Yamaha FJR1300RC Motorcycle Maintenance Manuals

Manuals and User Guides for Yamaha FJR1300RC Motorcycle Maintenance. We have 2 Yamaha FJR1300RC Motorcycle Maintenance manuals available for free PDF download: Service Manual, Owner's Manual

Yamaha FJR1300RC Service Manual (572 pages)

Yamaha Motorcycles Service manual

Brand: Yamaha | Category: Motorcycle | Size: 20 MB

Periodic Checks and
4
General Information

5
Specifications

5
- Table of Contents
  7
Periodic Checks and Adjustments

5
Chassis

5
Engine

5
Cooling System

5
Fuel Injection System

5
Electrical System

5
Troubleshooting

17
Chapter 1 General Information

19
Motorcycle Identification

19
- Vehicle Identification Number
  19
- Model Code
  19
Features

20
- Outline
  20
- Fi System
  21
- Components
  23
- Fuel Injection System
  35
- Three-Way Catalytic Converter System
  44
- Air Induction System
  48
- Components
  49
Important Information

53
- Preparation for Removal and Disassembly
  53
- Replacement Parts
  53
- Gaskets, Oil Seals and O-Rings
  53
- Lock Washers/Plates and Cotter Pins
  54
- Bearings and Oil Seals
  54
- Circlips
  54
- Checking the Connections
  55
Special Tools

56
Chapter 2 Specifications

61
Spec

61
General Specifications

61
Engine Specifications

62
Chassis Specifications

71
Electrical Specifications

75
Conversion Table

78
General Tightening Torque Specifications

78
- Tightening Torques
  79
Lubrication Points and Lubricant Types

85
- Engine Lubrication Points and Lubricant Types
  85
- Chassis Lubrication Points and Lubricant Types
  87
Oil Flow Diagrams

88
Cooling System Diagrams

98
Cable Routing

102
Chapter 3 Periodic Checks and Adjustments

117
Introduction

117
Periodic Maintenance Chart for the Emission Control System

117
General Maintenance and Lubrication Chart

117
Chk Adj

117
Seats and Fuel Tank

120
- Seats
  120
- Fuel Tank
  121
- T-Bar
  122
- Removing the Fuel Tank
  123
- Removing the Fuel Pump
  123
- Installing the Fuel Pump
  124
- Installing the Fuel Hose
  124
- Installing the T-Bar
  124
Air Filter Case

125
Cowlings and Covers

127
- Cowlings
  127
- Covers
  131
Engine

132
- Adjusting the Valve Clearance
  132
- Synchronizing the Throttle Bodies
  138
- Adjusting the Engine Idling Speed
  141
- Adjusting the Throttle Cable Free Play
  142
- Checking the Spark Plugs
  144
- Checking the Ignition Timing
  145
- Measuring the Compression Pressure
  147
- Checking the Engine Oil Level
  149
- Changing the Engine Oil
  151
- Measuring the Engine Oil Pressure
  153
- Adjusting the Clutch Lever
  155
- Checking the Clutch Fluid Level
  155
- Bleeding the Hydraulic Clutch System
  156
- Cleaning the Air Filter Element
  158
- Checking the Throttle Body Joints
  159
- Checking the Fuel and Vacuum Hoses
  160
- Checking the Crankcase Breather Hose
  160
- Checking the Exhaust System
  161
- Checking the Coolant Level
  162
- Checking the Cooling System
  163
- Changing the Coolant
  164
Chassis

167
- Adjusting the Front Brake
  167
- Adjusting the Rear Brake
  168
- Checking the Brake Fluid Level
  169
- Checking the Brake Pads
  170
- Adjusting the Rear Brake Light Switch
  171
- Checking the Brake Hoses
  171
- Bleeding the Hydraulic Brake System
  172
- Adjusting the Shift Pedal
  173
- Checking the Final Drive Oil Level
  174
- Changing the Final Drive Oil
  175
- Checking and Adjusting the Steering Head
  175
- Checking the Front Fork
  177
- Adjusting the Front Fork Legs
  178
- Adjusting the Rear Shock Absorber Assembly
  180
- Checking the Tires
  182
- Checking the Wheels
  183
- Checking and Lubricating the Cables
  184
- Lubricating the Levers and Pedals
  184
- Lubricating the Sidestand
  184
- Lubricating the Centerstand
  185
- Lubricating the Rear Suspension
  185
Electrical System

