: • “T” mark on the pickup rotor (with the crankcase mating surface) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft clockwise. b.

  • Page 345: Checking The Camshafts

    CAMSHAFTS 4. Measure: EAS30257 CHECKING THE CAMSHAFTS • Camshaft-journal-to-camshaft-cap clearance Out of specification → Measure the camshaft 1. Check: • Camshaft lobes journal diameter. Blue discoloration/pitting/scratches → Re- Camshaft-journal-to-camshaft- place the camshaft. cap clearance 2. Measure: 0.028–0.062 mm (0.0011–0.0024 • Camshaft lobe dimensions “a” Out of specification →...

  • Page 346: Checking The Camshaft Sprockets

    CAMSHAFTS EAS30265 CHECKING THE TIMING CHAIN GUIDES 1. Check: • Timing chain guide (exhaust side) • Timing chain guide (intake side) • Timing chain guide (upper side) Damage/wear → Replace the defective part(s). EAS30266 CHECKING THE TIMING CHAIN TENSIONER 1. Check: ▲...
  • Page 347 CAMSHAFTS • Intake camshaft sprocket ECA13740 NOTICE Camshaft sprocket bolt Do not turn the crankshaft when installing 24 Nm (2.4 m·kgf, 17 ft·lbf) the camshaft(s) to avoid damage or improper valve timing. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...
  • Page 348 CAMSHAFTS • Make sure the arrow mark “a” on each cam- shaft points towards the right side of the en- gine. • Make sure the holes “b” in the camshafts are aligned with arrow mark “a” on the camshaft caps. E3 E ▲...
  • Page 349 ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ • Apply Yamaha bond No.1215® “2” onto the 7. Turn: mating surfaces of the cylinder head cover • Crankshaft gasket and cylinder head. (several turns clockwise) • Install a new cylinder head cover gasket “3”, 8.

  • Page 350: Cylinder Head

    CYLINDER HEAD EAS20044 CYLINDER HEAD Removing the cylinder head (10) 25 Nm (2.5 m kgf, 18 ft Ibf) • • 25 Nm (2.5 m kgf, 18 ft Ibf) • • Final Specified angle 175–185˚ 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...

  • Page 351: Removing The Cylinder Head

    CYLINDER HEAD EAS30276 ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ REMOVING THE CYLINDER HEAD a. Place a straightedge “1” and a thickness 1. Remove: gauge “2” across the cylinder head. •...
  • Page 352 CYLINDER HEAD Cylinder head bolt (M10) 25 Nm (2.5 m·kgf, 18 ft·lbf) 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 Specified angle 175–185° ▲...
  • Page 353 VALVES AND VALVE SPRINGS EAS20045 VALVES AND VALVE SPRINGS Removing the valves and valve springs ’ Order Job/Parts to remove 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 354: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS30283 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 “2”.
  • Page 355 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 356: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 2. Check: Valve guide remover (ø5) • Valve seat 90890-04097 Pitting/wear → Replace the cylinder head. Valve guide remover (5.0 mm) 3. Measure: YM-04097 • Valve seat width “a” Valve guide installer (ø5) Out of specification → Replace the cylinder 90890-04098 head.

  • Page 357: Checking The Valve Springs

    VALVES AND VALVE SPRINGS After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 358: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 2. Measure: 2. Lubricate: • Valve spring tilt “a” • Valve stem “1” Out of specification → Replace the valve • Valve stem end spring. • Valve stem seal “2” (with the recommended lubricant) Spring tilt (intake) 1.7 mm (0.07 in) Recommended lubricant Spring tilt (exhaust)
  • Page 359 VALVES AND VALVE SPRINGS 6. Lubricate: b. Smaller pitch • Valve lifter 4. Install: (with the recommended lubricant) • Valve cotters Recommended lubricant Engine oil Install the valve cotters by compressing the valve spring with the valve spring compressor 7. Install: “1”...

  • Page 360: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS20140 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch 130 Nm (13 m kgf, 94 ft lbf) • • 32 Nm (3.2 m kgf, 23 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...
  • Page 361 GENERATOR AND STARTER CLUTCH Removing the stator coil assembly 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Stator coil assembly lead holder Stator coil assembly 5-32...

  • Page 362: Removing The Generator

    GENERATOR AND STARTER CLUTCH EAS30867 EAS30868 REMOVING THE GENERATOR REMOVING THE STARTER CLUTCH 1. Remove: 1. Remove: • Generator rotor bolt “1” • Starter clutch bolts “1” • Washer While holding the generator rotor with the rotor While holding the generator rotor “2” with the ro- holding tool, remove the starter clutch bolts.

  • Page 363: Installing The Starter Clutch

    Rotor holding tool 90890-04166 YM-04166 3. Apply: • Sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) EAS30872 INSTALLING THE GENERATOR 1. Install: • Woodruff key •...
  • Page 364 GENERATOR AND STARTER CLUTCH Tighten the generator cover bolts in stages and in a crisscross pattern. 5-35...

  • Page 365: Pickup Rotor

    PICKUP ROTOR EAS20147 PICKUP ROTOR Removing the pickup rotor 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 65 Nm (6.5 m kgf, 47 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • ’ Order Job/Parts to remove Remarks...

  • Page 366: 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®) 5-37...
  • Page 367 PICKUP ROTOR 4. Measure: • Gap (between the crankshaft position sensor “1” and pickup rotor “2”) “a” Out of specification → Reinstall or replace. Gap (between the crankshaft po- sition sensor and pickup rotor) 0.5 mm (0.02 in) 5. Install: •...

  • Page 368: Electric Starter

    ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Throttle bodies Refer to “THROTTLE BODIES” on page 7-4. Starter motor lead Disconnect. Starter motor assembly 5-39...
  • Page 369 ELECTRIC STARTER Disassembling the starter motor ’ Order Job/Parts to remove 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 5-40...

  • Page 370: Checking The Starter Motor

    ELECTRIC STARTER EAS30325 CHECKING THE STARTER MOTOR Digital circuit tester 1. Check: 90890-03174 • Commutator Model 88 Multimeter with ta- Dirt → Clean with 600 grit sandpaper. chometer YU-A1927 2. Measure: • Commutator diameter “1” Out of specification → Replace the starter Armature coil resistance motor.

  • Page 371: 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). EAS30326 ASSEMBLING THE STARTER MOTOR 1. Install: • Brush seat “1” Align the slot “a” on the brush seat with the tab “b”...
  • Page 372 CLUTCH EAS20055 CLUTCH Removing the clutch cover 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • (10) 12 Nm (1.2 m kgf, 8.7 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (2)”...
  • Page 373 CLUTCH Removing the clutch 90 Nm (9.0 m kgf, 65 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Rear balancer Refer to “BALANCERS”...
  • Page 374 CLUTCH Removing the clutch 19 18 90 Nm (9.0 m kgf, 65 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Clutch damper spring seat Clutch boss...
  • Page 375 CLUTCH Removing the clutch master cylinder 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • ’ Order Job/Parts to remove Remarks Drain. Clutch fluid Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM”...
  • Page 376 CLUTCH Disassembling the clutch master cylinder ’ Order Job/Parts to remove Remarks Clutch master cylinder push rod Dust boot Circlip Washer Clutch master cylinder kit Clutch master cylinder body 5-47...
  • Page 377 CLUTCH Removing the clutch release cylinder 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • ’ Order Job/Parts to remove Remarks Drain. Clutch fluid Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM”...

  • Page 378: Clutch

    CLUTCH EAS31965 REMOVING THE CLUTCH There is a built-in damper between the clutch 1. Remove: boss and the clutch plate. It is not necessary to • Clutch cover “1” remove the wire circlip “4” and disassemble the built-in damper unless there is serious clutch Loosen each bolt 1/4 of a turn at a time, in stag- chattering.

  • Page 379: Checking The Friction Plates

    CLUTCH Out of specification → Replace the clutch EAS31966 CHECKING THE FRICTION PLATES plates as a set. The following procedure applies to all of the fric- tion plates. Thickness gauge 1. Check: 90890-03180 • Friction plate Feeler gauge set Damage/wear → Replace the friction plates YU-26900-9 as a set.

  • Page 380: Checking The Clutch Springs

    CLUTCH Clutch plate “1” Part No. Thickness 2H7-16325-00 2.0 mm (0.079 in) 2H7-16324-00 2.6 mm (0.102 in) 2. Check: • Bearing Damage/wear → Replace the bearing and clutch housing. EAS31970 CHECKING THE CLUTCH BOSS ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 381: Checking The Primary Driven Gear

    CLUTCH 2. Measure: • Long clutch push rod bending limit Out of specification → Replace the long clutch push rod. Push rod bending limit 0.20 mm (0.008 in) EAS31973 CHECKING THE PRIMARY DRIVEN GEAR 1. Check: 2. Install: • Primary driven gear “1” Damage/wear →...

  • Page 382: Disassembling The Clutch Master Cylinder

    CLUTCH 9,19 10,20 • Install the clutch boss nut with its large inner di- 8,18 ameter side facing inward as shown in the illus- 1,11 tration. 7,17 • While holding the clutch boss with the univer- 2,12 sal clutch holder “4”, tighten the clutch boss nut.

  • Page 383: Checking The Clutch Master Cylinder

    CLUTCH • Whenever a clutch master cylinder is disas- sembled, replace the piston seals. Specified brake and clutch fluid DOT 4 EAS31978 INSTALLING THE CLUTCH MASTER CYLINDER 1. Install: • Clutch master cylinder “1” EAS31976 • Clutch master cylinder holder “2” CHECKING THE CLUTCH MASTER CYLINDER •...

  • Page 384: Removing The Clutch Release Cylinder

    CLUTCH Refer to “CHECKING THE CLUTCH FLUID LEVEL” on page 3-11. 3. Fill: • Clutch master cylinder reservoir (with the specified amount of the specified 6. Check: brake and clutch fluid) • Clutch lever operation Soft or spongy feeling → Bleed the clutch Specified brake and clutch fluid system.

  • Page 385: Assembling The Clutch Release Cylinder

    CLUTCH EAS31981 ASSEMBLING THE CLUTCH RELEASE Specified brake and clutch fluid CYLINDER DOT 4 EWA16590 WARNING EWA17270 WARNING • Before installation, all internal clutch com- ponents must be cleaned and lubricated • Use only the designated clutch fluid. Other with clean or new clutch fluid. clutch fluids may cause the rubber seals to •...
  • Page 386 CLUTCH 5. Check: • Clutch lever operation Soft or spongy feeling → Bleed the clutch system. Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” on page 3-12. 5-57...

  • Page 387: Shift Shaft

    SHIFT SHAFT EAS20057 SHIFT SHAFT Removing the shift shaft and stopper lever 22 Nm (2.2 m kgf, 16 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 388: Checking The Shift Shaft

    SHIFT SHAFT 3. Install: EAS30377 CHECKING THE SHIFT SHAFT • Shift arm “1” 1. Check: • Shift shaft Shift arm pinch bolt Bends/damage/wear → Replace. 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Shift shaft spring Damage/wear → Replace. Align the punch mark “a” in the shift shaft with EAS30378 CHECKING THE STOPPER LEVER the slot in the shift shaft arm.
  • Page 389 SHIFT SHAFT c. Tighten both locknuts to specification. Shift rod locknut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5-60...

  • Page 390: Oil Pump

    OIL PUMP EAS20054 OIL PUMP Removing the oil pan and oil pump 12 Nm (1.2 m kgf, 8.7 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...
  • Page 391 OIL PUMP Removing the oil pan and oil pump 12 Nm (1.2 m kgf, 8.7 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 392 OIL PUMP Disassembling the oil pump 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • ’ Order Job/Parts to remove Remarks Oil pump housing cover Oil pump inner rotor Oil pump outer rotor Washer Oil pump driven sprocket...

  • Page 393: Checking The Oil Pump

    OIL PUMP EAS30337 CHECKING THE OIL PUMP Inner-rotor-to-outer-rotor-tip 1. Check: clearance • Oil pump driven sprocket 0.000–0.120 mm (0.0000–0.0047 • Oil pump housing Limit • Oil pump housing cover Cracks/damage/wear → Replace the defec- 0.20 mm (0.0079 in) Outer-rotor-to-oil-pump-housing tive part(s). clearance 2.

  • Page 394: Checking The Oil Strainer

    OIL PUMP 1. Check: Oil pan bolt • Oil delivery pipes 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Damage → Replace. Obstruction → Wash and blow out with com- pressed air. Tighten the oil pan bolts in stages and in a criss- EAS30340 cross pattern.

  • Page 395: Middle Gear

    MIDDLE GEAR EAS20060 MIDDLE GEAR Removing the middle gear 160 Nm (16 m kgf, 116 ft lbf) • • 110 Nm (11 m kgf, 80 ft lbf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 396 MIDDLE GEAR Removing the middle gear 160 Nm (16 m kgf, 116 ft lbf) • • 110 Nm (11 m kgf, 80 ft lbf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 397 MIDDLE GEAR Disassembling the middle drive shaft assembly ’ Order Job/Parts to remove Remarks Spring retainer Spring seat Damper spring Damper driven cam Damper drive cam Middle drive shaft 5-68...
  • Page 398 MIDDLE GEAR Disassembling the middle driven shaft assembly 110 Nm (11 m kgf, 80 ft lbf) • • 180 Nm (18 m kgf, 130 ft lbf) • • ’ Order Job/Parts to remove Remarks Oil seal Middle driven pinion gear nut Middle driven shaft Middle driven pinion gear Bearing retainer...

  • Page 399: Removing The Middle Drive Shaft Assembly

    MIDDLE GEAR EAS30399 REMOVING THE MIDDLE DRIVE SHAFT ASSEMBLY 1. Remove: • Middle drive pinion gear nut “1” • Lock washer “2” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a.

