Yamaha FJR1300AS(X) Service Manual Download Page 371

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CLUTCH

5-66

b. If the thickness of the shim installed on the

vehicle is 1.5 mm (0.06 in), refer to the follow-
ing table.

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7. Check:

• Rear wheel drag torque

Refer to “CHECKING THE VEHICLE AFTER
BLEEDING THE HYDRAULIC CLUTCH
SYSTEM (FJR1300AS only)” on page 3-21.

8. Check:

• Shift operation

Refer to “CHECKING THE VEHICLE AFTER
BLEEDING THE HYDRAULIC CLUTCH
SYSTEM (FJR1300AS only)” on page 3-21.

9. Check:

• Starting-off performance of vehicle

Refer to “CHECKING THE VEHICLE AFTER
BLEEDING THE HYDRAULIC CLUTCH
SYSTEM (FJR1300AS only)” on page 3-21.

ET3P66070

INSTALLING THE CLUTCH ACTUATOR
(FJR1300AS only)

1. Install:

• Clutch actuator
• Clutch master cylinder
• Clutch hose
• Clutch fluid reservoir hose

2. Bleed:

• Hydraulic clutch system

Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM (FJR1300AS)” on page
3-19.

3. Check:

• Pressure plate stroke

Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM (FJR1300AS)” on page
3-19.

4. Adjust:

• Clutch engagement point

Refer to “Diagnostic code table (Diagnostic
code No. Sh_ _66)”.

NOTE:

Adjust the clutch engagement point if the clutch
actuator was replaced.

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a. Select diagnostic code No. Sh_ _66 in the di-

agnostic mode and operate the hand shift le-
ver switch (shift up) until the clutch
engagement point is at the maximum setting.

NOTE:

The hand shift select indicator light stops coming
on when the maximum setting is reached.

b. Operate the hand shift lever switch (shift

down) ten times and check that the hand shift
select indicator light comes on.

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▲ ▲▲▲

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5. Check:

• Rear wheel drag torque

Refer to “CHECKING THE VEHICLE AFTER
BLEEDING THE HYDRAULIC CLUTCH
SYSTEM (FJR1300AS only)” on page 3-21.

6. Check:

• Shift operation

Refer to “CHECKING THE VEHICLE AFTER
BLEEDING THE HYDRAULIC CLUTCH
SYSTEM (FJR1300AS only)” on page 3-21.

7. Check:

• Starting-off performance of vehicle

Refer to “CHECKING THE VEHICLE AFTER
BLEEDING THE HYDRAULIC CLUTCH
SYSTEM (FJR1300AS only)” on page 3-21.

Pressure plate

stroke

Action

Pressure plate stroke

before replacing the

clutch master cylin-

der kit was 2.90 mm

(0.11 in) or more, or

the difference in the

pressure plate stroke

before and after re-

placing is 0.10 mm

(0.004 in) or more

Select diagnostic

code No. Sh_ _66 in

the diagnostic mode

and operate the hand

shift lever switch

(shift up) three times.

For all other cases

Select diagnostic

code No. Sh_ _66 in

the diagnostic mode

and operate the hand

shift lever switch

(shift up) one time.

Pressure plate

stroke

Action

Pressure plate stroke

before replacing the

clutch master cylin-

der kit was 2.90 mm

(0.11 in) or more, or

the difference in the

pressure plate stroke

before and after re-

placing is 0.10 mm

(0.004 in) or more

Select diagnostic

code No. Sh_ _66 in

the diagnostic mode

and operate the hand

shift lever switch

(shift up) two times.

For all other cases

No adjustment is nec-

essary.

Summary of Contents for FJR1300AS(X)

Page 1: ...2008 SERVICE MANUAL FJR1300A X FJR1300AS X 3P6 28197 E2...

Page 2: ...JR1300AS X 2008 SERVICE MANUAL 2007 by Yamaha Motor Co Ltd First edition October 2007 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is...

Page 3: ...models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE...

Page 4: ...b section titles 2 appear in smaller print than the section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section...

Page 5: ...1 2 3 4 5 6 7 8 1 Serviceable with engine mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening torque 6 Wear limit clearance 7 Engine speed 8 Electrical data 9 Engine oil 10 Gear oil 11 Mo...

Page 6: ......

Page 7: ...EAS20110 TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9...

Page 8: ......

Page 9: ...PERATION 1 15 ABS SELF DIAGNOSIS FUNCTION 1 17 ABS WARNING LIGHT AND OPERATION 1 20 OUTLINE OF THE YCC S Yamaha Chip Controlled Shift SYSTEM FJR1300AS 1 21 INSTRUMENT FUNCTIONS 1 24 IMPORTANT INFORMAT...

Page 10: ...S20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the frame This in...

Page 11: ...necessary to control the air fuel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically controlled fuel injection FI system in place of th...

Page 12: ...d by the ECU Signals that are input from the throttle position sensor coolant temperature sensor cylinder identification sensor lean angle sensor crankshaft position sensor intake air pressure sensor...

Page 13: ...rake line from the rear brake master cylinder is split at the hydraulic unit to transmit brake fluid pressure to both the rear brake caliper and part of the right front brake caliper in the unified br...

Page 14: ...ween the right front brake caliper and the rear brake caliper in the uni fied brake system is determined mechanically be sure to use the specified brake pads Each set of brake pads should be checked i...

Page 15: ...e reduced However the chassis travels forward by its inertia even though the wheel speed is reduced Brake force The force applied by braking to reduce the wheel speed Wheel lock A condition that occur...

Page 16: ...losely related to wheel slippage Wheel slippage is represented by the slip ratio Side force is also closely related to wheel slippage See figure A If the brakes are applied while keep ing the proper s...

Page 17: ...nd the vehicle is approaching the limit of control To make the rider aware of this condition the ABS has been designed to generate a reaction force pulsating action in the brake lever and brake pedal...

Page 18: ...if the ABS is operating Electronic ABS features The Yamaha ABS anti lock brake system has been developed with the most advanced electronic technology The ABS control is processed with good response u...

Page 19: ...sensor rotor rotates the Hall element in the Hall IC installed in the wheel sensor generates pulses The pulse frequency which is proportional to the magnetic flux density is converted into a wave in t...

Page 20: ...lash or come on If this occurs turn the main switch to OFF then back to ON The ABS operation is normal if the ABS warning light comes on for 2 seconds then goes off Hydraulic unit assembly The hydraul...

Page 21: ...and the outlet solenoid valve 2 is closed The brake line between the brake master cylinder and brake caliper is open 2 When the ABS is activated the inlet solenoid valve 1 closes and the outlet soleno...

Page 22: ...5 6 2 3 1 9 10 11 12 16 14 23 19 21 22 20 25 35 26 27 28 29 30 31 32 33 17 18 15 34 24 8 1 Battery 2 AC magneto 3 Rectifier regulator 4 Main fuse 5 Main switch 6 ABS ECU fuse 7 ABS motor fuse 8 ABS s...

Page 23: ...ECU fuse The ABS performs a self diagnosis test for a few seconds each time the vehicle first starts off after the main switch was turned on During this test a clicking noise can be heard from under...

Page 24: ...ic pressure in the brake master cylinder increases and the brake fluid is sent to the brake caliper At this time the inlet and outlet check valves of the hydraulic pump are closed As a result of elimi...

Page 25: ...n the buffer chamber is pumped back to the brake master cylinder by the hy draulic pump linked to the ABS motor 2 Pressurizing phase The outlet solenoid valve is closed by the pressurization signal tr...

Page 26: ...tected by the ABS self diagnosis It is located in the meter assembly 12 13 7 6 11 3 4 5 9 8 10 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Outlet solen...

Page 27: ...er to ELECTRIC STARTING SYSTEM on page 8 13 3 The ABS warning light comes on while riding If the ABS warning light comes on while riding a malfunction has been detected in the ABS The ABS hydraulic co...

Page 28: ...multi function display when the test coupler adapter 3 is connected to the ABS test coupler 4 for troubleshooting the ABS The ABS test coupler can be accessed by removing front cowling right inner pan...

Page 29: ...n is normal if the ABS warning light comes on for 2 seconds then goes off The ABS operation is normal if the ABS warning light flashes Even if the ABS warning light remains on and does not go off or i...

Page 30: ...ng at traffic lights or in traffic jams YCC S operates the clutch instead of the user Basic function To shift gears after starting the engine the user must use the shift pedal However depending on the...

Page 31: ...bled by pressing the hand shift select button 3 prior to being used The gear positions are shown in the illustration 1 2 3 4 5 6 8 11 12 7 10 9 1 YCC S test coupler 2 YCC S indicator and warning light...

Page 32: ...ain switch to LOCK when parking the vehicle YCC S indicator and warning light The YCC S system is constantly performing a self diagnosis The YCC S system also performs a self diagnosis when the main s...

Page 33: ...e Multi function display WARNING EW3P61020 Be sure to stop the vehicle before making any setting changes to the multi function display The multi function display is equipped with the following an odom...

Page 34: ...eturn to the prior mode after refueling and traveling 5 km 3 mi Clock To set the clock 1 Push the SELECT button and RESET but ton together for at least two seconds 2 When the hour digits start flashin...

Page 35: ...s downshift until the display stops flashing FJR1300AS Ambient temperature instantaneous fuel consumption and average fuel consumption modes except for the UK Push the RESET button to switch the displ...

Page 36: ...or five seconds and then depending on the unit set AV _ _ _ km L average distance that can be traveled using 1 0 L of fuel or AV _ _ _ L 100 km average amount of fuel necessary to travel 100 km is dis...

Page 37: ...fuel consump tion since it was last reset When the average fuel consumption mode is se lected the display flashes for five seconds and then AV _ _ _ MPG average distance that can be traveled using 1...

Page 38: ...y is turned to ON NOTE If the multi function display indicates fault code 52 this could be caused by transponder interfer ence If this fault code appears try the following 1 Use the code re registerin...

Page 39: ...correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha...

Page 40: ...ease Oil bearings liberally when installing if appropriate CAUTION ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfac es EAS20240 CIRCLIPS Before reassemb...

Page 41: ...l times 3 Check All connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector NOTE Make sure all connections are tight 5...

Page 42: ...y mistakes NOTE For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Test coupler adapter 90890...

Page 43: ...ure adapter B 90890 03124 3 16 Vacuum pressure pump gauge set 90890 06756 Mityvac brake bleeding tool YS 42423 3 19 Magnet base B 90890 06844 Magnetic base stand YU A8438 3 20 Dial gauge stand set 908...

Page 44: ...0890 01511 Middle drive gear lash tool YM 01230 4 106 Coupling gear middle shaft tool 90890 01229 Gear holder YM 01229 4 108 4 111 Bearing retainer wrench 90890 04050 Pinion bearing retainer remover Y...

Page 45: ...4 Model 88 Multimeter with tachometer YU A1927 5 11 5 72 7 8 Rotor holding tool 90890 01235 Universal magneto rotor holder YU 01235 5 15 5 18 Yamaha bond No 1215 90890 85505 Three Bond No 1215 5 20 5...

Page 46: ...mer 5 0 mm YM 04099 5 28 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 36 5 37 5 40 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 36 Universal clutch holder 90890 04086 YM...

Page 47: ...g retainer wrench YM 04140 5 90 Gear lash measurement tool 90890 01467 YM 01467 5 93 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 108 Piston ring compressor 90890 05158 YM 08037 5 11...

Page 48: ...Radiator cap tester adapter 90890 01352 Radiator pressure tester adapter YU 33984 6 3 Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A 6 13 Middle driven shaft bearing drive...

Page 49: ...1 40 Pressure gauge 90890 03153 YU 03153 7 7 Fuel pressure adapter 90890 03176 YM 03176 7 7 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 8 248 Tool name Tool No Illustration Ref...

Page 50: ...SPECIAL TOOLS 1 41...

Page 51: ...TIGHTENING TORQUE SPECIFICATIONS 2 15 ENGINE TIGHTENING TORQUES 2 16 CHASSIS TIGHTENING TORQUES 2 21 LUBRICATION POINTS AND LUBRICANT TYPES 2 26 ENGINE 2 26 CHASSIS 2 28 LUBRICATION SYSTEM CHART AND...

Page 52: ...AS 2D2E B F FJR1300AS 2D2F AUS Dimensions Overall length 2230 mm 87 8 in Overall width 750 mm 29 5 in Overall height 1450 mm 57 1 in Seat height 805 mm 31 7 in Wheelbase 1545 mm 60 8 in Ground clearan...

Page 53: ...0 or SAE 20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Total amount 4 90 L 5 18 US qt 4 31 Imp qt Without oil filter cartridge replacement 3 80...

Page 54: ...mm 10 78 in Depth 22 0 mm 0 87 in Water pump Water pump type Single suction centrifugal pump Reduction ratio 75 48 25 28 1 395 Impeller shaft tilt limit 0 15 mm 0 006 in Spark plug s Manufacturer mod...

Page 55: ...t width C intake 0 90 1 10 mm 0 0354 0 0433 in Valve seat width C exhaust 0 90 1 10 mm 0 0354 0 0433 in Valve margin thickness D intake 0 80 1 20 mm 0 0315 0 0472 in Valve margin thickness D exhaust 0...

Page 56: ...mm Spring rate K2 intake 28 34 N mm 161 82 lb in 2 89 kgf mm Spring rate K1 exhaust 21 85 N mm 124 76 lb in 2 23 kgf mm Spring rate K2 exhaust 28 34 N mm 161 82 lb in 2 89 kgf mm Installed compressio...

Page 57: ...35 0 45 mm 0 0138 0 0177 in Limit 0 70 mm 0 0276 in Ring side clearance 0 030 0 070 mm 0 0012 0 0028 in Limit 0 120 mm 0 0047 in 2nd ring Ring type Taper Dimensions B T 1 00 2 90 mm 0 04 0 11 in End...

Page 58: ...ess 2 90 3 10 mm 0 114 0 122 in Wear limit 2 80 mm 0 1102 in Plate quantity 9 pcs Clutch plate thickness 1 90 2 10 mm 0 075 0 083 in Plate quantity 8 pcs Warpage limit 0 10 mm 0 0039 in Clutch spring...

Page 59: ...9 at 20 C 68 F Cylinder identification sensor output voltage ON More than 4 8 V Cylinder identification sensor output voltage OFF Less than 0 6 V Intake air pressure sensor output voltage 3 75 4 25 V...

Page 60: ...ess Size 120 70 ZR17M C 58W Manufacturer model METZELER Roadtec Z6G Manufacturer model BRIDGESTONE BT021F F Wear limit front 1 6 mm 0 06 in Rear tire Type Tubeless Size 180 55 ZR17M C 73W Manufacturer...

Page 61: ...t 4 5 mm 0 18 in Brake disc deflection limit 0 15 mm 0 0059 in Brake pad lining thickness inner 6 3 mm 0 25 in Limit 0 8 mm 0 03 in Brake pad lining thickness outer 6 3 mm 0 25 in Limit 0 8 mm 0 03 in...

Page 62: ...Spring free length 154 6 mm 6 09 in Installed length 136 2 mm 5 36 in Spring free length 73 9 mm 2 91 in Installed length 67 3 mm 2 65 in Soft Spring rate K1 91 00 N mm 519 61 lb in 9 28 kgf mm Sprin...

Page 63: ...Material Resin Resistance 10 0 k AC magneto Model manufacturer LNX07 DENSO Standard output 14 0 V 590 W at 5000 r min Stator coil resistance 0 13 0 19 at 20 C 68 F Voltage regulator Rectifier regulato...

Page 64: ...force 5 28 7 92 N 19 01 28 51 oz 538 808 gf Commutator diameter 24 5 mm 0 96 in Limit 23 5 mm 0 93 in Mica undercut depth 1 50 mm 0 06 in Starter relay Model manufacturer RC19 085A MITSUBA Amperage 1...

Page 65: ...S 4 0 6 0 k Foot shift switch Output voltage FJR1300AS 2 4 2 6 V Resistance FJR1300AS 4 0 6 0 k Grip warmer Grip warmer resistance L 1 21 1 48 at 20 C 68 F Grip warmer resistance R 1 17 1 43 at 20 C 6...

Page 66: ...To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque speci...

Page 67: ...Nm 1 0 m kg 7 2 ft lb Timing chain tensioner cap bolt M6 1 6 Nm 0 6 m kg 4 3 ft lb Camshaft sprocket bolt M7 4 24 Nm 2 4 m kg 17 ft lb Water pump assembly bolt M6 3 12 Nm 1 2 m kg 8 7 ft lb Water pump...

Page 68: ...20 Nm 2 0 m kg 14 ft lb Lower crankcase plug bolt FJR1300A M6 1 10 Nm 1 0 m kg 7 2 ft lb YCC S speed sensor bolt FJR1300AS M6 1 10 Nm 1 0 m kg 7 2 ft lb Generator cover bolt M6 11 12 Nm 1 2 m kg 8 7 f...

Page 69: ...middle driven shaft M68 1 110 Nm 11 0 m kg 80 ft lb Stake Middle driven shaft end cover bolt M8 3 25 Nm 2 5 m kg 18 ft lb Shift drum retainer bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Shift shaft spring stop...

Page 70: ...5 1 ft lb Coolant reservoir bracket bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Clutch fluid reservoir bolt FJR1300AS M6 1 7 Nm 0 7 m kg 5 1 ft lb Clutch actuator bracket bolt FJR1300AS M8 2 19 Nm 1 9 m kg 13...

Page 71: ...TIGHTENING TORQUES 2 20 Cylinder head tightening sequence Crankcase tightening sequence 17 20 16 15 19 22 3 6 9 8 23 14 24 29 30 27 26 28 31 12 11 2 1 18 5 4 21 13 7 10 25...