186
- Checking and Charging the Battery
  186
- Checking the Fuses
  191
- Replacing the Headlight Bulbs
  193
- Adjusting the Headlight Beams
  194
Chapter 4 Chassis

197
Front Wheel and Brake Discs

197
- Removing the Front Wheel
  199
- Checking the Front Wheel
  199
- Checking the Brake Discs
  201
- Installing the Front Wheel
  202
- Adjusting the Front Wheel Static Balance
  203
Chas

197
Rear Wheel and Brake Disc

205
- Removing the Rear Wheel
  207
- Checking the Rear Wheel
  207
- Installing the Rear Wheel
  208
- Adjusting the Rear Wheel Static Balance
  208
Front and Rear Brakes

209
Hydraulic Clutch

242
Front Fork

256
- Removing the Front Fork Legs
  259
- Disassembling the Front Fork Legs
  259
- Checking the Front Fork Legs
  261
- Assembling the Front Fork Legs
  262
- Installing the Front Fork Legs
  266
Handlebars

268
- Left Handlebar
  268
- Right Handlebar
  269
- Removing the Handlebars
  270
- Checking the Handlebars
  270
- Installing the Handlebars
  271
Steering Head

274
- Removing the Lower Bracket
  276
- Checking the Steering Head
  276
- Installing the Steering Head
  277
Rear Shock Absorber Assembly and Relay Arm

279
Swingarm

284
- Removing the Swingarm
  286
- Checking the Swingarm
  286
- Installing the Swingarm
  287
Shaft Drive

289
Chapter 5 Engine

310
- Mufflers and Exhaust Pipe Assembly
  310
- Leads and Hoses
  311
- Engine
  311
- Installing the Engine
  315
Eng

310
Camshafts

317
- Cylinder Head Cover
  317
- Camshafts
  318
- Removing the Camshafts
  320
- Checking the Camshafts
  321
- Checking the Camshaft Sprockets
  322
- Checking the Timing Chain Tensioner
  323
- Installing the Camshafts
  323
Cylinder Head

328
- Removing the Cylinder Head
  329
- Checking the Cylinder Head
  329
- Installing the Cylinder Head
  330
Valves and Valve Springs

332
- Removing the Valves
  333
- Checking the Valves and Valve Guides
  334
- Checking the Valve Seats
  336
- Checking the Valve Springs
  338
- Checking the Valve Lifters
  339
- Installing the Valves
  340
Generator and Starter Clutch

342
- Generator Rotor and Starter Clutch
  342
- Stator Assembly
  344
- Removing the Generator
  345
- Removing the Starter Clutch
  346
- Checking the Starter Clutch
  346
- Installing the Starter Clutch
  347
- Installing the Generator
  347
Pickup Coil Rotor

349
- Removing the Pickup Coil Rotor
  351
- Installing the Pickup Coil Rotor
  351
Clutch

353
- Clutch Cover
  353
- Clutch
  354
- Removing the Clutch
  356
- Checking the Friction Plates
  357
- Checking the Clutch Plates
  358
- Checking the Clutch Spring Plate
  358
- Checking the Clutch Housing
  358
- Checking the Clutch Boss
  359
- Checking the Pressure Plate
  359
- Checking the Clutch Push Rods
  359
- Checking the Primary Driven Gear
  359
- Installing the Clutch
  360
Shift Shaft

363
- Checking the Shift Shaft
  365
- Checking the Stopper Lever
  365
- Installing the Shift Shaft
  365
Oil Pan and Oil Pump

367
- Oil Pump
  369
- Removing the Oil Pan
  370
- Checking the Oil Pump
  370
- Checking the Relief Valve
  371
- Checking the Oil Delivery Pipes
  371
- Checking the Oil Strainer
  371
- Assembling the Oil Pump
  371
- Installing the Oil Pump
  372
- Installing the Oil Strainer
  372
- Installing the Oil Pan
  372
Middle Gear