  • Page 400: Checking The Middle Drive Shaft Assembly

    MIDDLE GEAR 4. Check: • Bearings Damage/pitting → Replace. EAS30404 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 Damage/pitting → Replace. ▲...

  • Page 401: Installing The Middle Drive Shaft Assembly

    MIDDLE GEAR c. Tighten the bearing retainer to specification. Bearing retainer 110 Nm (11.0 m·kgf, 80 ft·lbf) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS30408 INSTALLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1.

  • Page 402: Installing The Middle Driven Shaft Assembly

    MIDDLE GEAR • Middle drive pinion gear nut “2” • Middle driven shaft end cover ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ • Middle driven shaft bearing housing bolts a.

  • Page 403: Measuring The Middle Gear Backlash

    MIDDLE GEAR EAS30410 MEASURING THE MIDDLE GEAR Measure the middle gear backlash at four posi- BACKLASH tions. Rotate the middle driven shaft 90° each 1. Measure: time and observe the reading on the dial gauge. • Middle gear backlash Out of specification → Refer to “ADJUSTING ▲...

  • Page 404: Aligning The Middle Gear

    MIDDLE GEAR Middle driven shaft bearing hous- While carefully tightening the middle driven shaft ing bolt bearing housing bolts in stages and in a criss- 25 Nm (2.5 m·kgf, 18 ft·lbf) cross pattern, turn the middle driven shaft back LOCTITE® and forth until the dial gauge reads 0.10–0.20 mm (0.0039–0.0079 in).
  • Page 405 MIDDLE GEAR “d” = a numeral on the middle driven pinion ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Position the middle gears with the appropri- gear, to be divided by 100 and either added ate shim(s) that has had its respective thick- to or subtracted from “34”...
  • Page 406 MIDDLE GEAR Middle driven pinion gear shim Thickness (mm) 0.10 0.15 0.20 0.30 0.40 0.50 ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5-77...

  • Page 407: Crankcase

    CRANKCASE EAS20059 CRANKCASE Separating the crankcase 10 Nm (1.0 m kgf, 7.2 ft Ibf) 20 Nm (2.0 m kgf, 14 ft Ibf) • • • • 2nd 20 Nm (2.0 m kgf, 14 ft Ibf) • • (10) 24 Nm (2.4 m kgf, 17 ft Ibf) •...
  • Page 408 CRANKCASE Separating the crankcase 10 Nm (1.0 m kgf, 7.2 ft Ibf) 20 Nm (2.0 m kgf, 14 ft Ibf) • • • • 2nd 20 Nm (2.0 m kgf, 14 ft Ibf) (10) • • 24 Nm (2.4 m kgf, 17 ft Ibf) •...
  • Page 409 CRANKCASE Removing the oil baffle plate and bearings 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 70 Nm (7.0 m kgf, 51 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 410 CRANKCASE Removing the oil baffle plate and bearings 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 70 Nm (7.0 m kgf, 51 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 411: Disassembling The Crankcase

    CRANKCASE EAS30389 EAS30390 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. 3.
  • Page 412 Engine oil 2. Apply: • Sealant (onto the crankcase mating surfaces and oil baffle plate 2) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings.
  • Page 413 CRANKCASE Crankcase bolt “1” –“10” • Lubricate the bolts “1”–“10” thread and wash- ers with engine oil. 20 Nm (2.0 m·kgf, 14 ft·lbf) • Lubricate the bolts “11”–“31” thread part and mating surface with engine oil. b. Loosen and retighten the crankcase bolts in •...

  • Page 414: Installing The Oil Pump Drive Sprocket

    CRANKCASE 13 21 19 22 EAS31872 INSTALLING THE OIL PUMP DRIVE SPROCKET 1. Install: • Conical spring washer “1” • Collar “2” • Oil pump drive sprocket “3” • Oil pump drive chain Make sure that the white paint mark on the con- ical spring washer is facing outward as shown in the illustration.
  • Page 415 CONNECTING RODS AND PISTONS EAS20132 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons 20 Nm (2.0 m kgf, 14 ft Ibf) • • Final Specified angle 115–125˚ ’ Order Job/Parts to remove Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-78. Connecting rod cap Big end lower bearing Piston pin clip...

  • Page 416: Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS EAS30745 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” Identify the position of each connecting rod so that it can be reinstalled in its original place. 4.

  • Page 417: Checking The Piston Rings

    CONNECTING RODS AND PISTONS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Measure cylinder bore “C” with the cylinder bore gauge. Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cylinder. Bore 79.000–79.010 mm (3.1102–...

  • Page 418: Checking The Piston Pin

    CONNECTING RODS AND PISTONS 1. Check: • Piston pin Blue discoloration/grooves → Replace the piston pin and then check the lubrication sys- tem. 2. Measure: • Piston pin outside diameter “a” Out of specification → Replace the piston pin. Piston pin outside diameter 18.991–19.000 mm (0.7477–...

  • Page 419: Checking The Connecting Rods

    CONNECTING RODS AND PISTONS Piston-pin-to-piston-pin-bore clearance 0.004–0.024 mm (0.0002–0.0009 EAS30750 CHECKING THE CONNECTING RODS 1. Measure: • Crankshaft-pin-to-big-end-bearing clearance Out of specification → Replace the big end d. Assemble the connecting rod halves. bearings. Oil clearance • Do not move the connecting rod or crankshaft 0.031–0.048 mm (0.0012–0.0019 until the clearance measurement has been completed.

  • Page 420: 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 Code 1 Blue...
  • Page 421 CONNECTING RODS AND PISTONS • Make sure that the “Y” mark “a” on the connect- Recommended lubricant ing rod is facing to the left when the punch Engine oil mark “b” on the piston is pointing up. Refer to the illustration. 5.
  • Page 422 CONNECTING RODS AND PISTONS c. Tighten the connecting rod nuts further to reach the specified angle 115–125°. Connecting rod nut (final) Specified angle 115–125° EWA13400 WARNING If the connecting rod nut is tightened more than the specified angle, do not loosen the nut and then retighten it.

  • Page 423: Crankshaft

    CRANKSHAFT EAS20061 CRANKSHAFT Removing the crankshaft ’ Order Job/Parts to remove Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-78. Front balancer weight Refer to “BALANCERS” on page 5-103. Refer to “CONNECTING RODS AND PIS- Connecting rod caps TONS” on page 5-86. Crankshaft Crankshaft journal upper bearing Crankshaft journal lower bearing...

  • Page 424: Removing The Crankshaft Journal Bearings

    CRANKSHAFT EAS30419 REMOVING THE CRANKSHAFT JOURNAL Journal oil clearance BEARINGS 0.027–0.045 mm (0.0011–0.0018 1. Remove: • Crankshaft journal upper bearings ECA13920 (from the upper crankcase) NOTICE • Crankshaft journal lower bearings Do not interchange the crankshaft journal (from the lower crankcase) bearings.
  • Page 425 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. • Align the projections “c” of the crankshaft jour- nal lower bearings with the notches “d”...

  • Page 426: Installing The Crankshaft

    CRANKSHAFT Bearing color code Code 2 Black Code 3 Brown Code 4 Green Code 5 Yellow Code 6 Pink Code 7 Code 8 White EAS30791 INSTALLING THE CRANKSHAFT 1. Install: • Crankshaft journal upper bearings (into the upper crankcase) • Crankshaft journal lower bearings (into the lower crankcase) •...

  • Page 427: Transmission

    TRANSMISSION EAS20062 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • ’ Order Job/Parts to remove Remarks Separate. Crankcase Refer to “CRANKCASE”...
  • Page 428 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • ’ Order Job/Parts to remove Remarks Spring Shift drum assembly Shift fork-C Main axle assembly Middle drive gear...

  • Page 429: Removing The Transmission

    TRANSMISSION EAS30430 EWA12840 REMOVING THE TRANSMISSION WARNING 1. Remove: Do not attempt to straighten a bent shift fork • Main axle assembly guide bar. Remove the main axle assembly with the slide hammer bolts “1” and weight. Slide hammer bolt 90890-01083 Slide hammer bolt 6 mm YU-01083-1...

  • Page 430: Checking The Transmission

    TRANSMISSION EAS30433 CHECKING THE TRANSMISSION 1. Measure: • 5th wheel gear to spacer clearance “a” Out of specification → Replace the drive axle assembly. Clearance “a” Below 0.20 mm (0.008 in) 4. Check: • Transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect →...
  • Page 431 TRANSMISSION Install the washer with its chamfered side facing towards the drive axle assembly as shown in the illustration. 5. Install: • Drive axle assembly • The bearing pin “1” must face towards the rear of the upper crankcase. • Make sure the bearing circlip “2” is inserted into 2.

  • Page 432: Balancers

    BALANCERS EAS20229 BALANCERS Removing the front balancer 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) • • ’ Order Job/Parts to remove Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-78. Front balancer lever Front balancer shaft Washer...
  • Page 433 BALANCERS Removing the rear balancer 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) • • ’ Order Job/Parts to remove Remarks Throttle bodies Refer to “THROTTLE BODIES”...

  • Page 434: Checking The Balancers

    BALANCERS 2. Align: EAS31873 CHECKING THE BALANCERS • “T” mark on the pickup rotor 1. Check: (with the crankcase mating surface) • Front balancer gear ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 435: Installing The Rear Balancer

    BALANCERS Front balancer lever bolt 14 Nm (1.4 m·kgf, 10 ft·lbf) Front balancer shaft pinch bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Make sure that the balancer shaft does not ro- tate. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...
  • Page 436 BALANCERS b. Align the balancer gear punch mark “c” with the primary driven gear point “d” as shown. • 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 437 BALANCERS Rear balancer lever bolt 14 Nm (1.4 m·kgf, 10 ft·lbf) Rear balancer shaft pinch bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Make sure that the balancer shaft does not ro- tate. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...
  • Page 438 BALANCERS 5-109...

  • Page 439: Cooling System

    COOLING SYSTEM RADIATOR ...................... 6-1 REMOVING THE RADIATOR ..............6-3 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....................6-10 DISASSEMBLING THE WATER PUMP..........
  • Page 440 RADIATOR EAS20063 RADIATOR Removing the radiator 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 441 RADIATOR Removing the radiator 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 442 RADIATOR EAS31659 REMOVING THE RADIATOR Radiator cap tester 1. Pull the top of electrical components tray “1” 90890-01325 slightly outward as shown in the illustration Mityvac cooling system tester kit and then remove the radiator bolt “2”. YU-24460-A Radiator cap tester adapter 90890-01352 Pressure tester adapter YU-33984...
  • Page 443 OIL COOLER EAS20064 OIL COOLER Removing the oil cooler 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • ’ Order Job/Parts to remove Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-25.
  • Page 444 OIL COOLER EAS30441 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 445 THERMOSTAT EAS20065 THERMOSTAT Removing the thermostat assembly 22 Nm (2.2 m kgf, 16 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 446 THERMOSTAT Removing the thermostat assembly 22 Nm (2.2 m kgf, 16 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 447 THERMOSTAT 2. Check: EAS30443 CHECKING THE THERMOSTAT • Thermostat housing 1. Check: Cracks/damage → Replace. • Thermostat 3. Check: Does not open at 69.0–73.0 °C (156.20– • Thermostat hoses 163.40 °F) → Replace. • Thermostat pipes • Radiator inlet hose •...
  • Page 448 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 449 WATER PUMP EAS20066 WATER PUMP Removing the water pump 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (2)” on page Side cowling (right) 4-5.
  • Page 450 WATER PUMP Disassembling the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Water pump housing cover O-ring Circlip Impeller shaft Rubber damper holder Rubber damper Water pump seal Oil seal Bearing Water pump housing 6-11...
  • Page 451 WATER PUMP EAS30446 EAS30447 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Mechanical seal (impeller side) “1” • Water pump housing cover (from the impeller, with a thin, flat-head • Water pump housing screwdriver) • Impeller shaft Cracks/damage/wear →...
  • Page 452 WATER PUMP Mechanical seal installer If the surface “a” of the mechanical seal (impeller 90890-04078 side) that contacts the mechanical seal (housing Water pump seal installer side) is dirty, clean it. YM-33221-A Middle driven shaft bearing driv- Impeller shaft tilt limit 90890-04058 0.15 mm (0.006 in) Middle drive bearing installer 40...
  • Page 453 WATER PUMP 2. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-29. 3. Check: • Cooling system Leaks → Repair or replace any faulty part. 4. Measure: • Radiator cap opening pressure Below the specified pressure →...
  • Page 454 WATER PUMP 6-15...