Page 72: ...M10 2 37 Nm 3 7 m kg 27 ft lb Pinch bolt front side M8 1 24 Nm 2 4 m kg 17 ft lb Pinch bolt rear side M8 2 24 Nm 2 4 m kg 17 ft lb Pivot shaft M28 1 23 Nm 2 3 m kg 17 ft lb Pivot shaft nut M18 1 125 N...

Page 73: ...t lb Windshield inner bracket and windshield drive unit bolt M6 4 7 Nm 0 7 m kg 5 1 ft lb Rearview mirror nut M6 4 7 Nm 0 7 m kg 5 1 ft lb Windshield drive unit bolt M6 4 10 Nm 1 0 m kg 7 2 ft lb Wind...

Page 74: ...e joint assembly flare nut M10 3 16 Nm 1 6 m kg 11 ft lb Brake pipe joint assembly bolt M6 3 7 Nm 0 7 m kg 5 1 ft lb Front brake caliper bolt M10 4 40 Nm 4 0 m kg 29 ft lb Front brake hose holder bolt...

Page 75: ...Nm 1 0 m kg 7 2 ft lb Shift rod locknut FJR1300A M6 2 7 Nm 0 7 m kg 5 1 ft lb Drive shaft dust cover bolt M5 2 4 Nm 0 4 m kg 2 9 ft lb Final gear oil drain bolt M14 1 23 Nm 2 3 m kg 17 ft lb Final ge...

Page 76: ...push the front axle or lightly tap it with a soft hammer until its end is flush with the front fork However if the surface of the front axle end is not parallel to the surface of the front fork align...

Page 77: ...nd exhaust Water pump impeller shaft Oil pump rotors inner and outer and oil pump shaft Oil pump drive sprocket Oil strainer Oil nozzle O ring Starter clutch idle gear inner surface Starter clutch ass...

Page 78: ...r head cover gasket Yamaha bond No 1215 Three Bond No 1215 Crankcase mating surface Yamaha bond No 1215 Three Bond No 1215 Crankshaft position sensor lead grommet Yamaha bond No 1215 Three Bond No 121...

Page 79: ...guide throttle grip inner surface and throttle cables Brake lever pivot bolt and metal to metal moving parts Clutch lever pivot bolt and metal to metal moving parts FJR1300A Rear shock absorber assem...

Page 80: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 15 14 13 12 6 5 4 3 2 1 7 8 9 10 11 9 9 9...

Page 81: ...trainer 2 Oil pump 3 Relief valve assembly 4 Oil filter 5 Oil cooler 6 Main gallery 7 Front balancer shaft 8 Rear balancer shaft 9 Oil nozzle 10 Intake camshaft 11 Exhaust camshaft 12 Main axle 13 Oil...

Page 82: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 EAS20410 LUBRICATION DIAGRAMS 5 6 7 1 2 3 4...

Page 83: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Intake camshaft 2 Cylinder head 3 Exhaust camshaft 4 Oil check bolt 5 Main gallery bolt 6 Crankshaft 7 Oil nozzle...

Page 84: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 1 3 2...

Page 85: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Main axle 2 Drive axle 3 Oil delivery pipe 1...

Page 86: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 6 5 4 3 2 1...

Page 87: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Oil check bolt 2 Crankshaft 3 Oil cooler 4 Oil strainer 5 Oil delivery pipe 3 6 Oil pump...

Page 88: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 1 2 3 4 5 6 7 8 9...

Page 89: ...ATION SYSTEM CHART AND DIAGRAMS 2 38 1 Rear balancer 2 Oil delivery pipe 2 3 Engine oil drain bolt 4 Oil level switch 5 Crankshaft 6 Front balancer 7 Crank pin 8 Oil delivery pipe 3 9 Relief valve ass...

Page 90: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39 4 5 3 2 1 9 8 6 7...

Page 91: ...UBRICATION SYSTEM CHART AND DIAGRAMS 2 40 1 Oil strainer 2 Oil delivery pipe 2 3 Oil cooler 4 Engine oil drain bolt 5 Oil level switch 6 Oil filter cartridge 7 Oil delivery pipe 3 8 Oil pan 9 Oil pump...

Page 92: ...COOLING SYSTEM DIAGRAMS 2 41 EAS20420 COOLING SYSTEM DIAGRAMS A C D B B D A 6 5 15 6 7 8 9 9 10 1 2 3 4 12 11 16 17 18 19 13 14 5 C...

Page 93: ...outlet hose 6 Radiator 7 Coolant reservoir breather hose 8 Thermostat inlet pipe 2 9 Coolant reservoir hose 10 Radiator inlet hose 11 Thermostat inlet hose 2 12 Thermostat assembly 13 Water jacket jo...

Page 94: ...COOLING SYSTEM DIAGRAMS 2 43 A A 7 1 2 3 4 5 5 7 8 6 8 9 10 11 12...

Page 95: ...2 Thermostat inlet hose 2 3 Radiator inlet hose 4 Radiator 5 Radiator outlet hose 6 Oil cooler outlet hose 7 Water jacket joint inlet hose 8 Water pump outlet pipe 9 Water pump outlet hose 10 Water p...

Page 96: ...ROUTING FJR1300A 2 45 EAS20430 CABLE ROUTING FJR1300A C C B B A A C C A B C D E G H H I I J K L 1 2 2 2 3 4 5 6 7 8 9 10 11 12 13 13 14 14 15 16 17 18 19 20 21 1 2 3 22 3 13 14 1 3 7 8 B B F M 21 21 2...

Page 97: ...e of the clutch hose E Fasten the right handlebar switch lead right grip warmer lead main switch lead and immobilizer unit lead with a plastic locking tie Face the end of the plastic locking tie downw...

Page 98: ...D D E E A A F F A A D E D E A B C E I J K L 1 1 2 3 3 4 4 5 5 5 5 5 6 7 8 9 10 11 12 13 13 14 15 16 17 18 18 19 20 21 22 23 24 25 26 23 27 28 29 25 30 31 32 33 34 D F G M N 23 25 25 18 H C C B B 5 18...

Page 99: ...ead to the battery box with a plastic locking tie Face the end of the plastic locking tie rearward Do not cut off the excess end of the plastic locking tie F Route the positive battery lead between th...

Page 100: ...CABLE ROUTING FJR1300A 2 49 2 3 4 5 6 7 8 9 11 10 12 13 14 15 16 A B C D E F 1 1...

Page 101: ...ly 14 Brake pipe brake pipe upper joint assembly to front brake calipers 15 Rear brake light switch 16 Brake hose brake pipe to rear brake caliper A Route the rear wheel sensor lead to the inside of t...

Page 102: ...CABLE ROUTING FJR1300A 2 51 1 2 3 4 5 6 7 8 A B C D E 9 10 11 12 13...

Page 103: ...cking tie rearward along the side of the accessory box Do not cut off the excess end of the plastic locking tie B Fasten the wire harness and left radiator fan motor lead with the holder C Route the g...

Page 104: ...CABLE ROUTING FJR1300A 2 53 A A B C C B D A A A D F H I J K L M N O P Q U V 1 2 7 7 16 16 10 11 14 12 13 15 17 18 19 22 23 24 25 26 27 28 G 8 9 7 3 5 4 30 27 29 D R 10 S T B 6 C 20 21 E...

Page 105: ...nch off from the wire harness to the guide on the holder with a plastic locking tie making sure that the end of the tie faces upward Do not cut off the excess end of the plastic locking tie E Fasten t...

Page 106: ...CABLE ROUTING FJR1300A 2 55 B B A A A A B B C C 1 2 12 13 14 15 16 17 18 E F G 3 4 3 4 H I J K L 1 2 3 4 5 6 A B C D 7 8 9 10 11...

Page 107: ...ctifier regulator lead through the guide on the frame E Securely connect the ABS ECU coupler F Secure the plastic band by inserting the projection on the band into the hole in the rear fender and then...

Page 108: ...CABLE ROUTING FJR1300A 2 57 H A D E F G I I J K L M N O P 1 2 4 5 6 7 8 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 31 30 C B 3 9 10...

Page 109: ...astic locking tie B Position the plastic locking tie 0 20 mm 0 0 79 in from the end of the protective sleeve of the front wheel sensor lead C Position the plastic locking tie 10 30 mm 0 39 1 18 in fro...

Page 110: ...CABLE ROUTING FJR1300A 2 59 1 2 3 4 A B B C D E...

Page 111: ...older on the rear fender making sure that the leads are not routed on top of the holder B Fasten the tail brake light assembly lead and license plate light lead with the holder C Route the tail brake...

Page 112: ...CABLE ROUTING FJR1300A 2 61 A 1 13 A A B P O C D E F G H I J K L M N 2 3 4 5 6 7 8 9 10 11 12 A...

Page 113: ...ess at the location shown in the illustration by inserting the projection on its holder into the hole in the windshield drive unit meter assembly stay I Fasten the leads to windshield drive unit that...

Page 114: ...CABLE ROUTING FJR1300A 2 63 A A 1 1 2 3 4 5 6 7 7 8 9 10 1 2 3 4 5 6 7 8 9 10 10 1 3 4 5 6 7 8 9 13 13 11 12 12 A 2 1 5 4 3...

Page 115: ...oportioning valve to rear brake hose 8 Brake pipe front brake master cylinder to brake pipe lower joint assembly 9 Brake pipe brake pipe upper joint assembly to front brake calipers 10 Brake pipe mete...

Page 116: ...ROUTING FJR1300AS 2 65 ET3P66048 CABLE ROUTING FJR1300AS 17 C C A A C C A B C D E F F G G H I J K L 1 3 2 2 2 3 7 5 4 8 6 9 13 13 14 14 10 13 12 11 14 15 16 18 19 20 22 21 21 21 22 22 1 2 3 B B B B 1...

Page 117: ...d left handlebar switch lead through the guide D Fasten the right handlebar switch lead right grip warmer lead main switch lead and immobilizer unit lead with a plastic locking tie Face the end of the...

Page 118: ...7 C C D D E E A A B B F F A A CB E D E A B C E I J K L 1 1 2 3 3 4 4 5 5 5 5 5 5 6 7 8 9 10 11 12 13 13 14 15 16 17 18 18 18 19 20 21 22 29 23 24 25 26 27 28 30 31 32 33 34 D D F G M N 18 H 23 25 23 2...

Page 119: ...ead to the battery box with a plastic locking tie Face the end of the plastic locking tie rearward Do not cut off the excess end of the plastic locking tie F Route the positive battery lead between th...

Page 120: ...CABLE ROUTING FJR1300AS 2 69 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 A B C E D F 1 1 H 10 18 G...

Page 121: ...r brake light switch 18 Brake hose brake pipe to rear brake caliper A Route the rear wheel sensor lead to the inside of the swingarm making sure that the lead does not protrude above the swingarm B 45...

Page 122: ...CABLE ROUTING FJR1300AS 2 71 1 2 3 4 5 6 7 8 A B C D E 9 10 11 12 13...

Page 123: ...e plastic locking tie rearward along the side of the accessory box Do not cut off the excess end of the plastic locking tie B Fasten the wire harness and left radiator fan motor lead with the holder C...

Page 124: ...CABLE ROUTING FJR1300AS 2 73 UP A A B D C C B D A A A B D C F G H I J K L M N O T R S 1 3 2 19 19 11 12 13 11 15 14 17 18 20 21 22 23 10 24 25 26 16 27 28 29 30 31 32 33 E 7 9 8 4 6 5 30 34 35 16 P Q...

Page 125: ...ess end of the plastic band C Fasten the leads to oil level switch and crankshaft position sensor that branch off from the wire harness to the guide on the holder with a plastic locking tie making sur...

Page 126: ...CABLE ROUTING FJR1300AS 2 75 B B A A A A B B C C 1 2 19 15 14 13 12 18 17 F G 4 5 4 5 I J K L 1 2 3 4 5 6 7 A B C D 8 9 10 11 M H 21 22 23 24 20 E 16...

Page 127: ...h the guide on the frame E Fasten the shift actuator motor lead shift actuator sensor lead and foot shift switch lead with a plastic locking tie making sure to install the tie on each lead s protectiv...

Page 128: ...CABLE ROUTING FJR1300AS 2 77 H A D E F G I I J K L M N O P 1 2 4 5 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 C B 3 10 6 7 8 9...

Page 129: ...ocking tie B Position the plastic locking tie 0 20 mm 0 0 79 in from the end of the protective sleeve of the front wheel sensor lead C Position the plastic locking tie 10 30 mm 0 39 1 18 in from the e...

Page 130: ...CABLE ROUTING FJR1300AS 2 79 1 4 2 5 6 A B C D D E 3 F G...

Page 131: ...on top of the storage compartment projection C Route the tail brake light assembly lead and license plate light lead between the rib and the U lock holder on the rear fender making sure that the lead...

Page 132: ...CABLE ROUTING FJR1300AS 2 81 A 1 13 A A B P O C D E F G H I J K L M N 2 3 4 5 6 7 8 9 10 11 12 A...

Page 133: ...ness at the location shown in the illustration by inserting the projection on its holder into the hole in the windshield drive unit meter assembly stay I Fasten the leads to windshield drive unit that...

Page 134: ...CABLE ROUTING FJR1300AS 2 83 A A 1 1 2 3 4 5 6 7 7 8 9 10 1 2 3 4 5 6 7 8 9 10 10 1 3 4 5 6 7 8 9 13 13 11 12 12 A 2 1 5 4 3...

Page 135: ...roportioning valve to rear brake hose 8 Brake pipe front brake master cylinder to brake pipe lower joint assembly 9 Brake pipe brake pipe upper joint assembly to front brake calipers 10 Brake pipe met...

Page 136: ...CABLE ROUTING FJR1300AS 2 85...

Page 137: ...3 14 CHANGING THE ENGINE OIL 3 15 MEASURING THE ENGINE OIL PRESSURE 3 16 ADJUSTING THE CLUTCH LEVER FJR1300A only 3 17 CHECKING THE CLUTCH FLUID LEVEL FJR1300A 3 17 CHECKING THE CLUTCH FLUID LEVEL FJ...

Page 138: ...CKING AND ADJUSTING THE STEERING HEAD 3 33 ADJUSTING THE HANDLEBAR POSITION 3 34 CHECKING THE FRONT FORK 3 35 ADJUSTING THE FRONT FORK LEGS 3 36 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3 37 ADJUSTI...

Page 139: ......

Page 140: ...30000 km 18000 mi 40000 km 24000 mi 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 24000 m...

Page 141: ...connecting arm pivoting points Check operation Lubricate with lithium soap based grease 24 Fuel injection Adjust engine idling speed and synchronization 25 Engine oil Change Check oil level and vehicl...

Page 142: ...ation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 8 Brake hoses Check for cracks or damage Replace Every 4 years 9 Wheels Check runout and for damage 10 Tir...

Page 143: ...25 Engine oil filter cartridge Replace 26 Cooling system Check coolant level and vehi cle for coolant leakage Change Every 3 years 27 Final gear oil Check oil level and vehicle for oil leakage Change...

Page 144: ...r to THERMOSTAT on page 6 6 2 Disconnect Throttle cables 3 Remove Spark plugs Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS on page 5 13 4 Remove Hose holder 1 Lead holders 2 Picku...

Page 145: ...crankcase Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be in stalled in the correct place b Calculate the difference between the speci fied valve clearance and t...

Page 146: ...ge 5 13 Lubricate the camshaft bearings camshaft lobes and camshaft journals First install the exhaust camshaft Turn the crankshaft clockwise several full turns to seat the parts h Measure the valve c...

Page 147: ...le bodies 1 2 and 4 using the air screw 1 NOTE After each step rev the engine two or three times each time for less than a second and check the synchronization again If the air screw was removed turn...

Page 148: ...meter disappear except the odometer tripmeter fuel reserve tripmeter dis plays dIAG appears on the odometer tripmeter fuel reserve tripmeter LCD 3 Press the SELECT button to select the CO adjustment...

Page 149: ...e 7 1 T bar Refer to GENERAL CHASSIS on page 4 1 3 Install Digital tachometer onto the spark plug lead of cylinder 1 4 Install Fuel tank Refer to FUEL TANK on page 7 1 5 Check Engine idling speed Out...

Page 150: ...ubber covers to its original position 4 Install T bar Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS20680 CHECKING TH...

Page 151: ...NOTE Prior to checking the ignition timing check the wiring connections of the entire ignition system Make sure all connections are tight and free of corrosion 1 Stand the vehicle on a level surface N...

Page 152: ...ecification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 5 2 Start the engine warm it up for several min utes and then turn it off 3 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1...

Page 153: ...e vehicle is upright 2 Start the engine warm it up for several min utes and then turn it off 3 Check Engine oil level The engine oil level should be between the minimum level mark a and maximum level...

Page 154: ...the following procedure a Remove the oil filter cartridge 1 with an oil filter wrench 2 b Lubricate the O ring 3 of the new oil filter cartridge with a thin coat of engine oil CAUTION ECA13390 Make su...

Page 155: ...right side cowling Refer to GEN ERAL CHASSIS on page 4 1 EAS20820 MEASURING THE ENGINE OIL PRESSURE 1 Check Engine oil level Below the minimum level mark Add the recommended engine oil to the proper l...

Page 156: ...iorate causing leakage and poor clutch performance Refill with the same type of clutch fluid that is already in the system Mixing clutch flu ids may result in a harmful chemical reac tion leading to p...

Page 157: ...of the reservoir is horizontal 4 Install Left side cover Refer to GENERAL CHASSIS on page 4 1 EAS20900 BLEEDING THE HYDRAULIC CLUTCH SYSTEM FJR1300A WARNING EWA13000 Bleed the hydraulic clutch system...

Page 158: ...out the flu id using the vacuum pressure gauge set Ig noring this precaution could allow air to enter the hydraulic clutch system considerably lengthening the bleeding procedure If bleeding is diffic...

