Yamaha FJR 1300 AE 2014 Manuals

Manuals and User Guides for Yamaha FJR 1300 AE 2014. We have 1 Yamaha FJR 1300 AE 2014 manual available for free PDF download: Service Manual

Yamaha FJR 1300 AE 2014 Service Manual

Yamaha FJR 1300 AE 2014 Service Manual (694 pages)

Brand: Yamaha | Category: Motorcycle | Size: 21.8 MB

Table of Contents

Table of Contents

7
- General Information
  9
- Identification
  10
- Vehicle Identification Number
  10
- Model Label
  10
- Outline of the Fi System
  11
- Fi System
  12
- YCC-T (Yamaha Chip Controlled Throttle)
  13
- Outline of the Cruise Control System
  15
- Outline of the Unified Brake System
  22
- Outline of the Abs
  24
- Abs Component Functions
  28
- Abs Operation
  34
- Abs Self-Diagnosis Function
  37
- Abs Warning Light and Operation
  40
- OUTLINE of the TCS (Traction Control System)
  41
- Multi-Function Meter Unit
  44
- Important Information
  55
- Preparation for Removal and Disassembly
  55
- Replacement Parts
  55
- Gaskets, Oil Seals and O-Rings
  55
- Lock Washers/Plates and Cotter Pins
  55
- Rubber Parts
  56
- Circlips
  56
- Bearings and Oil Seals
  56
- Basic Service Information
  57
- Quick Fasteners
  57
- Electrical System
  58
- Special Tools
  62
Specifications

71
- General Specifications
  72
- Engine Specifications
  73
- Chassis Specifications
  81
- Electrical Specifications
  84
- General Tightening Torque Specifications
  87
- Tightening Torques
  87
- Engine Tightening Torques
  88
- Chassis Tightening Torques
  93
- Engine
  99
- Lubrication Points and Lubricant Types
  99
- Chassis
  101
- Engine Oil Lubrication Chart
  102
- Lubrication System Chart and Diagrams
  102
- Lubrication Diagrams
  104
- Cooling System Diagrams
  114
- Cable Routing
  118
Periodic Checks and Adjustments

139
- General Maintenance and Lubrication Chart
  142
- Introduction
  142
- Periodic Maintenance
  142
- Periodic Maintenance Chart for the Emission Control System
  142
- Checking the Fuel Line
  145
- Checking the Spark Plugs
  145
- Adjusting the Valve Clearance
  146
- Checking the Engine Idling Speed
  148
- Synchronizing the Throttle Bodies
  149
- Checking the Exhaust System
  150
- Adjusting the Exhaust Gas Volume
  151
- Checking the Air Induction System
  152
- Checking the Crankcase Breather Hose
  152
- Cleaning the Air Filter Element
  152
- Adjusting the Clutch Lever
  153
- Checking the Clutch Fluid Level
  153
- Adjusting the Front Disc Brake
  154
- Bleeding the Hydraulic Clutch System
  154
- Checking the Brake Fluid Level
  155
- Bleeding the Hydraulic Brake System (Abs)
  156
- Adjusting the Rear Disc Brake
  157
- Checking the Front Brake Pads
  157
- Checking the Brake Hoses
  158
- Checking the Rear Brake Pads
  158
- Checking the Tires
  158
- Checking the Wheels
  158
- Checking and Adjusting the Steering Head
  160
- Checking the Swingarm Pivot
  160
- Checking the Wheel Bearings
  160
- Lubricating the Swingarm Pivot
  160
- Checking the Chassis Fasteners
  161
- Lubricating the Levers
  161
- Lubricating the Pedals
  161
- Lubricating the Steering Head
  161
- Adjusting the Damping Force of the Front Fork Legs and Rear Shock Absorber Assembly
  162
- Checking the Centerstand
  162
- Checking the Front Fork
  162
- Checking the Sidestand
  162
- Checking the Sidestand Switch
  162
- Lubricating the Centerstand
  162
- Lubricating the Sidestand
  162
- Adjusting the Preload of the Rear Shock Absorber Assembly
  163
- Checking the Rear Suspension
  163
- Checking the Engine Oil Level
  165
- Lubricating the Rear Suspension
  165
- Changing the Engine Oil
  166
- Measuring the Engine Oil Pressure
  167
- Checking the Coolant Level
  168
- Checking the Cooling System
  168
- Changing the Coolant
  169
- Checking the Final Gear Oil Level
  170
- Adjusting the Rear Brake Light Switch
  171
- Changing the Final Gear Oil
  171
- Checking the Brake Light Switches
  171
- Checking and Lubricating the Cables
  172
- Checking the Throttle Grip Operation
  172
- Adjusting the Headlight Beams
  173
- Checking the Switches, Lights and Signals
  173
- Replacing the Headlight Bulbs
  173
Chassis