  • Page 455: Fuel System

    FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP ..............7-2 CHECKING THE FUEL PUMP BODY............7-2 INSTALLING THE FUEL PUMP..............7-2 INSTALLING THE FUEL TANK..............7-2 THROTTLE BODIES ..................7-4 CHECKING THE INJECTORS (BEFORE REMOVING) ......7-7 REMOVING THE INJECTORS ..............7-7 CHECKING THE INJECTORS ..............7-7 CHECKING AND CLEANING THE THROTTLE BODIES......7-7 CHECKING THE THROTTLE BODY JOINTS ..........
  • Page 456 FUEL TANK EAS20067 FUEL TANK Removing the fuel tank 10 Nm (1.0 m kgf, 7.2 ft Ibf) 16 Nm (1.6 m kgf, 12 ft Ibf) • • • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • ’ Order Job/Parts to remove Remarks...
  • Page 457 FUEL TANK EAS30450 EAS30454 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 458 FUEL TANK 2. Install: • Fuel hose (fuel pump side) • Fuel hose holder ECA19970 NOTICE When installing the fuel hose, make sure that it is securely connected, and that the fuel hose holder is in the correct position, other- wise the fuel hose will not be properly in- stalled.
  • Page 459 THROTTLE BODIES EAS20070 THROTTLE BODIES Removing the throttle bodies 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks...
  • Page 460 THROTTLE BODIES Removing the throttle bodies 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Throttle servo motor coupler Disconnect.
  • Page 461 THROTTLE BODIES Removing the injectors 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) •...
  • Page 462 CHECKING THE INJECTORS will be affected. 1. Check: • Injectors Recommended cleaning solvent Obstruction → Replace and check the fuel Yamaha Oil & Brake Cleaner pump/fuel supply system. Deposit → Replace. Damage → Replace. 2. Check: • Injector resistance Refer to “CHECKING THE FUEL INJEC-...
  • Page 463 THROTTLE BODIES • Do not allow any cleaning solvent to enter the opening for the injectors. • Do not apply any cleaning solvent to the por- tions of the throttle valve shafts between the throttle bodies. e. Remove the carbon deposits from the inside of each throttle body in a downward direction, from the air filter case side of the throttle body to the engine side.
  • Page 464 THROTTLE BODIES Refer to “SELF-DIAGNOSTIC FUNCTION EAS30480 INSTALLING THE INJECTORS AND DIAGNOSTIC CODE TABLE (ECU)” on ECA23351 page 9-5. NOTICE 6. Adjust: • Always use new O-rings and seals. • Throttle bodies synchronizing • When checking the injectors, do not allow Out of specification →...
  • Page 465 THROTTLE BODIES b. Connect the pressure gauge “4” to the injec- ECA23360 NOTICE tor pressure adapter “1”. When lifting up the fuel tank, be careful not Pressure gauge to pull the fuel tank breather/overflow hose. 90890-03153 Pressure gauge YU-03153 Fuel injector pressure adapter 90890-03210 Fuel injector pressure adapter YU-03210...
  • Page 466 Refer to “CHECKING THE ACCELERATOR d. Remove the protective cap, and then connect POSITION SENSOR” on page 8-263. the Yamaha diagnostic tool to coupler “1”. 2. Adjust: • Accelerator position sensor angle For information about using the Yamaha diag-...
  • Page 467 Yamaha diagnostic tool to coupler “1”. value is not 95–109, adjust the accelerator position sensor angle. q. Repeat steps (f) to (p) until the Yamaha diag- For information about using the Yamaha diag- nostic tool screen values are within the spec- nostic tool, refer to the operation manual that is ified ranges.
  • Page 468 AIR INDUCTION SYSTEM EAS20071 AIR INDUCTION SYSTEM 7-13...
  • Page 469 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 470 AIR INDUCTION SYSTEM Removing the air cut-off valve Order Job/Parts to remove ’ Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1. Refer to “GENERAL CHASSIS (6)” on page – 4-22. Fuel tank Refer to “FUEL TANK” on page 7-1. Air induction system solenoid coupler Disconnect.
  • Page 471 AIR INDUCTION SYSTEM Removing the reed valves 14 Nm (1.4 m kgf, 10 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1. Refer to “GENERAL CHASSIS (6)” on page –...
  • Page 472 AIR INDUCTION SYSTEM • 3-way joint EAS30488 CHECKING THE AIR INDUCTION SYSTEM Cracks/damage → Replace. 2. Check: Air injection • Reed valve The air induction system burns unburned ex- • Reed valve stopper haust gases by injecting fresh air (secondary air) •...

