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2006 FJR1300AV
Yamaha 2006 FJR1300AV Manuals
Manuals and User Guides for Yamaha 2006 FJR1300AV. We have
2
Yamaha 2006 FJR1300AV manuals available for free PDF download: Service Manual
Yamaha 2006 FJR1300AV Service Manual (586 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 32.55 MB
Table of Contents
Table of Contents
7
How to Use this Manual
4
Symbols
5
General Information
9
Identification
10
Vehicle Identification Number
10
Model Label
10
Features
11
Outline of the Fi System
11
Fi System
12
Outline of the Unified Brake System
13
Outline of the Abs
14
Abs Component Functions
19
Abs Operation
25
Abs Self-Diagnosis Function
29
Abs Warning Light and Operation
31
Instrument Functions
33
Important Information
39
Preparation for Removal and Disassembly
39
Replacement Parts
39
Gaskets, Oil Seals and O-Rings
39
Lock Washers/Plates and Cotter Pins
39
Bearings and Oil Seals
40
Circlips
40
Checking the Connections
41
Special Tools
42
Specifications
49
General Specifications
50
Engine Specifications
51
Chassis Specifications
58
Electrical Specifications
61
Tightening Torques
64
General Tightening Torque Specifications
64
Engine Tightening Torques
65
Chassis Tightening Torques
69
Lubrication Points and Lubricant Types
74
Engine
74
Chassis
76
Lubrication System Chart and Diagrams
78
Engine Oil Lubrication Chart
78
Lubrication Diagrams
80
Cooling System Diagrams
90
Cable Routing
94
Periodic Checks and Adjustments
115
Periodic Maintenance
118
Introduction
118
Periodic Maintenance and Lubrication Chart
118
Engine
120
Adjusting the Valve Clearance
120
Synchronizing the Throttle Bodies
122
Adjusting the Exhaust Gas Volume
124
Adjusting the Engine Idling Speed
125
Adjusting the Throttle Cable Free Play
125
Checking the Spark Plugs
126
Checking the Ignition Timing
127
Measuring the Compression Pressure
128
Checking the Engine Oil Level
129
Changing the Engine Oil
130
Measuring the Engine Oil Pressure
131
Adjusting the Clutch Lever
132
Checking the Clutch Fluid Level
132
Bleeding the Hydraulic Clutch System
132
Cleaning the Air Filter Element
133
Checking the Throttle Body Joints
133
Checking the Fuel Line
134
Checking the Crankcase Breather Hose
134
Checking the Exhaust System
134
Checking the Coolant Level
135
Checking the Cooling System
135
Changing the Coolant
136
Chassis
138
Adjusting the Front Disc Brake
138
Adjusting the Rear Disc Brake
138
Checking the Brake Fluid Level
139
Checking the Front Brake Pads
139
Checking the Rear Brake Pads
140
Checking the Brake Hoses
140
Adjusting the Rear Brake Light Switch
140
Bleeding the Hydraulic Brake System (Abs)
140
Adjusting the Shift Pedal
142
Checking the Final Gear Oil Level
142
Changing the Final Gear Oil
143
Checking and Adjusting the Steering Head
143
Adjusting the Handlebar Position
144
Checking the Front Fork
145
Adjusting the Front Fork Legs
145
Adjusting the Rear Shock Absorber Assembly
146
Adjusting the Side Panels
147
Adjusting the Rider Seat Height
148
Checking the Tires
149
Checking the Wheels
151
Checking and Lubricating the Cables
151
Lubricating the Levers
151
Lubricating the Pedals
151
Lubricating the Sidestand
152
Lubricating the Centerstand
152
Lubricating the Rear Suspension
152
Electrical System
153
Checking and Charging the Battery
153
Checking the Fuses
153
Replacing the Headlight Bulbs
153
Adjusting the Headlight Beams
153
Chassis
155
General Chassis
158
Removing the Side Panels
164
Installing the Front Cowling Left Inner Panel 2
164
Installing the Front Cowling Right Inner Panel 2