374
Crankcase

390
- Disassembling the Crankcase
  394
- Checking the Crankcase
  395
- Checking the Bearings and Oil Seals
  395
- Checking the Timing Chain and Oil Pump Drive Chain
  396
- Assembling the Crankcase
  396
- Removing the Connecting Rods and Pistons
  401
- Checking the Cylinders and Pistons
  402
- Checking the Piston Rings
  403
- Checking the Piston Pins
  404
- Checking the Connecting Rods
  406
- Installing the Connecting Rods and Pistons
  408
Crankshaft

412
- Removing the Crankshaft
  413
- Checking the Crankshaft
  413
- Installing the Crankshaft
  416
Transmission

417
- Removing the Transmission
  423
- Checking the Shift Forks
  423
- Checking the Shift Drum Assembly
  424
- Checking the Transmission
  424
- Installing the Transmission
  426
Balancers

427
- Front Balancer
  427
- Rear Balancer
  428
- Checking the Balancer
  429
- Installing the Front Balancer
  429
- Installing the Rear Balancer
  431
Chapter 6 Cooling System

434
Cool

434
Radiator

434
- Checking the Radiator
  436
- Installing the Radiator
  437
Oil Cooler

438
- Checking the Oil Cooler
  439
- Installing the Oil Cooler
  439
Thermostat

441
Water Pump

445
- Disassembling the Water Pump
  448
- Checking the Water Pump
  448
- Assembling the Water Pump
  449
- Installing the Water Pump
  451
Chapter 7 Fuel Injection System

452
- Wiring Diagram
  453
- Ecu's Self-Diagnostic Function
  454
- Substitute Characteristics Operation Control (Fail-Safe Action)
  458
- Troubleshooting
  459
- Throttle Bodies
  484
- Checking the Injector
  488
- Checking the Throttle Body
  488
- Checking the Pressure Regulator
  488
- Checking the Fuel Pump and Pressure Regulator Operation
  489
Air Induction System

491
- Air Injection
  491
- Air Cut-Off Valve
  491
- Air Induction System Diagrams
  492
- Air Cut-Off Valve Assembly and Air Induction System Hoses
  493
- Reed Valves
  494
- Checking the Air Induction System
  495
Canister (for California Only)

496
Chapter 8

497
Elec

497
Electrical Components

497
Checking Switch Continuity

499
Checking the Switches

500
Checking the Bulbs and Bulb Sockets

502
Ignition System

505
- Circuit Diagram
  505
- Troubleshooting
  506
- Circuit Diagram
  510
- Starting Circuit Cut-Off System Operation
  511
- Troubleshooting
  512
Starter Motor

516
- Checking the Starter Motor
  519
- Assembling the Starter Motor
  521
Charging System

522
- Circuit Diagram
  522
- Troubleshooting
  523
Lighting System

525
- Circuit Diagram
  525
- Troubleshooting
  526
- Checking the Lighting System
  528
Signaling System

532
- Circuit Diagram
  532
- Troubleshooting
  534
- Checking the Signaling System
  535
Cooling System

542
- Circuit Diagram
  542
- Troubleshooting
  543
Fuel Injection System

547
- Circuit Diagram
  547
- Troubleshooting
  548
- Checking the Fuel Pump
  554
- Checking and Adjusting the Throttle
  555
- Position Sensor
  555
Windshield Drive System

559
- Circuit Diagram
  559
- Troubleshooting
  562
Chapter 9

562
- Engine
  562
- Fuel System
  562
Starting Problems

562
Incorrect Engine Idling Speed

563
- Engine
  563
- Fuel System
  563
Trbl Shtg

563
- Electrical Systems
  563
Poor Medium-And-High-Speed Performance

564
- Engine
  564
- Fuel System
  564
Faulty Gear Shifting

564
- Shifting Is Difficult
  564
- Shift Pedal Does Not Move
  564
- Jumps out of Gear
  564
Faulty Clutch

565
- Clutch Slips
  565
- Clutch Drags
  565
Overheating

565
- Engine
  565
- Cooling System
  565
- Fuel System
  565
- Chassis
  565
- Electrical Systems
  565
Poor Braking Performance