Page 159: ...fer to CHECKING THE CLUTCH FLUID LEVEL FJR1300AS on page 3 18 3 Check Pressure plate stroke a Remove the pickup rotor cover bolts 1 b Remove the clutch cover 2 Refer to CLUTCH on page 5 46 c Manually...

Page 160: ...hand 2 Check Shift operation Engine stalls Check the pressure plate stroke Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM FJR1300AS on page 3 19 a Place the vehicle on the centerstand b Start the engin...

Page 161: ...IS on page 4 1 NOTE When installing the air filter element into the air filter case cover make sure their sealing surfac es are aligned to prevent any air leaks ET3P66028 CLEANING THE AIR FILTER ELEME...

Page 162: ...age 4 1 EAS21030 CHECKING THE FUEL LINE 1 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 T bar Refer to GENERAL CHASSIS on page 4 1 2 Check Fuel hose 1...

Page 163: ...assembly and muffler bolts 6 Muffler bolts 7 4 Install Side cowlings Refer to GENERAL CHASSIS on page 4 1 EAS21110 CHECKING THE COOLANT LEVEL 1 Stand the vehicle on a level surface NOTE Place the vehi...

Page 164: ...el Refer to GENERAL CHASSIS on page 4 1 EAS21120 CHECKING THE COOLING SYSTEM 1 Remove Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 1 2 Check Radiator 1 Oil cooler outlet hose 2 Radiator inl...

Page 165: ...r cap 2 7 Drain Coolant from the coolant reservoir 8 Install Coolant reservoir 9 Connect Radiator outlet hose 10 Install Coolant drain bolt water pump along with the copper washer 11 Fill Cooling syst...

Page 166: ...be used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 12 Install Radiator cap 13 Fill Coolant reservoir with the recom...

Page 167: ...brake drag EAS21190 ADJUSTING THE REAR DISC BRAKE 1 Check Brake pedal position distance a from the top of the rider footrest to the top of the brake pedal Out of specification Adjust 2 Adjust Brake p...

Page 168: ...brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake...

Page 169: ...of the brake hoses and brake hose holders 1 Check Brake hoses Cracks damage wear Replace 2 Check Brake hose holders Loose Tighten the holder bolts 3 Hold the vehicle upright and apply the brake sever...

Page 170: ...ng procedure when the tiny bubbles in the hose have disappeared 1 Remove Right side cover Refer to GENERAL CHASSIS on page 4 1 2 Bleed ABS a Fill the brake master cylinder reservoir or brake fluid res...

Page 171: ...enter of the shift pedal end 1 is aligned with the center of the middle gear case cover bolt 2 as shown in the illus tration when viewed directly from the side Incorrect Adjust 2 Adjust Shift pedal po...

Page 172: ...gear oil filler bolt 1 Final gear oil drain bolt 2 Completely drain the final gear case of its oil 3 Check Final gear oil drain bolt gasket Damage Replace 4 Install Final gear oil drain bolt along wi...

Page 173: ...the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD on page 4 88 e Install the rubber washer 3...

Page 174: ...uts EAS21530 CHECKING THE FRONT FORK 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Check Inner tube Damage scratc...

Page 175: ...a Turn the adjusting bolt 1 in direction a or b Rebound damping CAUTION ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Rebound damping a Turn the adjusting knob 1 in di...

Page 176: ...e adjusting lever 1 in direction a or b b Adjust the adjusting lever to HARD or SOFT Rebound damping CAUTION ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Rebound dampi...

Page 177: ...quick fastener screws 1 To close a side panel a Remove the quick fastener screws 1 b Push the side panel to the closed position and then install the quick fastener screws 1 Direction a Rebound dampin...

Page 178: ...OTE Remove the rider seat height position adjuster by pulling it upward 4 Adjust Rider seat height To change to the high position a Move the rider seat holder cover 1 to the lower position as shown b...

Page 179: ...to lock it in place as shown 5 Install Passenger seat Refer to GENERAL CHASSIS on page 4 1 EAS21650 CHECKING THE TIRES The following procedure applies to both of the tires 1 Check Tire pressure Out o...

Page 180: ...ires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tires should always be by the same manufacturer and of the same design No guarantee con cerning handling c...

Page 181: ...as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubricate NOTE Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit ab...

Page 182: ...1740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension Recommended lubricant Lithium soap based grease Recommended lubricant Lithium s...

Page 183: ...rom the bulb until it has cooled down 6 Install Headlight bulb Secure the new headlight bulb with the head light bulb holder CAUTION ECA13690 Avoid touching the glass part of the head light bulb to ke...

Page 184: ...djusting screws 1 in direction a or b Left headlight Right headlight Direction a Headlight beam moves to the left Direction b Headlight beam moves to the right Direction a Headlight beam moves to the...

Page 185: ...ISASSEMBLING THE REAR WHEEL 4 27 CHECKING THE REAR WHEEL 4 28 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR 4 28 ASSEMBLING THE REAR WHEEL 4 28 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 29 INS...

Page 186: ...57 REMOVING THE HYDRAULIC UNIT ASSEMBLY 4 62 CHECKING THE HYDRAULIC UNIT ASSEMBLY 4 62 CHECKING THE PROPORTIONING VALVE AND METERING VALVE 4 63 CHECKING THE BRAKE PIPES 4 63 INSTALLING THE HYDRAULIC U...

Page 187: ...FT DRIVE 4 100 TROUBLESHOOTING 4 104 CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND CHECKING THE SHAFT DRIVE FOR LEAKS 4 105 MEASURING THE FINAL GEAR BACKLASH 4 105 ADJUSTING THE FINAL GEAR BACKLA...

Page 188: ...t 1 3 Grab bar 1 4 Left rear cowling 1 5 Right rear cowling 1 6 Center rear cowling 1 7 Left side cover 1 8 Right side cover 1 9 Rider seat height position adjuster 1 For installation reverse the remo...

Page 189: ...Disconnect 7 Bottom cowling 1 8 Front cowling right inner panel 1 1 9 Headlight beam adjusting knob 2 10 Front cowling right inner panel 2 1 11 Adjusting knob shaft 2 12 Headlight beam adjusting cable...

Page 190: ...21 Horn connector 4 Disconnect 22 Grip warmer coupler 2 Disconnect 23 Front cowling assembly 1 For installation reverse the removal proce dure Removing the front cowling assembly FJR1300A Order Job P...

Page 191: ...onnect 7 Bottom cowling 1 8 Front cowling right inner panel 1 1 9 Headlight beam adjusting knob 2 10 Front cowling right inner panel 2 1 11 Adjusting knob shaft 2 12 Headlight beam adjusting cable 2 D...

Page 192: ...ler 6 Disconnect 22 Horn connector 4 Disconnect 23 Grip warmer coupler 2 Disconnect 24 Front cowling assembly 1 For installation reverse the removal proce dure Removing the front cowling assembly FJR1...

Page 193: ...3 Windshield inner bracket 1 4 Rearview mirror 2 5 Accessory box solenoid coupler 1 Disconnect 6 Auxiliary DC jack coupler 1 Disconnect 7 Accessory box 1 8 Accessory box solenoid 1 9 Headlight couple...

Page 194: ...S 4 7 Removing the headlight assembly Order Job Parts to remove Q ty Remarks Front cowling Refer to Disassembling the front cowling assembly 1 Headlight assembly 1 For installation reverse the removal...

Page 195: ...drive unit 1 3 Windshield drive unit side rail 2 4 Meter assembly coupler 1 Disconnect 5 Meter assembly 1 6 Turn signal hazard relay coupler 1 Disconnect 7 Turn signal hazard relay 1 8 Headlight relay...

Page 196: ...bar completely to the left c Install the adjusting knob shaft 1 onto the left headlight beam adjusting cable 2 d Place front cowling left inner panel 2 3 be tween the front cowling assembly and the st...

Page 197: ...n front cowling right inner panel 2 3 making sure to align the projection a on the shaft s sleeve with the slot b in the panel and then install the nut d Install the headlight beam adjusting knob 4 e...

Page 198: ...GENERAL CHASSIS 4 11 b a 1 2...

Page 199: ...rts to remove Q ty Remarks Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 T bar 1 2 Heat protector 1 For installation reverse the removal proce dure 1 2 T R...

Page 200: ...7 Storage compartment 1 8 ECU engine control unit 1 9 Rear lower fuel tank bracket 1 10 Intake air temperature sensor 1 11 Bypass air unit inlet hose 1 Disconnect 12 Crankcase breather hose 1 Disconne...

Page 201: ...ter assembly 1 For installation reverse the removal proce dure Removing the air filter case FJR1300A Order Job Parts to remove Q ty Remarks T R 8 Nm 0 8 m kg 5 8 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib New...

Page 202: ...1 2 Air duct 1 3 Air filter case cover 1 4 Air filter element 1 5 Tool kit 1 6 ECU coupler 1 Disconnect 7 MCU coupler 2 Disconnect 8 MCU 1 9 Storage compartment 1 10 ECU engine control unit 1 11 Rear...

Page 203: ...ase joint assembly 1 18 Air filter case 1 19 Air filter case breather hose 2 20 Filter assembly 1 For installation reverse the removal proce dure Removing the air filter case FJR1300AS Order Job Parts...

Page 204: ...t brake caliper 2 5 Front wheel axle pinch bolt 4 Loosen 6 Front wheel axle bolt 1 7 Front wheel axle 1 8 Front wheel 1 9 Front wheel sensor housing 1 10 Collar 1 11 Front brake disc 2 For installatio...

Page 205: ...ONT WHEEL 4 18 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Front wheel sensor rotor 1 3 Wheel bearing 2 4 Spacer 1 For assembly reverse the disassembly pro cedu...

Page 206: ...the front wheel is elevated EAS21910 DISASSEMBLING THE FRONT WHEEL CAUTION ECA3P6D003 Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the wheel sensor rotor Do not d...

Page 207: ...y replace with a new one Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the wheel sensor rotor Do not drop or shock the wheel sensor or the wheel sensor rotor 1 Chec...

Page 208: ...om the wheel sensor rotor Do not drop the wheel sensor rotor or sub ject it to shocks If any solvent gets on the wheel sensor ro tor wipe it off immediately 1 Install Wheel bearings a Install the new...

Page 209: ...lace the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positi...

Page 210: ...E Tighten the brake disc bolts in stages and in a crisscross pattern 2 Check Front brake discs Refer to CHECKING THE FRONT BRAKE DISCS on page 4 37 3 Lubricate Oil seal lips 4 Install Collar Front whe...

Page 211: ...Measure NOTE Measure the distance a only if the wheel bear ings wheel sensor rotor or both were replaced Distance a between the wheel sensor rotor 1 and wheel sensor housing 2 Out of specification Rei...

Page 212: ...r 1 3 Rear wheel axle pinch bolt 1 Loosen 4 Rear wheel axle nut 1 5 Brake torque rod 1 6 Rear wheel axle 1 7 Rear brake caliper 1 8 Rear wheel 1 9 Rear wheel sensor housing 1 10 Collar 1 11 Rear brake...

Page 213: ...1 Dust cover 1 2 Rear wheel drive hub 1 3 Dust seal 1 4 Wheel bearing 1 5 Rear wheel drive hub damper 6 6 Oil seal 1 7 Bearing retainer 1 8 Rear wheel sensor rotor 1 9 Wheel bearing 1 10 Spacer 1 11...

Page 214: ...sensor before removing the rear wheel sensor housing otherwise the sensor could be damaged NOTE Move the rear wheel to the right to separate it from the final drive assembly ET3P6D002 DISASSEMBLING T...

Page 215: ...replace with a new one Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the wheel sensor rotor Do not drop or shock the wheel sensor or the wheel sensor rotor 1 Check...

Page 216: ...terclockwise 5 Measure Wheel sensor rotor deflection Out of specification Correct the wheel sen sor rotor deflection or replace the wheel sen sor rotor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR A...

Page 217: ...sing is aligned with the projection d on the bracket CAUTION ECA14470 Make sure there are no foreign materials in the wheel hub Foreign materials cause dam age to the inner sensor rotor and wheel sen...

Page 218: ...NOTE When installing the rear wheel sensor check the rear wheel sensor lead for twists and the sensor electrode for foreign materials 8 Check Rear wheel sensor installation Check if the wheel sensor...

Page 219: ...both of the front brake calipers 1 Brake hose holder 1 2 Front brake caliper 1 3 Brake pad bolt 2 4 Brake pad spring 2 5 Front brake pad 4 For installation reverse the removal proce dure 4 T R 6 Nm 0...

Page 220: ...agm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Brake lever 1 5 Front brake light switch connector 2 Disconnect 6 Brake hose union bolt 1 7 Copper washer 2 8 Brake hose front brake maste...

Page 221: ...ont brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder push rod 1 2 Dust boot 1 3 Circlip 1 4 Brake master cylinder kit 1 5 Brake master cylinder body 1 For assembly...

Page 222: ...e hose union bolt 1 3 Copper washer 2 4 Brake hose brake pipe upper joint assembly to right front brake caliper 1 5 Brake hose union bolt unified brake system 1 Right side only 6 Copper washer 2 Right...

Page 223: ...ake pad spring 2 3 Front brake pad 4 4 Brake caliper piston 4 5 Brake caliper piston dust seal 4 6 Brake caliper piston seal 4 7 Bleed screw 1 8 Bleed screw 1 Right side only For assembly reverse the...

Page 224: ...e applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 17 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake di...

Page 225: ...iper 1 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 2 Install Brake pads Brake pad spring NOTE Always install new brake pads and a new brake pad spring as a set...

Page 226: ...stem 1 Remove Brake hose holder 1 Brake hose union bolts 2 Copper washers Brake hose brake pipe upper joint assembly to right front brake caliper 3 Brake hose metering valve to right front brake calip...

Page 227: ...com ponents as they will cause the brake caliper piston dust seals and brake caliper piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston dust s...

Page 228: ...int of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake s...

Page 229: ...an or new brake fluid Never use solvents on internal brake com ponents EAS22530 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Brake master cylinder 1 Brake master cylinder holder 2 NOTE Install...

Page 230: ...e When refilling be careful that water does not enter the brake master cylinder reser voir and brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause...

Page 231: ...KE Removing the rear brake pads Order Job Parts to remove Q ty Remarks 1 Rear brake caliper bolt 2 2 Rear brake caliper 1 3 Brake pad shim 2 4 Rear brake pad 2 5 Brake pad spring 2 For installation re...

Page 232: ...ir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir 1 5 Brake fluid reservoir hose 1 6 Rear brake light switch coupler 1 Disconnect 7 Right footrest assembly 1 8 Rear bra...

Page 233: ...ion reverse the removal proce dure Removing the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 2 3 4 5 6 7 9 10 11 8 12 T R 28 Nm 2 8 m kg 20 ft Ib New New T R 28 Nm 2 8 m kg 20 f...

Page 234: ...r Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder push rod 1 4 Brake master cylinder kit 1 5 Brake master cylinder body 1 For assembly reverse the disassembly...

Page 235: ...SYSTEM ABS on page 3 31 1 Brake hose union bolt 1 2 Copper washer 2 3 Brake hose proportioning valve to rear brake caliper 1 4 Rear brake caliper bolt 2 Loosen 5 Rear wheel axle pinch bolt 1 Loosen 6...

Page 236: ...Rear brake caliper bolt 2 2 Brake pad shim 2 3 Rear brake pad 2 4 Brake pad spring 2 5 Rear brake caliper bracket 1 6 Brake caliper piston 1 7 Brake caliper piston dust seal 1 8 Brake caliper piston s...

Page 237: ...Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 37...

Page 238: ...all Rear brake caliper 5 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 29 6 Check Brake p...

Page 239: ...Brake caliper cylinder 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passage brake caliper body Obstru...

Page 240: ...with the projection d on the bracket CAUTION ECA14470 Make sure there are no foreign materials in the wheel hub Foreign materials cause dam age to the inner sensor rotor and wheel sen sor WARNING EWA1...

Page 241: ...lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 7 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE...

Page 242: ...n internal brake com ponents EAS22740 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install Copper washers Brake hose rear brake master cylinder to brake pipe middle joint assembly 1 Rear brake hose uni...

Page 243: ...lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE S...

Page 244: ...g valve to rear brake hose 6 Hydraulic unit assembly 7 Rear wheel sensor 8 Rear wheel sensor rotor 9 Rear brake caliper 10 Brake hose brake pipe to rear brake caliper 11 Metering valve 12 Left front b...

Page 245: ...voir 1 Refer to REAR BRAKE on page 4 44 2 Tail brake light assembly coupler 1 Disconnect 3 License plate light connector 2 Disconnect 4 Tail brake light assembly 1 5 Lean angle sensor 1 6 Brake light...

Page 246: ...pipe brake pipe upper joint assembly to front brake calipers 1 Disconnect 12 Brake hose rear brake master cylinder to brake pipe middle joint assembly 1 Disconnect 13 Brake pipe front brake master cyl...

Page 247: ...o remove Q ty Remarks 9 9 11 15 16 14 17 9 9 10 13 1 1 1 1 3 2 5 8 6 7 4 12 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 16 Nm 1...

Page 248: ...1 ABS ECU coupler 1 Disconnect 2 Cap nut 3 3 Hydraulic unit assembly bracket 1 4 Hydraulic unit assembly 1 For installation reverse the removal proce dure 4 3 2 2 2 1 T R 16 Nm 1 6 m kg 11 ft Ib T R...

Page 249: ...mbly have been removed be sure to tighten them to the specified torque and bleed the brake system 1 Remove Brake pipes Brake hoses Metering valve Proportioning valve Brake hose holder NOTE Do not oper...

Page 250: ...Remove Rubber plugs or bolts M10 1 0 3 Connect ABS ECU coupler 1 NOTE Push the coupler ejection slider down until a click is heard making sure that is installed se curely 4 Install Brake pipe lower jo...