165
Installing the Side Panels
165
Front Wheel
170
Removing the Front Wheel
172
Disassembling the Front Wheel
172
Checking the Front Wheel
172
Maintenance of the Front Wheel Sensor and Sensor Rotor
173
Assembling the Front Wheel
174
Adjusting the Front Wheel Static Balance
174
Installing the Front Wheel (Front Brake Discs)
175
Rear Wheel
177
Removing the Rear Wheel
179
Disassembling the Rear Wheel
179
Checking the Rear Wheel
179
Maintenance of the Rear Wheel Sensor and Sensor Rotor
179
Assembling the Rear Wheel
179
Adjusting the Rear Wheel Static Balance
180
Installing the Rear Wheel (Rear Brake Disc)
180
Front Brake
182
Introduction
187
Checking the Front Brake Discs
187
Replacing the Front Brake Pads
188
Removing the Front Brake Calipers
189
Disassembling the Front Brake Calipers
189
Checking the Front Brake Calipers
190
Assembling the Front Brake Calipers
190
Installing the Front Brake Calipers
190
Removing the Front Brake Master Cylinder
192
Checking the Front Brake Master Cylinder
192
Assembling the Front Brake Master Cylinder
192
Installing the Front Brake Master Cylinder
192
Rear Brake
200
Introduction
200
Checking the Rear Brake Disc
200
Replacing the Rear Brake Pads
200
Removing the Rear Brake Caliper
201
Disassembling the Rear Brake Caliper
202
Checking the Rear Brake Caliper
202
Assembling the Rear Brake Caliper
202
Installing the Rear Brake Caliper
202
Removing the Rear Brake Master Cylinder
204
Checking the Rear Brake Master Cylinder
204
Assembling the Rear Brake Master Cylinder
204
Installing the Rear Brake Master Cylinder
205
Abs (Anti-Lock Brake System)
207
Abs Components Chart
207
Removing the Hydraulic Unit
211
Checking the Hydraulic Unit
211
Checking the Proportioning Valve and Metering Valve
212
Installing the Hydraulic Unit
212
Hydraulic Unit Operation Tests
213
Trial Run
216
Handlebars
217
Removing the Handlebars
219
Checking the Handlebars
219
Installing the Handlebars
219
Front Fork
222
Removing the Front Fork Legs
225
Disassembling the Front Fork Legs
225
Checking the Front Fork Legs
226
Assembling the Front Fork Legs
227
Installing the Front Fork Legs
230
Steering Head
232
Removing the Lower Bracket
234
Checking the Steering Head
234
Installing the Steering Head
234
Rear Shock Absorber Assembly
236
Handling the Rear Shock Absorber
238
Disposing of a Rear Shock Absorber
238
Removing the Rear Shock Absorber Assembly
238
Checking the Rear Shock Absorber Assembly
238
Checking the Connecting Arm and Relay Arm
239
Installing the Relay Arm
239
Installing the Rear Shock Absorber Assembly
239
Swingarm
242
Removing the Swingarm
242
Checking the Swingarm
242
Installing the Swingarm
242
Shaft Drive
244
Troubleshooting
248
Checking the Final Drive Oil for Contamination and Checking the Shaft Drive for Leaks
249
Measuring the Final Gear Backlash
249
Adjusting the Final Gear Backlash
250
Measuring the Ring-Gear-To-Stopper-Bolt Clearance
251
Adjusting the Ring-Gear-To-Stopper-Bolt Clearance
251
Disassembling the Final Drive Assembly
252
Removing and Installing the Bearings
253
Aligning the Final Drive Pinion Gear and Ring Gear
253
Checking the Drive Shaft
256
Installing the Drive Shaft and Final Drive Assembly
257
Engine
259
Engine Removal
262
Installing the Engine
267
Removing the Engine
267
Camshafts
270
Removing the Camshafts
272
Checking the Camshafts
273
Checking the Camshaft Sprockets
274
Checking the Timing Chain Guides
274
Checking the Timing Chain Tensioner
274
Installing the Camshafts
275
Cylinder Head
279
Removing the Cylinder Head
