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FJR1300A(X)
Yamaha FJR1300A(X) Manuals
Manuals and User Guides for Yamaha FJR1300A(X). We have
1
Yamaha FJR1300A(X) manual available for free PDF download: Service Manual
Yamaha FJR1300A(X) Service Manual (754 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 41.29 MB
Table of Contents
Table of Contents
7
How to Use this Manual
4
Symbols
5
General Information
9
Identification
10
Model Label
10
Vehicle Identification Number
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
26
Abs Warning Light and Operation
29
OUTLINE of the YCC-S (Yamaha Chip Controlled-Shift) SYSTEM (FJR1300AS)
30
Instrument Functions
33
Important Information
39
Gaskets, Oil Seals and O-Rings
39
Lock Washers/Plates and Cotter Pins
39
Preparation for Removal and Disassembly
39
Replacement Parts
39
Bearings and Oil Seals
40
Circlips
40
Checking the Connections
41
Special Tools
42
Specifications
51
General Specifications
52
Engine Specifications
53
Chassis Specifications
60
Electrical Specifications
63
Tightening Torques
66
General Tightening Torque Specifications
66
Engine Tightening Torques
67
Chassis Tightening Torques
72
Lubrication Points and Lubricant Types
77
Engine
77
Chassis
79
Lubrication System Chart and Diagrams
80
Engine Oil Lubrication Chart
80
Lubrication Diagrams
82
Cooling System Diagrams
92
Cable Routing (Fjr1300A)
96
Cable Routing (Fjr1300As)
116
Periodic Checks and Adjustments
137
Periodic Maintenance
140
Introduction
140
Periodic Maintenance and Lubrication Chart (Fjr1300A)
140
Periodic Maintenance and Lubrication Chart (Fjr1300As)
142
Engine
144
Adjusting the Valve Clearance
144
Synchronizing the Throttle Bodies
146
Adjusting the Exhaust Gas Volume
148
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 (FJR1300A Only)
156
Checking the Clutch Fluid Level (Fjr1300A)
156
Checking the Clutch Fluid Level (Fjr1300As)
157
Bleeding the Hydraulic Clutch System (Fjr1300A)
157
Bleeding the Hydraulic Clutch System (Fjr1300As)
158
CHECKING the VEHICLE after BLEEDING the HYDRAULIC CLUTCH SYSTEM (FJR1300AS Only)
160
Cleaning the Air Filter Element (Fjr1300A)
161
Cleaning the Air Filter Element (Fjr1300As)
161
Checking the Throttle Body Joints
162
Checking the Fuel Line
162
Checking the Crankcase Breather Hose
162
Checking the Exhaust System
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
Adjusting the Rear Brake Light Switch
169
Checking the Brake Hoses
169
Checking the Front Brake Pads
169
Checking the Rear Brake Pads
169
Bleeding the Hydraulic Brake System (Abs)
170
Adjusting the Shift Pedal (Fjr1300A)
171
Adjusting the Shift Pedal (Fjr1300As)
171
Changing the Final Gear Oil
172
Checking and Adjusting the Steering Head
172
Checking the Final Gear Oil Level
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
178
Checking the Tires
179
Checking and Lubricating the Cables
181
Checking the Wheels
181
Lubricating the Centerstand
181
Lubricating the Levers
181
Lubricating the Pedals
181
Lubricating the Sidestand
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
188
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
209
Installing the Front Wheel (Front Brake Discs)
210
Rear Wheel
212
Removing the Rear Wheel
214
Disassembling the Rear Wheel
214
Checking the Rear Wheel
215
Maintenance of the Rear Wheel Sensor and Sensor Rotor
215
Assembling the Rear Wheel
215
Adjusting the Rear Wheel Static Balance
216
Installing the Rear Wheel (Rear Brake Disc)
217
Front Brake
219
Introduction
224
Checking the Front Brake Discs
224
Replacing the Front Brake Pads
225
Removing the Front Brake Calipers
226
Disassembling the Front Brake Calipers
226