Page 251: ...ut 4 on the proportioning valve end 9 Install Brake pipe proportioning valve to rear brake hose 1 Brake hose holder 2 NOTE Temporarily tighten the brake pipe flare nuts and brake hose holder bolt 10 T...

Page 252: ...use the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemic...

Page 253: ...ling over NOTE Two people are necessary to perform hydraulic unit operation test 1 1 Place the vehicle on the centerstand 2 Turn the main switch to OFF 3 Remove Front cowling right inner panel 1 Refer...

Page 254: ...the second pulse in the brake pedal but during the pulse in the brake lever or during the first pulse in the brake pedal check that the brake hoses and brake pipes are con nected correctly to the hyd...

Page 255: ...force pulsating action consists of quick pulses Be sure to continue operating the brake lever and brake pedal even after the pulsating action has stopped 11 After the pulsating action has stopped in...

Page 256: ...the brake lever or brake pedal check that the brake hoses and brake pipes are con nected correctly to the hydraulic unit as sembly 13 Turn the main switch to OFF 14 Remove the test coupler adapter fr...

Page 257: ...marks 1 Clutch switch coupler 1 Disconnect 2 Clutch master cylinder holder 1 3 Clutch master cylinder assembly 1 4 Left handlebar 1 5 Left handlebar switch lead 1 6 Lead holder 1 1 7 Lead holder 2 1 8...

Page 258: ...Q ty Remarks 1 Left handlebar 1 2 Left grip warmer lead 1 3 Hand shift switch lead 1 4 Left handlebar switch lead 1 5 Lead holder 1 1 6 Hand shift switch 1 7 Lead holder 2 1 8 Left handlebar switch 1...

Page 259: ...ront brake master cylinder holder 1 3 Front brake master cylinder assembly 1 4 Grip end 1 5 Throttle cable housing 2 6 Throttle cable 2 Disconnect 7 Throttle grip 1 8 Right handlebar 1 9 Right grip wa...

Page 260: ...e WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Handlebar grip Grip end 1 a Apply a thin coat of rubber adhesive onto the end of the left handle...

Page 261: ...e housing so that it forms a loop as shown in the illustration Make sure that the loop is formed so that the section of the lead from the handlebar grip to the first molded grommet is routed above the...

Page 262: ...ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 10 ET3P66031 INSTALLING THE HANDLEBARS FJR1300AS 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is...

Page 263: ...rmer lead 3 and left handlebar switch lead 4 through the switch as shown in the illustration making sure to fasten the left grip warmer lead with the lead holder 2 After installing the hand shift swit...

Page 264: ...hole b in the right handlebar and be sure not to pinch the right grip warmer lead There should be 1 3 mm 0 04 0 12 in of clearance c between the throttle grip and the grip end 10 Install Front brake m...

Page 265: ...ront cowling assembly Refer to GENERAL CHASSIS on page 4 1 Front wheel Refer to FRONT WHEEL on page 4 17 1 Battery holder 1 2 Negative battery lead 1 Disconnect 3 Positive battery lead 1 Disconnect 4...

Page 266: ...cedure applies to both of the front fork legs 1 Cap bolt 1 2 O ring 1 3 Nut 1 4 Damper adjusting rod 1 5 Spacer 1 6 Washer 1 7 Fork spring 1 8 Dust seal 1 9 Oil seal clip 1 10 Oil seal 1 11 Washer 1 1...

Page 267: ...1 1 D 52 mm 2 05 in l 12 mm 0 47 in 19 Outer tube bushing 2 1 D 51 mm 2 01 in l 15 mm 0 59 in 20 Inner tube bushing 1 21 Outer tube 1 For assembly reverse the disassembly pro cedure Disassembling the...

Page 268: ...ING EWA13640 Before loosening the upper and lower brack et pinch bolts support the front fork leg EAS22980 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork l...

Page 269: ...assembly bolt 6 Remove Inner tube a Hold the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft jaws c Separate the inner tube from the outer tube by pulling th...

Page 270: ...s of stability NOTE When assembling the front fork leg be sure to replace the following parts Inner tube bushing Outer tube bushing 1 Outer tube bushing 2 Oil seal Dust seal Before assembling the fron...

Page 271: ...0 Make sure the numbered side of the oil seal faces up NOTE Before installing the oil seal lubricate its lips with lithium soap based grease Lubricate the outer surface of the inner tube with fork oil...

Page 272: ...do not allow any foreign ma terial to enter the front fork 11 After filling the front fork leg slowly stroke the damper rod assembly 1 up and down at least ten times to distribute the fork oil NOTE Be...

Page 273: ...stall the damper adjusting rod 2 c Install the cap bolt 3 and finger tighten it WARNING EWA13670 Always use a new cap bolt O ring d Hold the cap bolt and tighten the nut 1 to specification 17 Install...

Page 274: ...bolt 3 WARNING EWA13680 Make sure the brake hoses are routed prop erly 3 Adjust Spring preload Rebound damping Compression damping Refer to ADJUSTING THE FRONT FORK LEGS on page 3 36 T R Upper bracket...

Page 275: ...mmobilizer unit coupler cover holder 1 2 Immobilizer unit coupler cover 2 3 Immobilizer unit coupler 1 Disconnect 4 Main switch coupler 2 Disconnect 5 Lower bracket cover 1 6 Brake hose joint bracket...

Page 276: ...er bearing inner race 1 21 Upper bearing outer race 1 22 Lower bearing outer race 1 For installation reverse the removal proce dure Removing the lower bracket Order Job Parts to remove Q ty Remarks LS...

Page 277: ...races a Remove the bearing races from the steering head pipe 1 with a long rod 2 and hammer b Remove the bearing race from the lower bracket 3 with a floor chisel 4 and ham mer c Install new bearing...

Page 278: ...33 3 Install Upper bracket Steering stem nut NOTE Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 78 NOTE Temporarily tighten the upper and lower bra...

Page 279: ...ct 3 Rear shock absorber spring preload adjusting lever nut 3 4 Rear shock absorber assembly lower nut Wash er Bolt 1 1 1 5 Connecting arm nut Washer Bolt 2 2 2 6 Connecting arm 2 7 Rear shock absorbe...

Page 280: ...proce dure Removing the rear shock absorber assembly Order Job Parts to remove Q ty Remarks New New New New T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib 5 T R 6...

Page 281: ...the rear shock absorber at a point 15 20 mm 0 59 0 79 in from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23230 REMOVING THE REAR SH...

Page 282: ...3 Check Spacers Damage scratches Replace EAS23270 INSTALLING THE RELAY ARM 1 Lubricate Spacer Bearings 2 Install Bearing 1 2 to the relay arm 3 Install Relay arm NOTE Make sure that the embossed mark...

Page 283: ...on page 4 100 1 Right footrest bracket bolt 2 2 Pivot shaft end cover 1 3 Pivot shaft locknut retainer 1 4 Pivot shaft nut 1 5 Pivot shaft locknut 1 6 Pivot shaft 1 7 Swingarm 1 8 Spacer 1 9 Oil seal...

Page 284: ...l proce dure Removing the swingarm Order Job Parts to remove Q ty Remarks T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 125 Nm 12...

Page 285: ...not smooth or if there is binding check the spacers bear ings washers and dust covers EAS23360 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot sh...

Page 286: ...haft locknut Pivot shaft nut 3 Swingarm 4 Connecting arm A Left side B Right side T R Pivot shaft 23 Nm 2 3 m kg 17 ft lb T R Pivot shaft locknut 115 Nm 11 5 m kg 85 ft lb T R Pivot shaft nut 125 Nm 1...

Page 287: ...the final drive assembly Order Job Parts to remove Q ty Remarks Final gear oil Drain Refer to CHANGING THE ENGINE OIL on page 3 15 Rear wheel Refer to REAR WHEEL on page 4 25 1 Final drive assembly 1...

Page 288: ...AS Refer to SHIFT ACTUATOR AND SHIFT ROD FJR1300AS only on page 5 69 1 Shift arm 1 FJR1300A 2 Left footrest assembly 1 FJR1300A 3 Sidestand switch coupler 1 FJR1300A Disconnect 4 Sidestand 1 FJR1300A...

Page 289: ...seal 1 3 Drive shaft 1 4 Spring 1 5 Ring gear bearing housing 1 6 Dust cover 1 7 Oil seal 1 8 Stopper bolt 1 Left hand threads 9 Stopper bolt shim s 10 Ring gear shim s 11 Ring gear 1 12 Bearing 1 13...

Page 290: ...n gear 1 19 Bearing 1 20 Final drive pinion gear shim s 21 Final drive pinion gear bearing 1 22 Ring gear bearing 1 23 Oil seal 1 24 Collar 1 25 Final gear case 1 For assembly reverse the disassembly...

Page 291: ...oken gear teeth WARNING EWA13790 Stop riding immediately if broken gear teeth are suspected This condition could result in the shaft drive assembly locking up causing a loss of control and possible in...

Page 292: ...a new or fairly new vehicle may result from the applica tion of a rust preventive coating or excessive seal lubrication Always clean the vehicle and recheck the area where the leak is thought to orig...

Page 293: ...band and dial gauge i Repeat steps d to h three more times for a total of four measurements j If any of the readings are over specification adjust the final gear backlash EAS23590 ADJUSTING THE FINAL...

Page 294: ...THE FINAL GEAR BACKLASH on page 4 106 2 Measure Ring gear to stopper bolt clearance a Out of specification Adjust 3 Install Ring gear bearing housing along with the ring gear EAS23610 ADJUSTING THE RI...

Page 295: ...y loosened remove them 2 Remove Coupling gear nut Coupling gear 1 with the coupling gear middle shaft tool 2 3 Remove Bearing retainer with the bearing retainer wrench 1 CAUTION ECA14330 The bearing r...

Page 296: ...ring outer races with a socket or appropriate tool that matches the diameter of the races c Install the inner race onto the final drive pin ion gear 5 Install Collar 1 Oil seal 2 Bearing 3 with an app...

Page 297: ...shim thickness is 0 51 mm The chart instructs you to round off the 1 to 0 Thus you should use a 0 50 mm final drive pinion gear shim c To find ring gear shim thickness B use the following formula Whe...

Page 298: ...ulated Final drive pinion gear Bearing retainer with the bearing retainer wrench 1 CAUTION ECA14350 The bearing retainer has left hand threads To tighten the bearing retainer turn it coun terclockwise...

Page 299: ...ce with Plastigauge d Remove the ring gear bearing housing e Measure the width of the flattened Plasti gauge 1 f If the ring gear to thrust washer clearance is within specification install the ring ge...

Page 300: ...er weight 3 and oil seal installing tool 4 6 Install Universal joint Final drive assembly NOTE Align the drive shaft splines with the driven yoke of the universal joint 7 Tighten Final drive assembly...

Page 301: ...Y FJR1300AS 1 Lubricate Drive shaft spline final drive pinion gear side 2 Lubricate Drive shaft spline universal joint side 3 Install Oil seal 1 Washer 2 with the fork seal driver weight 3 and fork se...

Page 302: ...mbly Refer to SHIFT ACTUATOR AND SHIFT ROD FJR1300AS only on page 5 69 9 Install Rear wheel Refer to REAR WHEEL on page 4 25 10 Fill Final gear case Refer to CHECKING THE FINAL GEAR OIL LEVEL on page...

Page 303: ...8 CYLINDER HEAD 5 22 REMOVING THE CYLINDER HEAD 5 23 CHECKING THE CYLINDER HEAD 5 23 INSTALLING THE CYLINDER HEAD 5 23 VALVES AND VALVE SPRINGS 5 25 REMOVING THE VALVES 5 26 CHECKING THE VALVES AND VA...

Page 304: ...LINDER FJR1300AS only 5 65 INSTALLING THE CLUTCH ACTUATOR FJR1300AS only 5 66 REMOVING THE CLUTCH RELEASE CYLINDER 5 67 CHECKING THE CLUTCH RELEASE CYLINDER 5 67 ASSEMBLING THE CLUTCH RELEASE CYLINDER...

Page 305: ...INGS AND OIL SEAL 5 103 CHECKING THE TIMING CHAIN AND OIL PUMP DRIVE CHAIN 5 103 ASSEMBLING THE CRANKCASE 5 104 CONNECTING RODS AND PISTONS 5 107 REMOVING THE CONNECTING RODS AND PISTONS 5 108 CHECKIN...

Page 306: ...t Drain Refer to CHANGING THE COOLANT on page 3 25 Radiator Refer to RADIATOR on page 6 1 1 O2 sensor coupler 1 Disconnect 2 O2 sensor 1 3 Left muffler 1 4 Right muffler 1 5 Exhaust pipe assembly 1 6...

Page 307: ...ge 7 9 Thermostat Thermostat inlet pipe 1 Refer to THERMOSTAT on page 6 6 Engine oil Oil filter cartridge Drain Refer to CHANGING THE ENGINE OIL on page 3 15 Oil cooler Refer to OIL COOLER on page 6 4...

Page 308: ...oupler 1 Disconnect 7 Gear position switch coupler 1 Disconnect 8 Ground lead 1 Disconnect 9 Spark plug cap 4 For installation reverse the removal proce dure Disconnecting the leads and hoses FJR1300A...

Page 309: ...page 6 6 Engine oil Oil filter cartridge Drain Refer to CHANGING THE ENGINE OIL on page 3 15 Oil cooler Refer to OIL COOLER on page 6 4 Water pump Refer to WATER PUMP on page 6 10 Starter motor Refer...

Page 310: ...ion sensor coupler 1 Disconnect 9 Neutral switch coupler 1 Disconnect 10 YCC S speed sensor coupler 1 Disconnect 11 Ground lead 1 Disconnect 12 Spark plug cap 4 For installation reverse the removal pr...

Page 311: ...1 11 Spacer 2 12 Engine mounting bolt right front upper side 1 13 Engine mounting bolt left front lower side 1 14 Engine mounting bolt left front upper side 1 15 Engine mounting nut rear upper side 1...

Page 312: ...Q ty Remarks T R 32 Nm 3 2 m kg 23 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 37 Nm 3 7 m kg 27 ft Ib T R 37 Nm 3 7 m kg 27 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 45 Nm 4 5 m kg...

Page 313: ...haft wrench 1 and pivot shaft wrench adapter 2 2 Remove Engine NOTE Make sure that the engine does not strike the clutch actuator 1 when removing it EAS23720 INSTALLING THE ENGINE 1 Install Engine NOT...

Page 314: ...t rear upper side threads with engine oil 7 Tighten Engine mounting bolt left front lower side 6 Engine mounting bolt right front upper side 8 Engine mounting bolt right front lower side 9 8 Install E...

Page 315: ...lt left rear side 2 Engine mounting bolts left rear side 3 NOTE Do not fully tighten the bolts 14 Tighten Engine bracket bolt left rear side 2 15 Tighten Engine mounting bolts left rear side 3 16 Inst...

Page 316: ...FJR1300AS only 1 Check Gear position sensor Refer to CHECKING THE GEAR POSITION SENSOR FJR1300AS only on page 8 256 2 Adjust Gear position sensor angle a Connect the gear position sensor coupler to t...

Page 317: ...ENGINE REMOVAL 5 12 3 Check Gear position setting Refer to Diagnostic code table Diagnostic code No Sh_ _65 1 2 3...

Page 318: ...Air cut off valve Reed valves Refer to AIR INDUCTION SYSTEM on page 7 9 1 Spark plug 4 2 Cylinder identification sensor 1 3 Cylinder head cover 1 4 Cylinder head cover gasket 1 5 Dowel pin 4 6 Timing...

Page 319: ...KUP ROTOR on page 5 39 1 Timing chain tensioner 1 2 Timing chain tensioner gasket 1 3 Intake camshaft cap 4 4 Exhaust camshaft cap 4 5 Intake camshaft 1 6 Exhaust camshaft 1 7 Intake camshaft sprocket...

Page 320: ...1 NOTE Make sure that the tensioner rod has been fully set clockwise 4 Remove Timing chain tensioner Timing chain tensioner gasket 5 Remove Camshaft caps Dowel pins CAUTION ECA13720 To prevent damage...

Page 321: ...aft into the cylinder head without the dowel pins and camshaft caps b Position a strip of Plastigauge 1 onto the camshaft journal as shown c Install the dowel pins and camshaft caps Camshaft lobe dime...

Page 322: ...eck Timing chain guide exhaust side Timing chain guide intake side Timing chain guide upper side Damage wear Replace the defective part s EAS23970 CHECKING THE TIMING CHAIN TENSIONER 1 Check Timing ch...

Page 323: ...ft 2 Intake camshaft 3 with the camshaft sprockets CAUTION ECA13740 Do not turn the crankshaft when installing the camshaft s to avoid damage or improper valve timing a Install the timing chain onto b...

Page 324: ...ner caps out 5 Align T mark on the pickup rotor with the crankcase mating surface a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres sion stroke align the T mark a on the pick up...

Page 325: ...tion steps above 9 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 5 10 Install Cylinder head cover gasket Cylinder head cover NOTE Apply Three Bo...

Page 326: ...CAMSHAFTS 5 21...

Page 327: ...VAL on page 5 1 Camshafts Refer to CAMSHAFTS on page 5 13 1 Cylinder head 1 2 Cylinder head gasket 1 3 Dowel pin 2 For installation reverse the removal proce dure T R 12 Nm 1 2 m kg 8 7 ft Ib T R 1st...

Page 328: ...If the limit is exceeded resurface the cylinder head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding pattern NOTE To...

Page 329: ...w one and perform the procedure again CAUTION EC3P61033 Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angle NOTE On a hexagonal bo...