175
- General Chassis
  178
- Installing the Center Rear Cowling
  179
- Installing the Rear Cowlings
  179
- Removing the Center Rear Cowling
  179
- Removing the Rear Cowlings
  179
- Installing the Seats
  180
- Installing the Side Covers
  180
- Removing the Side Covers
  180
- Adjusting the Side Panels
  184
- Removing the Front Cowling Inner Panel
  184
- Installing the Front Cowling Inner Panel
  185
- Installing the Side Cowlings
  186
- Removing the Side Cowlings
  186
- Installing the Center Covers
  189
- Installing the Windshield Bracket Covers
  189
- Removing the Center Covers
  189
- Removing the Windshield Bracket Covers
  189
- Installing the Front Cowling Assembly
  190
- Installing the Headlight Beam Adjusting Knob Joints
  190
- Installing the Windshield Drive Unit
  193
- Front Wheel
  199
- Checking the Front Wheel
  201
- Disassembling the Front Wheel
  201
- Removing the Front Wheel
  201
- Maintenance of the Front Wheel Sensor and Sensor Rotor
  202
- Assembling the Front Wheel
  203
- Adjusting the Front Wheel Static Balance
  204
- Installing the Front Wheel (Front Brake Discs)
  205
- Rear Wheel
  207
- Disassembling the Rear Wheel
  209
- Removing the Rear Wheel
  209
- Assembling the Rear Wheel
  210
- Checking the Rear Wheel
  210
- Maintenance of the Rear Wheel Sensor and Sensor Rotor
  210
- Adjusting the Rear Wheel Static Balance
  211
- Installing the Rear Wheel (Rear Brake Disc)
  212
- Front Brake
  214
- Checking the Front Brake Discs
  219
- Introduction
  219
- Replacing the Front Brake Pads
  220
- Disassembling the Front Brake Calipers
  221
- Removing the Front Brake Calipers
  221
- Assembling the Front Brake Calipers
  222
- Checking the Front Brake Calipers
  222
- Installing the Front Brake Calipers
  222
- Removing the Front Brake Master Cylinder
  223
- Assembling the Front Brake Master Cylinder
  224
- Checking the Front Brake Master Cylinder
  224
- Installing the Front Brake Master Cylinder
  224
- Rear Brake
  226
- Checking the Rear Brake Disc
  232
- Introduction
  232
- Replacing the Rear Brake Pads
  232
- Removing the Rear Brake Caliper
  233
- Assembling the Rear Brake Caliper
  234
- Checking the Rear Brake Caliper
  234
- Disassembling the Rear Brake Caliper
  234
- Installing the Rear Brake Caliper
  235
- Checking the Rear Brake Master Cylinder
  236
- Removing the Rear Brake Master Cylinder
  236
- Assembling the Rear Brake Master Cylinder
  237
- Installing the Rear Brake Master Cylinder
  237
- Abs (Anti-Lock Brake System)
  239
- Abs Components Chart
  239
- Removing the Hydraulic Unit Assembly
  243
- Checking the Brake Pipes
  244
- Checking the Hydraulic Unit Assembly
  244
- Checking the Proportioning Valve and Metering Valve
  244
- Installing the Hydraulic Unit Assembly
  244
- Hydraulic Unit Operation Tests
  247
- Checking the Abs Warning Light
  250
- Handlebars
  251
- Adjusting the Handlebar Position
  253
- Removing the Handlebars
  253
- Checking the Handlebars
  254
- Installing the Handlebars
  254
- Front Fork
  257
- Disassembling the Front Fork Legs
  259
- Removing the Front Fork Legs
  259
- Checking the Front Fork Legs
  260
- Assembling the Front Fork Legs
  261
- Installing the Front Fork Legs
  265
- Steering Head
  266
- Checking the Steering Head
  268
- Installing the Steering Head
  268
- Removing the Lower Bracket
  268
- Rear Shock Absorber Assembly
  270
- Handling the Rear Shock Absorber
  275
- Removing the Rear Fender Assembly
  275
- Checking the Connecting Arm and Relay Arm
  276
- Checking the Rear Shock Absorber Assembly
  276
- Disposing of a Rear Shock Absorber
  276
- Removing the Rear Shock Absorber Assembly
  276
- Adjusting the Rear Shock Absorber Assembly DC Motor
  277
- Installing the Rear Shock Absorber Assembly
  277
- Replacing the Stepping Motor
  277
- Installing the Rear Fender Assembly
  278
- Swingarm
  280
- Checking the Swingarm
  282
- Installing the Swingarm
  282
- Removing the Swingarm
  282
- Shaft Drive
  284
- Troubleshooting
  288
- Checking the Final Drive Oil for Contamination and Checking the Shaft Drive for Leaks
  290
- Measuring the Final Gear Backlash
  290
- Adjusting the Final Gear Backlash
  291
- Adjusting the Ring-Gear-To-Stopper-Bolt Clearance
  292
- Measuring the Ring-Gear-To-Stopper-Bolt Clearance
  292
- Disassembling the Final Drive Assembly
  293
- Removing and Installing the Bearings
  293
- Aligning the Final Drive Pinion Gear and Ring Gear
  294
- Checking the Drive Shaft
  297
- Installing the Drive Shaft and Final Drive Assembly
  297
Engine