  • Page 473: Electrical System

    ELECTRICAL SYSTEM IGNITION SYSTEM ..................8-1 CIRCUIT DIAGRAM (FJR13AG) ............... 8-1 CIRCUIT DIAGRAM (FJR13ESG)............. 8-3 ENGINE STOPPING DUE TO SIDESTAND OPERATION.......8-5 TROUBLESHOOTING ................8-6 ELECTRIC STARTING SYSTEM ..............8-9 CIRCUIT DIAGRAM (FJR13AG) ............... 8-9 CIRCUIT DIAGRAM (FJR13ESG)............8-11 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......8-13 TROUBLESHOOTING ................8-14...
  • Page 474 CRUISE CONTROL SYSTEM ..............8-137 CIRCUIT DIAGRAM (FJR13AG) ............8-137 CIRCUIT DIAGRAM (FJR13ESG)............8-139 CRUISE CONTROL CIRCUIT OPERATION.........8-141 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ......8-143 BASIC PROCESS FOR TROUBLESHOOTING ........8-144 [A] CHECKING THE CRUISE CONTROL SYSTEM INDICATOR LIGHT ....................8-145 [B-1] DIAGNOSIS USING THE FAULT CODES ........8-145 [B-2] DIAGNOSIS USING THE MALFUNCTION HISTORY CODES..8-155...
  • Page 475 ABS (ANTI-LOCK BRAKE SYSTEM)............8-187 CIRCUIT DIAGRAM (FJR13AG) ............8-187 CIRCUIT DIAGRAM (FJR13ESG)............8-189 ABS COMPONENTS CHART ...............8-191 ABS COUPLER LOCATION CHART ............8-193 MAINTENANCE OF THE ABS ECU .............8-195 ABS TROUBLESHOOTING OUTLINE..........8-195 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ......8-196 BASIC PROCESS FOR TROUBLESHOOTING ........8-197 [A] CHECKING THE ABS WARNING LIGHT........8-198 [A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON...8-198...
  • Page 476 CHECKING THE RELAY UNIT (DIODE) ..........8-256 CHECKING THE IGNITION COILS............8-257 CHECKING THE IGNITION SPARK GAP..........8-258 CHECKING THE CRANKSHAFT POSITION SENSOR......8-258 CHECKING THE LEAN ANGLE SENSOR (FJR13AG) ......8-259 CHECKING THE STARTER MOTOR OPERATION ......8-259 CHECKING THE STATOR COIL ............8-260 CHECKING THE RECTIFIER/REGULATOR ........8-260 CHECKING THE HEADLIGHT ASSEMBLY .........8-260...
  • Page 478 IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS31988 CIRCUIT DIAGRAM (FJR13AG)
  • Page 479 IGNITION SYSTEM 1. Main switch 8. Ignition fuse 15.Fuel injection system fuse 22.Joint coupler 32.Main fuse 33.Battery 34.Engine ground 51.Relay unit 57.Sidestand switch 59.Handlebar switch (right) 61.Start/engine stop switch 63.Gear position switch 95.Crankshaft position sensor 98.Cylinder identification sensor 99.Lean angle sensor 108.ECU (Engine Control Unit) 109.Ignition coil #1 110.Ignition coil #2...
  • Page 480 IGNITION SYSTEM EAS31930 CIRCUIT DIAGRAM (FJR13ESG)
  • Page 481 IGNITION SYSTEM 1. Main switch 9. Ignition fuse 16.Fuel injection system fuse 20.Joint coupler 26.Main fuse 27.Battery 28.Engine ground 35.Relay unit 38.Sidestand switch 45.Handlebar switch (right) 47.Start/engine stop switch 49.Gear position switch 103.Crankshaft position sensor 106.Cylinder identification sensor 113.ECU (Engine Control Unit) 114.Ignition coil #1 115.Ignition coil #2 116.Ignition coil #3...
  • Page 482 IGNITION SYSTEM EAS30491 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 the neutral circuit of the gear position switch is open and the sidestand switch is set to “OFF”, thereby preventing the spark plugs from producing a spark.
  • Page 483 IGNITION SYSTEM EAS30492 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Side cowlings 2. Front cowling assembly 3. Fuel tank 4. T–bar 5. Storage compartment 6. Side covers 7.
  • Page 484 NG → 14.Check the entire ignition system wiring. Refer to “CIRCUIT DIAGRAM Properly connect or replace the wire har- (FJR13AG)” on page 8-1 or refer to ness. “CIRCUIT DIAGRAM (FJR13ESG)” on page 8-3. OK ↓ Replace the ECU or IMU (Inertial Mea- surement Unit) (FJR13ESG).
  • Page 485 IGNITION SYSTEM...
  • Page 486 ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS31989 CIRCUIT DIAGRAM (FJR13AG)
  • Page 487 ELECTRIC STARTING SYSTEM 1. Main switch 8. Ignition fuse 22.Joint coupler 32.Main fuse 33.Battery 34.Engine ground 36.Starter relay 37.Starter motor 40.Clutch switch 51.Relay unit 52.Starting circuit cut-off relay 57.Sidestand switch 59.Handlebar switch (right) 61.Start/engine stop switch 63.Gear position switch A. Wire harness C.
  • Page 488 ELECTRIC STARTING SYSTEM EAS31931 CIRCUIT DIAGRAM (FJR13ESG) 8-11...
  • Page 489 ELECTRIC STARTING SYSTEM 1. Main switch 9. Ignition fuse 20.Joint coupler 26.Main fuse 27.Battery 28.Engine ground 30.Starter relay 31.Starter motor 34.Clutch switch 35.Relay unit 36.Starting circuit cut-off relay 38.Sidestand switch 45.Handlebar switch (right) 47.Start/engine stop switch 49.Gear position switch A. Wire harness C.
  • Page 490 ELECTRIC STARTING SYSTEM EAS30494 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is turned to “ON” and the “ ” side of the start/engine stop switch is pushed, the starter motor can only operate if at least one of the following conditions is met: •...
  • Page 491 ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Side cowlings 2. Front cowling assembly 3. Fuel tank 4. T–bar 5. Throttle bodies NG → 1. Check the fuses. (Main and ignition) Replace the fuse(s).
  • Page 492 NG → 13.Check the entire starting system wiring. Refer to “CIRCUIT DIAGRAM Properly connect or replace the wire har- (FJR13AG)” on page 8-9 or refer to ness. “CIRCUIT DIAGRAM (FJR13ESG)” on page 8-11. OK ↓ The starting system circuit is OK.
  • Page 493 ELECTRIC STARTING SYSTEM 8-16...
  • Page 494 CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS31990 CIRCUIT DIAGRAM (FJR13AG) 8-17...
  • Page 495 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 32.Main fuse 33.Battery 34.Engine ground A. Wire harness C. Negative battery sub-wire harness 8-18...
  • Page 496 CHARGING SYSTEM EAS31936 CIRCUIT DIAGRAM (FJR13ESG) 8-19...
  • Page 497 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 26.Main fuse 27.Battery 28.Engine ground A. Wire harness C. Negative battery sub-wire harness 8-20...
  • Page 498 NG → 5. Check the entire charging system wiring. Refer to “CIRCUIT DIAGRAM Properly connect or replace the wire har- (FJR13AG)” on page 8-17 or refer ness. to “CIRCUIT DIAGRAM (FJR13ESG)” on page 8-19. OK ↓ The charging system circuit is OK.
  • Page 499 CHARGING SYSTEM 8-22...
  • Page 500 LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS31991 CIRCUIT DIAGRAM (FJR13AG) 8-23...
  • Page 501 LIGHTING SYSTEM 1. Main switch 8. Ignition fuse 10.Signaling system fuse 15.Fuel injection system fuse 18.Headlight fuse 22.Joint coupler 25.Headlight relay 26.License plate light 27.Tail/brake light assembly 28.Taillight 32.Main fuse 33.Battery 34.Engine ground 45.Headlight assembly (left) 46.Headlight (low beam) 47.Headlight (high beam) 48.Headlight control unit (left) 49.Headlight assembly (right) 50.Headlight control unit (right)
  • Page 502 LIGHTING SYSTEM EAS31939 CIRCUIT DIAGRAM (FJR13ESG) 8-25...
  • Page 503 LIGHTING SYSTEM 1. Main switch 9. Ignition fuse 11.Signaling system fuse 16.Fuel injection system fuse 19.Headlight fuse 20.Joint coupler 23.Headlight relay 26.Main fuse 27.Battery 28.Engine ground 52.Handlebar switch (left) 55.Dimmer/pass switch 60.License plate light 61.Tail/brake light assembly 62.Taillight 66.Headlight assembly (left) 67.Headlight (low beam) 68.Headlight (high beam) 69.Headlight control unit (left)
  • Page 504 NG → 4. Check the entire lighting system wiring. Refer to “CIRCUIT DIAGRAM Properly connect or replace the wire har- (FJR13AG)” on page 8-23 or refer ness. to “CIRCUIT DIAGRAM (FJR13ESG)” on page 8-25. OK ↓ Check the condition of each of the lighting system circuits.
  • Page 505 OK ↓ NG → 4. Check the entire lighting system wiring. Refer to “CIRCUIT DIAGRAM Properly connect or replace the wire har- (FJR13AG)” on page 8-23 or refer ness. to “CIRCUIT DIAGRAM (FJR13ESG)” on page 8-25. OK ↓ Replace the ECU.
  • Page 506 CORNERING LIGHT SYSTEM (FJR13ESG) EAS20239 CORNERING LIGHT SYSTEM (FJR13ESG) EAS32019 CIRCUIT DIAGRAM 8-29...
  • Page 507 34.Clutch switch 35.Relay unit 49.Gear position switch 52.Handlebar switch (left) 55.Dimmer/pass switch 72.CLCU (cornering light control unit) 107.Yamaha diagnostic tool coupler 113.ECU (Engine Control Unit) 127.IMU (Inertial Measurement Unit) 129.ABS ECU 130.Front wheel sensor 131.Rear wheel sensor A. Wire harness B.
  • Page 508 After the check and service of the malfunctioning part have been completed, delete the fault codes dis- played on the Yamaha diagnostic tool according to the reinstatement method. Fault code No.: Fault code number displayed on the Yamaha diagnostic tool when the cornering light system failed to work normally. Diagnostic code No.: Diagnostic code number to be used when the diagnostic mode is operated.
  • Page 509 Yamaha diagnostic tool.) — (The cornering lights are malfunctioning, but a fault code number Fault code No. is not displayed on the Yamaha diagnostic tool.) Defective connection of the CLCU coupler. Item CLCU does not receive normal signals from the IMU.
  • Page 510 CORNERING LIGHT SYSTEM (FJR13ESG) — (The cornering lights are malfunctioning, but a fault code number Fault code No. is not displayed on the Yamaha diagnostic tool.) Defective connection of the CLCU coupler. Item CLCU does not receive normal signals from the IMU.
  • Page 511 Turn the main switch to “ON”, bank angle fine adjustment val- and then execute diagnostic code No. 66 in the diagnosis of function mode of the Yamaha diagnostic tool to select the fine adjustment value. Fine adjustment value cannot be changed to a value other than “0”...
  • Page 512 CORNERING LIGHT SYSTEM (FJR13ESG) Fault code No. C0520 CLCU receives a signal from the IMU indicating that a malfunction Item was detected or the CLCU does not receive normal signals from the IMU. Improperly connected → Con- Connection of IMU coupler. Turn the main switch to “ON”, Check the locking condition of nect the coupler securely or re-...
  • Page 513 CORNERING LIGHT SYSTEM (FJR13ESG) Fault code No. C0520 CLCU receives a signal from the IMU indicating that a malfunction Item was detected or the CLCU does not receive normal signals from the IMU. Malfunction in IMU. Replace the IMU. Turn the main switch to “ON”, and then check that the corner- ing lights come on and go off in the proper sequence.
  • Page 514 CORNERING LIGHT SYSTEM (FJR13ESG) Fault code No. U0100 Item Signals cannot be transmitted between the CLCU and the ECU. Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check pletion Improperly connected → Con- Connection of ECU coupler. Turn the main switch to “ON”, Check the locking condition of nect the coupler securely or re-...
  • Page 515 CORNERING LIGHT SYSTEM (FJR13ESG) Fault code No. U0125 Fault code No. U0125 Item Signals cannot be transmitted between the CLCU and the IMU. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Tool display — Procedure —...
  • Page 516 CORNERING LIGHT SYSTEM (FJR13ESG) Fault code No. U0125 Item Signals cannot be transmitted between the CLCU and the IMU. Installed condition of IMU. Check for looseness or pinch- Turn the main switch to “ON”, ing. and then check that the corner- Check the rubber components ing lights come on and go off in for cracks.
  • Page 517 CORNERING LIGHT SYSTEM (FJR13ESG) 8-40...
  • Page 518 SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS31992 CIRCUIT DIAGRAM (FJR13AG) 8-41...
  • Page 519 SIGNALING SYSTEM 1. Main switch 6. Hazard lighting fuse 7. ABS ECU fuse 8. Ignition fuse 10.Signaling system fuse 15.Fuel injection system fuse 16.Backup fuse 22.Joint coupler 23.Horn 27.Tail/brake light assembly 29.Brake light 30.Rear turn signal light (left) 31.Rear turn signal light (right) 32.Main fuse 33.Battery 34.Engine ground...
  • Page 520 SIGNALING SYSTEM EAS31944 CIRCUIT DIAGRAM (FJR13ESG) 8-43...
  • Page 521 SIGNALING SYSTEM 1. Main switch 7. Hazard lighting fuse 8. ABS ECU fuse 9. Ignition fuse 11.Signaling system fuse 16.Fuel injection system fuse 17.Backup fuse 20.Joint coupler 21.Horn 26.Main fuse 27.Battery 28.Engine ground 33.Brake light fuse 35.Relay unit 42.Rear brake light switch 44.Front brake light switch 45.Handlebar switch (right) 48.Hazard switch...
  • Page 522 NG → 4. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM Properly connect or replace the wire har- (FJR13AG)” on page 8-41 or refer ness. to “CIRCUIT DIAGRAM (FJR13ESG)” on page 8-43. OK ↓ Check the condition of each of the sig- naling system circuits.
  • Page 523 OK ↓ NG → 2. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM Properly connect or replace the wire har- (FJR13AG)” on page 8-41 or refer ness. to “CIRCUIT DIAGRAM (FJR13ESG)” on page 8-43. OK ↓ Replace the horn.
  • Page 524 NG → 4. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM Properly connect or replace the wire har- (FJR13AG)” on page 8-41 or refer ness. to “CIRCUIT DIAGRAM (FJR13ESG)” on page 8-43. OK ↓ Replace the meter assembly or tail/brake light assembly.
  • Page 525 NG → 2. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM Properly connect or repair the signaling (FJR13AG)” on page 8-41 or refer system wiring. to “CIRCUIT DIAGRAM (FJR13ESG)” on page 8-43. OK ↓ Replace the meter assembly.
  • Page 526 NG → 2. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM Properly connect or replace the wiring har- (FJR13AG)” on page 8-41 refer to ness. “CIRCUIT DIAGRAM (FJR13ESG)” on page 8-43. OK ↓ Replace the ECU or meter assembly.
  • Page 527 SIGNALING SYSTEM 8-50...
  • Page 528 COOLING SYSTEM EAS20077 COOLING SYSTEM EAS31993 CIRCUIT DIAGRAM (FJR13AG) 8-51...
  • Page 529 COOLING SYSTEM 1. Main switch 8. Ignition fuse 11.Radiator fan motor fuse (right) 12.Radiator fan motor fuse (left) 15.Fuel injection system fuse 19.Radiator fan motor (left) 20.Radiator fan motor (right) 22.Joint coupler 24.Radiator fan motor relay 32.Main fuse 33.Battery 34.Engine ground 35.Main fuse 2 107.Coolant temperature sensor 108.ECU (Engine Control Unit)
  • Page 530 COOLING SYSTEM EAS31946 CIRCUIT DIAGRAM (FJR13ESG) 8-53...
  • Page 531 COOLING SYSTEM 1. Main switch 9. Ignition fuse 12.Radiator fan motor fuse (right) 13.Radiator fan motor fuse (left) 16.Fuel injection system fuse 20.Joint coupler 22.Radiator fan motor relay 24.Radiator fan motor (left) 25.Radiator fan motor (right) 26.Main fuse 27.Battery 28.Engine ground 29.Main fuse 2 112.Coolant temperature sensor 113.ECU (Engine Control Unit)
  • Page 532 COOLING SYSTEM EAS30503 TROUBLESHOOTING The radiator fan motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Side cowlings 2. Fuel tank 3. T–bar NG → 1. Check the fuses. (Main, ignition, Main 2, fuel injection system, left radiator fan motor, and Replace the fuse(s).
  • Page 533 NG → 7. Check the entire cooling system wiring. Refer to “CIRCUIT DIAGRAM Properly connect or replace the wire har- (FJR13AG)” on page 8-51 or refer ness. to “CIRCUIT DIAGRAM (FJR13ESG)” on page 8-53. OK ↓ Replace the ECU. Refer to “REPLAC- ING THE ECU (engine control unit)”...
  • Page 534 FUEL INJECTION SYSTEM EAS20078 FUEL INJECTION SYSTEM EAS31994 CIRCUIT DIAGRAM (FJR13AG) 8-57...
  • Page 535 84.Engine trouble warning light 93.Fuel pump 95.Crankshaft position sensor 96.Intake air pressure sensor 97.Atmospheric pressure sensor 98.Cylinder identification sensor 99.Lean angle sensor 100.Yamaha diagnostic tool coupler 102.ABS ECU 103.O sensor 104.Throttle position sensor 105.Accelerator position sensor 106.Air temperature sensor 107.Coolant temperature sensor 108.ECU (Engine Control Unit)
  • Page 536 FUEL INJECTION SYSTEM EAS31948 CIRCUIT DIAGRAM (FJR13ESG) 8-59...
  • Page 537 84.Multi-function meter 90.Engine trouble warning light 100.Fuel pump 103.Crankshaft position sensor 104.Intake air pressure sensor 105.Atmospheric pressure sensor 106.Cylinder identification sensor 107.Yamaha diagnostic tool coupler 108.O sensor 109.Throttle position sensor 110.Accelerator position sensor 111.Air temperature sensor 112.Coolant temperature sensor 113.ECU (Engine Control Unit) 114.Ignition coil #1...
  • Page 538 ▼ ▼▼▼▼ ▼▼ ▼ a. Check the fault code numbers that have a condition of “Detected” using the Yamaha diagnostic tool. b. Identify the faulty system with the fault code number. c. Identify the probable cause of the malfunction. ▲...
  • Page 539 EAS30951 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool USB 90890-03250 Yamaha diagnostic tool (A/I) 90890-03252 A generic scan tool can also be used to identify malfunctions.