Page 330: ...nder head Refer to CYLINDER HEAD on page 5 22 1 Valve lifter 16 2 Valve pad 16 3 Valve cotter 32 4 Upper spring seat 16 5 Intake valve spring 8 6 Exhaust valve spring 8 7 Intake valve 8 8 Exhaust valv...

Page 331: ...28 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal NOTE There should be no leakage at the valve seat 1 3 Remove Valve cotters NOTE Remove the valve cot...

Page 332: ...ide with the valve guide installer 2 and valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide cle...

Page 333: ...ies to all of the valves and valve seats 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width C a Out of...

Page 334: ...enum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound NO...

Page 335: ...ge scratches Replace the valve lift ers and cylinder head EAS24340 INSTALLING THE VALVES The following procedure applies to all of the valves and related components 1 Deburr Valve stem end with an oil...

Page 336: ...s installed in its original place Install the valve springs with the larger pitch a facing up 5 Install Valve cotters NOTE Install the valve cotters by compressing the valve spring with the valve spri...

Page 337: ...13800 Hitting the valve tip with excessive force could damage the valve 7 Lubricate Valve lifter with the recommended lubricant 8 Install Valve pad Valve lifter NOTE The valve lifter must move smoothl...

Page 338: ...Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 15 1 Stator coil coupler 1 Disconnect 2 Generator cover...

Page 339: ...GENERATOR AND STARTER CLUTCH 5 34 10 Starter clutch 1 For installation reverse the removal proce dure Removing the generator rotor and starter clutch Order Job Parts to remove Q ty Remarks...

Page 340: ...R AND STARTER CLUTCH 5 35 Removing the stator coil assembly Order Job Parts to remove Q ty Remarks 1 Stator coil assembly lead holder 1 2 Stator coil assembly 1 For installation reverse the removal pr...

Page 341: ...CLUTCH 1 Remove Starter clutch bolts 1 NOTE While holding the generator rotor with the sheave holder remove the starter clutch bolts EAS24570 CHECKING THE STARTER CLUTCH 1 Check Starter clutch roller...

Page 342: ...ator rotor Washer Generator rotor bolt NOTE Clean the tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure the woodruff key is properly seated in...

Page 343: ...OR AND STARTER CLUTCH 5 38 4 Install Generator cover gasket Generator cover NOTE Tighten the generator cover bolts in stages and in a crisscross pattern T R Generator cover bolt 12 Nm 1 2 m kg 8 7 ft...

Page 344: ...tor cover Refer to GENERATOR AND STARTER CLUTCH on page 5 33 1 Pickup rotor cover 1 2 Pickup rotor cover gasket 1 3 Dowel pin 2 4 Crankshaft position sensor coupler 1 Disconnect 5 Crankshaft position...

Page 345: ...kup rotor align the groove a in the crankshaft sprocket with the projection b in the pickup rotor 2 Tighten Pickup rotor bolt 1 NOTE While holding the generator rotor 2 with the sheave holder 3 tighte...

Page 346: ...P ROTOR 5 41 4 Install Pickup rotor cover gasket Pickup rotor cover NOTE Tighten the pickup rotor cover bolts in stages and in a crisscross pattern T R Pickup rotor cover bolt 12 Nm 1 2 m kg 8 7 ft lb...

Page 347: ...C STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks Throttle bodies Refer to THROTTLE BODIES on page 7 4 1 Starter motor lead 1 Disconnect 2 Starter motor assembly 1 For instal...

Page 348: ...rks 1 O ring 1 2 Starter motor front cover 1 3 Brush 2 4 Brush seat along with brushes 1 5 Washer 1 6 Lock washer 1 7 Oil seal 1 8 Bearing 1 9 Starter motor rear cover 1 10 Collar 1 11 O ring 2 12 Sta...

Page 349: ...s commutator and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester b If any resistance is out of specification re place the s...

Page 350: ...SSEMBLING THE STARTER MOTOR 1 Install Brush seat 1 NOTE Align the slot a on the brush seat with the tab b in the starter motor front cover 2 Install Starter motor yoke 1 Starter motor front cover 2 St...

Page 351: ...L CHASSIS on page 4 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 15 1 Clutch cover 1 2 Clutch cover gasket 1 3 Dowel pin 2 4 Damper cover 1 5 Damper 1 For installation reverse the rem...

Page 352: ...rod 1 7 Ball 1 8 Long clutch push rod 1 9 Friction plate 1 1 Inside diameter 124 mm 4 88 in 10 Clutch plate 8 11 Friction plate 2 7 Inside diameter 124 mm 4 88 in 12 Friction plate 3 1 Inside diamete...

Page 353: ...For installation reverse the removal proce dure Removing the clutch Order Job Parts to remove Q ty Remarks 19 18 17 16 14 15 12 1110 9 8 7 6 5 4 3 2 1 13 6 New New LT T R 90 Nm 9 0 m kg 65 ft Ib T R...

Page 354: ...page 3 18 1 Clutch master cylinder reservoir cap 1 2 Clutch master cylinder reservoir diaphragm holder 1 3 Clutch master cylinder reservoir diaphragm 1 4 Clutch lever 1 5 Clutch master cylinder push...

Page 355: ...CLUTCH 5 50 12 Clutch master cylinder 1 For installation reverse the removal proce dure Removing the clutch master cylinder FJR1300A Order Job Parts to remove Q ty Remarks...

Page 356: ...sensor coupler 1 Disconnect 4 Clutch actuator bracket 1 5 Clutch fluid reservoir cap 1 6 Clutch fluid reservoir diaphragm holder 1 7 Clutch fluid reservoir diaphragm 1 8 Clutch fluid reservoir 1 9 Clu...

Page 357: ...proce dure Removing the clutch actuator and clutch master cylinder FJR1300AS Order Job Parts to remove Q ty Remarks T R 19 Nm 1 9 m kg 13 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft...

Page 358: ...r cylinder FJR1300A Order Job Parts to remove Q ty Remarks 1 Clutch master cylinder push rod 1 2 Dust boot 1 3 Circlip 1 4 Washer 1 5 Clutch master cylinder kit 1 6 Clutch master cylinder body 1 For a...

Page 359: ...Disassembling the clutch master cylinder FJR1300AS Order Job Parts to remove Q ty Remarks 1 Clutch master cylinder kit 1 2 Clutch master cylinder body 1 For assembly reverse the disassembly pro cedur...

Page 360: ...emove Q ty Remarks Clutch fluid Drain Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM FJR1300A on page 3 18 1 Clutch hose union bolt 1 2 Copper washer 2 3 Clutch hose 1 Disconnect 4 Clutch release cylin...

Page 361: ...emove Q ty Remarks Clutch fluid Drain Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM FJR1300AS on page 3 19 1 Clutch hose union bolt 1 2 Copper washer 2 3 Clutch hose 1 Disconnect 4 Clutch release cyli...

Page 362: ...remove Q ty Remarks 1 Clutch release cylinder piston 1 2 Clutch release cylinder spring 1 3 Clutch release cylinder piston seal 1 4 Bleed screw 1 5 Clutch release cylinder body 1 For assembly reverse...

Page 363: ...ed screwdriver into one of the holes of the clutch housing and primary driven gear and then rotate the inner primary driven gear until both primary drive gears are aligned The teeth of both primary dr...

Page 364: ...ECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing NOTE Pitting on the clutch housing dogs will cause er ratic clutc...

Page 365: ...g operation Replace the clutch housing and crankshaft as a set EAS25250 INSTALLING THE CLUTCH 1 Install Clutch housing 1 NOTE Make sure that the projections a in the clutch housing align with the slot...

Page 366: ...stration 6 Lubricate Friction plates Clutch plates with the recommended lubricant 7 Install Friction plates Clutch plates NOTE First install a friction plate and then alternate be tween a clutch plate...

Page 367: ...hese preventive measures Never disassemble clutch components un less absolutely necessary If any connection on the hydraulic clutch system is disconnected the entire clutch system must be disassembled...

Page 368: ...R1300A 1 Install Clutch master cylinder 1 Clutch master cylinder holder 2 WARNING EW3P61016 Install the clutch lever holder with the UP mark facing up Align the end of the clutch lever holder with the...

Page 369: ...H SYSTEM FJR1300A on page 3 18 5 Check Clutch fluid level Below the minimum level mark a Add the recommended clutch fluid to the proper level Refer to CHECKING THE CLUTCH FLUID LEVEL FJR1300A on page...

Page 370: ...Clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM FJR1300AS on page 3 19 4 Check Clutch fluid level Below the minimum level mark a Add the recommended clutch fluid to the proper level Refer...

Page 371: ...coming on when the maximum setting is reached b Operate the hand shift lever switch shift down ten times and check that the hand shift select indicator light comes on 5 Check Rear wheel drag torque R...

Page 372: ...h com ponents must be cleaned and lubricated with clean or new clutch fluid Never use solvents on internal clutch com ponents as they will cause the piston seal to swell and distort Whenever a clutch...

Page 373: ...ic parts Therefore always clean up any spilt clutch fluid immediately NOTE In order to ensure a correct reading of the clutch fluid level make sure that the top of the reservoir is horizontal 3 Bleed...

Page 374: ...or motor coupler 1 Disconnect 5 Shift actuator 1 6 Sidestand switch coupler 1 Disconnect 7 Left footrest assembly 1 8 Sidestand 1 9 Foot shift switch coupler 1 Disconnect 10 Foot shift switch 1 11 Hol...

Page 375: ...ator shift rod and foot shift switch Order Job Parts to remove Q ty Remarks LT LT T R 65 Nm 6 5 m kg 47 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 1...

Page 376: ...he shift actuator sensor coupler and shift actuator motor coupler e Remove the shift actuator front bolt 4 and then remove the rear bolt 5 f Remove the shift actuator ET2D21008 CHECKING THE SHIFT ROD...

Page 377: ...page 5 72 ET3P66040 ADJUSTING THE FOOT SHIFT SWITCH 1 Check Foot shift switch Refer to CHECKING THE FOOT SHIFT SWITCH FJR1300AS only on page 8 257 2 Adjust Foot shift switch angle a Connect the foot s...

Page 378: ...oles in the rear shift arm and shift actuator to secure the shift rod e Install the shift rod 4 NOTE Check that the hole a in the shift rod is aligned with the hole b in the front shift arm If the hol...

Page 379: ...SHIFT ACTUATOR AND SHIFT ROD FJR1300AS only 5 74 h Pull out the rod from the holes T R Shift rod front locknut 7 Nm 0 7 m kg 5 1 ft lb Shift rod rear locknut 10 Nm 1 0 m kg 7 2 ft lb...

Page 380: ...CH on page 5 46 Shift rod FJR1300AS Refer to SHIFT ACTUATOR AND SHIFT ROD FJR1300AS only on page 5 69 1 Oil baffle plate 1 1 2 Shift arm 1 3 Circlip 1 4 Shift shaft 1 5 Shift shaft spring 1 6 Spacer 1...

Page 381: ...3 Mesh the stopper lever with the shift drum seg ment assembly 2 Install Shift shaft 1 NOTE Hook the end of the shift shaft spring onto the shift shaft spring stopper 2 3 Install Shift arm 1 NOTE Ali...

Page 382: ...SHIFT SHAFT 5 77 3 Install Front shift arm 1 NOTE Align the punch mark a on the front shift arm with the punch mark b on the shift shaft T R Front shift arm bolt 10 Nm 1 0 m kg 7 2 ft lb 2 1 b a 1...

Page 383: ...Refer to THROTTLE BODIES on page 7 4 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 1 Sidestand Refer to SHAFT DRIVE on page 4 100 Water pump Refer to WATER PUMP on page 6 10 1 Oil level swi...

Page 384: ...OIL PUMP 5 79 11 Relief valve assembly 1 For installation reverse the removal proce dure Removing the oil pan and oil pump Order Job Parts to remove Q ty Remarks...

Page 385: ...Order Job Parts to remove Q ty Remarks 1 Oil pump housing cover 1 2 Pin 2 3 Oil pump inner rotor 1 4 Oil pump outer rotor 1 5 Pin 1 6 Washer 1 7 Oil pump driven sprocket 1 8 Oil pump housing 1 For ass...

Page 386: ...nd 2 or replace the defective part s EAS24970 CHECKING THE RELIEF VALVE 1 Check Relief valve body 1 Relief valve 2 Spring 3 O ring 4 Damage wear Replace the defective part s EAS24980 CHECKING THE OIL...

Page 387: ...2 Install Oil pump driven sprocket Oil pump housing 1 Washer 2 Pin 3 Oil pump inner rotor 4 Oil pump outer rotor NOTE When installing the inner rotor align the pin 3 in the oil pump shaft with the gro...

Page 388: ...UMP on page 5 78 1 Middle gear case cover 1 2 Middle gear case cover gasket 1 3 Dowel pin 2 4 Damper cover 1 5 Damper 1 6 Middle drive shaft bearing housing 1 7 Bearing 1 8 Middle driven shaft end cov...

Page 389: ...1 16 Middle driven gear 1 17 Bearing retainer 1 18 Bearing 1 19 Middle drive pinion gear shim 20 Bearing 1 For installation reverse the removal proce dure Removing the middle gear FJR1300A Order Job P...

Page 390: ...1 Middle gear case cover 1 2 Middle gear case cover gasket 1 3 Dowel pin 2 4 Damper cover 1 5 Damper 1 6 Middle drive shaft bearing housing 1 7 Bearing 1 8 Middle driven shaft end cover 1 9 Middle dr...

Page 391: ...ddle driven gear 1 17 Bearing retainer 1 18 Bearing 1 19 Middle drive pinion gear shim 20 Bearing 1 For installation reverse the removal proce dure Removing the middle gear FJR1300AS Order Job Parts t...

Page 392: ...middle drive shaft assembly Order Job Parts to remove Q ty Remarks 1 Spring retainer 2 2 Spring seat 1 3 Damper spring 1 4 Damper driven cam 1 5 Damper drive cam 1 6 Middle drive shaft 1 For assembly...

Page 393: ...y Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Middle driven pinion gear nut 1 3 Middle driven shaft 1 4 Middle driven pinion gear 1 5 Bearing retainer 1 6 Bearing 1 7 Middle driven shaft bea...

Page 394: ...the bearing retainer EAS25750 DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1 Remove Spring retainers 1 NOTE While compressing the spring with the damper spring compressor 2 remove the spring retain...

Page 395: ...90 CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1 Check Middle driven pinion gear Galling pitting wear Replace 2 Check Bearings Damage pitting Replace EAS25800 ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY...

Page 396: ...ift punch EAS25860 INSTALLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1 Tighten Bearing retainer 1 a Attach the bearing retainer wrench 2 b Tighten the bearing retainer to specification c Lock the threads wit...

Page 397: ...aft end cover Middle driven shaft bearing housing bolts NOTE Finger tighten the middle driven shaft bearing housing bolts 2 Tighten Middle driven shaft bearing housing bolts NOTE Before tightening the...

Page 398: ...driven shaft bearing housing bolts 2 Remove Middle driven pinion gear shim s 3 Tighten Middle driven shaft bearing housing bolts CAUTION ECA14050 Do not overtighten the middle driven shaft bearing ho...

Page 399: ...nd the middle driven shaft bear ing housing is 0 42 mm Therefore the chart instructs you to round off the 2 to 0 Thus you should use one 0 40 mm shim Shims are supplied in the following thickness es 8...

Page 400: ...ed number is 0 51 The chart instructs you to round off the 1 to 0 Thus the shim thickness is 0 50 mm Shims are supplied in the following thickness es c To find middle driven pinion gear shim thick nes...

Page 401: ...he hundredths digit and select the appropriate shim s NOTE In the above example the calculated number is 0 51 The chart instructs you to round off the 1 to 0 Thus the shim thickness is 0 50 mm Shims a...

Page 402: ...Refer to MIDDLE GEAR on page 5 83 Clutch housing Refer to CLUTCH on page 5 46 1 Timing chain 1 2 Oil pump drive chain guide 1 3 Oil pump drive chain 1 4 Oil pump drive sprocket 1 5 Spacer 1 6 Collar...

Page 403: ...move Q ty Remarks T R 24 Nm 2 4 m kg 17 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 1st 20 Nm 2 0 m kg 14 ft lb 2nd 20 Nm 2 0 m kg 14 ft lb Final Specified angle 115 125 T R 10...

Page 404: ...using Refer to CLUTCH on page 5 46 1 Timing chain 1 2 Oil pump drive chain guide 1 3 Oil pump drive chain 1 4 Oil pump drive sprocket 1 5 Spacer 1 6 Collar 1 7 Spring washer 1 8 Neutral switch 1 9 YCC...

Page 405: ...Nm 2 4 m kg 17 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 1st 20 Nm 2 0 m kg 14 ft Ib 2nd 20 Nm 2 0 m kg 14 ft Ib Final Specified angle 115 125 T R 10 Nm 1 0 m kg 7 2 ft Ib T...

Page 406: ...livery pipe 1 1 3 Plate 1 4 Oil baffle plate 3 1 5 Bearing 1 6 Oil seal 1 7 Bearing 1 8 Upper crankcase 1 9 Bearing 1 10 Oil filter cartridge bolt 1 11 Upper crankcase damper 1 12 Crankcase plug 1 10...

Page 407: ...to remove Q ty Remarks 10 LS LS 2 LT LT LT LT LT LT 4 8 3 LT 5 7 6 12 1 9 13 T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10...

Page 408: ...oughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Bl...

Page 409: ...e into contact with the oil gallery or crankshaft journal bear ings Do not apply sealant to within 2 3 mm 0 08 0 12 in of the crankshaft journal bearings 3 Install Dowel pins 4 Set the shift drum asse...

Page 410: ...21 27 30 M6 45 mm bolt 31 7 Tighten Crankcase bolts M9 115 mm 1 10 WARNING EW3P61013 Replace the bolts with new ones NOTE The tightening procedure of crankcase bolts 1 10 is angle controlled therefor...

