Yamaha 2002 FJR1300 Supplementary Service Manual
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Yamaha 2002 FJR1300 Supplementary Service Manual

Yamaha 2002 FJR1300 Supplementary Service Manual

Yamaha 2002 fjr1300 (p) motorcycle supplementary service manual
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2002
FJR1300
P
(
)
5JW1-AE2
SUPPLEMENTARY
SERVICE MANUAL

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Summary of Contents for Yamaha 2002 FJR1300

  • Page 1 2002 FJR1300 5JW1-AE2 SUPPLEMENTARY SERVICE MANUAL...
  • Page 3 Service Manual together with the following manual. FJR1300(N) 2001 SERVICE MANUAL: 5JW1-AE1 FJR1300(P) 2002 SUPPLEMENTARY SERVICE MANUAL © 2001 by Yamaha Motor Co., Ltd. First edition, November 2001 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

  • Page 4: Important Manual Information

    EAS00002 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

  • Page 5: How To Use This Manual

    EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.
  • Page 6 EAS00008 SYMBOLS The following symbols are not relevant to SPEC every vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information CHAS 2 Specifications 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system 7 Fuel injection system COOL 8 Electrical system...

  • Page 7: Table Of Contents

    CONTENTS SPECIFICATIONS ....................1 GENERAL SPECIFICATIONS ..............1 ENGINE SPECIFICATIONS ..............1 CHASSIS SPECIFICATIONS ..............2 ELECTRICAL SPECIFICATIONS .............4 TIGHTENING TORQUES .................5 ENGINE TIGHTENING TORQUES ............5 CHASSIS TIGHTENING TORQUES ............5 LUBRICATION POINTS AND LUBRICANT TYPES .........6 CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES ...6 CABLE ROUTING ..................7 PERIODIC CHECKS AND ADJUSTMENTS ..........10 INTRODUCTION ..................10 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS .....10...

  • Page 9: Specifications

    GENERAL SPECIFICATIONS/ SPEC ENGINE SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5JW4 (for Europe) ---- 5JW5 (for F) ---- 5JW6 (for Oceania) ---- ENGINE SPECIFICATIONS Item Standard Limit Fuel Recommended fuel Regular unleaded gasoline only ---- (for Europe) Unleaded gasoline only (for Oceania) ---- Fuel tank capacity...

  • Page 10: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Front wheel Wheel type Cast wheel ---- 17M/C × MT3.50 Size ---- 17 × MT3.50 ---- Material Aluminum ---- Wheel travel 135 mm ---- Wheel runout Max. radial wheel runout ---- 1 mm Max.
  • Page 11 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear suspension Suspension type Swingarm (link suspension) ---- Rear shock absorber assembly type Coil spring/gas-oil damper ---- Rear shock absorber assembly travel 60 mm ---- Upper spring Free length 159 mm 155.82 mm Installed length 138.1 mm ---- Lower spring...

  • Page 12: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit Ignition system Ignition system type Transistorized coil ignition (digital) ---- Ignition timing 5° BTDC at 1,050 r/min ---- Advancer type Electric ---- 420.8 ~ 569.3 Ω/Gy–B Pickup coil resistance/color ---- Transistorized coil ignition unit model F8T911 (MITSUBISHI) (for Europe) ---- (manufacturer)

  • Page 13: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening Thread torque Part to be tightened Part name Q’ty Remarks size m·kgf Timing chain tensioner cap Bolt CHASSIS TIGHTENING TORQUES Tightening Thread torque Part to be tightened Remarks size m·kgf Rear brake caliper retaining bolt –...

  • Page 14: Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Front wheel oil seal (right and left) Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Rear brake pedal pivot Footrest pivoting point...

  • Page 15: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING 1 Air cut-off valve 9 Spark plug lead #3 2 Clutch cable 0 Spark plug lead #2 3 Left handlebar switch lead A Spark plug lead #1 4 Headlight lead B Spark plug lead #4 5 Main switch lead C Throttle position sensor 6 Throttle cable...
  • Page 16 SPEC CABLE ROUTING È Connect the wire harness and right handlebar Ì To the cylinder identification sensor Í To the fuel tank switch lead. É Pass the left handlebar switch lead, main switch Î Pass the cylinder identification sensor lead lead, headlight lead, and clutch cable through through the lead guide of throttle body.
  • Page 17 SPEC CABLE ROUTING Ñ Support the throttle cables with the T-bar located Ó To the left slit of the plate behind the cable guide. Ò Pass the throttle cables under spark plug leads #1, #2, #3, and #4, and the wire harness, head- light lead, main switch lead, right handlebar switch lead, and left handlebar switch lead.

  • Page 18: Periodic Checks And Adjustments

    • From 50,000 km, repeat the maintenance intervals starting from 10,000 km. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1,000 km)

  • Page 19: Periodic Maintenance And Lubrication

    PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ODOMETER READING (× 1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK • Make sure that all nuts, bolts and screws are √ √ √ √ √ 14 * Chassis fasteners properly tightened. Sidestand/ • Check operation. √...

