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FJR1300N 2001
Yamaha FJR1300N 2001 Manuals
Manuals and User Guides for Yamaha FJR1300N 2001. We have
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Yamaha FJR1300N 2001 manual available for free PDF download: Service Manual
Yamaha FJR1300N 2001 Service Manual (617 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 17.15 MB
Table of Contents
General Information
6
Specifications
6
Periodic Checks and Adjustments
6
Chassis
6
Engine
6
Cooling System
6
Electrical System
6
Troubleshooting
6
Table of Contents
7
Chapter 1 General Information
12
Motorcycle Identification
12
Vehicle Identification Number
12
Model Code
12
Features
13
Outline
13
Fi System
14
Components
16
Gen Info
28
Fuel Injection System
28
Three-Way Catalytic Converter System
37
Air Induction System
41
Components
42
Important Information
46
Preparation for Removal and Disassembly
46
Replacement Parts
46
Gaskets, Oil Seals and O-Rings
46
Lock Washers/Plates and Cotter Pins
47
Bearings and Oil Seals
47
Circlips
47
Checking the Connections
48
Special Tools
49
Spec
54
Chapter 2 Specifications
57
General Specifications
57
Engine Specifications
58
Chassis Specifications
67
Electrical Specifications
71
Conversion Table
74
General Tightening Torque Specifications
74
Tightening Torques
75
Engine Tightening Torques
75
Chassis Tightening Torques
79
Lubrication Points and Lubricant Types
81
Engine Lubrication Points and Lubricant Types
81
Chassis Lubrication Points and Lubricant Types
83
Oil Flow Diagrams
84
Cooling System Diagrams
94
Cable Routing
98
Chk Adj
113
Chapter 3 Periodic Checks and Adjustments
116
Introduction
116
Periodic Maintenance and Lubrication Intervals
116
Seats and Fuel Tank
118
Seats
118
Fuel Tank
119
T-Bar
120
Removing the Fuel Tank
121
Removing the Fuel Pump
121
Installing the Fuel Pump
122
Installing the Fuel Hose
122
Installing the T-Bar
122
Air Filter Case
123
Cowlings and Covers
125
Cowlings
125
Covers
129
Engine
130
Adjusting the Valve Clearance
130
Synchronizing the Throttle Bodies
136
Checking and Adjusting the Exhaust Gas at Idle
139
Adjusting the Exhaust Gas Volume
141
Checking the Exhaust Gas at Idle
142
Adjusting the Engine Idling Speed
143
Adjusting the Throttle Cable Free Play
145
Checking the Spark Plugs
147
Checking the Ignition Timing
148
Measuring the Compression Pressure
150
Checking the Engine Oil Level
152
Changing the Engine Oil
154
Measuring the Engine Oil Pressure
156
Adjusting the Clutch Lever
158
Checking the Clutch Fluid Level
158
Bleeding the Hydraulic Clutch System
159
Cleaning the Air Filter Element
161
Checking the Throttle Body Joints
162
Checking the Fuel and Vacuum Hoses
163
Checking the Crankcase Breather Hose
163
Checking the Exhaust System
164
Checking the Coolant Level
165
Checking the Cooling System
166
Changing the Coolant
167
Adjusting the Front Brake
170
Adjusting the Rear Brake
171
Checking the Brake Fluid Level
172
Checking the Brake Pads
173
Adjusting the Rear Brake Light Switch
174
Checking the Brake Hoses
174
Bleeding the Hydraulic Brake System
175
Adjusting the Shift Pedal
176
Checking the Final Drive Oil Level
177
Changing the Final Drive Oil
177
Checking and Adjusting the Steering Head
178
Checking the Front Fork
180
Adjusting the Front Fork Legs
181
Adjusting the Rear Shock Absorber Assembly
183
Checking the Tires
185
Checking the Wheels
186
Checking and Lubricating the Cables
187
Lubricating the Levers and Pedals
187
Lubricating the Sidestand
187
Lubricating the Centerstand
188
Lubricating the Rear Suspension
188
Electrical System
189
Checking and Charging the Battery
189
Checking the Fuses
194
Replacing the Headlight Bulbs
196
Adjusting the Headlight Beams
197
Chas
200
Front Wheel and Brake Discs
203
Chapter 4
205
Removing the Front Wheel
205
Checking the Front Wheel
205
Checking the Brake Discs
207
Installing the Front Wheel
208
Adjusting the Front Wheel Static Balance
209
Rear Wheel and Brake Disc
211
Removing the Rear Wheel
213
Checking the Rear Wheel
213
Installing the Rear Wheel
