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FJR13AY 2009
Yamaha FJR13AY 2009 Manuals
Manuals and User Guides for Yamaha FJR13AY 2009. We have
1
Yamaha FJR13AY 2009 manual available for free PDF download: Service Manual
Yamaha FJR13AY 2009 Service Manual (744 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 40.71 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
24
Abs Self-Diagnosis Function
27
Abs Warning Light and Operation
30
OUTLINE of the YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR13AE)
31
Instrument Functions
34
Important Information
38
Preparation for Removal and Disassembly
38
Replacement Parts
38
Gaskets, Oil Seals and O-Rings
38
Lock Washers/Plates and Cotter Pins
38
Bearings and Oil Seals
39
Circlips
39
Checking the Connections
40
Special Tools
41
Specifications
49
General Specifications
50
Engine Specifications
51
Chassis Specifications
58
Electrical Specifications
61
General Tightening Torque Specifications
64
Tightening Torques
64
Engine Tightening Torques
65
Chassis Tightening Torques
70
Engine
75
Lubrication Points and Lubricant Types
75
Chassis
77
Engine Oil Lubrication Chart
78
Lubrication System Chart and Diagrams
78
Lubrication Diagrams
80
Cooling System Diagrams
90
Cable Routing (Fjr13A)
94
Cable Routing (Fjr13Ae)
114
Periodic Checks and Adjustments
135
General Maintenance and Lubrication Chart (Fjr13A)
138
Introduction
138
Periodic Maintenance
138
Periodic Maintenance Chart for the Emission Control System (Fjr13A)
138
Periodic Maintenance Chart for the Emission Control System (Fjr13Ae)
140
General Maintenance and Lubrication Chart (Fjr13Ae)
141
Adjusting the Valve Clearance
143
Engine
143
Synchronizing the Throttle Bodies
145
Adjusting the Engine Idling Speed
147
Adjusting the Throttle Cable Free Play
147
Checking the Spark Plugs
148
Checking the Ignition Timing
149
Measuring the Compression Pressure
150
Checking the Engine Oil Level
151
Changing the Engine Oil
152
Measuring the Engine Oil Pressure
153
ADJUSTING the CLUTCH LEVER (FJR13A Only)
154
Checking the Clutch Fluid Level (Fjr13A)
154
Bleeding the Hydraulic Clutch System (Fjr13A)
155
Checking the Clutch Fluid Level (Fjr13Ae)
155
Bleeding the Hydraulic Clutch System (Fjr13Ae)
156
CHECKING the VEHICLE after BLEEDING the HYDRAULIC CLUTCH SYSTEM (FJR13AE Only)
158
Cleaning the Air Filter Element (Fjr13A)
159
Cleaning the Air Filter Element (Fjr13Ae)
159
Checking the Crankcase Breather Hose
160
Checking the Fuel Line
160
Checking the Throttle Body Joints
160
CHECKING the CANISTER (for California Only)
161
Checking the Coolant Level
161
Checking the Exhaust System
161
Changing the Coolant
162
Checking the Cooling System
162
Adjusting the Front Disc Brake
165
Adjusting the Rear Disc Brake
165
Chassis
165
Checking the Brake Fluid Level
166
Adjusting the Rear Brake Light Switch
167
Checking the Brake Hoses
167
Checking the Front Brake Pads
167
Checking the Rear Brake Pads
167
Bleeding the Hydraulic Brake System (Abs)
168
Adjusting the Shift Pedal (Fjr13A)
169
Adjusting the Shift Pedal (Fjr13Ae)
169
Changing the Final Gear Oil
170
Checking and Adjusting the Steering Head
170
Checking the Final Gear Oil Level
170
Adjusting the Handlebar Position
171
Checking the Front Fork
172
Adjusting the Front Fork Legs
173
Adjusting the Rear Shock Absorber Assembly
174
Adjusting the Side Panels
175
Adjusting the Rider Seat Height
176
Checking the Tires
177
Checking and Lubricating the Cables
179
Checking the Wheels
179
Lubricating the Levers
179
Lubricating the Pedals
179
Lubricating the Centerstand
180
Lubricating the Rear Suspension
180
Lubricating the Sidestand
180
Adjusting the Headlight Beams
181
Checking and Charging the Battery
181
Checking the Fuses
181
Electrical System
181
Replacing the Headlight Bulbs
181
Chassis
183
General Chassis
194
Installing the Front Cowling Left Inner Panel 2
194
Removing the Side Panels
194
Installing the Front Cowling Right Inner Panel 2
