Yamaha FJR13AYC 2009 Manuals

Manuals and User Guides for Yamaha FJR13AYC 2009. We have 1 Yamaha FJR13AYC 2009 manual available for free PDF download: Service Manual

Yamaha FJR13AYC 2009 Service Manual

Yamaha FJR13AYC 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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