214
Adjusting the Rear Wheel Static Balance
214
Front and Rear Brakes
215
Front Brake Pads
215
Rear Brake Pads
216
Replacing the Front Brake Pads
217
Replacing the Rear Brake Pads
219
Front Brake Master Cylinder
222
Rear Brake Master Cylinder
225
Disassembling the Front Brake Master Cylinder
228
Disassembling the Rear Brake Master Cylinder
228
Checking the Front and Rear Brake Master Cylinders
229
Assembling and Installing the Front Brake Master Cylinder
230
Assembling the Rear Brake Master Cylinder
232
Front Brake Calipers
235
Rear Brake Caliper
237
Disassembling the Front Brake Calipers
239
Disassembling the Rear Brake Caliper
240
Checking the Front and Rear Brake Calipers
241
Assembling and Installing the Front Brake Calipers
242
Assembling and Installing the Rear Brake Caliper
244
Hydraulic Clutch
248
Clutch Master Cylinder
248
Disassembling the Clutch Master Cylinder
251
Checking the Clutch Master Cylinder
252
Assembling and Installing the Clutch Master Cylinder
253
Clutch Release Cylinder
257
Disassembling the Clutch Release Cylinder
258
Checking the Clutch Release Cylinder
259
Assembling and Installing the Clutch Release Cylinder
259
Removing the Front Fork Legs
265
Disassembling the Front Fork Legs
265
Checking the Front Fork Legs
267
Assembling the Front Fork Legs
268
Installing the Front Fork Legs
272
Handlebars
273
Left Handlebar
273
Right Handlebar
274
Installing the Handlebars
274
Steering Head
279
Removing the Lower Bracket
281
Checking the Steering Head
281
Installing the Steering Head
282
Rear Shock Absorber Assembly and Relay Arm
284
Removing the Rear Shock Absorber Assembly
284
Installing the Rear Shock Absorber Assembly
284
Swingarm
289
Removing the Swingarm
291
Checking the Swingarm
291
Installing the Swingarm
292
Shaft Drive
294
Troubleshooting
294
Checking the Final Drive Oil for Contamination and Checking the Shaft Drive for Leaks
297
Measuring the Ring Gear Backlash
298
Adjusting the Ring Gear Backlash
299
Measuring the Ring-Gear-To-Stopper-Bolt Clearance
300
Adjusting the Ring-Gear-To-Stopper-Bolt Clearance
300
Removing the Left Footrest Bracket
306
Disassembling the Final Drive Assembly
306
Removing and Installing the Ring Gear Bearings
307
Aligning the Final Drive Pinion Gear and Ring Gear
309
Checking the Drive Shaft
314
Installing the Universal Joint and Final Drive Assembly
314
Eng
315
Chapter 5 Engine
320
Mufflers and Exhaust Pipe Assembly
320
Leads and Hoses
321
Engine
323
Installing the Engine
325
Camshafts
327
Cylinder Head Cover
327
Camshafts
328
Removing the Camshafts
330
Checking the Camshafts
331
Checking the Camshaft Sprockets
332
Checking the Timing Chain Tensioner
333
Installing the Camshafts
333
Cylinder Head
338
Removing the Cylinder Head
339
Checking the Cylinder Head
339
Installing the Cylinder Head
340
Valves and Valve Springs
343
Removing the Valves
344
Checking the Valves and Valve Guides
345
Checking the Valve Seats
347
Checking the Valve Springs
349
Checking the Valve Lifters
350
Installing the Valves
351
Generator and Starter Clutch
353
Generator Rotor and Starter Clutch
353
Stator Assembly
355
Removing the Generator
356
Removing the Starter Clutch
357
Checking the Starter Clutch
357
Installing the Starter Clutch
358
Installing the Generator
358
Pickup Coil Rotor
360
Removing the Pickup Coil Rotor
362
Installing the Pickup Coil Rotor
362
Clutch Cover
364
Clutch
364
Removing the Clutch
367
Checking the Friction Plates
368
Checking the Clutch Plates
369
Checking the Clutch Spring Plate
369
Checking the Clutch Housing
369
Checking the Clutch Boss
370
Checking the Pressure Plate
370
Checking the Clutch Push Rods
370
Checking the Primary Driven Gear
370
Installing the Clutch
371
Shift Shaft
374
Checking the Shift Shaft
376
Checking the Stopper Lever
376
Installing the Shift Shaft
376
Oil Pan and Oil Pump
378
Oil Pump
379
Removing the Oil Pan
381
Checking the Oil Pump
381
Checking the Relief Valve
382
Checking the Oil Delivery Pipes
382
Checking the Oil Strainer
382
Assembling the Oil Pump
382