  • Page 20: Cowlings And Covers

    COWLINGS AND COVERS EAS00041 COWLINGS AND COVERS COWLINGS 10 Nm (1.0 m • Order Job/Part Q’ty Remarks Removing the cowlings Remove the parts in the order listed. Rider seat/fuel tank Refer to “SEATS AND FUEL TANK”. (Manual No.: 5JW1-AE1) Left side cowling Right side cowling Front bottom cowling Front turn signal connector (left)
  • Page 21 COWLINGS AND COVERS ( 7 ) Order Job/Part Q’ty Remarks Disassembling the front cowling Remove the parts in the order listed. assembly Windshield outer bracket Windshield Grommet Windshield inner bracket Rear view mirror (left and right) Panel Front cowling Auxiliary light coupler Headlight coupler For assembly, reverse the disassembly procedure.
  • Page 22 COWLINGS AND COVERS Order Job/Part Q’ty Remarks Removing the windshield drive unit, Remove the parts in the order listed. meter assembly and relays Windshield drive unit Windshield drive unit coupler Meter assembly Meter assembly coupler Headlight relay 1 Headlight relay 2 Fuel injection system relay Turn signal relay Radiator fan motor relay...

  • Page 23: Covers

    COWLINGS AND COVERS COVERS Order Job/Part Q’ty Remarks Removing the covers Remove the parts in the order listed. Seats Refer to “SEATS AND FUEL TANK”. (Manual No.: 5JW1-AE1) Left side cover Right side cover Rear carrier Rear cover For installation, reverse the removal procedure.

  • Page 24: Chassis

    CHAS FRONT AND REAR BRAKES CHASSIS FRONT AND REAR BRAKES EAS00578 REAR BRAKE PADS Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Retaining bolt Brake pad Brake pad shim Bleed screw For installation, reverse the removal procedure.

  • Page 25: Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain. Union bolt Copper washer Refer to Brake hose Disconnect. “DISASSEMBLING/ Retaining bolt Loosen.
  • Page 26 CHAS FRONT AND REAR BRAKES EAS00617 Order Job/Part Q’ty Remarks Disassembling the rear brake cali- Remove the parts in the order listed. Retaining bolt Brake pad/brake pad shim Brake pad spring Rear brake caliper bracket Brake caliper piston Refer to “DISASSEMBLING THE REAR BRAKE CALIPER”.

  • Page 27: Front Fork

    CHAS FRONT FORK EAS00647 FRONT FORK Order Job/Part Q’ty Remarks Removing the front fork legs Remove the parts in the order listed. The following procedure applies to both of the front fork legs. Front cowling assembly Refer to “COWLINGS” AND “COVERS” in chapter 3.

  • Page 28: Installing The Front Fork Legs

    CHAS FRONT FORK EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: • front fork leg NOTE: • Make sure that the inner tube end is flush with the top of the upper bracket. •...
  • Page 29 CHAS FRONT FORK 3. Install: • collar 1 • collar 2 • front fender 3 • front fender bolts 6 Nm (0.6 m · kg) NOTE: • Install the collar 1 from the outside of the front fender. • Install the collar 2 from the inside of the front fender.

  • Page 30: Shaft Drive

    CHAS SHAFT DRIVE SHAFT DRIVE Order Job/Part Q’ty Remarks Disassembling the final drive Remove the parts in the order listed. assembly Circlip Oil seal Drive shaft Spring Ring gear bearing housing/oil seal Refer to “ALIGNING Dust cover THE FINAL DRIVE Ring gear/bearing PINION GEAR AND Ring gear shim(s)
  • Page 31 CHAS SHAFT DRIVE Order Job/Part Q’ty Remarks Left-hand threads. Refer to “DISASSEMBLING Gear coupling THE FINAL DRIVE Bearing retainer/oil seal Left-hand threads. ASSEMBLY” and Final drive pinion gear/bearing “ALIGNING THE Final drive pinion gear shim(s) FINAL DRIVE Bearing PINION GEAR AND Bearing RING GEAR”.

  • Page 32: Engine

    CAMSHAFTS ENGINE CAMSHAFTS EAS00196 CAMSHAFTS Order Job/Part Q’ty Remarks Removing the camshafts Remove the parts in the order listed. Throttle bodies Refer to “FUEL INJECTION SYSTEM” in chapter 7. (Manual No.: 5JW1-AE1) Pickup coil rotor cover Refer to “PICKUP COIL ROTOR”. (Manual No.: 5JW1-AE1) Timing chain tensioner Timing chain tensioner gasket...
  • Page 33 CAMSHAFTS Order Job/Part Q’ty Remarks Timing chain guide (exhaust side) Timing chain guide (intake side) For installation, reverse the removal procedure. – 25 –...

  • Page 34: Fuel Injection System

    FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM ECU’S SELF-DIAGNOSTIC FUNCTION Engine trouble warning light indication and FI system operating conditions (normal mode) Warning light ECU’s operating FI operating condition Starting and driving indication condition ON and OFF *1 Self-diagnostic func- FI function in operation Able tion in operation...
  • Page 35 FUEL INJECTION SYSTEM Code No. Symptom Open circuit is detected in the input line from the sidestand switch to the ECU. Used diagnostic code No. 20 (sidestand switch) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective sidestand switch Replace if defective.

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2002 fjr1300p

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