Checking the Front Brake Calipers
227
Assembling the Front Brake Calipers
227
Installing the Front Brake Calipers
227
Removing the Front Brake Master Cylinder
228
Checking the Front Brake Master Cylinder
229
Assembling the Front Brake Master Cylinder
229
Installing the Front Brake Master Cylinder
229
Rear Brake
237
Introduction
237
Checking the Rear Brake Disc
237
Replacing the Rear Brake Pads
237
Removing the Rear Brake Caliper
238
Disassembling the Rear Brake Caliper
239
Checking the Rear Brake Caliper
239
Assembling the Rear Brake Caliper
239
Installing the Rear Brake Caliper
240
Removing the Rear Brake Master Cylinder
241
Checking the Rear Brake Master Cylinder
242
Assembling the Rear Brake Master Cylinder
242
Installing the Rear Brake Master Cylinder
242
Abs (Anti-Lock Brake System)
244
Abs Components Chart
244
Removing the Hydraulic Unit Assembly
249
Checking the Hydraulic Unit Assembly
249
Checking the Proportioning Valve and Metering Valve
250
Checking the Brake Pipes
250
Installing the Hydraulic Unit Assembly
250
Hydraulic Unit Operation Tests
253
Trial Run
256
Handlebars
257
Removing the Handlebars
260
Checking the Handlebars
260
Installing the Handlebars (Fjr1300A)
260
Installing the Handlebars (Fjr1300As)
262
Front Fork
265
Removing the Front Fork Legs
268
Disassembling the Front Fork Legs
268
Checking the Front Fork Legs
269
Assembling the Front Fork Legs
270
Installing the Front Fork Legs
273
Steering Head
275
Removing the Lower Bracket
277
Checking the Steering Head
277
Installing the Steering Head
277
Rear Shock Absorber Assembly
279
Handling the Rear Shock Absorber
281
Disposing of a Rear Shock Absorber
281
Removing the Rear Shock Absorber Assembly
281
Checking the Rear Shock Absorber Assembly
281
Checking the Connecting Arm and Relay Arm
282
Installing the Relay Arm
282
Installing the Rear Shock Absorber Assembly
282
Swingarm
283
Removing the Swingarm
285
Checking the Swingarm
285
Installing the Swingarm
285
Shaft Drive
287
Troubleshooting
291
Checking the Final Drive Oil for Contamination and Checking the Shaft Drive for Leaks
292
Measuring the Final Gear Backlash
292
Adjusting the Final Gear Backlash
293
Measuring the Ring-Gear-To-Stopper-Bolt Clearance
294
Adjusting the Ring-Gear-To-Stopper-Bolt Clearance
294
Disassembling the Final Drive Assembly
295
Removing and Installing the Bearings
296
Aligning the Final Drive Pinion Gear and Ring Gear
296
Checking the Drive Shaft
299
Installing the Drive Shaft and Final Drive Assembly (Fjr1300A)
300
Installing the Drive Shaft and Final Drive Assembly (Fjr1300As)
301
Engine
303
Engine Removal
306
Engine
312
Installing the Engine
313
Removing the Engine (Fjr1300A)
313
Removing the Engine (Fjr1300As)
313
REMOVING the GEAR POSITION SENSOR (FJR1300AS Only)
313
ADJUSTING the GEAR POSITION SENSOR (FJR1300AS Only)
316
INSTALLING the GEAR POSITION SENSOR (FJR1300AS 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
Removing the Cylinder Head
328
Checking the Cylinder Head
328
Installing the Cylinder Head
328
Valves and Valve Springs
331
Removing the Valves
331
Checking the Valves and Valve Guides
331
Checking the Valve Seats
333
Checking the Valve Springs
335
Checking the Valve Lifters
335
Installing the Valves
335
Generator and Starter Clutch
338
Removing the Generator
341
Removing the Starter Clutch
341
Checking the Starter Clutch
341
Installing the Starter Clutch
342
Installing the Generator
342
Pickup Rotor
344
Removing the Pickup Rotor
345
Installing the Pickup Rotor
345
Electric Starter
347
Checking the Starter Motor
349
Assembling the Starter Motor
350
Clutch
363
Removing the Clutch
363
Checking the Friction Plates
363
Checking the Clutch Plates