280
Checking the Cylinder Head
280
Installing the Cylinder Head
280
Valves and Valve Springs
283
Removing the Valves
283
Checking the Valves and Valve Guides
283
Checking the Valve Seats
285
Checking the Valve Springs
286
Checking the Valve Lifters
287
Installing the Valves
287
Generator and Starter Clutch
289
Removing the Generator
292
Removing the Starter Clutch
292
Checking the Starter Clutch
292
Installing the Starter Clutch
293
Installing the Generator
293
Pickup Rotor
295
Removing the Pickup Rotor
296
Installing the Pickup Rotor
296
Electric Starter
298
Checking the Starter Motor
300
Assembling the Starter Motor
301
Clutch
309
Removing the Clutch
309
Checking the Friction Plates
309
Checking the Clutch Plates
310
Checking the Clutch Spring Plate
310
Checking the Clutch Housing
310
Checking the Clutch Boss
310
Checking the Pressure Plate
311
Checking the Clutch Push Rods
311
Checking the Primary Driven Gear
311
Installing the Clutch
311
Disassembling the Clutch Master Cylinder
312
Checking the Clutch Master Cylinder
313
Assembling the Clutch Master Cylinder
313
Installing the Clutch Master Cylinder
313
Removing the Clutch Release Cylinder
315
Checking the Clutch Release Cylinder
315
Assembling the Clutch Release Cylinder
315
Installing the Clutch Release Cylinder
315
Shift Shaft
317
Checking the Shift Shaft
318
Checking the Stopper Lever
318
Installing the Shift Shaft
318
Oil Pump
319
Checking the Oil Pump
322
Checking the Relief Valve
322
Checking the Oil Delivery Pipes
322
Checking the Oil Strainer
323
Assembling the Oil Pump
323
Installing the Oil Pan
323
Middle Gear
324
Removing the Middle Drive Shaft Assembly
328
Disassembling the Middle Drive Shaft Assembly
328
Disassembling the Middle Driven Shaft Assembly
328
Checking the Middle Drive Shaft Assembly
329
Checking the Middle Driven Shaft Assembly
329
Assembling the Middle Drive Shaft Assembly
329
Assembling the Middle Driven Shaft Assembly
329
Installing the Middle Drive Shaft Assembly
330
Installing the Middle Driven Shaft Assembly
331
Installing the Middle Gear Case Cover
331
Measuring the Middle Gear Backlash
332
Adjusting the Middle Gear Backlash
332
Aligning the Middle Gear
333
Crankcase
335
Disassembling the Crankcase
339
Checking the Crankcase
339
Checking the Oil Delivery Pipes
339
Checking the Bearings and Oil Seal
339
Checking the Timing Chain and Oil Pump Drive Chain
339
Assembling the Crankcase
339
Connecting Rods and Pistons
343
Removing the Connecting Rods and Pistons
344
Checking the Cylinders and Pistons
344
Checking the Piston Rings
345
Checking the Piston Pin
346
Checking the Connecting Rods
347
Installing the Connecting Rods and Pistons
348
Crankshaft
351
Removing the Crankshaft Journal Bearings
352
Checking the Oil Nozzles
352
Checking the Crankshaft
352
Installing the Crankshaft
353
Transmission
355
Removing the Transmission
360
Checking the Shift Forks
360
Checking the Shift Drum Assembly
360
Checking the Transmission
360
Assembling the Main Axle and Drive Axle
361
Installing the Transmission
362
Balancers
364
Checking the Balancers
366
Installing the Front Balancer
366
Installing the Rear Balancer
367
Cooling System
371
Radiator
372
Checking the Radiator
374
Installing the Radiator
374
Oil Cooler
376
Checking the Oil Cooler
376
Installing the Oil Cooler
376
Thermostat
377
Checking the Thermostat
379
Installing the Thermostat Assembly
379
Water Pump
381
Disassembling the Water Pump
383
Checking the Water Pump
383
Assembling the Water Pump
383
Installing the Water Pump
384
Fuel System
387
