Yamaha FJR13AG Manuals

Manuals and User Guides for Yamaha FJR13AG. We have 1 Yamaha FJR13AG manual available for free PDF download: Service Manual

Yamaha FJR13AG Service Manual

Yamaha FJR13AG Service Manual (784 pages)

Brand: Yamaha | Category: Motorcycle | Size: 30.35 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 YCC-T (Yamaha Chip Controlled-Throttle)
  11
- Outline of the Cruise Control System
  12
- Outline of the Unified Brake System
  20
- OUTLINE of the TCS (Traction Control System)
  21
- Multi-Function Meter Unit
  25
- Important Information
  36
- Preparation for Removal and Disassembly
  36
- Replacement Parts
  36
- Gaskets, Oil Seals and O-Rings
  36
- Lock Washers/Plates and Cotter Pins
  36
- Bearings and Oil Seals
  37
- Circlips
  37
- Rubber Parts
  37
- Basic Service Information
  38
- Quick Fasteners
  38
- Electrical System
  39
- Special Tools
  43
Specifications

53
- General Specifications
  54
- Engine Specifications
  55
- Chassis Specifications
  60
- Electrical Specifications
  63
- General Tightening Torque Specifications
  66
- Tightening Torques
  66
- Engine Tightening Torques
  67
- Chassis Tightening Torques
  68
- Engine
  69
- Lubrication Points and Lubricant Types
  69
- Chassis
  71
- Engine Oil Lubrication Chart
  72
- Lubrication System Chart and Diagrams
  72
- Lubrication Diagrams
  74
- Cooling System Diagrams
  84
- Cable Routing (Fjr13Ag)
  88
- Cable Routing (Fjr13Esg)
  110
Periodic Checks and Adjustments

133
- General Maintenance and Lubrication Chart
  136
- Introduction
  136
- Periodic Maintenance
  136
- Periodic Maintenance Chart for the Emission Control System
  136
- Checking the Fuel Line
  139
- Checking the Spark Plugs
  139
- Adjusting the Valve Clearance
  140
- Checking the Engine Idling Speed
  143
- Synchronizing the Throttle Bodies
  143
- Checking the Crankcase Breather Hose
  145
- Checking the Exhaust System
  145
- Adjusting the Clutch Lever
  146
- Checking the Air Induction System
  146
- Checking the Clutch Fluid Level
  146
- Cleaning the Air Filter Element
  146
- Bleeding the Hydraulic Clutch System
  147
- Adjusting the Front Disc Brake
  148
- Checking the Brake Fluid Level
  148
- Bleeding the Hydraulic Brake System (Abs)
  149
- Checking the Front Brake Pads
  150
- Checking the Rear Brake Pads
  150
- Checking the Brake Hoses
  151
- Checking the Tires
  151
- Checking the Wheels
  151
- Checking and Adjusting the Steering Head
  153
- Checking the Swingarm Pivot
  153
- Checking the Wheel Bearings
  153
- Lubricating the Swingarm Pivot
  153
- Checking the Centerstand
  154
- Checking the Chassis Fasteners
  154
- Checking the Front Fork
  154
- Checking the Sidestand
  154
- Checking the Sidestand Switch
  154
- Lubricating the Centerstand
  154
- Lubricating the Lever
  154
- Lubricating the Pedals
  154
- Lubricating the Sidestand
  154
- Lubricating the Steering Head
  154
- Adjusting the Front Fork Legs (Fjr13Ag)
  155
- Adjusting the Damping Force (Fjr13Esg)
  156
- Adjusting the Rear Shock Absorber Assembly (Fjr13Ag)
  157
- Checking the Rear Suspension
  157
- Adjusting the Preload of the Rear Shock Absorber Assembly (Fjr13Esg)
  158
- Changing the Engine Oil
  160
- Checking the Engine Oil Level
  160
- Lubricating the Rear Suspension
  160
- Checking the Coolant Level
  162
- Measuring the Engine Oil Pressure
  162
- Checking the Cooling System
  163
- Changing the Coolant
  164
- Checking the Final Gear Oil Level
  165
- Adjusting the Rear Brake Light Switch
  166
- Changing the Final Gear Oil
  166
- Checking the Brake Light Switches
  166
- Checking and Lubricating the Cables
  167
- Checking the Throttle Grip Operation
  167
- Adjusting the Headlight Beams
  168
- Checking the Switches, Lights and Signals
  168
Chassis