  • Page 540 Yamaha diagnostic tool according to the reinstatement method. Fault code No.: Fault code number displayed on the Yamaha diagnostic tool when the engine failed to work normally. Diagnostic code No.: Diagnostic code number to be used when the diagnostic mode is operated. Refer to “SELF-DIAGNOS- TIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU)”...
  • Page 541 Disconnect the coupler and function mode of the Yamaha di- check the pins (bent or broken agnostic tool. Condition is “Recovered” → Go terminals and locking condition of the pins).
  • Page 542 Replace the IMU. Turn the main switch to “ON”, and then check the condition of the fault code using the mal- function mode of the Yamaha di- agnostic tool. Condition is “Recovered” → Go to item 7 and finish the service.
  • Page 543 Check the locking condition of function mode of the Yamaha di- the coupler. agnostic tool. Disconnect the coupler and Condition is “Recovered” → Go check the pins (bent or broken to item 6 and finish the service.
  • Page 544 Turn the main switch to “ON”, and then check the condition of the fault code using the mal- function mode of the Yamaha di- agnostic tool. Condition is “Recovered” → Go to item 6 and finish the service. Condition is “Detected” → Start the engine, and then check the condition of the fault code.
  • Page 545 (Code No. 03) and then check the condition of When engine is stopped: the fault code using the mal- Atmospheric pressure at the function mode of the Yamaha current altitude and weather diagnostic tool. Condition is “Recovered” → Go conditions is indicated.
  • Page 546 Check the locking condition of place the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha di- Disconnect the coupler and agnostic tool. Condition is “Recovered” → Go check the pins (bent or broken terminals and locking condition to item 7 and finish the service.
  • Page 547 B/L P/W L G/Y L/Y L B/W Gy/R G/Y L/Y G/B L B/W Gy/R A. FJR13AG B. FJR13ESG [For P0108] Open circuit Between intake air pressure sensor coupler and ECU coupler: pink/white–pink/white If there is no continuity, replace the wire harness. Gy/W...
  • Page 548 Improperly installed sensor → the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha di- agnostic tool. Condition is “Recovered” → Go to item 7 and finish the service.
  • Page 549 (Code No. 03) check the condition of the fault When engine is stopped: code using the malfunction Atmospheric pressure at the mode of the Yamaha diagnostic current altitude and weather tool. Condition is “Recovered” → Go conditions is indicated. At sea level: Approx. 101 kPa to item 7 and finish the service.
  • Page 550 Check the locking condition of place the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha di- Disconnect the coupler and agnostic tool. Condition is “Recovered” → Go check the pins (bent or broken terminals and locking condition to item 7 and finish the service.
  • Page 551 B/L B/L B/Y Lg/B L/Y Gy B/L B/L B/Y Lg/B L/Y Gy A. FJR13AG B. FJR13ESG [For P0113] Open circuit Between air temperature sensor coupler and ECU coupler: black/blue–black/blue If there is no continuity, replace the wire harness. Gy/W Gy/W...
  • Page 552 Improperly installed sensor → the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha di- agnostic tool. Condition is “Recovered” → Go to item 7 and finish the service.
  • Page 553 Check the locking condition of place the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha di- Disconnect the coupler and agnostic tool. Condition is “Recovered” → Go check the pins (bent or broken terminals and locking condition to item 7 and finish the service.
  • Page 554 B/L B/L B/Y Lg/B L/Y Gy B/L B/L B/Y Lg/B L/Y Gy A. FJR13AG B. FJR13ESG [For P0118] Open circuit Between coolant temperature sensor coupler and ECU coupler: black/blue–black/blue If there is no continuity, replace the wire harness. Gy/W Gy/W...
  • Page 555 Improperly installed sensor → the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha di- agnostic tool. Condition is “Recovered” → Go to item 7 and finish the service.
  • Page 556 Check the locking condition of place the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha di- Disconnect the coupler and agnostic tool. Condition is “Recovered” → Go check the pins (bent or broken terminals and locking condition to item 8 and finish the service.
  • Page 557 FUEL INJECTION SYSTEM Fault code No. P0122, P0123, P0222, P0223, P2135 [P0122, P0222] Throttle position sensor: ground short circuit detect- Item [P0123, P0223] Throttle position sensor: open or power short circuit detected. [P2135] Deviation error 1. Throttle position sensor 2. ECU 3.
  • Page 558 B/L B/L B/Y Lg/B L/Y Gy B/L B/L B/Y Lg/B L/Y Gy A. FJR13AG B. FJR13ESG [For P0223] Open circuit [For P2135] Deviation error Between throttle position sensor coupler and ECU coupler: black–black If there is no continuity, replace the wire harness.
  • Page 559 Improperly installed sensor → the fault code using the mal- Reinstall or adjust the sensor. function mode of the Yamaha di- Refer to “ADJUSTING THE agnostic tool. Condition is “Recovered” → Go THROTTLE POSITION SEN- SOR”...
  • Page 560 Refer to “CHECKING THE function mode of the Yamaha di- THROTTLE POSITION SEN- agnostic tool. Condition is “Recovered” → Go SOR” on page 8-263. to item 8 and finish the service.
  • Page 561 Improperly installed sensor → the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha di- agnostic tool. Condition is “Recovered” → Go to item 7 and finish the service.
  • Page 562 Actuates fuel injector #1 five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated. Disconnect the fuel pump coupler. Check that fuel injector #1 is actuated Procedure five times by listening for the operating sound.
  • Page 563 Actuates fuel injector #2 five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated. Disconnect the fuel pump coupler. Check that fuel injector #2 is actuated Procedure five times by listening for the operating sound.
  • Page 564 Actuates fuel injector #3 five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated. Disconnect the fuel pump coupler. Check that fuel injector #3 is actuated Procedure five times by listening for the operating sound.
  • Page 565 Actuates fuel injector #4 five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated. Disconnect the fuel pump coupler. Check that fuel injector #4 is actuated Procedure five times by listening for the operating sound.
  • Page 566 5 seconds. light goes off. Confirm that the fault code has a condition of “Recovered” us- ing the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Fault code No. P0335 Fault code No. P0335...
  • Page 567 Check the locking condition of place the wire harness. code using the malfunction the coupler. mode of the Yamaha diagnostic Disconnect the coupler and tool. Condition is “Recovered” → Go check the pins (bent or broken terminals and locking condition to item 7 and finish the service.
  • Page 568 Delete the fault code and check Confirm that the fault code has that the engine trouble warning a condition of “Recovered” us- light goes off. ing the Yamaha diagnostic tool, and then delete the fault code. Fault code No. P0340 Fault code No. P0340...
  • Page 569 Diagnostic code No. Actuates the cylinder-#1 ignition coil five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated. Check that a spark is generated five times.
  • Page 570 Check the condition of the fault Disconnect the coupler and code using the malfunction check the pins (bent or broken mode of the Yamaha diagnostic terminals and locking condition tool. Condition is “Recovered” → Go of the pins).
  • Page 571 Diagnostic code No. Actuates the cylinder-#2 ignition coil five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated. Check that a spark is generated five times.
  • Page 572 Diagnostic code No. Actuates the cylinder-#3 ignition coil five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated. Check that a spark is generated five times.
  • Page 573 Check the condition of the fault Disconnect the coupler and code using the malfunction check the pins (bent or broken mode of the Yamaha diagnostic terminals and locking condition tool. Condition is “Recovered” → Go of the pins).
  • Page 574 Diagnostic code No. Actuates the cylinder-#4 ignition coil five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated. Check that a spark is generated five times.
  • Page 575 Check the condition of the fault Replace if out of specification. code using the malfunction Refer to “CHECKING THE IG- mode of the Yamaha diagnostic NITION COILS” on page 8-257. tool. Condition is “Recovered” → Go to item 7 and finish the service.
  • Page 576 FUEL INJECTION SYSTEM Fault code No. P0500 Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Neutral switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Value does not increase → Go Locate the malfunction.
  • Page 577 19 mph). Confirm that the fault code has a condition of “Recovered” us- ing the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Delete this fault code even if it has a condition of “Detected”.
  • Page 578 FUEL INJECTION SYSTEM Fault code No. P0500 Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Neutral switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Probable cause of malfunc- Confirmation of service com- Item Maintenance job...
  • Page 579 19 mph). Confirm that the fault code has a condition of “Recovered” us- ing the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Delete this fault code even if it has a condition of “Detected”.
  • Page 580 FUEL INJECTION SYSTEM Fault code No. P0500 Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Neutral switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 581 FUEL INJECTION SYSTEM Fault code No. P0500 Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Neutral switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Improperly connected → Con- Connection of clutch switch cou- Execute the diagnostic mode.
  • Page 582 19 mph). Confirm that the fault code has a condition of “Recovered” us- ing the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Delete this fault code even if it has a condition of “Detected”.
  • Page 583 8-17. Check the condition of the fault Defective rectifier/regulator or code using the malfunction AC magneto → Replace. mode of the Yamaha diagnostic Defective connection in the tool. charging system circuit → Prop- Condition is “Recovered” → Go erly connect or replace the wire to item 2 and finish the service.
  • Page 584 Delete the fault code and check Confirm that the fault code has that the engine trouble warning a condition of “Recovered” us- light goes off. ing the Yamaha diagnostic tool, and then delete the fault code. Fault code No. P0638 Fault code No. P0638 Item YCC-T drive system: malfunction detected.
  • Page 585 Disconnect the coupler and place the wire harness. the fault code using the mal- check the pins (bent or broken function mode of the Yamaha terminals and locking condition diagnostic tool. Condition is “Recovered” → Go of the pins).
  • Page 586 Actuates the relay unit five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen come on each time the relay is actuated. Check that the relay unit is actuated five times by listening for the operat- Procedure ing sound.
  • Page 587 Between fuel injection system Check the condition of the fault fuse and relay unit coupler. code using the malfunction brown/white–brown/white mode of the Yamaha diagnostic Between ignition fuse and right tool. Condition is “Recovered” → Go handlebar switch coupler. red/white–red/white to item 7 and finish the service.
  • Page 588 Actuates air induction system solenoid five times at one-second inter- Actuation vals. The “check” indicator on the Yamaha diagnostic tool screen comes on each time the air induction system solenoid is actuated. Check that air induction system solenoid is actuated five times by listen- Procedure ing for the operating sound.
  • Page 589 “Recovered” us- light goes off. ing the Yamaha diagnostic tool, and then delete the fault code. Fault code No. P1600 (FJR13ESG) If fault code numbers “U0125” and “P1600” are both indicated, take the actions specified for fault code number “U0125”...
  • Page 590 Check the rubber components the fault code using the mal- for deterioration. function mode of the Yamaha di- Improperly installed sensor → agnostic tool. Condition is “Recovered” → Go Reinstall or replace the sensor.
  • Page 591 Check the condition of the fault Disconnect the coupler and code using the malfunction check the pins (bent or broken mode of the Yamaha diagnostic terminals and locking condition tool. Condition is “Recovered” → Go of the pins).
  • Page 592 (loose bolts). function mode of the Yamaha di- agnostic tool. Condition is “Recovered” → Go to item 7 and finish the service. Condition is “Detected” → Go to item 2.
  • Page 593 “Recovered” us- light goes off. ing the Yamaha diagnostic tool, and then delete the fault code. Fault code No. P1604, P1605 (FJR13AG) Fault code No. P1604, P1605 [P1604] Lean angle sensor: ground short circuit detected. Item [P1605] Lean angle sensor: open or power short circuit.
  • Page 594 Check the condition of the fault Disconnect the coupler and code using the malfunction check the pins (bent or broken mode of the Yamaha diagnostic terminals and locking condition tool. Condition is “Recovered” → Go of the pins).
  • Page 595 FUEL INJECTION SYSTEM Fault code No. P1604, P1605 [P1604] Lean angle sensor: ground short circuit detected. Item [P1605] Lean angle sensor: open or power short circuit. [For P1604] Ground short circuit Between lean angle sensor coupler and ground: yellow/green–ground If there is continuity, replace the wire harness. L Y/G [For P1605] Open circuit Between lean angle sensor coupler and ECU coupler: blue–blue...
  • Page 596 “OFF”, and then back to Replace if defective. “ON”. Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered” → Go to item 6 and finish the service. Condition is “Detected” → Go to item 5.
  • Page 597 Check the locking condition of place the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha di- Disconnect the coupler and agnostic tool. Condition is “Recovered” → Go check the pins (bent or broken terminals and locking condition to item 8 and finish the service.
  • Page 598 FUEL INJECTION SYSTEM Fault code No. P2122, P2123, P2127, P2128, P2138 [P2122] Accelerator position sensor: open or ground short circuit detected. [P2123] Accelerator position sensor: power short circuit detected. Item [P2127] Accelerator position sensor: ground short circuit detected. [P2128] Accelerator position sensor: open or power short circuit de- tected.
  • Page 599 B/L B/L B/Y Lg/B L/Y Gy B/L B/L B/Y Lg/B L/Y Gy A. FJR13AG B. FJR13ESG [For P2122] Open circuit [For P2138] Deviation error Between accelerator position sensor coupler and ECU coupler: white–white If there is no continuity, replace the wire harness.
  • Page 600 B/L B/L B/Y Lg/B L/Y Gy B/L B/L B/Y Lg/B L/Y Gy A. FJR13AG B. FJR13ESG [For P2122, P2128] Open circuit Between accelerator position sensor coupler and ECU coupler: black/blue–black/blue If there is no continuity, replace the wire harness. Gy/W...
  • Page 601 Improperly installed sensor → the fault code using the mal- Reinstall or adjust the sensor. function mode of the Yamaha di- Refer to “ADJUSTING THE AC- agnostic tool. Condition is “Recovered” → Go CELERATOR POSITION SEN- SOR”...
  • Page 602 Refer to “CHECKING THE AC- function mode of the Yamaha di- CELERATOR POSITION SEN- agnostic tool. Condition is “Recovered” → Go SOR” on page 8-263.
  • Page 603 FUEL INJECTION SYSTEM Fault code No. P2158 Front wheel sensor: no normal signals are received from the front Item wheel sensor. Front wheel speed pulse Tool display 0–999 Check that the number increases when the front wheel is rotated. The Procedure number is cumulative and does not reset each time the wheel is stopped.
  • Page 604 19 mph). Confirm that the fault code has a condition of “Recovered” us- ing the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Delete this fault code even if it has a condition of “Detected”.
  • Page 605 Improperly installed sensor → Check the condition of the fault Reinstall or replace the sensor. code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered” → Go to item 8 and finish the service. Condition is “Detected” → Go to item 2.
  • Page 606 FUEL PRESSURE” on page approximately 10 seconds. 7-10. Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered” → Go to item 8 and finish the service. Condition is “Detected” → Go to item 6.
