User Manuals: Yamaha 2006 FJR1300AV Motorcycle

Manuals and User Guides for Yamaha 2006 FJR1300AV Motorcycle. We have 2 Yamaha 2006 FJR1300AV Motorcycle manuals available for free PDF download: Service Manual

Yamaha 2006 FJR1300AV Service Manual

Yamaha 2006 FJR1300AV Service Manual (586 pages)

Brand: Yamaha | Category: Motorcycle | Size: 32 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
- 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
- Front Wheel
  
  170
- Rear Wheel
  
  177
- Front Brake
  
  182
- 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
- Swingarm
  
  242
  - Removing the Swingarm
    242
  - Checking the Swingarm
    242
  - Installing the Swingarm
    242
- Shaft Drive
  
  244
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
- 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

Yamaha 2006 FJR1300AV Service Manual (150 pages)

Brand: Yamaha | Category: Motorcycle | Size: 8 MB

Table of Contents

Table of Contents

6
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
- 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
- Engine Removal
  
  56
- Clutch
  
  60
- Shift Actuator and Shift Rod
  
  66
- 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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