169
- General Chassis (1)
  174
- Installing the Center Rear Cowling
  175
- Installing the Rear Cowlings
  175
- Removing the Center Rear Cowling
  175
- Removing the Rear Cowlings
  175
- Removing the Side Covers
  175
- Installing the Seats
  176
- Installing the Side Covers
  176
- General Chassis (2)
  177
- Adjusting the Side Panels
  180
- Removing the Front Cowling Inner Panel
  180
- Installing the Front Cowling Inner Panel
  181
- Installing the Side Cowlings
  182
- Removing the Side Cowlings
  182
- General Chassis (3)
  183
- Installing the Center Covers
  185
- Installing the Windshield Bracket Covers
  185
- Removing the Center Covers
  185
- Removing the Windshield Bracket Covers
  185
- Installing the Front Cowling Assembly
  186
- Installing the Headlight Beam Adjusting Knob Joints
  186
- General Chassis (4)
  187
- Installing the Windshield Drive Unit
  191
- General Chassis (5)
  192
- General Chassis (6)
  192
- General Chassis (7)
  193
- Front Wheel
  200
- Checking the Front Wheel
  205
- Disassembling the Front Wheel
  205
- Removing the Front Wheel
  205
- Maintenance of the Front Wheel Sensor and Sensor Rotor
  206
- Assembling the Front Wheel
  207
- Adjusting the Front Wheel Static Balance
  208
- Installing the Front Wheel (Front Brake Discs)
  209
- Rear Wheel
  212
- Disassembling the Rear Wheel
  214
- Removing the Rear Wheel
  214
- Assembling the Rear Wheel
  215
- Checking the Rear Wheel
  215
- Maintenance of the Rear Wheel Sensor and Sensor Rotor
  215
- Adjusting the Rear Wheel Static Balance
  216
- Installing the Rear Wheel (Rear Brake Disc)
  217
- Front Brake
  219
- Checking the Front Brake Discs
  226
- Introduction
  226
- Replacing the Front Brake Pads
  227
- Disassembling the Front Brake Calipers
  228
- Removing the Front Brake Calipers
  228
- Assembling the Front Brake Calipers
  229
- Checking the Front Brake Calipers
  229
- Installing the Front Brake Calipers
  229
- Removing the Front Brake Master Cylinder
  230
- Assembling the Front Brake Master Cylinder
  231
- Checking the Front Brake Master Cylinder
  231
- Installing the Front Brake Master Cylinder
  231
- Rear Brake
  233
- Checking the Rear Brake Disc
  239
- Introduction
  239
- Replacing the Rear Brake Pads
  239
- Removing the Rear Brake Caliper
  240
- Assembling the Rear Brake Caliper
  241
- Checking the Rear Brake Caliper
  241
- Disassembling the Rear Brake Caliper
  241
- Installing the Rear Brake Caliper
  242
- Checking the Rear Brake Master Cylinder
  243
- Removing the Rear Brake Master Cylinder
  243
- Assembling the Rear Brake Master Cylinder
  244
- Installing the Rear Brake Master Cylinder
  244
- Abs (Anti-Lock Brake System)
  246
- Abs Components Chart
  251
- Removing the Hydraulic Unit Assembly
  252
- Checking the Brake Pipes
  253
- Checking the Hydraulic Unit Assembly
  253
- Checking the Proportioning Valve and Metering Valve
  253
- Installing the Hydraulic Unit Assembly
  253
- Hydraulic Unit Operation Tests
  256
- Checking the Abs Warning Light
  259
- Handlebars
  260
- Adjusting the Handlebar Position
  262
- Removing the Handlebars
  262
- Checking the Handlebars
  263
- Installing the Handlebars
  263
- Front Fork (Fjr13Ag)
  266
- Disassembling the Front Fork Legs
  271
- Removing the Front Fork Legs
  271
- Assembling the Front Fork Legs
  272
- Checking the Front Fork Legs
  272
- Installing the Front Fork Legs
  276
- Front Fork (Fjr13Esg)
  278
- Disassembling the Front Fork Legs
  280
- Removing the Front Fork Legs
  280
- Checking the Front Fork Legs
  281
- Assembling the Front Fork Legs
  282
- Installing the Front Fork Legs
  286
- Steering Head
  287
- Checking the Steering Head
  289
- Installing the Steering Head
  289
- Removing the Lower Bracket
  289
- Rear Shock Absorber Assembly (Fjr13Ag)
  291
- Checking the Rear Shock Absorber Assembly
  293
- Disposing of a Rear Shock Absorber
  293
- Handling the Rear Shock Absorber
  293
- Removing the Rear Shock Absorber Assembly
  293
- Checking the Connecting Arm and Relay Arm
  294
- Installing the Rear Shock Absorber Assembly
  294
- Installing the Relay Arm
  294
- Rear Shock Absorber Assembly (Fjr13Esg)
  296
- Handling the Rear Shock Absorber
  301
- Removing the Rear Fender Assembly
  301
- Checking the Connecting Arm and Relay Arm
  302
- Checking the Rear Shock Absorber Assembly
  302
- Disposing of a Rear Shock Absorber
  302
- Removing the Rear Shock Absorber Assembly
  302
- Adjusting the Rear Shock Absorber Assembly DC Motor
  303
- Installing the Rear Shock Absorber Assembly
  303
- Replacing the Stepping Motor
  303
- Installing the Rear Fender Assembly
  304
- Swingarm
  306
- Checking the Swingarm
  308
- Installing the Swingarm
  308
- Removing the Swingarm
  308
- Shaft Drive
  310
- Troubleshooting
  315
- Checking the Final Drive Oil for Contamination and Checking the Shaft Drive for Leaks
  317
- Measuring the Final Gear Backlash
  317
- Adjusting the Final Gear Backlash
  318
- Adjusting the Ring-Gear-To-Stopper-Bolt Clearance
  319
- Measuring the Ring-Gear-To-Stopper-Bolt Clearance
  319
- Disassembling the Final Drive Assembly
  320
- Removing and Installing the Bearings
  320
- Aligning the Final Drive Pinion Gear and Ring Gear
  321
- Checking the Drive Shaft
  324
- Installing the Drive Shaft and Final Drive Assembly
  324
Engine