  • Page 607 Check the locking condition of place the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha di- Disconnect the coupler and agnostic tool. Condition is “Recovered” → Go check the pins (bent or broken terminals and locking condition to item 7 and finish the service.
  • Page 608 B/L P L Gy/R G/Y L/Y L B/W Gy/R G/Y L/Y G/B L B/W A. FJR13AG B. FJR13ESG [For P2229] Open circuit Between atmospheric pressure sensor coupler and ECU coupler: pink–pink If there is no continuity, replace the wire harness. Gy/W...
  • Page 609 Improperly installed sensor → the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha di- agnostic tool. Condition is “Recovered” → Go to item 7 and finish the service.
  • Page 610 (Code No. 02) and then check the condition of When engine is stopped: the fault code using the mal- Atmospheric pressure at the function mode of the Yamaha di- current altitude and weather agnostic tool. Condition is “Recovered” →Go conditions is indicated.
  • Page 611 Disconnect the coupler and function mode of the Yamaha di- check the pins (bent or broken agnostic tool. Condition is “Recovered” → Go terminals and locking condition of the pins).
  • Page 612 Check the locking condition of place the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha di- Disconnect the coupler and agnostic tool. Condition is “Recovered” → Go check the pins (bent or broken terminals and locking condition to item 6 and finish the service.
  • Page 613 FUEL INJECTION SYSTEM 8-136...
  • Page 614 CRUISE CONTROL SYSTEM EAS20087 CRUISE CONTROL SYSTEM EAS31919 CIRCUIT DIAGRAM (FJR13AG) 8-137...
  • Page 615 64.Handlebar switch (left) 65.Cruise control power switch 66.Cruise control setting switch 77.Meter assembly 78.Multi-function meter 88.Cruise control system indicator light 89.Cruise control setting indicator light 100.Yamaha diagnostic tool coupler 108.ECU (Engine Control Unit) A. Wire harness C. Negative battery sub-wire harness 8-138...
  • Page 616 CRUISE CONTROL SYSTEM EAS31920 CIRCUIT DIAGRAM (FJR13ESG) 8-139...
  • Page 617 53.Cruise control power switch 54.Cruise control setting switch 83.Meter assembly 84.Multi-function meter 94.Cruise control system indicator light 95.Cruise control setting indicator light 107.Yamaha diagnostic tool coupler 113.ECU (Engine Control Unit) A. Wire harness B. Headlight sub-wire harness C. Negative battery sub-wire harness 8-140...
  • Page 618 CRUISE CONTROL SYSTEM EAS30666 CRUISE CONTROL CIRCUIT OPERATION 8-141...
  • Page 619 CRUISE CONTROL SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Backup fuse 5. Fuel injection system fuse 6. Signaling system fuse 7. Brake light fuse 8. Ignition fuse 9. Cruise control system fuse 10.Cruise control power switch 11.Cruise control setting switch 12.Clutch switch 13.Front brake light switch 14.Rear brake light switch...
  • Page 620 • Use sufficiently charged regular batteries only. [A] Malfunction check using the cruise control system indicator light. [B] Use the Yamaha diagnostic tool to determine the cause of the malfunction for the stored fault code from the condition and place where the malfunction occurred.
  • Page 621 Delete the fault codes. Return to [A]. DETAILS” (ECU). codes. Comes on [B-2] Check the malfunction history using the malfunction mode of the Yamaha diagnostic tool. Is there any malfunction history? Explain the conditions for [B-3] Is there automatic deactivation history for the...
  • Page 622 CRUISE CONTROL SYSTEM EWA17441 WARNING When maintenance or checks have been performed on components related to the cruise control system, be sure to perform a final check before delivering the vehicle to the customer. To final check, refer to “[C-2] FINAL CHECK” on page 8-155. EAS30669 [A] CHECKING THE CRUISE CONTROL SYSTEM INDICATOR LIGHT Turn the main switch to “ON”, and then push the cruise control power switch.
  • Page 623 Disconnect the coupler and mode of the Yamaha diagnostic check the pins (bent or broken tool. Condition is “Recovered” → Go terminals and locking condition of the pins).
  • Page 624 Disconnect the coupler and mode of the Yamaha diagnostic check the pins (bent or broken tool. Condition is “Recovered” → Go terminals and locking condition of the pins).
  • Page 625 Confirm that the fault code has that the engine trouble warning a condition of “Recovered” us- light goes off. ing the Yamaha diagnostic tool, and then delete the fault code. Fault code No. P056C A Front brake light switch: open or short circuit is detected.
  • Page 626 Disconnect the coupler and mode of the Yamaha diagnostic check the pins (bent or broken tool. Condition is “Recovered” → Go terminals and locking condition of the pins).
  • Page 627 Operate the brake pedal, and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered” → Go to item B-10 and finish the ser- vice. Condition is “Detected” → Go to item B-9.
  • Page 628 (bent or broken malfunction mode of the terminals and locking condition Yamaha diagnostic tool. Condition is “Recovered” → Go of the pins). to item A-9 and finish the ser- vice.
  • Page 629 “SET–” side of the cruise con- trol setting switch, and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered” → Go to item A-9 and finish the ser- vice.
  • Page 630 Disconnect the coupler and the fault code using the mal- check the pins (bent or broken function mode of the Yamaha terminals and locking condition diagnostic tool. Condition is “Recovered” → Go of the pins).
  • Page 631 Yamaha diagnostic tool. Condition is “Recovered” → Go to item B-9 and finish the ser- vice.
  • Page 632 EAS30674 [C-1] DELETING THE FAULT CODES 1. Delete the fault code using the malfunction of the Yamaha diagnostic tool, and check that the engine trouble warning light goes off. EAS30675 [C-2] FINAL CHECK 1.
  • Page 633 CRUISE CONTROL SYSTEM 8-156...
  • Page 634 FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS31997 CIRCUIT DIAGRAM (FJR13AG) 8-157...
  • Page 635 FUEL PUMP SYSTEM 1. Main switch 8. Ignition fuse 15.Fuel injection system fuse 32.Main fuse 33.Battery 34.Engine ground 51.Relay unit 53.Fuel pump relay 59.Handlebar switch (right) 61.Start/engine stop switch 93.Fuel pump 108.ECU (Engine Control Unit) A. Wire harness C. Negative battery sub-wire harness 8-158...
  • Page 636 FUEL PUMP SYSTEM EAS31950 CIRCUIT DIAGRAM (FJR13ESG) 8-159...
  • Page 637 FUEL PUMP SYSTEM 1. Main switch 9. Ignition fuse 16.Fuel injection system fuse 26.Main fuse 27.Battery 28.Engine ground 35.Relay unit 37.Fuel pump relay 45.Handlebar switch (right) 47.Start/engine stop switch 100.Fuel pump 113.ECU (Engine Control Unit) A. Wire harness C. Negative battery sub-wire harness 8-160...
  • Page 638 FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Side cowlings 2. Front cowling assembly 3. Fuel tank 4. T–bar NG → 1. Check the fuses. (Main, ignition, and fuel injection system) Replace the fuse(s).
  • Page 639 NG → 7. Check the entire fuel pump system wiring. Refer to “CIRCUIT DIAGRAM Properly connect or replace the wire har- (FJR13AG)” on page 8-157 or refer ness. to “CIRCUIT DIAGRAM (FJR13ESG)” on page 8-159. OK ↓ Replace the ECU. Refer to “CIRCUIT DIAGRAM (FJR13ESG)”...
  • Page 640 WINDSHIELD DRIVE SYSTEM EAS20083 WINDSHIELD DRIVE SYSTEM EAS31998 CIRCUIT DIAGRAM (FJR13AG) 8-163...
  • Page 641 WINDSHIELD DRIVE SYSTEM 1. Main switch 5. Windshield motor fuse 8. Ignition fuse 10.Signaling system fuse 32.Main fuse 33.Battery 34.Engine ground 54.Windshield drive unit 55.Windshield drive unit relay (down) 56.Windshield drive unit relay (up) 64.Handlebar switch (left) 69.Menu switch 70.Select switch 77.Meter assembly 78.Multi-function meter A.
  • Page 642 WINDSHIELD DRIVE SYSTEM EAS31952 CIRCUIT DIAGRAM (FJR13ESG) 8-165...
  • Page 643 WINDSHIELD DRIVE SYSTEM 1. Main switch 6. Windshield motor fuse 9. Ignition fuse 11.Signaling system fuse 26.Main fuse 27.Battery 28.Engine ground 39.Windshield drive unit 40.Windshield drive unit relay (down) 41.Windshield drive unit relay (up) 52.Handlebar switch (left) 57.Menu switch 58.Select switch 83.Meter assembly 84.Multi-function meter A.
  • Page 644 WINDSHIELD DRIVE SYSTEM EAS30518 TROUBLESHOOTING The windshield fails to move. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T–bar NG → 1. Check that there are no rocks or other foreign material in the wind- Remove the foreign material.
  • Page 645 NG → 11.Check the entire windshield drive system wiring. Refer to “CIRCUIT DIAGRAM Properly connect or replace the wire har- (FJR13AG)” on page 8-163 or refer ness. to “CIRCUIT DIAGRAM (FJR13ESG)” on page 8-165. OK ↓ Replace the meter assembly.
  • Page 646 ACCESSORY BOX SYSTEM EAS20232 ACCESSORY BOX SYSTEM EAS31999 CIRCUIT DIAGRAM (FJR13AG) 8-169...
  • Page 647 ACCESSORY BOX SYSTEM 1. Main switch 10.Signaling system fuse 32.Main fuse 33.Battery 34.Engine ground 75.Accessory box solenoid A. Wire harness C. Negative battery sub-wire harness D. Accessory box sub-wire harness 8-170...
  • Page 648 ACCESSORY BOX SYSTEM EAS31954 CIRCUIT DIAGRAM (FJR13ESG) 8-171...
  • Page 649 ACCESSORY BOX SYSTEM 1. Main switch 11.Signaling system fuse 26.Main fuse 27.Battery 28.Engine ground 76.Accessory box solenoid A. Wire harness C. Negative battery sub-wire harness D. Accessory box sub-wire harness 8-172...
  • Page 650 NG → 5. Check the entire accessory box system wiring. Refer to “CIRCUIT DIAGRAM Properly connect or replace the wire har- (FJR13AG)” on page 8-169 or refer ness. to “CIRCUIT DIAGRAM (FJR13ESG)” on page 8-171. OK ↓ This accessory box system circuit is...
  • Page 651 ACCESSORY BOX SYSTEM 8-174...
  • Page 652 IMMOBILIZER SYSTEM EAS20084 IMMOBILIZER SYSTEM EAS32000 CIRCUIT DIAGRAM (FJR13AG) 8-175...
  • Page 653 IMMOBILIZER SYSTEM 1. Main switch 8. Ignition fuse 15.Fuel injection system fuse 16.Backup fuse 21.Immobilizer unit 22.Joint coupler 32.Main fuse 33.Battery 34.Engine ground 77.Meter assembly 79.Immobilizer system indicator light 108.ECU (Engine Control Unit) A. Wire harness C. Negative battery sub-wire harness 8-176...
  • Page 654 IMMOBILIZER SYSTEM EAS31956 CIRCUIT DIAGRAM (FJR13ESG) 8-177...
  • Page 655 IMMOBILIZER SYSTEM 1. Main switch 4. Immobilizer unit 9. Ignition fuse 16.Fuel injection system fuse 17.Backup fuse 20.Joint coupler 26.Main fuse 27.Battery 28.Engine ground 83.Meter assembly 85.Immobilizer system indicator light 113.ECU (Engine Control Unit) A. Wire harness C. Negative battery sub-wire harness 8-178...
  • Page 656 IMMOBILIZER SYSTEM EAS30520 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) that can be re-registered with new codes •...
  • Page 657 IMMOBILIZER SYSTEM Parts to be replaced Main switch/immobi- Key registration re- Accessory lizer unit Standard quirement lock* and Main Immobilizer switch unit √ Standard key is lost New standard key All keys have been lost Code re-registering √ √ √ √...
  • Page 658 IMMOBILIZER SYSTEM Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced. Do not start the engine with a standard key that has not been registered. If the main switch is turned to “ON”...
  • Page 659 IMMOBILIZER SYSTEM Voiding the standard key code: If a standard key has been lost, it is possible to disable its use by re-registering the remaining standard key. Standard key registration erases the stored standard key code from the memory, thus disabling the lost standard key.
  • Page 660 NG → 4. Check the entire immobilizer sys- tem wiring. Refer to “CIRCUIT DIAGRAM Properly connect or replace the wire har- (FJR13AG)” on page 8-175 or refer ness. to “CIRCUIT DIAGRAM (FJR13ESG)” on page 8-177. OK ↓ • Check the condition each of the im- mobilizer system circuits.
  • Page 661 IMMOBILIZER SYSTEM EAS30523 SELF-DIAGNOSIS FAULT CODE INDICATION When a system malfunction occurs, the immobilizer system indicator light flashes. The pattern of flash- ing also shows the fault code. Fault code Part Symptom Cause Action IMMOBILIZER Code cannot be trans- 1. Radio wave interfer- 1.
  • Page 662 IMMOBILIZER SYSTEM Fault code Part Symptom Cause Action Unidentified code is Noise interference or dis- 1. Check the wire received. connected lead/cable. harness and con- nector. 2. Replace the main switch/immobiliz- er unit. 3. Replace the ECU. Refer to “RE- PLACING THE ECU (engine con- trol unit)”...
  • Page 663 IMMOBILIZER SYSTEM 8-186...
  • Page 664 ABS (ANTI-LOCK BRAKE SYSTEM) EAS20085 ABS (ANTI-LOCK BRAKE SYSTEM) EAS32001 CIRCUIT DIAGRAM (FJR13AG) 8-187...
  • Page 665 ABS (ANTI-LOCK BRAKE SYSTEM) 1. Main switch 7. ABS ECU fuse 8. Ignition fuse 10.Signaling system fuse 13.ABS motor fuse 14.ABS solenoid fuse 15.Fuel injection system fuse 16.Backup fuse 22.Joint coupler 32.Main fuse 33.Battery 34.Engine ground 36.Starter relay 39.Brake light fuse 41.Rear brake light switch 43.Brake switch relay 44.Brake light relay...
  • Page 666 ABS (ANTI-LOCK BRAKE SYSTEM) EAS31958 CIRCUIT DIAGRAM (FJR13ESG) 8-189...
  • Page 667 ABS (ANTI-LOCK BRAKE SYSTEM) 1. Main switch 8. ABS ECU fuse 9. Ignition fuse 11.Signaling system fuse 14.ABS motor fuse 15.ABS solenoid fuse 16.Fuel injection system fuse 17.Backup fuse 20.Joint coupler 26.Main fuse 27.Battery 28.Engine ground 30.Starter relay 33.Brake light fuse 42.Rear brake light switch 44.Front brake light switch 45.Handlebar switch (right)
  • Page 668 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30525 ABS COMPONENTS CHART 12,13 1. ABS test coupler 2. ABS warning light 3. ABS ECU fuse 4. ABS solenoid fuse 5. ABS motor fuse 6. Proportioning valve 7. Hydraulic unit assembly 8. Rear wheel sensor 9.
  • Page 669 ABS (ANTI-LOCK BRAKE SYSTEM) 8-192...
  • Page 670 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30844 ABS COUPLER LOCATION CHART W/L W/Y W/B B/Y P Y/W L/W B/R Gy Br/W Br/B Br/W Br/B L/R L/B Br/Y Sb/W Y G/R G/W R/G R/G R/G Ch (Gy) W Gy Gy W W Gy G/W L/W Gy W W/L G/Y...
  • Page 671 ABS (ANTI-LOCK BRAKE SYSTEM) 1. Meter assembly coupler 2. ABS test coupler 3. Rear wheel sensor coupler 4. ABS ECU coupler 5. Front wheel sensor coupler 8-194...
  • Page 672 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30845 MAINTENANCE OF THE ABS ECU Checking the ABS ECU 1. Check: • Terminals “1” of the ABS ECU Cracks/damages → Replace the hydraulic unit assembly and the brake pipes that are connected to the assembly as a set. •...
  • Page 673 ABS (ANTI-LOCK BRAKE SYSTEM) Self-diagnosis and servicing The ABS ECU has a self-diagnosis function. By utilizing this function, quick problem identification and service are possible. Previous malfunctions can be checked since the ABS ECU also stores the mal- function history. The multi-function meter right display indicates all the fault codes recorded in the ABS ECU.
  • Page 674 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30530 BASIC PROCESS FOR TROUBLESHOOTING Turn the main switch to [A-1] The ABS warning light does Fails to come on “ON”, and check the ABS not come on. warning light. The ABS warning light (LED) is •...
  • Page 675 ABS (ANTI-LOCK BRAKE SYSTEM) EWA16710 WARNING When maintenance or checks have been performed on components related to the ABS, be sure to perform a final check before delivering the vehicle to the customer. To final check, refer to “[C-3] FINAL CHECK” on page 8-220. EAS30531 [A] CHECKING THE ABS WARNING LIGHT Turn the main switch to “ON”.
  • Page 676 ABS (ANTI-LOCK BRAKE SYSTEM) 1. A fault code number “1” is not displayed in the multi-function meter right display. [B-1] 2. A fault code number “1” is displayed in the multi-function meter right display. (For example, fault code No. ABS_16) [B-3] GEAR EAS30965 [B-1] A FAULT CODE NUMBER IS NOT DISPLAYED IN THE MULTI-FUNCTION METER RIGHT...
  • Page 677 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30537 [B-2] THE ABS WARNING LIGHT REMAINS ON 1. The battery voltage is low. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-251. • If the battery voltage is low, clean the battery terminals and recharge it, or replace the battery. 2.
  • Page 678 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code Symptom Check point • Installation of the front wheel sensor ABS_11* Front wheel sensor signal is not received • Front wheel ABS_25* properly. • Front wheel sensor housing • Front wheel sensor rotor • Installation of the rear wheel sensor Rear wheel sensor signal is not received •...
  • Page 679 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code Symptom Check point Hydraulic unit solenoid relay is short-cir- ABS_32 • Hydraulic unit assembly cuited. • Battery voltage • ABS motor fuse ABS motor is defective. • Wire harness (ABS circuit) ABS_33 Power is not supplied to the ABS motor. •...