566
Faulty Front Fork Legs

566
- Leaking Oil
  566
- Malfunction
  566
Unstable Handling

567
Faulty Lighting or Signaling System

567
- Headlight Does Not Light
  567
- Headlight Bulb Burnt out
  567
- Tail/Brake Light Does Not Light
  567
- Tail/Brake Light Bulb Burnt out
  567
- Turn Signal Does Not Light
  567
- Turn Signal Blinks Slowly
  567
- Turn Signal Remains Lit
  567
- Turn Signal Blinks Quickly
  568
- Horn Does Not Sound
  568

Yamaha FJR1300RC Owner's Manual (119 pages)

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

Table of Contents

7
- Important Manual Information
  5
- Safety Information
  8
- Safe Riding
  9
  - Safety Information
    10
- Protective Apparel
  11
- Modifications
  11
- Loading and Accessories
  11
  - Safety Information
    11
  - Safety Information
    12
- Gasoline and Exhaust Gas
  13
- Location of Important Labels
  15
- Description
  18
  - Left View
    19
  - Right View
    20
  - Controls and Instruments
    21
Instrument and Control Functions

22
- Main Switch/Steering Lock
  23
- Instrument and Control Functions
  24
  - Indicator and Warning Lights
    24
  - Speedometer
    25
  - Tachometer
    25
  - Multi-Function Display
    26
  - Handlebar Switches
    28
  - Hazard Switch
    29
  - Clutch Lever
    29
  - Shift Pedal
    30
  - Brake Lever
    31
  - Brake Pedal
    31
  - Fuel Tank Cap
    32
  - Fuel
    33
  - Catalytic Converter
    34
  - Seats
    34
  - Storage Compartment
    35
  - Adjusting the Front Fork
    35
  - Adjusting the Shock Absorber Assembly
    37
  - Matching the Front and Rear Suspension Settings
    39
  - Locks for the Optional Side Cases and Travel Trunk
    40
  - Sidestand
    40
  - Ignition Circuit Cut-Off System
    41
- Pre-Operation Checks
  43
  - Pre-Operation Check List
    44
- Operation and Important Riding Points
  47
  - Operation and Important Riding Points
    49
  - Engine Break-In
    51
Periodic Maintenance and Minor Repair

53
Consumer Information

106
- Identification Numbers
  107
- Key Identification Number
  107
- Vehicle Identification Number
  107
- Consumer Information
  108
  - Model Label
    108
- Reporting Safety Defects
  109
- Motorcycle Noise Regulation
  110
- Maintenance Record
  111
- Yamaha Motor Corporation, U.s.a. Street and Enduro Motorcycle Limited Warranty
  113
- Yamaha Extended Service (Y.e.s.)
  115

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Yamaha FJR1300RC Service Manual (572 pages)

Table of Contents

General Information

Specifications

Periodic Checks and Adjustments

Chassis

Engine

Cooling System

Fuel Injection System

Electrical System

Troubleshooting

Chapter 1 General Information

Motorcycle Identification

Features

Important Information

Special Tools

Chapter 2 Specifications

Spec

General Specifications

Engine Specifications

Chassis Specifications

Electrical Specifications

Conversion Table

General Tightening Torque Specifications

Lubrication Points and Lubricant Types

Oil Flow Diagrams

Cooling System Diagrams

Cable Routing

Chapter 3 Periodic Checks and Adjustments

Introduction

Periodic Maintenance Chart for the Emission Control System

General Maintenance and Lubrication Chart

Chk Adj

Seats and Fuel Tank

Air Filter Case

Cowlings and Covers

Engine

Chassis

Electrical System

Chapter 4 Chassis

Front Wheel and Brake Discs

Chas

Rear Wheel and Brake Disc

Front and Rear Brakes

Hydraulic Clutch

Front Fork

Handlebars

Steering Head

Rear Shock Absorber Assembly and Relay Arm

Swingarm

Shaft Drive

Chapter 5 Engine

Eng

Camshafts

Cylinder Head

Valves and Valve Springs

Generator and Starter Clutch

Pickup Coil Rotor

Clutch

Shift Shaft

Oil Pan and Oil Pump

Middle Gear

Crankcase

Crankshaft

Transmission

Balancers

Chapter 6 Cooling System

Cool

Radiator

Oil Cooler

Thermostat

Water Pump

Chapter 7 Fuel Injection System

Air Induction System

Canister (for California Only)

Chapter 8

Elec

Electrical Components

Checking Switch Continuity