Installing the Oil Pump
383
Installing the Oil Strainer
383
Installing the Oil Pan
383
Middle Gear
385
Removing the Middle Gear
389
Disassembling the Middle Drive Shaft Assembly
390
Disassembling the Middle Driven Shaft Assembly
390
Checking the Middle Drive Shaft Assembly
390
Checking the Middle Driven Shaft Assembly
391
Assembling the Middle Drive Shaft Assembly
391
Assembling the Middle Driven Shaft Assembly
391
Installing the Middle Drive Shaft Assembly
392
Installing the Middle Driven Shaft Assembly
393
Measuring the Middle Gear Backlash
394
Adjusting the Middle Gear Backlash
395
Aligning the Middle Gear
398
Crankcase
401
Disassembling the Crankcase
405
Checking the Crankcase
406
Checking the Bearings and Oil Seals
406
Checking the Timing Chain and Oil Pump Drive Chain
407
Assembling the Crankcase
407
Connecting Rods and Pistons
411
Removing the Connecting Rods and Pistons
412
Checking the Cylinders and Pistons
413
Checking the Piston Rings
414
Checking the Piston Pins
415
Checking the Connecting Rods
417
Installing the Connecting Rods and Pistons
419
Crankshaft
423
Removing the Crankshaft
424
Checking the Crankshaft
424
Installing the Crankshaft
427
Transmission
428
Removing the Transmission
434
Checking the Shift Forks
434
Checking the Shift Drum Assembly
435
Checking the Transmission
435
Installing the Transmission
437
Balancers
438
Front Balancer
438
Rear Balancer
439
Checking the Balancer
440
Installing the Front Balancer
440
Installing the Rear Balancer
442
Cool
446
Chapter 6 Cooling System
449
Radiator
449
Checking the Radiator
451
Installing the Radiator
452
Oil Cooler
453
Checking the Oil Cooler
454
Installing the Oil Cooler
454
Thermostat
456
Checking the Thermostat
458
Assembling the Thermostat Assembly
459
Installing the Thermostat Assembly
459
Water Pump
460
Disassembling the Water Pump
463
Checking the Water Pump
463
Assembling the Water Pump
464
Installing the Water Pump
466
Chapter 7 Fuel Injection System
470
Wiring Diagram
471
Ecu's Self-Diagnostic Function
472
Substitute Characteristics Operation Control (Fail-Safe Action)
476
Troubleshooting
477
Throttle Bodies
502
Checking the Injector
506
Checking the Throttle Body
506
Checking the Pressure Regulator
506
Checking the Fuel Pump and Pressure Regulator Operation
507
Air Induction System
509
Air Injection
509
Air Cut-Off Valve
509
Air Cut-Off Valve Assembly and
511
Reed Valves
512
Checking the Air Induction System
513
Elec
514
Electrical Components
517
Chapter 8
517
Checking Switch Continuity
519
Checking the Switches
521
Checking the Bulbs and Bulb Sockets
523
Types of Bulbs
523
Checking the Condition of the Bulbs
523
Checking the Condition of the Bulb Sockets
525
Ignition System
526
Circuit Diagram
526
Troubleshooting
527
Electric Starting System
531
Circuit Diagram
531
Starting Circuit Cut-Off System Operation
532
Troubleshooting
533
Starter Motor
537
Checking the Starter Motor
540
Assembling the Starter Motor
542
Charging System
543
Circuit Diagram
543
Troubleshooting
544
Lighting System
546
Circuit Diagram
546
Troubleshooting
547
Checking the Lighting System
549
Signaling System
553
Circuit Diagram
553
Troubleshooting
555
Checking the Signaling System
556
Cooling System
563
Circuit Diagram
563
Troubleshooting
564
Fuel Injection System
568
Checking the Fuel Pump
575
Checking and Adjusting the Throttle Position Sensor
576
Windshield Drive System
580
Circuit Diagram
580
Trbl Shtg
583
Troubleshooting
584
Chapter 9
587
Engine
587
Fuel System
587
Electrical Systems
587
Starting Problems
587
Incorrect Engine Idling Speed
587
Engine
588
Fuel System
588
Poor Medium-And-High-Speed Performance
588
Faulty Gear Shifting
588
Shifting Is Difficult
588
Shift Pedal Does Not Move
588
Jumps out of Gear
588
Faulty Clutch
589
Clutch Slips
589
Clutch Drags
589
Overheating
589
Engine
589
Fuel System
589
Chassis
589
Electrical Systems
589
Poor Braking Performance
590
Faulty Front Fork Legs
590
Leaking Oil
590
Malfunction
590
Unstable Handling
591
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