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FJR13AEV(C)
Yamaha FJR13AEV(C) Manuals
Manuals and User Guides for Yamaha FJR13AEV(C). We have
2
Yamaha FJR13AEV(C) manuals available for free PDF download: Service Manual, Owner's Manual
Yamaha FJR13AEV(C) Service Manual (726 pages)
Brand:
Yamaha
| Category:
Farm Equipment
| Size: 41.71 MB
Table of Contents
Table of Contents
7
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
OUTLINE of the YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE)
32
Instrument Functions
35
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
59
Electrical Specifications
62
Tightening Torques
65
General Tightening Torque Specifications
65
Engine Tightening Torques
66
Chassis Tightening Torques
71
Lubrication Points and Lubricant Types
76
Engine
76
Chassis
78
Lubrication System Chart and Diagrams
80
Engine Oil Lubrication Chart
80
Lubrication Diagrams
82
Cooling System Diagrams
92
Cable Routing (Fjr13A)
96
Cable Routing (Fjr13Ae)
116
Periodic Checks and Adjustments
137
Periodic Maintenance
140
General Maintenance and Lubrication Chart (Fjr13A)
140
Introduction
140
Periodic Maintenance Chart for the Emission Control System (Fjr13A)
140
Periodic Maintenance Chart for the Emission Control System (Fjr13Ae)
142
General Maintenance and Lubrication Chart (Fjr13Ae)
143
Engine
145
Adjusting the Valve Clearance
145
Synchronizing the Throttle Bodies
147
Adjusting the Engine Idling Speed
149
Adjusting the Throttle Cable Free Play
149
Checking the Spark Plugs
150
Checking the Ignition Timing
151
Measuring the Compression Pressure
152
Checking the Engine Oil Level
153
Changing the Engine Oil
154
Measuring the Engine Oil Pressure
155
ADJUSTING the CLUTCH LEVER (FJR13A Only)
156
Checking the Clutch Fluid Level (Fjr13A)
156
Checking the Clutch Fluid Level (Fjr13Ae)
156
Bleeding the Hydraulic Clutch System (Fjr13A)
157
Bleeding the Hydraulic Clutch System (Fjr13Ae)
158
CHECKING the VEHICLE after BLEEDING the HYDRAULIC CLUTCH SYSTEM (FJR13AE Only)
160
Cleaning the Air Filter Element (Fjr13A)
161
Cleaning the Air Filter Element (Fjr13Ae)
161
Checking the Throttle Body Joints
161
Checking the Fuel Line
162
Checking the Crankcase Breather Hose
162
Checking the Exhaust System
163
CHECKING the CANISTER (for California Only)
163
Checking the Coolant Level
163
Checking the Cooling System
164
Changing the Coolant
164
Chassis
167
Adjusting the Front Disc Brake
167
Adjusting the Rear Disc Brake
167
Checking the Brake Fluid Level
168
Checking the Front Brake Pads
168
Checking the Rear Brake Pads
169
Checking the Brake Hoses
169
Adjusting the Rear Brake Light Switch
169
Bleeding the Hydraulic Brake System (Abs)
170
Adjusting the Shift Pedal (Fjr13A)
171
Adjusting the Shift Pedal (Fjr13Ae)
171
Checking the Final Gear Oil Level
172
Changing the Final Gear Oil
172
Checking and Adjusting the Steering Head
172
Adjusting the Handlebar Position
173
Checking the Front Fork
174
Adjusting the Front Fork Legs
175
Adjusting the Rear Shock Absorber Assembly
176
Adjusting the Side Panels
177
Adjusting the Rider Seat Height
177
Checking the Tires
179
Checking the Wheels
181
Checking and Lubricating the Cables
181
Lubricating the Levers
181
Lubricating the Pedals
181
Lubricating the Sidestand
181
Lubricating the Centerstand
181
Lubricating the Rear Suspension
182
Electrical System
183
Checking and Charging the Battery
183
Checking the Fuses
183
Replacing the Headlight Bulbs
183
Adjusting the Headlight Beams
183
Chassis
185
General Chassis
196
Removing the Side Panels