Page 411: ...specified angle Tighten the bolt until it is at the specified angle NOTE On a hexagonal bolt note that the angle from one corner to another is 60 8 Tighten Crankcase bolts 11 31 NOTE Tighten the crank...

Page 412: ...der Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 97 1 Connecting rod cap 4 2 Big end lower bearing 4 3 Piston pin clip 8 4 Piston pin 4 5 Piston 4 6 Connecting rod...

Page 413: ...erence during installation put an identi fication mark on each piston crown Before removing the piston pin deburr the pis ton pin clip s groove and the piston s pin bore area If both areas are deburre...

Page 414: ...r and replace the piston and piston rings as a set EAS24430 CHECKING THE PISTON RINGS 1 Measure Piston ring side clearance Out of specification Replace the piston and piston rings as a set NOTE Before...

Page 415: ...then check the lubrication sys tem 2 Measure Piston pin outside diameter a Out of specification Replace the piston pin 3 Measure Piston pin bore diameter b Out of specification Replace the piston Pis...

Page 416: ...he big end lower bearing into the connecting rod cap NOTE Align the projections a on the big end bearings with the notches b in the connecting rod and connecting rod cap c Put a piece of Plastigauge 1...

Page 417: ...n the connecting rods are used to determine the replacement big end bearing sizes P1 P4 refer to the bearings shown in the crank shaft illustration For example if the connecting rod P1 and the cranksh...

Page 418: ...s 4 Lubricate Piston Piston rings Cylinder with the recommended lubricant 5 Lubricate Bolt threads Nut seats with the recommended lubricant 6 Lubricate Crankshaft pins Big end bearings Connecting rod...

Page 419: ...ng rod nuts with a torque wrench b Put a mark 1 on the corner of the connecting rod nut 2 and the connecting rod 3 c Tighten the connecting rod nuts further to reach the specified angle 115 125 WARNIN...

Page 420: ...CONNECTING RODS AND PISTONS 5 115...

Page 421: ...to CRANKCASE on page 5 97 Front balancer weight Refer to BALANCERS on page 5 132 Connecting rod caps Refer to CONNECTING RODS AND PIS TONS on page 5 107 1 Crankshaft 1 2 Crankshaft journal upper beari...

Page 422: ...ankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings CAUTION ECA13920 Do not interchange the crankshaft journal bearings To obtain the correct crankshaft jo...

Page 423: ...cation select replacement crankshaft journal bear ings 4 Select Crankshaft journal bearings J1 J5 NOTE The numbers A stamped into the lower crank case and the numbers B stamped into the crankshaft web...

Page 424: ...CRANKSHAFT 5 119 NOTE Align the projections a on the crankshaft jour nal bearings 1 with the notches b in the crankcases Be sure to install each crankshaft journal bear ing in its original place...

Page 425: ...y Remarks Crankcase Separate Refer to CRANKCASE on page 5 97 Stopper lever Refer to SHIFT SHAFT on page 5 75 1 Drive axle assembly 1 2 Bearing 1 3 Washer 1 4 Bearing 1 5 Shift drum retainer 1 6 Long s...

Page 426: ...TRANSMISSION 5 121 13 Main axle assembly 1 For installation reverse the removal proce dure Removing the transmission shift drum assembly and shift forks FJR1300A Order Job Parts to remove Q ty Remarks...

Page 427: ...to CRANKCASE on page 5 97 Stopper lever Refer to SHIFT SHAFT on page 5 75 1 Gear position sensor bracket 1 2 Oil seal 1 3 Drive axle assembly 1 4 Bearing 1 5 Washer 1 6 Bearing 1 7 Shift drum retainer...

Page 428: ...RANSMISSION 5 123 15 Main axle assembly 1 For installation reverse the removal proce dure Removing the transmission shift drum assembly and shift forks FJR1300AS Order Job Parts to remove Q ty Remarks...

Page 429: ...3 Toothed lock washer retainer 1 4 5th pinion gear 1 5 Toothed spacer 1 6 Toothed washer 2 7 Circlip 2 8 3rd pinion gear 1 9 4th pinion gear 1 10 Collar 1 11 Main axle 1st pinion gear 1 12 Bearing 1...

Page 430: ...d wheel gear 1 4 Collar 1 5 Washer 1 6 5th wheel gear 1 7 Circlip 2 8 Toothed washer 2 9 3rd wheel gear 1 10 Toothed spacer 1 11 Toothed lock washer 1 12 Toothed lock washer retainer 1 13 4th wheel ge...

Page 431: ...126 18 Drive axle 1 For assembly reverse the disassembly pro cedure Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks 1 18 17 16 15 14 8 7 12 11 10 2 3 4 6 7 8 9 13 E M M M...

Page 432: ...to straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar as a set EAS26270 CHECKING THE SHIF...

Page 433: ...ective part s 6 Check Circlips Bends damage looseness Replace ET3P61030 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1 Install Toothed washer 1 Circlip 2 NOTE Be sure the circlip sharp edged corner a is po...

Page 434: ...g hole with the corresponding hole in the upper crankcase Stake the main axle bearing housing bolts at a cutout a in the main axle bearing housing 2 Install Shift fork C Shift drum assembly Springs Sh...

Page 435: ...bearing housing hole with the corresponding hole in the upper crankcase Stake the main axle bearing housing bolts at a cutout a in the main axle bearing housing 2 Install Shift fork C Shift drum assem...

Page 436: ...ankcase Make sure the bearing circlip 2 is inserted into the groove in the upper crankcase 5 Check Transmission Rough movement Repair NOTE Oil each gear shaft and bearing thoroughly 6 Install Oil seal...

Page 437: ...r Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 97 1 Front balancer lever 1 2 Front balancer shaft 1 3 Washer 2 4 Bearing 2 5 Front balancer gear 1 6 Damper 4 7 Fron...

Page 438: ...4 Pickup rotor cover Refer to PICKUP ROTOR on page 5 39 Clutch cover Refer to CLUTCH on page 5 46 1 Rear balancer cover 1 2 Rear balancer cover gasket 1 3 Rear balancer lever 1 4 Rear balancer shaft...

Page 439: ...ch damper is positioned to the outside of the gear projec tions as shown in the illustration Align the punch mark b in the balancer weight with the mark c in the balancer gear 2 Align T mark on the pi...

Page 440: ...om the balancer gear If noise is abnormal adjust the gear lash by turning the balancer shaft NOTE With each adjustment turn the balancer shaft one scale ET3P61033 INSTALLING THE REAR BALANCER 1 Instal...

Page 441: ...aft a Align the punch marks a in the balancer weight with the punch mark b in the upper crankcase b Align the balancer gear punch mark c with the primary driven gear point d as shown NOTE Make sure th...

Page 442: ...Rear balancer lever bolt 1 Rear balancer shaft pinch bolt 2 NOTE Make sure that the balancer shaft does not ro tate 7 Start the engine and check that there is no abnormal noise coming from the balance...

Page 443: ...OLER 6 4 CHECKING THE OIL COOLER 6 5 INSTALLING THE OIL COOLER 6 5 THERMOSTAT 6 6 CHECKING THE THERMOSTAT 6 8 INSTALLING THE THERMOSTAT ASSEMBLY 6 8 WATER PUMP 6 10 DISASSEMBLING THE WATER PUMP 6 12 C...

Page 444: ...t reservoir 1 6 Radiator inlet hose 1 7 Plunger control unit hose 2 1 8 Oil cooler outlet hose 1 9 Left horn low 1 10 Coolant reservoir bracket 1 11 Water pump breather hose 1 12 Radiator outlet hose...

Page 445: ...1 21 Air deflector 1 For installation reverse the removal proce dure Removing the radiator Order Job Parts to remove Q ty Remarks T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1...

Page 446: ...nd make sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 53 EAS26400 INSTALLING THE RADIATOR 1 Fill Cooling system w...

Page 447: ...ain Refer to CHANGING THE COOLANT on page 3 25 Radiator Refer to RADIATOR on page 6 1 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 1 1 Water pump outlet hose 1 2 Water pump outlet pipe 1 3...

Page 448: ...thinner 2 Install O ring Oil cooler NOTE Make sure the O ring is positioned properly 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page...

Page 449: ...ect 3 Radiator inlet hose 1 Disconnect 4 Thermostat inlet hose 2 1 5 Thermostat cover radiator filler pipe 1 6 Thermostat housing 1 7 Thermostat 1 8 Thermostat inlet pipe 2 1 9 Thermostat inlet hose 1...

Page 450: ...ion reverse the removal proce dure Removing the thermostat assembly Order Job Parts to remove Q ty Remarks T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib New T R...

Page 451: ...t pipes Radiator inlet hose Thermostat cover radiator filler pipe Plunger control unit hose 1 Cracks damage wear Replace EAS26490 INSTALLING THE THERMOSTAT ASSEMBLY 1 Install Copper washer Coolant tem...

Page 452: ...THERMOSTAT 6 9 5 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3...

Page 453: ...nt level is extremely low or the coolant contains engine oil Right side cowling Refer to GENERAL CHASSIS on page 4 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 25 1 Water pump breather hose...

Page 454: ...rts to remove Q ty Remarks 1 Water pump housing cover 1 2 O ring 1 3 Circlip 1 4 Impeller shaft 1 5 Rubber damper holder 1 6 Rubber damper 1 7 Water pump seal 1 8 Oil seal 1 9 Bearing 2 10 Water pump...

Page 455: ...pump housing Impeller shaft Cracks damage wear Replace 2 Check Bearing Rough movement Replace EAS26560 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 into the water pump housing NOTE Before installin...

Page 456: ...s smoothly EAS26580 INSTALLING THE WATER PUMP 1 Install O ring 1 Water pump assembly 2 NOTE Align the slit a on the impeller shaft with the projection b on the oil pump driven sprocket Lubricate the O...

Page 457: ...the recom mended coolant Refer to CHANGING THE COOLANT on page 3 25 3 Check Cooling system Leaks Repair or replace any faulty part 4 Measure Radiator cap opening pressure Below the specified pressure...

Page 458: ...WATER PUMP 6 15...

Page 459: ...PUMP 7 2 INSTALLING THE FUEL TANK 7 2 THROTTLE BODIES 7 4 CHECKING THE INJECTORS 7 7 CHECKING THE THROTTLE BODIES 7 7 CHECKING THE FUEL PRESSURE 7 7 ADJUSTING THE THROTTLE POSITION SENSOR 7 7 AIR INDU...

Page 460: ...k panel 1 2 Fuel sender coupler 1 Disconnect 3 Fuel pump coupler 1 Disconnect 4 Fuel tank breather hose 1 5 Fuel tank overflow hose 1 6 Fuel hose holder 1 7 Fuel hose 1 8 Fuel tank 1 9 Fuel pump 1 For...

Page 461: ...hock Do not touch the base section of the fuel sender EAS26670 CHECKING THE FUEL PUMP BODY 1 Check Fuel pump body Obstruction Clean Cracks damage Replace fuel pump as sembly EAS26700 INSTALLING THE FU...

Page 462: ...uel hose holder is in the correct position other wise the fuel hose will not be properly in stalled NOTE Install the fuel hose connector securely onto the fuel tank until a distinct click is heard and...

Page 463: ...THE COOLANT on page 3 25 1 O2 sensor coupler 1 Disconnect 2 Cylinder identification sensor coupler 1 Disconnect 3 Sub wire harness coupler 1 Disconnect 4 Engine idle speed adjusting screw 1 Disconnect...

Page 464: ...isconnect 11 Throttle body joint 4 For installation reverse the removal proce dure Removing the throttle bodies Order Job Parts to remove Q ty Remarks T R 3 Nm 0 3 m kg 2 2 ft Ib T R 3 Nm 0 3 m kg 2 2...

Page 465: ...3 injector coupler 1 Disconnect 6 Cylinder 4 injector coupler 1 Disconnect 7 Sub wire harness 1 8 Negative pressure hose 7 9 Bypass air unit inlet hose 1 10 Bypass air unit 1 11 Bypass air unit outlet...

Page 466: ...use fuel to spurt out when removing the hoses c Connect the fuel pressure adapter 3 be tween the fuel hose 1 and fuel rail 2 d Connect the pressure gauge 4 to fuel pres sure adapter 3 e Start the engi...

Page 467: ...t the voltage is within the specified range f After adjusting the throttle position sensor an gle tighten the throttle position sensor screws 3 to specification Digital circuit tester 90890 03174 Mode...

Page 468: ...AIR INDUCTION SYSTEM 7 9 EAS27040 AIR INDUCTION SYSTEM 1 2 3 4 5 1 1 1 1 2 2 5 2 3 3 4 7 8 6...

Page 469: ...er 3 Air induction system hose air cut off valve to 3 way joint 4 Air induction system hose 3 way joint to air cut off valve 5 Air cut off valve 6 Air induction system hose 3 way joint to hose plug 7...

Page 470: ...Disconnect 2 Air induction system hose air filter case joint assembly to 3 way joint 1 3 Air induction system hose 3 way joint to hose plug 1 4 Air induction system hose 3 way joint to air cut off val...

Page 471: ...inlet pipe 1 Refer to THERMOSTAT on page 6 6 1 Reed valve cover cylinder 1 1 2 Reed valve cover cylinders 2 3 1 3 Reed valve cover cylinder 4 1 4 Reed valve assembly 4 5 Reed valve plate 4 For instal...

Page 472: ...valve opens to allow the air to flow during idle and closes to cut off the flow when the vehicle is be ing driven However if the coolant temperature is below the specified value the air cut off valve...

Page 473: ...2 2 FJR1300AS 8 19 STARTING CIRCUIT CUT OFF SYSTEM OPERATION FJR1300A 8 21 STARTING CIRCUIT CUT OFF SYSTEM OPERATION FJR1300AS 8 22 TROUBLESHOOTING FJR1300A 8 23 TROUBLESHOOTING FJR1300AS 8 25 CHARGIN...

Page 474: ...P SYSTEM 8 99 CIRCUIT DIAGRAM 1 2 8 99 CIRCUIT DIAGRAM 2 2 8 101 TROUBLESHOOTING 8 103 WINDSHIELD DRIVE SYSTEM 8 105 CIRCUIT DIAGRAM 1 2 8 105 CIRCUIT DIAGRAM 2 2 8 107 TROUBLESHOOTING 8 109 ACCESSORY...

Page 475: ...GOES OFF 8 146 B 5 MALFUNCTION ARE CURRENTLY DETECTED 8 147 C 1 ONLY THE ABS WARNING LIGHT FAILS TO COME ON 8 147 C 2 ALL INDICATOR LIGHTS FAIL TO COME ON 8 148 C 3 THE ABS WARNING LIGHT REMAINS ON 8...

Page 476: ...IER REGULATOR 8 250 CHECKING THE HORNS 8 250 CHECKING THE OIL LEVEL SWITCH 8 251 CHECKING THE FUEL SENDER 8 251 CHECKING THE RADIATOR FAN MOTORS 8 252 CHECKING THE COOLANT TEMPERATURE SENSOR 8 252 CHE...

Page 477: ......

Page 478: ...K B L BLACK B1 BB B B B B BB2 BB1 BB4 BB3 B2 B1 WIRE HARNESS SUB WIRE HARNESS A A A A A A A A A A A A Sb W W B Br B L W W Y L B B W Gy W G R L R Y G W L G Y Sb Br W B W B G R R L ON P OFF R R W Br B G...

Page 479: ...re harness front cowling wire harness 21 Relay unit 24 Sidestand switch 36 Cylinders 1 4 ignition coil 37 Spark plug 38 Cylinders 2 3 ignition coil 44 ECU engine control unit 45 Crankshaft position se...

Page 480: ...Dg Br R B B Br W Ch G Y G Y Dg Br W L R W Ch Br G R B B B Ch B W B R R B Dg W B B Y G Y G Y R B B R Ch B W W B B Y Dg B Y R Y Dg B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg B R Br G L B P Sb W B Y Ch...

Page 481: ...IGNITION SYSTEM 8 4 20 Coupler 3 wire harness front cowling wire harness 54 Coupler 4 wire harness front cowling wire harness 70 Engine stop switch...

Page 482: ...LACK L B W Dg G Y B Ch W B R B R Y G L R Y Y W L W2 L W Y G G R Br B R W G Y Y G Br G Y Br B ON P OFF R R Br W Br L Br R Br R R R G R R R R B O R L Gy R R L R L B R R R B B B R R W L W L R B1 BB B2 BB...

Page 483: ...oupler 3 wire harness front cowling wire harness 36 Sidestand switch 37 Cylinders 1 4 ignition coil 38 Spark plug 39 Cylinders 2 3 ignition coil 45 ECU engine control unit 46 Crankshaft position senso...

Page 484: ...B B R B B B BLACK W B Br L BLACK B B BLACK Br Br L BLACK L R Br G B W G Y B Dg Ch W B R B R B G Y B W W B Dg Ch B R W L W Dg Br R B B Br W Ch G Y G Y Dg Br W L R W Ch Br G R B B Lg W R B BLACK UP DOW...

Page 485: ...IGNITION SYSTEM 8 8 27 Coupler 3 wire harness front cowling wire harness 66 Coupler 5 wire harness front cowling wire harness 90 Engine stop switch...

Page 486: ...engine continues to run under the following con ditions The transmission is in gear the neutral circuit of the gear position switch is open and the sidestand is up the sidestand switch circuit is clos...

Page 487: ...TERY on page 8 240 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 11 Re gap or replace the spark plug s 4 Check the ign...

Page 488: ...SWITCHES on page 8 233 Replace the neutral switch 12 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 233 Replace the sidestand switch 13 Check the relay unit diode Refer to CHECKI...

Page 489: ...IGNITION SYSTEM 8 12...