327
- Engine Inspection
  330
- Measuring the Compression Pressure
  330
- Engine Removal
  332
- Engine
  337
- Installing the Engine
  338
- Removing the Engine
  338
- Camshafts
  341
- Removing the Camshafts
  344
- Checking the Camshafts
  345
- Checking the Camshaft Sprockets
  346
- Checking the Timing Chain Guides
  346
- Checking the Timing Chain Tensioner
  346
- Installing the Camshafts
  346
- Cylinder Head
  350
- Checking the Cylinder Head
  351
- Installing the Cylinder Head
  351
- Removing the Cylinder Head
  351
- Checking the Valves and Valve Guides
  354
- Removing the Valves
  354
- Valves and Valve Springs
  354
- Checking the Valve Seats
  356
- Checking the Valve Springs
  357
- Checking the Valve Lifters
  358
- Installing the Valves
  358
- Generator and Starter Clutch
  360
- Checking the Starter Clutch
  362
- Removing the Generator
  362
- Removing the Starter Clutch
  362
- Installing the Generator
  363
- Installing the Starter Clutch
  363
- Pickup Rotor
  365
- Installing the Pickup Rotor
  366
- Removing the Pickup Rotor
  366
- Electric Starter
  368
- Checking the Starter Motor
  370
- Assembling the Starter Motor
  371
- Clutch
  378
- Removing the Clutch
  378
- Checking the Clutch Plates
  379
- Checking the Friction Plates
  379
- Checking the Clutch Boss
  380
- Checking the Clutch Housing
  380
- Checking the Clutch Push Rods
  380
- Checking the Clutch Springs
  380
- Checking the Pressure Plate
  380
- Checking the Primary Driven Gear
  381
- Installing the Clutch
  381
- Disassembling the Clutch Master Cylinder
  382
- Assembling the Clutch Master Cylinder
  383
- Checking the Clutch Master Cylinder
  383
- Installing the Clutch Master Cylinder
  383
- Checking the Clutch Release Cylinder
  384
- Removing the Clutch Release Cylinder
  384
- Assembling the Clutch Release Cylinder
  385
- Installing the Clutch Release Cylinder
  385
- Shift Shaft
  387
- Adjusting the Shift Pedal
  388
- Checking the Shift Shaft
  388
- Checking the Stopper Lever
  388
- Installing the Shift Shaft
  388
- Oil Pump
  390
- Checking the Oil Delivery Pipes
  393
- Checking the Oil Pump
  393
- Checking the Relief Valve
  393
- Assembling the Oil Pump
  394
- Checking the Oil Strainer
  394
- Installing the Oil Pan
  394
- Middle Gear
  395
- Disassembling the Middle Drive Shaft Assembly
  399
- Disassembling the Middle Driven Shaft Assembly
  399
- Removing the Middle Drive Shaft Assembly
  399
- Assembling the Middle Drive Shaft Assembly
  400
- Assembling the Middle Driven Shaft Assembly
  400
- Checking the Middle Drive Shaft Assembly
  400
- Checking the Middle Driven Shaft Assembly
  400
- Installing the Middle Drive Shaft Assembly
  401
- Installing the Middle Driven Shaft Assembly
  402
- Installing the Middle Gear Case Cover
  402
- Adjusting the Middle Gear Backlash
  403
- Measuring the Middle Gear Backlash
  403
- Aligning the Middle Gear
  404
- Crankcase
  407
- Assembling the Crankcase
  411
- Checking the Bearings and Oil Seal
  411
- Checking the Crankcase
  411
- Checking the Oil Delivery Pipes
  411
- Checking the Timing Chain and Oil Pump Drive Chain
  411
- Disassembling the Crankcase
  411
- Installing the Oil Pump Drive Sprocket
  414
- Checking the Cylinders and Pistons
  416
- Connecting Rods and Pistons
  416
- Removing the Connecting Rods and Pistons
  416
- Checking the Piston Rings
  417
- Checking the Piston Pin
  418
- Checking the Connecting Rods
  419
- Installing the Connecting Rods and Pistons
  420
- Crankshaft
  423
- Checking the Crankshaft
  424
- Checking the Oil Nozzles
  424
- Removing the Crankshaft Journal Bearings
  424
- Installing the Crankshaft
  426
- Transmission
  427
- Checking the Shift Drum Assembly
  429
- Checking the Shift Forks
  429
- Removing the Transmission
  429
- Checking the Transmission
  430
- Installing the Transmission
  430
- Balancers
  432
- Checking the Balancers
  434
- Installing the Front Balancer
  434
- Installing the Rear Balancer
  435
- Cooling System
  439
- Fuel System
  455
- Electrical System
  473
- Troubleshooting
  745

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