195
Installing the Side Panels
195
Front Wheel
202
Checking the Front Wheel
204
Disassembling the Front Wheel
204
Removing the Front Wheel
204
Maintenance of the Front Wheel Sensor and Sensor Rotor
205
Assembling the Front Wheel
206
Adjusting the Front Wheel Static Balance
207
Installing the Front Wheel (Front Brake Discs)
208
Rear Wheel
210
Disassembling the Rear Wheel
212
Removing the Rear Wheel
212
Assembling the Rear Wheel
213
Checking the Rear Wheel
213
Maintenance of the Rear Wheel Sensor and Sensor Rotor
213
Adjusting the Rear Wheel Static Balance
214
Installing the Rear Wheel (Rear Brake Disc)
215
Front Brake
217
Checking the Front Brake Discs
222
Introduction
222
Replacing the Front Brake Pads
223
Disassembling the Front Brake Calipers
224
Removing the Front Brake Calipers
224
Assembling the Front Brake Calipers
225
Checking the Front Brake Calipers
225
Installing the Front Brake Calipers
225
Removing the Front Brake Master Cylinder
226
Assembling the Front Brake Master Cylinder
227
Checking the Front Brake Master Cylinder
227
Installing the Front Brake Master Cylinder
227
Checking the Rear Brake Disc
235
Introduction
235
Rear Brake
235
Replacing the Rear Brake Pads
235
Removing the Rear Brake Caliper
236
Assembling the Rear Brake Caliper
237
Checking the Rear Brake Caliper
237
Disassembling the Rear Brake Caliper
237
Installing the Rear Brake Caliper
238
Checking the Rear Brake Master Cylinder
239
Removing the Rear Brake Master Cylinder
239
Assembling the Rear Brake Master Cylinder
240
Installing the Rear Brake Master Cylinder
240
Abs (Anti-Lock Brake System)
242
Abs Components Chart
242
Checking the Hydraulic Unit Assembly
247
Removing the Hydraulic Unit Assembly
247
Checking the Brake Pipes
248
Checking the Proportioning Valve and Metering Valve
248
Installing the Hydraulic Unit Assembly
248
Hydraulic Unit Operation Tests
251
Trial Run
254
Handlebars
255
Checking the Handlebars
259
Installing the Handlebars (Fjr13A)
259
Removing the Handlebars
259
Installing the Handlebars (Fjr13Ae)
261
Front Fork
264
Disassembling the Front Fork Legs
267
Removing the Front Fork Legs
267
Checking the Front Fork Legs
268
Assembling the Front Fork Legs
269
Installing the Front Fork Legs
272
Steering Head
274
Checking the Steering Head
276
Installing the Steering Head
276
Removing the Lower Bracket
276
Rear Shock Absorber Assembly
278
Checking the Rear Shock Absorber Assembly
280
Disposing of a Rear Shock Absorber
280
Handling the Rear Shock Absorber
280
Removing the Rear Shock Absorber Assembly
280
Checking the Connecting Arm and Relay Arm
281
Installing the Rear Shock Absorber Assembly
281
Installing the Relay Arm
281
Swingarm
282
Checking the Swingarm
284
Installing the Swingarm
284
Removing the Swingarm
284
Shaft Drive
286
Troubleshooting
290
Checking the Final Drive Oil for Contamination and Checking the Shaft Drive for Leaks
291
Measuring the Final Gear Backlash
291
Adjusting the Final Gear Backlash
292
Adjusting the Ring-Gear-To-Stopper-Bolt Clearance
293
Measuring the Ring-Gear-To-Stopper-Bolt Clearance
293
Disassembling the Final Drive Assembly
294
Aligning the Final Drive Pinion Gear and Ring Gear
295
Removing and Installing the Bearings
295
Checking the Drive Shaft
298
Installing the Drive Shaft and Final Drive Assembly (Fjr13A)
299
Installing the Drive Shaft and Final Drive Assembly (Fjr13Ae)
300
Engine
303
Engine Removal
306
Engine
312
Installing the Engine
313
Removing the Engine (Fjr13A)
313
Removing the Engine (Fjr13Ae)
313
REMOVING the GEAR POSITION SENSOR (FJR13AE Only)
313
ADJUSTING the GEAR POSITION SENSOR (FJR13AE Only)
316
INSTALLING the GEAR POSITION SENSOR (FJR13AE Only)
316
Camshafts
318
Removing the Camshafts
320
Checking the Camshafts
321
Checking the Camshaft Sprockets
322
Checking the Timing Chain Guides
322
Checking the Timing Chain Tensioner
322
Installing the Camshafts
323
Cylinder Head
327
Checking the Cylinder Head
328
Installing the Cylinder Head