196
Installing the Front Cowling Left Inner Panel 2
196
Installing the Front Cowling Right Inner Panel 2
197
Installing the Side Panels
197
Front Wheel
204
Removing the Front Wheel
206
Disassembling the Front Wheel
206
Checking the Front Wheel
206
Maintenance of the Front Wheel Sensor and Sensor Rotor
207
Assembling the Front Wheel
208
Adjusting the Front Wheel Static Balance
208
Installing the Front Wheel (Front Brake Discs)
209
Rear Wheel
211
Removing the Rear Wheel
213
Disassembling the Rear Wheel
213
Checking the Rear Wheel
213
Maintenance of the Rear Wheel Sensor and Sensor Rotor
213
Assembling the Rear Wheel
213
Adjusting the Rear Wheel Static Balance
214
Installing the Rear Wheel (Rear Brake Disc)
214
Front Brake
216
Introduction
221
Checking the Front Brake Discs
221
Replacing the Front Brake Pads
222
Removing the Front Brake Calipers
223
Disassembling the Front Brake Calipers
223
Checking the Front Brake Calipers
224
Assembling the Front Brake Calipers
224
Installing the Front Brake Calipers
224
Removing the Front Brake Master Cylinder
226
Checking the Front Brake Master Cylinder
226
Assembling the Front Brake Master Cylinder
226
Installing the Front Brake Master Cylinder
226
Rear Brake
234
Introduction
234
Checking the Rear Brake Disc
234
Replacing the Rear Brake Pads
234
Removing the Rear Brake Caliper
235
Disassembling the Rear Brake Caliper
236
Checking the Rear Brake Caliper
236
Assembling the Rear Brake Caliper
236
Installing the Rear Brake Caliper
236
Removing the Rear Brake Master Cylinder
238
Checking the Rear Brake Master Cylinder
238
Assembling the Rear Brake Master Cylinder
238
Installing the Rear Brake Master Cylinder
239
Abs (Anti-Lock Brake System)
241
Abs Components Chart
241
Removing the Hydraulic Unit
245
Checking the Hydraulic Unit
245
Checking the Proportioning Valve and Metering Valve
246
Installing the Hydraulic Unit
246
Hydraulic Unit Operation Tests
247
Trial Run
250
Handlebars
251
Removing the Handlebars
255
Checking the Handlebars
255
Installing the Handlebars (Fjr13A)
255
Installing the Handlebars (Fjr13Ae)
257
Front Fork
260
Removing the Front Fork Legs
263
Disassembling the Front Fork Legs
263
Checking the Front Fork Legs
264
Assembling the Front Fork Legs
265
Installing the Front Fork Legs
268
Steering Head
270
Removing the Lower Bracket
272
Checking the Steering Head
272
Installing the Steering Head
272
Rear Shock Absorber Assembly
274
Handling the Rear Shock Absorber
276
Disposing of a Rear Shock Absorber
276
Removing the Rear Shock Absorber Assembly
276
Checking the Rear Shock Absorber Assembly
276
Checking the Connecting Arm and Relay Arm
277
Installing the Relay Arm
277
Installing the Rear Shock Absorber Assembly
277
Swingarm
280
Removing the Swingarm
280
Checking the Swingarm
280
Installing the Swingarm
280
Shaft Drive
282
Troubleshooting
286
Checking the Final Drive Oil for Contamination and Checking the Shaft Drive for Leaks
287
Measuring the Final Gear Backlash
287
Adjusting the Final Gear Backlash
288
Measuring the Ring-Gear-To-Stopper-Bolt Clearance
289
Adjusting the Ring-Gear-To-Stopper-Bolt Clearance
289
Disassembling the Final Drive Assembly
290
Removing and Installing the Bearings
291
Aligning the Final Drive Pinion Gear and Ring Gear
291
Checking the Drive Shaft
294
Installing the Drive Shaft and Final Drive Assembly (Fjr13A)
295
Installing the Drive Shaft and Final Drive Assembly (Fjr13Ae)
296
Engine
299
Engine Removal
302
Engine
308
REMOVING the GEAR POSITION SENSOR (FJR13AE Only)
309
Removing the Engine (Fjr13A)