Fuel Tank
388
Removing the Fuel Tank
389
Removing the Fuel Pump
389
Checking the Fuel Pump Body
389
Installing the Fuel Pump
389
Installing the Fuel Tank
389
Throttle Bodies
391
Checking the Injectors
394
Checking the Throttle Bodies
394
Checking the Fuel Pressure
394
Adjusting the Throttle Position Sensor
394
Air Induction System
396
Checking the Pressure Regulator
400
Checking the Air Induction System
400
Installing the Air Induction System
400
Electrical System
401
General Information
402
Ignition System
409
Electric Starting System
412
Checking the Switches
552
Troubleshooting
575
Wiring Diagram
580
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Yamaha 2006 FJR1300AV Service Manual (150 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 8.43 MB
Table of Contents
Table of Contents
6
How to Use this Manual
4
Symbols
5
Features
10
OUTLINE of the YCC-S (Yamaha Chip Controlled-Shift) SYSTEM
10
Special Tools
13
Tool Name/Tool no
14
General Specifications
15
Engine Specifications
16
Chassis Specifications
17
Electrical Specifications
18
Tightening Torques
19
Engine Tightening Torques
19
Chassis Tightening Torques
20
Cable Routing
22
Periodic Maintenance
38
Introduction
38
Periodic Maintenance and Lubrication Chart
38
Engine
40
Checking the Clutch Fluid Level
40
Bleeding the Hydraulic Clutch System
40
Vacuum/Pressure Pump Gauge Set
41
90890-06756 Mityvac Brake Bleeding Tool YS-42423
41
Checking the Vehicle after Bleeding the Hydraulic Clutch System
42
Magnet Base B
42
Magnetic Base Stand
42
Yu-A8438
42
Dial Gauge & Stand Set
42
Cleaning the Air Filter Element
43
Chassis
44
Adjusting the Shift Pedal
44
Electrical System
45
Replacing the Headlight Bulbs
45
General Chassis
46
Handlebars
50
Installing the Handlebars
52
Shaft Drive
55
Installing the Drive Shaft and Final Drive Assembly
55
Fork Seal Driver Weight
55
Fork Seal Driver Attachment
55
Replacement 27 MM YM-A9409-1
55
Oil Seal Installing Tool
55
Engine Removal
56
Removing the Gear Position Sensor
58
Removing the Engine
58
Installing the Gear Position Sensor
58
Pivot Shaft Wrench
58
Frame Spanner Socket
58
Adjusting the Gear Position Sensor
59
Clutch
60
Breaking in the Friction Plates after Replacement
64
Replacing the Clutch Master Cylinder
64
Installing the Clutch Actuator
65
Shift Actuator and Shift Rod
66
Removing the Shift Actuator
68
Checking the Shift Rod
68
Installing the Foot Shift Switch
68
Adjusting the Foot Shift Switch
69
Installing the Left Footrest Assembly
70
Installing the Shift Actuator
70
Shift Shaft
72
Installing the Shift Shaft
72
Middle Gear
73
Crankcase
75
Transmission
77
Electric Starting System
80
Circuit Diagram (1/2)
80
Circuit Diagram (2/2)
82
Starting Circuit Cut-Off System Operation
84
Troubleshooting
85
Grip Warmer System
88
Circuit Diagram (1/2)
88
Circuit Diagram (2/2)
90
Troubleshooting
92
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM
94
Circuit Diagram (1/2)
94
Circuit Diagram (2/2)
96
Troubleshooting
98
Maintenance of the Mcu
99
MCU (Motor Control Unit) SELF-DIAGNOSTIC FUNCTION
99
Self-Diagnostic Function Table
100
Troubleshooting Method
103
Diagnostic Mode
104
Troubleshooting Details
108
Electrical Components
132
Checking the Switches
136
Checking the Relays
139
Checking the Ycc-S Speed Sensor
141
Checking the Gear Position Sensor
141
Checking the Foot Shift Switch
142
Checking the Grip Warmers
142
Checking the Grip Warmer Control Unit
143
Checking the Diode 2
143
Wiring Diagram
145
Fjr1300As(V) 2006 Wiring Diagram
149
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