364
Checking the Clutch Spring Plate
364
Checking the Clutch Housing
364
Checking the Clutch Boss
364
Checking the Pressure Plate
365
Checking the Clutch Push Rods
365
Checking the Primary Driven Gear
365
Installing the Clutch
365
BREAKING in the FRICTION PLATES after REPLACEMENT (FJR1300AS Only)
367
Disassembling the Clutch Master Cylinder
367
Checking the Clutch Master Cylinder
368
Assembling the Clutch Master Cylinder
368
Installing the Clutch Master Cylinder (Fjr1300A)
368
Installing the Clutch Master Cylinder (Fjr1300As)
369
REPLACING the CLUTCH MASTER CYLINDER (FJR1300AS Only)
370
INSTALLING the CLUTCH ACTUATOR (FJR1300AS Only)
371
Removing the Clutch Release Cylinder
372
Checking the Clutch Release Cylinder
372
Assembling the Clutch Release Cylinder
372
Installing the Clutch Release Cylinder
372
SHIFT ACTUATOR and SHIFT ROD (FJR1300AS Only)
374
Removing the Shift Actuator
376
Checking the Shift Rod
376
Installing the Foot Shift Switch
376
Adjusting the Foot Shift Switch
377
Installing the Left Footrest Assembly
378
Installing the Shift Actuator
378
Shift Shaft
380
Checking the Shift Shaft
381
Checking the Stopper Lever
381
Installing the Shift Shaft (Fjr1300A)
381
Installing the Shift Shaft (Fjr1300As)
381
Oil Pump
383
Checking the Oil Pump
386
Checking the Relief Valve
386
Checking the Oil Delivery Pipes
386
Checking the Oil Strainer
387
Assembling the Oil Pump
387
Installing the Oil Pan
387
Middle Gear
388
Removing the Middle Drive Shaft Assembly
394
Disassembling the Middle Drive Shaft Assembly
394
Disassembling the Middle Driven Shaft Assembly
394
Checking the Middle Drive Shaft Assembly
395
Checking the Middle Driven Shaft Assembly
395
Assembling the Middle Drive Shaft Assembly
395
Assembling the Middle Driven Shaft Assembly
395
Installing the Middle Drive Shaft Assembly
396
Installing the Middle Driven Shaft Assembly
397
Installing the Middle Gear Case Cover
397
Measuring the Middle Gear Backlash
398
Adjusting the Middle Gear Backlash
398
Aligning the Middle Gear
399
Crankcase
402
Disassembling the Crankcase
408
Checking the Crankcase
408
Checking the Oil Delivery Pipes
408
Checking the Bearings and Oil Seal
408
Checking the Timing Chain and Oil Pump Drive Chain
408
Assembling the Crankcase
409
Connecting Rods and Pistons
412
Removing the Connecting Rods and Pistons
413
Checking the Cylinders and Pistons
413
Checking the Piston Rings
414
Checking the Piston Pin
415
Checking the Connecting Rods
416
Installing the Connecting Rods and Pistons
417
Crankshaft
421
Removing the Crankshaft Journal Bearings
422
Checking the Oil Nozzles
422
Checking the Crankshaft
422
Installing the Crankshaft
423
Transmission
425
Removing the Transmission
432
Checking the Shift Forks
432
Checking the Shift Drum Assembly
432
Checking the Transmission
432
Assembling the Main Axle and Drive Axle
433
Installing the Transmission (Fjr1300A)
434
Installing the Transmission (Fjr1300As)
435
Balancers
437
Checking the Balancers
439
Installing the Front Balancer
439
Installing the Rear Balancer
440
Cooling System
443
Radiator
444
Checking the Radiator
446
Installing the Radiator
446
Oil Cooler
447
Checking the Oil Cooler
448
Installing the Oil Cooler
448
Thermostat
449
Checking the Thermostat
451
Installing the Thermostat Assembly
451
Water Pump
453
Disassembling the Water Pump
455
Checking the Water Pump
455
Assembling the Water Pump
455
Installing the Water Pump
456
Fuel System
459
Fuel Tank
461
Air Induction System
468
Electrical System
473
General Information
474
Electric Starting System
490
Checking the Switches
710
Troubleshooting
737
Wiring Diagram
742
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