301
- Engine Inspection
  304
- Measuring the Compression Pressure
  304
- Engine Removal
  306
- Engine
  310
- Installing the Engine
  311
- Removing the Engine
  311
- Camshafts
  314
- Removing the Camshafts
  316
- Checking the Camshafts
  317
- Checking the Camshaft Sprockets
  318
- Checking the Timing Chain Guides
  318
- Checking the Timing Chain Tensioner
  318
- Installing the Camshafts
  319
- Cylinder Head
  323
- Checking the Cylinder Head
  324
- Installing the Cylinder Head
  324
- Removing the Cylinder Head
  324
- Checking the Valves and Valve Guides
  327
- Removing the Valves
  327
- Valves and Valve Springs
  327
- Checking the Valve Seats
  329
- Checking the Valve Springs
  330
- Checking the Valve Lifters
  331
- Installing the Valves
  331
- Generator and Starter Clutch
  334
- Checking the Starter Clutch
  335
- Removing the Generator
  335
- Removing the Starter Clutch
  335
- Installing the Generator
  336
- Installing the Starter Clutch
  336
- Pickup Rotor
  338
- Installing the Pickup Rotor
  339
- Removing the Pickup Rotor
  339
- Electric Starter
  341
- Checking the Starter Motor
  343
- Assembling the Starter Motor
  344
- Clutch
  345
- Removing the Clutch
  351
- Checking the Clutch Plates
  352
- Checking the Clutch Spring Plate
  352
- Checking the Friction Plates
  352
- Checking the Clutch Boss
  353
- Checking the Clutch Housing
  353
- Checking the Clutch Push Rods
  353
- Checking the Pressure Plate
  353
- Checking the Primary Driven Gear
  353
- Installing the Clutch
  354
- Checking the Clutch Master Cylinder
  355
- Disassembling the Clutch Master Cylinder
  355
- Assembling the Clutch Master Cylinder
  356
- Installing the Clutch Master Cylinder
  356
- Assembling the Clutch Release Cylinder
  357
- Checking the Clutch Release Cylinder
  357
- Removing the Clutch Release Cylinder
  357
- Installing the Clutch Release Cylinder
  358
- Shift Shaft
  359
- Adjusting the Shift Pedal
  360
- Checking the Shift Shaft
  360
- Checking the Stopper Lever
  360
- Installing the Shift Shaft
  360
- Oil Pump
  362
- Checking the Oil Delivery Pipes
  365
- Checking the Oil Pump
  365
- Checking the Relief Valve
  365
- Assembling the Oil Pump
  366
- Checking the Oil Strainer
  366
- Installing the Oil Pan
  366
- Middle Gear
  367
- Disassembling the Middle Drive Shaft Assembly
  371
- Disassembling the Middle Driven Shaft Assembly
  371
- Removing the Middle Drive Shaft Assembly
  371
- Assembling the Middle Drive Shaft Assembly
  372
- Assembling the Middle Driven Shaft Assembly
  372
- Checking the Middle Drive Shaft Assembly
  372
- Checking the Middle Driven Shaft Assembly
  372
- Installing the Middle Drive Shaft Assembly
  373
- Installing the Middle Driven Shaft Assembly
  374
- Installing the Middle Gear Case Cover
  374
- Adjusting the Middle Gear Backlash
  375
- Measuring the Middle Gear Backlash
  375
- Aligning the Middle Gear
  376
- Crankcase
  379
- Assembling the Crankcase
  383
- Checking the Bearings and Oil Seal
  383
- Checking the Crankcase
  383
- Checking the Oil Delivery Pipes
  383
- Checking the Timing Chain and Oil Pump Drive Chain
  383
- Disassembling the Crankcase
  383
- Installing the Oil Pump Drive Sprocket
  386
- Checking the Cylinders and Pistons
  388
- Connecting Rods and Pistons
  388
- Removing the Connecting Rods and Pistons
  388
- Checking the Piston Rings
  389
- Checking the Piston Pin
  390
- Checking the Connecting Rods
  391
- Installing the Connecting Rods and Pistons
  392
- Crankshaft
  395
- Checking the Crankshaft
  396
- Checking the Oil Nozzles
  396
- Removing the Crankshaft Journal Bearings
  396
- Installing the Crankshaft
  397
- Transmission
  399
- Checking the Shift Drum Assembly
  404
- Checking the Shift Forks
  404
- Checking the Transmission
  404
- Removing the Transmission
  404
- Assembling the Main Axle and Drive Axle
  405
- Installing the Transmission
  406
- Balancers
  410
- Checking the Balancers
  410
- Installing the Front Balancer
  410
- Installing the Rear Balancer
  411
Cooling System