309
Removing the Engine (Fjr13Ae)
309
Installing the Engine
309
INSTALLING the GEAR POSITION SENSOR (FJR13AE Only)
312
ADJUSTING the GEAR POSITION SENSOR (FJR13AE Only)
312
Camshafts
313
Removing the Camshafts
315
Checking the Camshafts
316
Checking the Camshaft Sprockets
317
Checking the Timing Chain Guides
317
Checking the Timing Chain Tensioner
317
Installing the Camshafts
318
Cylinder Head
322
Removing the Cylinder Head
323
Checking the Cylinder Head
323
Installing the Cylinder Head
323
Valves and Valve Springs
326
Removing the Valves
326
Checking the Valves and Valve Guides
326
Checking the Valve Seats
328
Checking the Valve Springs
329
Checking the Valve Lifters
330
Installing the Valves
330
Generator and Starter Clutch
332
Removing the Generator
335
Removing the Starter Clutch
335
Checking the Starter Clutch
335
Installing the Starter Clutch
336
Installing the Generator
336
Pickup Rotor
338
Removing the Pickup Rotor
339
Installing the Pickup Rotor
339
Electric Starter
341
Checking the Starter Motor
343
Assembling the Starter Motor
344
Clutch
357
Removing the Clutch
357
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
358
Checking the Pressure Plate
359
Checking the Clutch Push Rods
359
Checking the Primary Driven Gear
359
Installing the Clutch
359
BREAKING in the FRICTION PLATES after REPLACEMENT (FJR13AE Only)
360
Disassembling the Clutch Master Cylinder
361
Checking the Clutch Master Cylinder
361
Assembling the Clutch Master Cylinder
362
Installing the Clutch Master Cylinder (Fjr13A)
362
Installing the Clutch Master Cylinder (Fjr13Ae)
363
REPLACING the CLUTCH MASTER CYLINDER (FJR13AE Only)
364
INSTALLING the CLUTCH ACTUATOR (FJR13AE Only)
365
Removing the Clutch Release Cylinder
365
Checking the Clutch Release Cylinder
366
Assembling the Clutch Release Cylinder
366
Installing the Clutch Release Cylinder
366
SHIFT ACTUATOR and SHIFT ROD (FJR13AE Only)
368
Removing the Shift Actuator
370
Checking the Shift Rod
370
Installing the Foot Shift Switch
370
Adjusting the Foot Shift Switch
371
Installing the Left Footrest Assembly
372
Installing the Shift Actuator
372
Shift Shaft
374
Checking the Shift Shaft
375
Checking the Stopper Lever
375
Installing the Shift Shaft (Fjr13A)
375
Installing the Shift Shaft (Fjr13Ae)
375
Oil Pump
377
Checking the Oil Pump
380
Checking the Relief Valve
380
Checking the Oil Delivery Pipes
381
Checking the Oil Strainer
381
Assembling the Oil Pump
381
Installing the Oil Pan
381
Middle Gear
382
Removing the Middle Drive Shaft Assembly
388
Disassembling the Middle Drive Shaft Assembly
388
Disassembling the Middle Driven Shaft Assembly
388
Checking the Middle Drive Shaft Assembly
389
Checking the Middle Driven Shaft Assembly
389
Assembling the Middle Drive Shaft Assembly
389
Assembling the Middle Driven Shaft Assembly
389
Installing the Middle Drive Shaft Assembly
390
Installing the Middle Driven Shaft Assembly
391
Installing the Middle Gear Case Cover
391
Measuring the Middle Gear Backlash
392
Adjusting the Middle Gear Backlash
392
Aligning the Middle Gear
393
Crankcase
395
Disassembling the Crankcase
401
Checking the Crankcase
401
Checking the Oil Delivery Pipes
401
Checking the Bearings and Oil Seal
401
Checking the Timing Chain and Oil Pump Drive Chain
401
Assembling the Crankcase
401
Connecting Rods and Pistons
405
Removing the Connecting Rods and Pistons
406
Checking the Cylinders and Pistons
406
Checking the Piston Rings
407
Checking the Piston Pin
408
Checking the Connecting Rods
409