Page 490: ...BLACK BLACK B L BLACK B1 BB B B B B BB2 BB1 BB4 BB3 B2 B1 WIRE HARNESS SUB WIRE HARNESS A A A A A A A A A A A A Sb W W B Br B L W W Y L B B W Gy W G R L R Y G W L G Y Sb Br W B W B G R R L ON P OFF R...

Page 491: ...2 Starter motor 15 Gear position switch 16 Coupler 1 wire harness front cowling wire harness 20 Coupler 3 wire harness front cowling wire harness 21 Relay unit 22 Starting circuit cut off relay 24 Sid...

Page 492: ...L W Dg Br R B B Br W Ch G Y G Y Dg Br W L R W Ch Br G R B B B Ch B W B R R B Dg W B B Y G Y G Y R B B R Ch B W W B B Y Dg B Y R Y Dg B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg B R Br G L B P Sb W B...

Page 493: ...EM 8 16 16 Coupler 1 wire harness front cowling wire harness 20 Coupler 3 wire harness front cowling wire harness 54 Coupler 4 wire harness front cowling wire harness 70 Engine stop switch 71 Start sw...

Page 494: ...B L BLACK L B W Dg G Y B Ch W B R B R Y G L R Y Y W L W2 L W Y G G R Br B R W G Y Y G Br G Y Br B ON P OFF R R Br W Br L Br R Br R R R G R R R R B O R L Gy R R L R L B R R R B B B R R W L W L R B1 BB...

Page 495: ...re harness 18 Relay unit 19 Starting circuit cut off relay 21 Neutral switch 27 Coupler 3 wire harness front cowling wire harness 29 Brake light relay 30 Rear brake light switch 36 Sidestand switch 58...

Page 496: ...P R B B B R B B B BLACK W B Br L BLACK B B BLACK Br Br L BLACK L R Br G B W G Y B Dg Ch W B R B R B G Y B W W B Dg Ch B R W L W Dg Br R B B Br W Ch G Y G Y Dg Br W L R W Ch Br G R B B Lg W R B BLACK U...

Page 497: ...20 14 Coupler 1 wire harness front cowling wire harness 27 Coupler 3 wire harness front cowling wire harness 66 Coupler 5 wire harness front cowling wire harness 89 Front brake light switch 90 Engine...

Page 498: ...lay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay stays open so current cannot reach the starter motor Wh...

Page 499: ...e starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay stays open so current cannot reach the starter motor When at least one...

Page 500: ...ry terminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 249 Starter motor is OK Perform the electric starting system t...

Page 501: ...Replace the gear position switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 233 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on p...

Page 502: ...the battery terminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 249 Starter motor is OK Perform the electric startin...

Page 503: ...witch Refer to CHECKING THE SWITCHES on page 8 233 Replace the right handlebar switch 12 Check the neutral switch Refer to CHECKING THE SWITCHES on page 8 233 Replace the neutral switch 13 Check the s...

Page 504: ...8 27 NG OK 17 Check the entire starting system wiring Refer to CIRCUIT DIAGRAM 1 2 FJR1300AS on page 8 17 and CIRCUIT DIAGRAM 2 2 FJR1300AS on page 8 19 Properly connect or repair the starting sys te...

Page 505: ...ELECTRIC STARTING SYSTEM 8 28...

Page 506: ...Lg R W R G B2 Br B R Y R W L R G L Br R Y Br B R W L R G L Br R Y G L R Y Y W R R B Gy R P W B L BLAC Y L L ON P OFF R R W Br B G Y R Br L Br R Br R Br L R Br L R Y R W Br L Br L Br L Br B B Lg W B G...

Page 507: ...CHARGING SYSTEM 8 30 2 Rectifier regulator 3 AC magneto 8 Main fuse 9 Battery...

Page 508: ...Refer to CHECKING AND CHARGING THE BATTERY on page 8 240 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 249 Replace th...

Page 509: ...CHARGING SYSTEM 8 32...

Page 510: ...L BLACK B1 BB B B B B BB2 BB1 BB4 BB3 B2 B1 WIRE HARNESS SUB WIRE HARNESS A A A A A A A A A A A A Sb W W B Br B L W W Y L B B W Gy W G R L R Y G W L G Y Sb Br W B W B G R R L ON P OFF R R W Br B G Y R...

Page 511: ...er 3 wire harness front cowling wire harness 31 License plate light 33 Tail brake light 44 ECU engine control unit 54 Coupler 4 wire harness front cowling wire harness 55 Headlight on off grip warmer...

Page 512: ...r R B B Br W Ch G Y G Y Dg Br W L R W Ch Br G R B B B Ch B W B R R B Dg W B B Y G Y G Y R B B R Ch B W W B B Y Dg B Y R Y Dg B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg B R Br G L B P Sb W B Y Ch UP D...

Page 513: ...3 wire harness front cowling wire harness 54 Coupler 4 wire harness front cowling wire harness 75 Pass switch 76 Dimmer switch 90 Meter light 91 High beam indicator light 98 Headlight relay dimmer 10...

Page 514: ...eadlight ignition and haz ard lighting Refer to CHECKING THE FUS ES on page 8 239 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 240 Clean the battery term...

Page 515: ...fer to CHECKING THE RE LAYS on page 8 243 Replace the headlight relay dimmer 9 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 33 and CIRCUIT DIA GRAM 2 2 on page 8 35 P...

Page 516: ...ACK B L BLACK B1 BB B B B B BB2 BB1 BB4 BB3 B2 B1 WIRE HARNESS SUB WIRE HARNESS A A A A A A A A A A A A Sb W W B Br B L W W Y L B B W Gy W G R L R Y G W L G Y Sb Br W B W B G R R L ON P OFF R R W Br B...

Page 517: ...der 19 Coupler 2 wire harness front cowling wire harness 20 Coupler 3 wire harness front cowling wire harness 21 Relay unit 26 ABS ECU electronic control unit 28 Rear wheel sensor 29 Rear brake light...

Page 518: ...Dg Br R B B Br W Ch G Y G Y Dg Br W L R W Ch Br G R B B B Ch B W B R R B Dg W B B Y G Y G Y R B B R Ch B W W B B Y Dg B Y R Y Dg B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg B R Br G L B P Sb W B Y Ch...

Page 519: ...e harness front cowling wire harness 67 Turn signal hazard relay 69 Front brake light switch 72 Hazard switch 78 Turn signal switch 79 Horn switch 84 Neutral indicator light 87 Multi function meter 88...

Page 520: ...BLACK L B W Dg G Y B Ch W B R B R Y G L R Y Y W L W2 L W Y G G R Br B R W G Y Y G Br G Y Br B ON P OFF R R Br W Br L Br R Br R R R G R R R R B O R L Gy R R L R L B R R R B B B R R W L W L R B1 BB B2 B...

Page 521: ...l unit 25 Rear wheel sensor 26 Coupler 2 wire harness front cowling wire harness 27 Coupler 3 wire harness front cowling wire harness 28 Diode 29 Brake light relay 30 Rear brake light switch 33 Tail b...

Page 522: ...B B B R B B B BLACK W B Br L BLACK B B BLACK Br Br L BLACK L R Br G B W G Y B Dg Ch W B R B R B G Y B W W B Dg Ch B R W L W Dg Br R B B Br W Ch G Y G Y Dg Br W L R W Ch Br G R B B Lg W R B BLACK UP DO...

Page 523: ...harness front cowling wire harness 81 Turn signal hazard relay 86 Turn signal switch 87 Horn switch 89 Front brake light switch 92 Hazard switch 95 Neutral indicator light 98 Multi function meter 99 O...

Page 524: ...o CHECKING THE FUS ES on page 8 239 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 240 Clean the battery terminals Recharge or replace the battery 3 Check...

Page 525: ...ge 8 41 CIRCUIT DIAGRAM 1 2 FJR1300AS on page 8 43 and CIRCUIT DIAGRAM 2 2 FJR1300AS on page 8 45 Properly connect or repair the signaling system wiring This circuit is OK 1 Check the tail brake light...

Page 526: ...CIRCUIT DIAGRAM 2 2 FJR1300AS on page 8 45 Properly connect or repair the signaling system wiring This circuit is OK 1 Check the turn signal light bulbs and sockets Refer to CHECKING THE BULBS AND BUL...

Page 527: ...KING THE SWITCHES on page 8 233 Replace the gear position switch 2 Check the neutral switch FJR1300AS Refer to CHECKING THE SWITCHES on page 8 233 Replace the neutral switch 3 Check the relay unit dio...

Page 528: ...ing system wiring Refer to CIRCUIT DIAGRAM 1 2 FJR1300A on page 8 39 CIR CUIT DIAGRAM 2 2 FJR1300A on page 8 41 CIRCUIT DIAGRAM 1 2 FJR1300AS on page 8 43 and CIRCUIT DIAGRAM 2 2 FJR1300AS on page 8 4...

Page 529: ...oupler and ECU coupler white yellow white yellow Between ECU coupler and meter assembly coupler yellow blue yellow blue 1 Check the rear wheel sensor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND...

Page 530: ...LACK B1 BB B B B B BB2 BB1 BB4 BB3 B2 B1 WIRE HARNESS SUB WIRE HARNESS A A A A A A A A A A A A Sb W W B Br B L W W Y L B B W Gy W G R L R Y G W L G Y Sb Br W B W B G R R L ON P OFF R R W Br B G Y R Br...

Page 531: ...n fuse 9 Battery 44 ECU engine control unit 48 Coolant temperature sensor 59 Ignition fuse 62 Radiator fan motor relay 63 Left radiator fan motor fuse 64 Left radiator fan motor 65 Right radiator fan...

Page 532: ...s Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 233 Replace the main switch immobilizer unit 4 Check the radiator fan motors Refer to CHECKING THE RA...

Page 533: ...COOLING SYSTEM 8 56...

Page 534: ...CK BLACK B L BLACK B1 BB B B B B BB2 BB1 BB4 BB3 B2 B1 WIRE HARNESS SUB WIRE HARNESS A A A A A A A A A A A A Sb W W B Br B L W W Y L B B W Gy W G R L R Y G W L G Y Sb Br W B W B G R R L ON P OFF R R W...

Page 535: ...ignition coil 37 Spark plug 38 Cylinders 2 3 ignition coil 39 Injector 4 40 Injector 3 41 Injector 2 42 Injector 1 43 Air induction system solenoid 44 ECU engine control unit 45 Crankshaft position se...

Page 536: ...L W Dg Br R B B Br W Ch G Y G Y Dg Br W L R W Ch Br G R B B B Ch B W B R R B Dg W B B Y G Y G Y R B B R Ch B W W B B Y Dg B Y R Y Dg B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg B R Br G L B P Sb W B Y...

Page 537: ...upler 1 wire harness front cowling wire harness 20 Coupler 3 wire harness front cowling wire harness 54 Coupler 4 wire harness front cowling wire harness 70 Engine stop switch 87 Multi function meter...

Page 538: ...L BLACK L B W Dg G Y B Ch W B R B R Y G L R Y Y W L W2 L W Y G G R Br B R W G Y Y G Br G Y Br B ON P OFF R R Br W Br L Br R Br R R R G R R R R B O R L Gy R R L R L B R R R B B B R R W L W L R B1 BB B2...

Page 539: ...ition coil 38 Spark plug 39 Cylinders 2 3 ignition coil 40 Injector 4 41 Injector 3 42 Injector 2 43 Injector 1 44 Air induction system solenoid 45 ECU engine control unit 46 Crankshaft position senso...

Page 540: ...B B BLACK Br Br L BLACK L R Br G B W G Y B Dg Ch W B R B R B G Y B W W B Dg Ch B R W L W Dg Br R B B Br W Ch G Y Lg W R B BLACK G Y Dg Br W L R W Ch Br G R B B L B Y B Dg Br W P Lg Sb Ch R Y BLACK UP...

Page 541: ...upler 1 wire harness front cowling wire harness 27 Coupler 3 wire harness front cowling wire harness 66 Coupler 5 wire harness front cowling wire harness 90 Engine stop switch 98 Multi function meter...

Page 542: ...de has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel injection system operation The warning light flashes when any one...

Page 543: ...de No Item Symptom Able un able to start Able un able to drive 11 Cylinder identification sensor No normal signals are received from the cylinder identification sensor Unable Unable 12 Crankshaft posi...

Page 544: ...faulty cylin ders 34 Cylinders 2 3 igni tion coil faulty ignition Malfunction detected in the prima ry wire of the cylinders 2 3 igni tion coil Able depending on the number of faulty cylin ders Able d...

Page 545: ...alfunc tion Faulty ECU memory When this malfunction is detected in the ECU the fault code number might not appear on the meter Unable Unable Fault code No Item Symptom Able un able to start Able un ab...

Page 546: ...All displays on the meter disappear except the odometer tripmeter fuel reserve tripmeter displays dIAG appears on the odometer tripmeter fuel reserve tripmeter LCD 4 Press the SELECT button to select...

Page 547: ...2 No normal signals are re ceived from the crankshaft position sensor Open or short circuit in wire harness Defective crankshaft position sensor Malfunction in pickup rotor Malfunction in ECU Improper...

Page 548: ...unction in ECU Improperly installed lean angle sensor d 08 31 The amount of air fuel ratio feedback compensation is maintained continuously in the vicinity of the upper lim it lean air fuel ratio Open...

Page 549: ...i tor the battery voltage an open or short circuit in the line to the ECU Open or short circuit in front cowling wire harness Open or short circuit in wire harness Malfunction in ECU d 09 44 An error...

Page 550: ...ened position 97 100 Check with throttle fully open d 03 Pressure difference atmospheric pressure and intake air pressure Displays the intake air pres sure Set the engine stop switch to and then push...

Page 551: ...eutral ON In gear OFF d 60 EEPROM fault code dis play No history 00 History exists 01 04 Cylinder fault code If more than one cylinder is defective the display alter nates every two seconds to show al...

Page 552: ...4 ignition coil five times at one second intervals Illuminates the engine trou ble warning light Check the spark five times Connect an ignition checker d 31 Cylinders 2 3 ignition coil Actuates the c...

Page 553: ...he engine trou ble warning light The engine trouble warning light is OFF when the relay is ON and the engine trouble warning light is ON when the relay is OFF Check the operating sound of the fuel pum...

Page 554: ...tion sensor Check for looseness or pinching Starting the en gine and oper ating it at idle 2 Connections Cylinder identification sensor cou pler Wire harness ECU coupler Sub wire harness coupler Check...

Page 555: ...s Crankshaft position sensor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and c...

Page 556: ...ective intake air pressure sensor Execute the diagnostic mode Code No d 03 Replace if defective Refer to CHECKING THE IN TAKE AIR PRESSURE SEN SOR on page 8 254 Fault code No 14 Symptom Intake air pre...

Page 557: ...oupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness and or sub wire harness Repair or replace if there is an open or short circuit Betw...

Page 558: ...U coupler Sub wire harness coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curel...

Page 559: ...n of the coupler If there is a malfunction repair it and connect the coupler se curely If the transmis sion is in gear retracting the sidestand If the transmis sion is in neu tral reconnecting the wir...

Page 560: ...temperature sensor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect th...

Page 561: ...temperature sensor cou pler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect t...

Page 562: ...ay unit coupler Wire harness ECU coupler Sub wire harness coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it a...

Page 563: ...engine can not be restarted unless the main switch is first turned OFF 2 Installed condition of lean angle sen sor Check the installed direction and condition of the sensor 3 Connections Lean angle s...

Page 564: ...lfunction repair it and connect the coupler se curely Starting the en gine warming it up until the coolant temper ature is 60 C 140 F or more and then running it be tween 2000 3000 r min un til the en...

Page 565: ...r to CHECKING THE FUEL PRESSURE on page 7 7 Check the throttle position sen sor Execute the diagnostic mode Code No d 01 Replace if defective Check the fuel system discon nection etc Repair or replace...

Page 566: ...pen or short circuit in wire harness and or sub wire harness Repair or replace if there is an open or short circuit Between O2 sensor coupler and ECU coupler black blue black blue gray white gray whit...

Page 567: ...ocking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and oper ating it at idle 2 Open or short circuit in wire harness and or fron...

Page 568: ...cking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and oper ating it at idle 2 Open or short circuit in wire harness and or front...

Page 569: ...pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to ON 2 Open or short circuit in w...

Page 570: ...ler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and input ting the vehicle...

Page 571: ...etween relay unit coupler and ECU coupler black red black red Between neutral switch coupler and ECU coupler sky blue sky blue FJR1300AS B 3 Faulty shift drum neutral detection ar ea Replace if defect...

Page 572: ...blue Between relay unit coupler and engine stop switch coupler red black red black 3 Malfunction or open circuit in fuel pump relay Execute the diagnostic mode Code No d 09 Replace if defective If th...

Page 573: ...page 8 240 3 Malfunction in rectifier regulator Replace if defective Refer to CHARGING SYS TEM on page 8 29 4 Open or short circuit in wire harness Repair or replace if there is an open or short circ...

Page 574: ...ue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 2 Symptom No signals are received from the ECU within the specified duration Diagnos...

Page 575: ...ue yellow blue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 4 Symptom Non registered data has been received from the meter Diagnosti...

Page 576: ...L BLACK B1 BB B B B B BB2 BB1 BB4 BB3 B2 B1 WIRE HARNESS SUB WIRE HARNESS A A A A A A A A A A A A Sb W W B Br B L W W Y L B B W Gy W G R L R Y G W L G Y Sb Br W B W B G R R L ON P OFF R R W Br B G Y...

Page 577: ...l injection system fuse 8 Main fuse 9 Battery 17 Fuel pump 20 Coupler 3 wire harness front cowling wire harness 21 Relay unit 23 Fuel pump relay 44 ECU engine control unit 54 Coupler 4 wire harness fr...