415
- Radiator
  416
- Checking the Radiator
  418
- Installing the Radiator
  418
- Removing the Radiator
  418
- Oil Cooler
  419
- Checking the Oil Cooler
  420
- Installing the Oil Cooler
  420
- Thermostat
  421
- Checking the Thermostat
  423
- Installing the Thermostat Assembly
  423
- Water Pump
  425
- Assembling the Water Pump
  427
- Checking the Water Pump
  427
- Disassembling the Water Pump
  427
- Installing the Water Pump
  428
Fuel System

431
- Fuel Tank
  432
- Checking the Fuel Pump Body
  433
- Installing the Fuel Pump
  433
- Installing the Fuel Tank
  433
- Removing the Fuel Pump
  433
- Removing the Fuel Tank
  433
- Throttle Bodies
  435
- Checking and Cleaning the Throttle Bodies
  438
- Checking the Injectors
  438
- Checking the Injectors (before Removing)
  438
- Removing the Injectors
  438
- Checking the Injector Pressure
  440
- Checking the Throttle Body Joints
  440
- Installing the Injectors
  440
- Replacing the Throttle Bodies
  440
- Checking the Fuel Pressure
  441
- Adjusting the Accelerator Position Sensor
  442
- Adjusting the Throttle Position Sensor
  442
- Air Induction System
  444
- Checking the Air Induction System
  448
- Installing the Air Induction System
  448
- Electrical System
  449
- Troubleshooting
  667

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