Installing the Connecting Rods and Pistons
410
Crankshaft
413
Removing the Crankshaft Journal Bearings
414
Checking the Oil Nozzles
414
Checking the Crankshaft
414
Installing the Crankshaft
415
Transmission
417
Removing the Transmission
424
Checking the Shift Forks
424
Checking the Shift Drum Assembly
424
Checking the Transmission
424
Assembling the Main Axle and Drive Axle
425
Installing the Transmission
426
Balancers
428
Checking the Balancers
430
Installing the Front Balancer
430
Installing the Rear Balancer
431
Cooling System
435
Fuel System
451
Electrical System
467
General Information
709
Troubleshooting
709
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Yamaha FJR13AEV(C) Owner's Manual (112 pages)
Motorcycle
Brand:
Yamaha
| Category:
Motorcycle
| Size: 6 MB
Table of Contents
Important Manual Information
4
Table of Contents
7
Safety Information
9
Location of Important Labels
13
Description
16
Left View
16
Right View
17
Controls and Instruments
18
Instrument and Control Functions
19
YCC-S System
19
Main Switch/Steering Lock
19
Indicator and Warning Lights
20
Lock
20
Speedometer
23
Tachometer
23
Multi-Function Display
23
Handlebar Switches
28
Shift Pedal
30
Hand Shift Lever
31
Brake Lever
31
Brake Pedal
31
Abs
32
Fuel Tank Cap
32
Fuel
33
Catalytic Converter
34
Seats
34
Adjusting the Rider Seat Height
36
Storage Compartment
38
Accessory Box
38
Adjusting the Headlight Beams
39
Handlebar Position
39
Opening and Closing the Cowlings
39
Rear View Mirrors
40
Adjusting the Front Fork
41
Adjusting the Shock Absorber Assembly
42
Specifications
42
Grip Warmer Adjusting Knob
44
Sidestand
44
Ignition Circuit Cut-Off System
45
Auxiliary DC Jack
47
Pre-Operation Checks
48
Pre-Operation Check List
49
Operation and Important Riding Points
51
Starting the Engine
51
Shifting
52
Engine Break-In
54
Parking
54
Periodic Maintenance and Minor Repair
56
Periodic Maintenance
56
Owner's Tool Kit
56
Periodic Maintenance Chart for the Emission Control System
58
General Maintenance and Lubrication Chart
59
Removing and Installing Panels
63
Checking the Spark Plugs
65
Canister (for California Only)
66
Engine Oil and Oil Filter Cartridge
66
Final Gear Oil
69
Coolant
70
Air Filter Element
72
Checking the Throttle Cable Free Play
72
Valve Clearance
72
Tires
73
Cast Wheels
75
Accessories and Replacement Parts
76
YCC-S Clutch
76
Adjusting the Rear Brake Light Switch
77
Checking the Front and Rear Brake Pads
77
Checking the Brake and YCC-S Clutch Fluid Levels
78
Changing the Brake and YCC-S Clutch Fluids
79
Checking and Lubricating the Cables
79
Checking and Lubricating the Throttle Grip and Cable
80
Checking and Lubricating the Brake and Shift Pedals
80
Checking and Lubricating the Brake Lever
81
Checking and Lubricating the Centerstand and Sidestand
81
Lubricating the Swingarm Pivots
81
Lubricating the Rear Suspension
82
Checking the Front Fork
82
Checking the Steering
83
Checking the Wheel Bearings
83
Battery
84
Replacing the Fuses
85
Headlight Bulb
86
Front Turn Signal Light
87
Replacing a Rear Turn Signal Light Bulb or a Tail/Brake Light Bulb
87
Replacing the License Plate Light Bulb
88
Troubleshooting
88
Troubleshooting Charts
89
Motorcycle Care and Storage
91
Care
91
Storage
93
Specifications
95
Consumer Information
98
Identification Numbers
98
Reporting Safety Defects
100
Motorcycle Noise Regulation
101
Maintenance Record
102
Yamaha Motor Corporation, U.s.a. Street and Enduro Motorcycle Limited Warranty
104
Yamaha Extended Service (Y.e.s.)
106
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