  • Page 680 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_11, ABS_25 With front wheel stopped, rear wheel was rotated for longer than about 20 seconds (fault code No. ABS_11) or for longer than about 2 seconds (fault code No. ABS_25). Fault code No. ABS_11 Symptom Front wheel sensor signal is not received properly.
  • Page 681 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_13 Symptom Incorrect signal from the front wheel sensor is de- ABS_26 tected. Order Item/components and probable cause Check or maintenance job Installed condition of wheel sensor. Check for looseness. Properly install or replace the wheel sensor if necessary.
  • Page 682 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_15 Fault code No. ABS_15 Symptom No continuity in the front wheel sensor circuit. Order Item/components and probable cause Check or maintenance job Connections • Check the coupler for any pins that may be pulled out. •...
  • Page 683 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_16 Fault code No. ABS_16 Symptom No continuity in the rear wheel sensor circuit. Order Item/components and probable cause Check or maintenance job Connections • Check the coupler for any pins that may be pulled out. •...
  • Page 684 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_17, ABS_45 Fault code No. ABS_17 Symptom Missing pulses detected in the front wheel sensor ABS_45 signal. Order Item/components and probable cause Check or maintenance job Installed condition of wheel bearings, ax- Check the components for looseness, distortion, and le, sensor housing, and sensor rotor.
  • Page 685 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_22 Symptom Start switch signal is not received properly (start switch circuit or start switch monitor circuit). Order Item/components and probable cause Check or maintenance job Connections • Check the coupler for any pins that may be pulled out. •...
  • Page 686 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_24 Fault code No. ABS_24 Symptom Brake light signal is not received properly while vehi- cle is traveling (brake light circuit, or front or rear brake light switch circuit). Order Item/components and probable cause Check or maintenance job Brake light operation.
  • Page 687 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_31 Symptom Solenoid relay is defective. Power is not supplied to the solenoid relay. Order Item/components and probable cause Check or maintenance job Open or short circuit in wire harness. • Replace if there is an open or short circuit. •...
  • Page 688 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_41 EWA17490 WARNING The front brakes will not function properly if the connections are reversed. • Brake pipe/lower joint assembly “1” and brake pipe “2” inlet: from the front brake master cyl- inder •...
  • Page 689 • Check the brake lines for kinks and deterioration. EWA16730 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • Check that the connections of the brake lines from the...
  • Page 690 EWA16730 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • Check that the connections of the brake lines from the...
  • Page 691 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_43 Fault code No. ABS_43 Symptom Incorrect signal from the front wheel sensor is de- tected. Order Item/components and probable cause Check or maintenance job Installed condition of wheel sensor. Check for looseness. Properly install or replace the wheel sensor if necessary.
  • Page 692 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_53 Fault code No. ABS_53 Symptom Power voltage is too low. Order Item/components and probable cause Check or maintenance job Battery voltage Recharge or replace the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-251.
  • Page 693 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_63 Fault code No. ABS_63 Symptom Front wheel sensor power is abnormal. Order Item/components and probable cause Check or maintenance job Short circuit in wire harness. • Check that there is no short circuit between the white terminal “1”...
  • Page 694 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_64 Symptom Rear wheel sensor power is abnormal. Order Item/components and probable cause Check or maintenance job Short circuit in rear wheel sensor lead. • Check that there is no short circuit between the white terminal “3”...
  • Page 695 ABS (ANTI-LOCK BRAKE SYSTEM) 5. Push the “ ” side of the start/engine stop EAS30539 [C-1] DELETING THE FAULT CODES switch “1” at least 10 times in 4 seconds to 1. Check: delete the fault codes. • Engine stop due to sidestand operation EWA17470 WARNING •...
  • Page 696 ABS (ANTI-LOCK BRAKE SYSTEM) 2. Disconnect the ABS ECU coupler. • Positive tester probe → 3. Connect the test coupler adapter to the ABS white/blue “1” (ABS ECU) • Negative tester probe → test coupler. white/blue “2” (right handlebar switch) 4.
  • Page 697 ABS (ANTI-LOCK BRAKE SYSTEM) d. Measure the ABS ECU voltage. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 8. If the above-mentioned checks are within specification, replace the hydraulic unit as- sembly.
  • Page 698 GRIP WARMER SYSTEM EAS20167 GRIP WARMER SYSTEM EAS32002 CIRCUIT DIAGRAM (FJR13AG) 8-221...
  • Page 699 GRIP WARMER SYSTEM 1. Main switch 8. Ignition fuse 15.Fuel injection system fuse 22.Joint coupler 32.Main fuse 33.Battery 34.Engine ground 64.Handlebar switch (left) 69.Menu switch 70.Select switch 77.Meter assembly 78.Multi-function meter 108.ECU (Engine Control Unit) 120.Grip warmer (left) 121.Grip warmer (right) A.
  • Page 700 GRIP WARMER SYSTEM EAS31960 CIRCUIT DIAGRAM (FJR13ESG) 8-223...
  • Page 701 GRIP WARMER SYSTEM 1. Main switch 9. Ignition fuse 16.Fuel injection system fuse 20.Joint coupler 26.Main fuse 27.Battery 28.Engine ground 52.Handlebar switch (left) 57.Menu switch 58.Select switch 83.Meter assembly 84.Multi-function meter 113.ECU (Engine Control Unit) 125.Grip warmer (left) 126.Grip warmer (right) A.
  • Page 702 NG → 6. Check the entire grip warmer sys- tem wiring. Refer to “CIRCUIT DIAGRAM Properly connect or replace the wiring har- (FJR13AG)” on page 8-221 or refer ness. to “CIRCUIT DIAGRAM (FJR13ESG)” on page 8-223. OK ↓ NG →...
  • Page 703 No. P0500. Refer to “TROUBLESHOOT- No. P0500 is displayed in the ING DETAILS (ECU) (FAULT CODE)” on Yamaha diagnostic tool display. page 8-62. OK ↓ Replace the ECU. Refer to “REPLAC- ING THE ECU (engine control unit)”...
  • Page 704 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (FJR13ESG) EAS20251 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (FJR13ESG) EAS31009 CIRCUIT DIAGRAM 8-227...
  • Page 705 82.Rear shock absorber assembly DC motor 83.Meter assembly 84.Multi-function meter 96.Electronically adjustable suspension system warning light 107.Yamaha diagnostic tool coupler 113.ECU (Engine Control Unit) A. Wire harness B. Headlight sub-wire harness C. Negative battery sub-wire harness F. Left front fork stepping motor sub-wire harness G.
  • Page 706 ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼▼ ▼▼ ▼ a. Check the fault code numbers that have a condition of “Detected” using the Yamaha diagnostic tool. b. Identify the faulty system with the fault code number. 8-229...
  • Page 707 8-62. EAS31014 TROUBLESHOOTING DETAILS (SCU) This section describes the measures per fault code number displayed on the Yamaha diagnostic tool. Check and service the items or components that are the probable cause of the malfunction following the order given.
  • Page 708 DC motor and adjust it by hand. After adjusting the DC motor, perform the procedure for diagnostic code No. 84 again. If the “check” indicator on the Yamaha diagnostic tool screen flashes again, replace the rear shock absorber assembly.
  • Page 709 • Left front fork stepping motor mode of the Yamaha diagnostic • Right front fork stepping motor tool. Condition is “Recovered” → • Rear shock absorber assem- bly stepping motor Service is finished.
  • Page 710 “ON”, and then • Between the SCU coupler and check the condition of the fault SCU fuse. code using the malfunction brown/blue–brown/blue mode of the Yamaha diagnostic • Between the SCU fuse and tool. Condition is “Recovered” → battery. red–red Service is finished.
  • Page 711 Connect the pocket tester (Ω the fault code using the mal- × 10) to the stepping motor. function mode of the Yamaha • Positive tester probe “1” diagnostic tool. Condition is “Recovered” →...
  • Page 712 DC motor and adjust it by hand. After adjusting the DC motor, perform the procedure for diagnostic code No. 84 again. If the “check” indicator on the Yamaha diagnostic tool screen flashes again, replace the rear shock absorber assembly.
  • Page 713 Open or short circuit → Replace the condition of the fault code the wire harness. using the malfunction mode of • Between SCU coupler and the Yamaha diagnostic tool. Condition is “Recovered” → rear shock absorber assembly DC motor. Service is finished.
  • Page 714 DC motor. and luggage), and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered” → As- semble the motor and rear shock absorber assembly, in- stall the rear shock absorber as-...
  • Page 715 DC motor and adjust it by hand. After adjusting the DC motor, perform the procedure for diagnostic code No. 84 again. If the “check” indicator on the Yamaha diagnostic tool screen flashes again, replace the rear shock absorber assembly.
  • Page 716 DC motor and adjust it by hand. After adjusting the DC motor, perform the procedure for diagnostic code No. 84 again. If the “check” indicator on the Yamaha diagnostic tool screen flashes again, replace the rear shock absorber assembly.
  • Page 717 TEM” on page 8-17. Check the condition of the fault Defective rectifier/regulator or code using the malfunction AC magneto → Replace. mode of the Yamaha diagnostic Defective connection in the tool. charging system circuit → Prop- Condition is “Recovered” →...
  • Page 718 Turn the main switch to “ON”, the wire harness. and then check the condition of Between SCU coupler and joint the fault code using the mal- coupler. function mode of the Yamaha blue/black–blue/black diagnostic tool. Condition is “Recovered” → blue/red–blue/red Between the joint coupler and Service is finished.
  • Page 719 Turn the main switch to “ON”, the wire harness. and then check the condition of Between SCU coupler and joint the fault code using the mal- coupler. function mode of the Yamaha blue/black–blue/black diagnostic tool. Condition is “Recovered” → blue/red–blue/red Between the joint coupler and Service is finished.
  • Page 720 ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 11 12 8-243...
  • Page 721 2. Battery 3. Starter relay 4. Main fuse 2 5. Front brake light switch 6. Clutch switch 7. Fuse box 3 (FJR13AG) 8. Fuse box 1 (FJR13AG) 9. Fuse box 3 (FJR13ESG) 10. Fuse box 1 (FJR13ESG) 11. Fuse box 2 12.
  • Page 722 ELECTRICAL COMPONENTS 8-245...
  • Page 723 ELECTRICAL COMPONENTS 1. Coolant temperature sensor 2. Accelerator position sensor 3. Throttle position sensor 4. Intake air pressure sensor 5. Atmospheric pressure sensor 6. Brake light relay 7. SCU (Suspension Control Unit) (FJR13ESG) 8. Brake switch relay 9. Hydraulic unit assembly 10.
  • Page 724 ELECTRICAL COMPONENTS EAS30549 CHECKING THE SWITCHES G/L B/W Br/L Br/G G/L Y/B Br/L W/R B/W W/G R/B W/L B Y/B O/W Br/G W/L B/W Y Y/W Y MENU PASS W/B L/R W/Y MODE G/W G/Y Y/B Y/W PULL Br Y/B G/Y G/W PULL Br/R B/R L/Y Br/L Br/R L/Y B/R...
  • Page 725 ELECTRICAL COMPONENTS 1. Start/engine stop switch 2. Hazard switch 3. Mode switch 4. Front brake light switch 5. Main switch 6. Rear brake light switch 7. Gear position switch 8. Sidestand switch 9. Clutch switch 10. Horn switch 11. Dimmer/pass switch 12.
  • Page 726 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14371 NOTICE Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end “a”...
  • Page 727 ELECTRICAL COMPONENTS EAS30551 Amperage CHECKING THE FUSES Fuses Q’ty rating The following procedure applies to all of the fus- Right radiator fan motor 10 A ECA20520 Signaling system 7.5 A NOTICE Electronic throttle valve 7.5 A To avoid a short circuit, always turn the main Hazard lighting 7.5 A switch to “OFF”...
  • Page 728 ELECTRICAL COMPONENTS 5. Check: charged, the electrolyte level will drop con- • Engine idling speed siderably. Therefore, take special care Start the engine, warm it up, and then mea- when charging the battery. sure the engine idling speed. Engine idling speed Since VRLA (Valve Regulated Lead Acid) bat- 950–1150 r/min teries are sealed, it is not possible to check the...
  • Page 729 ELECTRICAL COMPONENTS • No charging is necessary when the open-cir- • If it is impossible to regulate the charging cuit voltage equals or exceeds 12.8 V. current on the battery charger, be careful not to overcharge the battery. b. Check the charge of the battery, as shown in •...
  • Page 730 ELECTRICAL COMPONENTS c. Make sure that the current is higher than the standard charging current written on the bat- Voltage should be measured 30 minutes after tery. the engine is stopped. b. Connect a charger and ammeter to the bat- If the current is lower than the standard charging tery and start charging.
  • Page 731 ELECTRICAL COMPONENTS 10.Install: 2. Negative battery terminal • Upper inner panel (right) 3. Positive tester probe Refer to “GENERAL CHASSIS (2)” on page 4. Negative tester probe 4-5. Result EAS30553 Continuity CHECKING THE RELAYS (between “3” and “4”) Check each switch for continuity with the pocket tester.
  • Page 732 ELECTRICAL COMPONENTS Brake switch relay 4. Negative tester probe Result No continuity (between “3” and “4”) Radiator fan motor relay Lg/B 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Br/B Result Continuity 1.
  • Page 733 ELECTRICAL COMPONENTS Second step: Second step: Br/G Br/G 1. Positive battery terminal 1. Positive battery terminal 2. Negative battery terminal 2. Negative battery terminal 3. Positive tester probe 3. Positive tester probe 4. Negative tester probe 4. Negative tester probe 5.
  • Page 734 ELECTRICAL COMPONENTS c. Check the relay unit (diode) for continuity. Continuity d. Check the relay unit (diode) for no continuity. Positive tester probe → sky blue ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...
  • Page 735 ELECTRICAL COMPONENTS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester (Ω × 1k) to the ig- nition coil as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C •...
  • Page 736 • Lean angle sensor output voltage Out of specification → Replace. starting system troubleshooting, starting with step 4. Lean angle sensor output voltage Refer to “TROUBLESHOOTING” on page Operating angle 8-14. 65 ° (FJR13AG) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼...
  • Page 737 ELECTRICAL COMPONENTS EAS30566 CHECKING THE STATOR COIL Charging voltage 1. Disconnect: 14.0 V at 5000 r/min • Stator coil coupler (from the wire harness) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
  • Page 738 • Positive tester probe → white “1” • Negative tester probe → body ground “2” L/B L/B L/B Y/W B L/R L/R b. Check the oil level switch for continuity. A. FJR13AG ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲...
  • Page 739 ELECTRICAL COMPONENTS EAS32020 CHECKING THE FRONT TURN SIGNAL/POSITION LIGHT ASSEMBLY The following procedure applies to both of the front turn signal/position light assemblies. 1. Check: • Front turn signal/position light assembly Faulty → Replace. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
  • Page 740 ELECTRICAL COMPONENTS • Positive battery terminal → blue “1” • Negative battery terminal → black “2” B/L W b. Measure the throttle position sensor maxi- mum resistance. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...
  • Page 741 ELECTRICAL COMPONENTS • Positive tester probe → blue “1” • Negative tester probe → black/blue “2” L B/L W b. Measure the accelerator position sensor maximum resistance. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...
  • Page 742 ELECTRICAL COMPONENTS EAS30681 CHECKING THE FUEL INJECTORS Result 1. Check: Neutral position • Fuel injector resistance Continuity Positive tester probe → Out of specification → Replace the fuel injec- sky blue “1” tor. Negative tester probe → Switch terminal “a” Resistance 12.0 Ω...
  • Page 743 ELECTRICAL COMPONENTS c. Measure the accessory box solenoid resis- tance. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS31891 CHECKING THE GRIP WARMERS The following procedure applies to both of the grip warmers.
  • Page 744 ELECTRICAL COMPONENTS 8-267...