328
Removing the Cylinder Head
328
Checking the Valves and Valve Guides
331
Removing the Valves
331
Valves and Valve Springs
331
Checking the Valve Seats
333
Checking the Valve Lifters
335
Checking the Valve Springs
335
Installing the Valves
335
Generator and Starter Clutch
338
Checking the Starter Clutch
341
Removing the Generator
341
Removing the Starter Clutch
341
Installing the Generator
342
Installing the Starter Clutch
342
Pickup Rotor
344
Installing the Pickup Rotor
345
Removing the Pickup Rotor
345
Electric Starter
347
Checking the Starter Motor
349
Assembling the Starter Motor
350
Clutch
365
Removing the Clutch (Fjr13A)
365
Checking the Friction Plates
366
Removing the Clutch (Fjr13Ae)
366
Checking the Clutch Boss
367
Checking the Clutch Housing
367
Checking the Clutch Plates
367
Checking the Clutch Spring Plate
367
Checking the Clutch Push Rods
368
Checking the Pressure Plate
368
Checking the Primary Driven Gear
368
Installing the Clutch (Fjr13A)
368
Installing the Clutch (Fjr13Ae)
369
BREAKING in the FRICTION PLATES after REPLACEMENT (FJR13AE Only)
371
Disassembling the Clutch Master Cylinder
371
Assembling the Clutch Master Cylinder
372
Checking the Clutch Master Cylinder
372
Installing the Clutch Master Cylinder (Fjr13A)
372
Installing the Clutch Master Cylinder (Fjr13Ae)
374
REPLACING the CLUTCH MASTER CYLINDER (FJR13AE Only)
374
INSTALLING the CLUTCH ACTUATOR (FJR13AE Only)
375
Assembling the Clutch Release Cylinder
376
Checking the Clutch Release Cylinder
376
Installing the Clutch Release Cylinder
376
Removing the Clutch Release Cylinder
376
SHIFT ACTUATOR and SHIFT ROD (FJR13AE Only)
378
Checking the Shift Rod
380
Installing the Foot Shift Switch
380
Removing the Shift Actuator
380
Adjusting the Foot Shift Switch
381
Installing the Left Footrest Assembly
382
Installing the Shift Actuator
382
Shift Shaft
384
Checking the Shift Shaft
385
Checking the Stopper Lever
385
Installing the Shift Shaft (Fjr13A)
385
Installing the Shift Shaft (Fjr13Ae)
385
Oil Pump
387
Checking the Oil Delivery Pipes
390
Checking the Oil Pump
390
Checking the Relief Valve
390
Assembling the Oil Pump
391
Checking the Oil Strainer
391
Installing the Oil Pan
391
Middle Gear
392
Disassembling the Middle Drive Shaft Assembly
398
Disassembling the Middle Driven Shaft Assembly
398
Removing the Middle Drive Shaft Assembly
398
Assembling the Middle Drive Shaft Assembly
399
Assembling the Middle Driven Shaft Assembly
399
Checking the Middle Drive Shaft Assembly
399
Checking the Middle Driven Shaft Assembly
399
Installing the Middle Drive Shaft Assembly
400
Installing the Middle Driven Shaft Assembly
401
Installing the Middle Gear Case Cover
401
Adjusting the Middle Gear Backlash
402
Measuring the Middle Gear Backlash
402
Aligning the Middle Gear
403
Crankcase
406
Checking the Bearings and Oil Seal
412
Checking the Crankcase
412
Checking the Oil Delivery Pipes
412
Checking the Timing Chain and Oil Pump Drive Chain
412
Disassembling the Crankcase
412
Assembling the Crankcase
413
Connecting Rods and Pistons
416
Checking the Cylinders and Pistons
417
Removing the Connecting Rods and Pistons
417
Checking the Piston Rings
418
Checking the Piston Pin
419
Checking the Connecting Rods
420
Installing the Connecting Rods and Pistons
421
Crankshaft
425
Checking the Crankshaft
426
Checking the Oil Nozzles
426
Removing the Crankshaft Journal Bearings
426
Installing the Crankshaft
427
Transmission
429
Checking the Shift Drum Assembly
436
Checking the Shift Forks
436
Checking the Transmission
436
Removing the Transmission
436
Assembling the Main Axle and Drive Axle
437
Installing the Transmission (Fjr13A)
438
Installing the Transmission (Fjr13Ae)
439
Balancers
441
Checking the Balancers
443
Installing the Front Balancer
443
Installing the Rear Balancer
444
Cooling System
447
Fuel System
463
Electrical System
479
Troubleshooting
731
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