  • Page 745: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING..................9-1 GENERAL INFORMATION ............... 9-1 STARTING FAILURES................9-1 INCORRECT ENGINE IDLING SPEED ............ 9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING................ 9-2 SHIFT PEDAL DOES NOT MOVE ............9-2 JUMPS OUT OF GEAR................9-2 FAULTY CLUTCH ..................9-2 OVERHEATING ..................9-3 OVERCOOLING..................9-3 POOR BRAKING PERFORMANCE............
  • Page 746 TROUBLESHOOTING Electrical system EAS20090 TROUBLESHOOTING 1. Battery • Discharged battery EAS30599 • Faulty battery GENERAL INFORMATION 2. Fuse(s) • Blown, damaged or incorrect fuse The following guide for troubleshooting does not • Improperly installed fuse cover all the possible causes of trouble. It should 3.
  • Page 747 TROUBLESHOOTING Electrical system EAS30605 JUMPS OUT OF GEAR 1. Battery • Discharged battery Shift shaft • Faulty battery • Incorrect shift pedal position 2. Spark plug(s) • Improperly returned stopper lever • Incorrect spark plug gap • Incorrect spark plug heat range Shift forks •...
  • Page 748 • Damaged fork spring 2. Air filter • Worn or damaged outer tube bushing • Clogged air filter element (FJR13AG) • Bent or damaged damper rod (FJR13AG) Chassis • Bent or damaged damper rod assembly 1. Brake(s) (FJR13ESG) • Dragging brake •...
  • Page 749 TROUBLESHOOTING • Damaged ball bearing or bearing race • Faulty front turn signal light 2. Front fork leg(s) • Incorrect connection • Incorrect oil level • Damaged or faulty wire harness • Unevenly tensioned fork spring (both front • Improperly grounded circuit fork legs) •...
  • Page 750 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) EAS20162 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) EAS31794 SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM) For details of the fault code, refer to “TROUBLESHOOTING METHOD (ECU)” on page 8-61. Fault code Probable cause of Fail-safe system op- Item Vehicle symptom...
  • Page 751 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Fault code Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P0107 [P0107] Intake air [P0107] Low voltage Engine idling speed is Intake air pressure P0108 pressure sensor of the intake air pres- unstable.
  • Page 752 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Fault code Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P0117 [P0117] Coolant tem- [P0117] Low voltage Engine is difficult to The radiator fan motor P0118 perature sensor of the coolant tem- start.
  • Page 753 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Fault code Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P0132 sensor (power [P0132] High voltage Increased exhaust feedback is not of the O sensor cir- emissions. short circuit detected) carried out.
  • Page 754 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Fault code Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P0340 Cylinder identification • Defective coupler Engine cannot be The vehicle is operat- sensor (no normal between cylinder started. ed using only the cyl- signals are received identification sensor inder identification...
  • Page 755 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Fault code Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P0500 • Rear wheel sensor • Open or short cir- Vehicle speed is not Vehicle speed dis- (no normal signals cuit in wire harness displayed on the me- played on the meter =...
  • Page 756 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Fault code Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P0601 Faulty ECU memory. • Malfunction in ECU. Engine cannot be Engine cannot be (When this malfunc- started. started. tion is detected in the ECU, the fault code number might not ap- pear on the tool dis-...
  • Page 757 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Fault code Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P0657 Fuel system voltage • Open or short cir- Engine is difficult to Monitor voltage = 12 (incorrect voltage sup- cuit in wire harness start.
  • Page 758 Engine cannot be Engine cannot be P1605 sensor (ground short of the lean angle sen- started. started. (FJR13AG circuit detected) sor circuit (0.2 V or [P1605] Lean angle less) sensor (open or pow- [P1605] High voltage er short circuit detect- of the lean angle sen- sor circuit (4.8 V or...
  • Page 759 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Fault code Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P2195 sensor (open cir- • Signal voltage is Increased exhaust feedback is not 0.25–0.53 V. emissions. cuit detected) carried out. •...
  • Page 760 The number is cu- mulative and does not reset each time the wheel is stopped. Lean angle sensor Lean angle sensor output Remove the lean angle sen- (FJR13AG) voltage sor and incline it more than 65 degrees. • Upright 0.4–1.4 • Overturned 3.7–4.4...
  • Page 761 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Diagnostic Item Tool display Procedure code No. Fuel system voltage Approximately 12.0 Set the start/engine stop (battery voltage) switch to “ ”, and then com- pare the actually measured battery voltage with the tool display value.
  • Page 762 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Diagnostic Item Tool display Procedure code No. EEPROM fault code display • No history — • No malfunctions detected (If the self-diagnosis fault code P062F is indicated, the ECU is defective.) • History exists 01–04 (CO adjustment val- —...
  • Page 763 • Connect an ignition check- The “check” indicator on the Yamaha diagnostic tool screen come on each time the ignition coil is actuated. Cylinder-#2 ignition coil Actuates the cylinder-#2 igni-...
  • Page 764 • Connect an ignition check- The “check” indicator on the Yamaha diagnostic tool screen come on each time the ignition coil is actuated. Injector #1 Actuates the injector #1 five...
  • Page 765 The “check” indicator on the erating sound. Yamaha diagnostic tool screen come on each time the relay is actuated. Headlight relay Actuates the headlight relay Check that the headlight re-...
  • Page 766 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (SCU) (FJR13ESG) EAS20255 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (SCU) (FJR13ESG) EAS30963 SELF-DIAGNOSTIC FUNCTION TABLE For details of the fault code, refer to “TROUBLESHOOTING METHOD (SCU)” on page 8-229. Fault code Probable cause of Fail-safe system op- Item Vehicle symptom...
  • Page 767 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (SCU) (FJR13ESG) Fault code Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration C1005 Defective preload ad- • Short circuit in wire The following adjust- justing motor (DC mo- harness. ments and operation tor).
  • Page 768 Preload home position ad- The “check” indicator on the justment Yamaha diagnostic tool screen comes on when the preload home position ad- justment starts. When completed successful- The “check” indicator on the Yamaha diagnostic tool screen goes off.
  • Page 769 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (CLCU) (FJR13ESG) EAS20243 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (CLCU) (FJR13ESG) EAS31984 SELF-DIAGNOSTIC FUNCTION TABLE For details of the fault code, refer to “CLCU SELF-DIAGNOSTIC FUNCTION” on page 8-31. Fault code Probable cause of Fail-safe system op- Item Vehicle symptom...
  • Page 770 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (CLCU) (FJR13ESG) Fault code Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration U0125 Signals cannot be • Defective coupler • Cornering lights go Cornering lights go transmitted between between IMU and off.
  • Page 771 • Vehicle has over- Perform the checks (FJR13 turned and maintenance jobs • Improperly installed for event code number sensor 30 (FJR13AG). • Sensor malfunction • Defective ECU Latch up detected Latch up detected • Vehicle has over- Perform the checks (FJR13...
  • Page 772 EVENT CODE TABLE Item Symptom Possible cause Remarks sensor Correction value re- • Open or short circuit • If a fault code is indi- mains at upper limit in the wire harness cated, perform the (Correction value re- during O feedback between the sensor checks and mainte-...
  • Page 773 EVENT CODE TABLE Item Symptom Possible cause Remarks Engine stall Engine stall detected • Empty fuel tank • If a fault code is indi- • Improperly adjusted cated, perform the throttle cable checks and mainte- • Defective fuel injec- nance jobs for the tion system fault code first.
  • Page 774 EVENT CODE TABLE EAS32023 TROUBLESHOOTING DETAILS (EVENT CODE) Event code No. 30 (FJR13AG) Event code No. Item Latch up detected. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. Lean angle sensor output voltage Tool display •...
  • Page 775 EVENT CODE TABLE Event code No. Item Latch up detected. Procedure Hold the vehicle upright and place the vehicle on the sidestand. Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check pletion The vehicle has overturned. Raise the vehicle upright.
  • Page 776 44. Brake light relay 98. Cylinder identification sensor 45. Headlight assembly (left) 99. Lean angle sensor 46. Headlight (low beam) 100.Yamaha diagnostic tool cou- 47. Headlight (high beam) pler 48. Headlight control unit (left) 101.ABS test coupler 49. Headlight assembly (right) 102.ABS ECU (electronic control...
  • Page 777 FJR13ESG 2016 59. Turn signal switch 107.Yamaha diagnostic tool cou- 1. Main switch 60. License plate light pler 2. AC magneto 61. Tail/brake light assembly 108.O sensor 3. Rectifier/regulator 62. Taillight 109.Throttle position sensor 4. Immobilizer unit 63. Brake light 110.Accelerator position sensor...
  • Page 778 EAS30613 Yellow/Blue COLOR CODE Yellow/Red Black Yellow/White Brown Chocolate Dark green Green Gray Blue Light green Orange Pink Sky blue White Yellow Black/Green Black/Blue Black/Red Black/White Black/Yellow Br/B Brown/Black Br/G Brown/Green Br/L Brown/Blue Br/R Brown/Red Br/W Brown/White Br/Y Brown/Yellow Green/Black Green/Blue Green/Red Green/White...
  • Page 781 FJR13AG 2016 SCHÉMA DE CÂBLAGE FJR13AG 2016 WIRING DIAGRAM R/W R/W L/B L/B L/B L/R L/R Y/W B Br/R R/G B R/B R/B R/B Br/R W W W (Gy) Gy/B Gy/B Br/L Br/L G/B Y/B Br/L Br/L Br/L Br/L Y/L G/B R/W...
  • Page 782 FJR13AG 2016 SCHÉMA DE CÂBLAGE FJR13AG 2016 WIRING DIAGRAM (Gy) E E E F F F F (Dgy) (Gy) (Gy) (Gy) PULL (Gy) (Gy) PRESS (Gy) (Gy) PULL MODE MENU PASS (Dg) (Gy)
  • Page 783 FJR13ESG 2016 SCHÉMA DE CÂBLAGE FJR13ESG 2016 WIRING DIAGRAM Y/W Y Y Y/W Br/R R/G B R/B R/B R/B Br/R (Gy) O R/B W W W Y/L G/B R/W L/W L/W Br/L Gy/W L/W L/W O Gy O/B Br/R Lg/R Y/R R/L Br/W R/W Br/L Br/W...
  • Page 784 FJR13ESG 2016 SCHÉMA DE CÂBLAGE FJR13ESG 2016 WIRING DIAGRAM (Gy) (Gy) (Gy) (Gy) PULL (Gy) (Gy) PRESS MODE PULL (Gy) (Gy) MENU PASS (Dg) (Gy) 28 29 30 31...

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