Page 578: ...Br R B B Br W Ch G Y G Y R B B R Ch B W W B B Y Dg B Y R Y Dg B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg B R Br G L B P Sb W B Y Ch G Y Dg Br W L R W Ch Br G R B B B Ch B W B R R B Dg W B B Y G Y UP...

Page 579: ...FUEL PUMP SYSTEM 8 102 20 Coupler 3 wire harness front cowling wire harness 54 Coupler 4 wire harness front cowling wire harness 70 Engine stop switch...

Page 580: ...rminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 233 Replace the main switch immobilizer unit 4 Check the engine stop switch Refer to CHECKING T...

Page 581: ...FUEL PUMP SYSTEM 8 104...

Page 582: ...BLACK B L BLACK B1 BB B B B B BB2 BB1 BB4 BB3 B2 B1 WIRE HARNESS SUB WIRE HARNESS A A A A A A A A A A A A Sb W W B Br B L W W Y L B B W Gy W G R L R Y G W L G Y Sb Br W B W B G R R L ON P OFF R R W B...

Page 583: ...switch 7 Backup fuse odometer clock immobilizer system and windshield drive system 8 Main fuse 9 Battery 19 Coupler 2 wire harness front cowling wire harness 54 Coupler 4 wire harness front cowling w...

Page 584: ...Dg Br R B B Br W Ch G Y G Y R B B R Ch B W W B B Y Dg B Y R Y Dg B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg B R Br G L B P Sb W B Y Ch G Y Dg Br W L R W Ch Br G R B B B Ch B W B R R B Dg W B B Y G Y...

Page 585: ...WINDSHIELD DRIVE SYSTEM 8 108 19 Coupler 2 wire harness front cowling wire harness 54 Coupler 4 wire harness front cowling wire harness 77 Windshield position switch 103 Windshield drive unit...

Page 586: ...is no foreign mate rial between the cable and the pul ley Remove the foreign material 3 Check the fuses Main signaling system and back up Refer to CHECKING THE FUS ES on page 8 239 Replace the fuse s...

Page 587: ...OK 7 Check the entire windshield drive system wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 105 and CIRCUIT DIA GRAM 2 2 on page 8 107 Properly connect or repair the windshield drive system wiring Re...

Page 588: ...BB B Y L Lg R W R G B2 Br B R Y R W L R G L Br R Y Br B R W L R G L Br R Y G L R Y Y W R R B Gy R P W B L BLAC Y L L ON P OFF R R W Br B G Y R Br L Br R Br R Br L R Br L R Y R W Br L Br L Br L Br B B...

Page 589: ...ACCESSORY BOX SYSTEM 8 112 1 Main switch 8 Main fuse 9 Battery 54 Coupler 4 wire harness front cowling wire harness 57 Signaling system fuse...

Page 590: ...g Br R B B Br W Ch G Y G Y R B B R Ch B W W B B Y Dg B Y R Y Dg B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg B R Br G L B P Sb W B Y Ch G Y Dg Br W L R W Ch Br G R B B B Ch B W B R R B Dg W B B Y G Y U...

Page 591: ...ACCESSORY BOX SYSTEM 8 114 54 Coupler 4 wire harness front cowling wire harness 80 Accessory box solenoid...

Page 592: ...THE BATTERY on page 8 240 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 233 Replace the main switch immobilizer unit 4 C...

Page 593: ...ACCESSORY BOX SYSTEM 8 116...

Page 594: ...K B L BLACK B1 BB B B B B BB2 BB1 BB4 BB3 B2 B1 WIRE HARNESS SUB WIRE HARNESS A A A A A A A A A A A A Sb W W B Br B L W W Y L B B W Gy W G R L R Y G W L G Y Sb Br W B W B G R R L ON P OFF R R W Br B G...

Page 595: ...e system 8 Main fuse 9 Battery 13 Immobilizer unit 16 Coupler 1 wire harness front cowling wire harness 19 Coupler 2 wire harness front cowling wire harness 20 Coupler 3 wire harness front cowling wir...

Page 596: ...Br R B B Br W Ch G Y G Y R B B R Ch B W W B B Y Dg B Y R Y Dg B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg B R Br G L B P Sb W B Y Ch G Y Dg Br W L R W Ch Br G R B B B Ch B W B R R B Dg W B B Y G Y UP...

Page 597: ...s front cowling wire harness 19 Coupler 2 wire harness front cowling wire harness 20 Coupler 3 wire harness front cowling wire harness 54 Coupler 4 wire harness front cowling wire harness 85 Immobiliz...

Page 598: ...key is lost regis tering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is m...

Page 599: ...tandby mode To enable the immobilizer system turn the ignition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours...

Page 600: ...h then turn the key to ON within 5 seconds to activate the key registration mode NOTE The existing standard key code is erased from the memory when the key registration mode is activated When the key...

Page 601: ...Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g First standard key h Second standard key i Registration mode A Registration of the second standard key is complete B Im...

Page 602: ...ls Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 233 Replace the main switch immobilizer unit 4 Check the entire immobilizer sys tem wiring Refer to...

Page 603: ...it mal function 4 ECU malfunction 1 Check the wire harness and connector 2 Replace the main switch im mobilizer unit 3 Replace the ECU 54 IMMOBILIZER UNIT Codes transmitted between the ECU and the imm...

Page 604: ...IMMOBILIZER SYSTEM 8 127 a Light on b Light off...

Page 605: ...IMMOBILIZER SYSTEM 8 128...

Page 606: ...Y BLACK BLACK B L BLACK B1 BB B B B B BB2 BB1 BB4 BB3 B2 B1 WIRE HARNESS SUB WIRE HARNESS A A A A A A A A A A A A Sb W W B Br B L W W Y L B B W Gy W G R L R Y G W L G Y Sb Br W B W B G R R L ON P OFF...

Page 607: ...harness 20 Coupler 3 wire harness front cowling wire harness 22 Starting circuit cut off relay 25 ABS test coupler 26 ABS ECU electronic control unit 27 Front wheel sensor 28 Rear wheel sensor 29 Rea...

Page 608: ...W L W Dg Br R B B Br W Ch G Y G Y R B B R Ch B W W B B Y Dg B Y R Y Dg B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg B R Br G L B P Sb W B Y Ch G Y Dg Br W L R W Ch Br G R B B B Ch B W B R R B Dg W B B...

Page 609: ...harness front cowling wire harness 20 Coupler 3 wire harness front cowling wire harness 54 Coupler 4 wire harness front cowling wire harness 69 Front brake light switch 70 Engine stop switch 71 Start...

Page 610: ...B L BLACK L B W Dg G Y B Ch W B R B R Y G L R Y Y W L W2 L W Y G G R Br B R W G Y Y G Br G Y Br B ON P OFF R R Br W Br L Br R Br R R R G R R R R B O R L Gy R R L R L B R R R B B B R R W L W L R B1 BB...

Page 611: ...ng circuit cut off relay 22 ABS test coupler 23 ABS ECU electronic control unit 24 Front wheel sensor 25 Rear wheel sensor 27 Coupler 3 wire harness front cowling wire harness 28 Diode 29 Brake light...

Page 612: ...ACK B B BLACK Br Br L BLACK L R Br G B W G Y B Dg Ch W B R B R B G Y B W W B Dg Ch B R W L W Dg Br R B B Br W Ch G Y Lg W R B BLACK G Y Dg Br W L R W Ch Br G R B B L B Y B Dg Br W P Lg Sb Ch R Y BLACK...

Page 613: ...harness front cowling wire harness 27 Coupler 3 wire harness front cowling wire harness 66 Coupler 5 wire harness front cowling wire harness 89 Front brake light switch 90 Engine stop switch 91 Start...

Page 614: ...ght 3 ABS ECU fuse 4 ABS solenoid fuse 5 ABS motor fuse 6 Proportioning valve 7 Hydraulic unit assembly 8 Rear wheel sensor 9 Rear wheel sensor rotor 10 Rear brake caliper 11 Metering valve 12 Left fr...

Page 615: ...ABS ANTI LOCK BRAKE SYSTEM 8 138...

Page 616: ...W B Y G W W L W L W P B R G B G R B Y Y W Y L Sb W L W W W LG W P G R G B B R Ch Dg R G B W G R Sb B L B W W G B B R L W Y W P B Y R W G W Y L Sb W Y W B W Gy Gy W W Gy B Ch B W B R R B Dg W B B Y G Y...

Page 617: ...BS ANTI LOCK BRAKE SYSTEM 8 140 1 Meter assembly coupler 2 ABS test coupler 3 Rear wheel sensor coupler 4 ABS ECU coupler 5 Front wheel sensor coupler 6 Wire harness front cowling wire harness coupler...

Page 618: ...B Sb 5 W B W Gy 1 6 Ch Dg R G B W G R Sb B L Lg W W G B B R L W Y W P B Y R W G W Y L Sb W Y 3 Gy W W Gy Sb W Y L Y W B Y G W W L W L W P B R G B G R B Y Y W Y L Sb W L W W W L G W P G R G B B R G Y...

Page 619: ...BS ANTI LOCK BRAKE SYSTEM 8 142 1 Meter assembly coupler 2 ABS test coupler 3 Rear wheel sensor coupler 4 ABS ECU coupler 5 Front wheel sensor coupler 6 Wire harness front cowling wire harness coupler...

Page 620: ...erform a final check before delivering the vehicle to the customer Refer to D 3 FINAL CHECK on page 8 180 ABS operation when the ABS warning light comes on 1 The ABS warning light remains on ABS opera...

Page 621: ...malfunction occurs EAS27800 BASIC INSTRUCTIONS FOR TROUBLESHOOTING WARNING EW3P61004 Perform the troubleshooting A B C D in order Be sure to follow the order since a wrong diagnosis could result if t...

Page 622: ...ault codes D 1 Delete the fault codes D 2 Delete function test Finished B 5 Malfunctions are currently detected C 3 Does the ABS warning light remain on Connect the test coupler adapter to the ABS tes...

Page 623: ...tch is turned to ON C 1 2 The ABS warning light and all other indicator lights fail to come on C 2 ET3P6D008 B 2 THE ABS WARNING LIGHT FLASHES 1 Test coupler adapter Check if the test coupler adapter...

Page 624: ...ected to the ABS test coupler to display the fault codes If the adapter is not connected the ABS warning light will come on or flash but no fault codes will be dis played ET3P6D011 B 5 MALFUNCTION ARE...

Page 625: ...REMAINS ON 1 The battery voltage is low Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 240 If the battery voltage is low clean the battery terminals and rechar...

Page 626: ...to the ground the internal circuit of the meter assembly is defective Replace the meter assembly ET3P6D016 C 5 DIAGNOSIS USING THE FAULT CODES Connect the test coupler adapter to the ABS test coupler...

Page 627: ...ght signal is not received prop erly when main switch is turned to ON brake light circuit or front or rear brake light switch circuit Improper adjustment of the rear brake light switch Brake light swi...

Page 628: ...ydraulic unit operation tests Rear wheel brake lines Hydraulic unit assembly AbS_43 Incorrect signal from the front wheel sensor is detected Installation of the front wheel sensor Front wheel sensor h...

Page 629: ...ff Perform a tri al run at a constant speed of 30 km h and check that the ABS warning light does not come on 2 Installed condition of wheel bearings axle sensor housing and sensor ro tor Check the com...

Page 630: ...g light does not come on 2 Installed condition of wheel bearings axle sensor housing and sensor ro tor Check the components for loose ness distortion and bends Refer to CHECKING THE REAR WHEEL on page...

Page 631: ...come on 2 Installed condition of wheel bearings axle sensor housing and sensor ro tor Check the components for loose ness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 19 3 Foreign...

Page 632: ...f the sensor rotor for foreign material such as metal particles Clean the sensor housing and sensor rotor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 28 4 Def...

Page 633: ...rminal 4 If there is continuity the wire harness is defective Properly repair or replace the wire har ness Check that there is no continuity between the white terminal 1 and the black terminal 2 and b...

Page 634: ...el sensor circuit Order Item components and probable cause Check or maintenance job Reinstatement confirmation method 1 Connections Rear wheel sensor coupler ABS ECU coupler Check the coupler for any...

Page 635: ...minal 4 If there is continuity the wire harness is defective Properly repair or replace the wire har ness Check that there is no continuity between the gray terminal 1 and the white terminal 2 and bet...

Page 636: ...codes If fault code No AbS_16 could not be deleted the rear wheel sensor is defective Re place the rear wheel sensor NOTE Before deleting the fault codes record all of the fault codes and perform the...

Page 637: ...ve sensor rotor Check the surface of the sensor rotor for damage If there is visible damage re place the sensor rotor Fault code No AbS_18 AbS_46 Symptom Missing pulses detected in the rear wheel sen...

Page 638: ...electric starting sys tem Refer to ELECTRIC STARTING SYSTEM on page 8 13 Push the start switch and check that the engine starts Turn the main switch to ON and check that the ABS warning light comes on...

Page 639: ...efer to CHECKING THE SWITCHES on page 8 233 Check that the brake light comes on when the front or rear brake is applied Turn the main switch to ON and check that the ABS warning light comes on for 2 s...

Page 640: ...hat the ABS warning light does not flash when the front rear or both brakes are applied for 2 seconds or more 2 Connections ABS ECU coupler Brake light relay coupler Front brake light switch connector...

Page 641: ...fuse Check the ABS solenoid fuse If the ABS solenoid fuse is blown replace the fuse and check the wire harness Refer to CHECKING THE FUS ES on page 3 44 3 Connections ABS ECU coupler Check the couple...

Page 642: ...ement confirmation method 1 Short circuit in solenoid relay Replace the hydraulic unit as sembly Turn the main switch to ON and check that the ABS warning light comes on for 2 seconds then goes off Pe...

Page 643: ...fuse Check the ABS motor fuse If the ABS motor fuse is blown replace the fuse and check the wire har ness Refer to CHECKING THE FUS ES on page 3 44 3 Connections ABS ECU coupler Starter relay coupler...

Page 644: ...s normal Order Item components and probable cause Check or maintenance job Reinstatement confirmation method 1 Rotation of wheel Check that there is no brake disc drag on the front wheel and make sure...

Page 645: ...ster cylinder to the hydraulic unit and from the hydraulic unit to the front brake calipers and the metering valve are correct See WARNING and NOTE Fault code No AbS_41 Symptom Front wheel will not re...

Page 646: ...the reverse order when the final check on page D 3 FINAL CHECK on page 8 180 is performed If the brake pipes to the proportioning valve and the metering valve are switched during assembly the brakes w...

Page 647: ...e master cylinder and brake cali per Check that the brake fluid pres sure is correctly transmitted to the brake caliper when the brake pedal is operated and that the pressure decreases when the pedal...

Page 648: ...al check on page D 3 FINAL CHECK on page 8 180 is performed If the brake pipes to the proportioning valve and the metering valve are switched during assembly the brakes will continue to operate as nor...

Page 649: ...f 30 km h and check that the ABS warning light does not come on 2 Installed condition of wheel bearings axle sensor housing and sensor ro tor Check the components for loose ness distortion and bends R...

Page 650: ...or housing and the surface of the sensor rotor for foreign material such as metal particles Clean the sensor housing and sensor rotor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SEN...

Page 651: ...Perform a tri al run and check that the ABS warning light does not come on 2 Connections ABS ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupl...

Page 652: ...on 2 Connections ABS ECU coupler Starter relay coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect...

Page 653: ...use Check or maintenance job Reinstatement confirmation method 1 Defective internal monitor circuit sen sor power Replace the hydraulic unit as sembly Turn the main switch to ON and check that the ABS...

Page 654: ...ess NOTE Disconnect the ABS ECU coupler before checking the wire har ness Turn the main switch to ON and check that the ABS warn ing light comes on for 2 sec onds then goes off 2 Short circuit in fron...

Page 655: ...ess NOTE Disconnect the ABS ECU coupler before checking the wire har ness Turn the main switch to ON and check that the ABS warn ing light comes on for 2 sec onds then goes off 2 Short circuit in rear...

Page 656: ...tions have not been re paired Diagnose the malfunctions using the fault codes 8 Turn the main switch to OFF 9 Disconnect the test coupler adapter from the ABS test coupler and then install the protec...

Page 657: ...LEVEL on page 3 29 2 Check the wheel sensor housings and wheel sensors for proper installation Refer to INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS on page 4 23 and IN STALLING THE REAR WHEEL REAR B...

Page 658: ...CK B L BLACK B1 BB B B B B BB2 BB1 BB4 BB3 B2 B1 WIRE HARNESS SUB WIRE HARNESS A A A A A A A A A A A A Sb W W B Br B L W W Y L B B W Gy W G R L R Y G W L G Y Sb Br W B W B G R R L ON P OFF R R W Br B...

Page 659: ...9 Battery 20 Coupler 3 wire harness front cowling wire harness 44 ECU engine control unit 54 Coupler 4 wire harness front cowling wire harness 55 Headlight on off grip warmer relay 57 Signaling system...

Page 660: ...Br R B B Br W Ch G Y G Y R B B R Ch B W W B B Y Dg B Y R Y Dg B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg B R Br G L B P Sb W B Y Ch G Y Dg Br W L R W Ch Br G R B B B Ch B W B R R B Dg W B B Y G Y UP...

Page 661: ...GRIP WARMER SYSTEM 8 184 20 Coupler 3 wire harness front cowling wire harness 54 Coupler 4 wire harness front cowling wire harness 81 Left grip warmer 82 Right grip warmer...

Page 662: ...g system and head light Refer to CHECKING THE FUS ES on page 8 239 Replace the fuse s 2 Check that the engine is started Start the engine 3 Check that the headlight is on Replace the headlight on off...

Page 663: ...een white and check for continuity between the light green white terminal of the ECU coupler and the light green white terminal of the grip warmer control unit coupler The wiring system from ECU coupl...

Page 664: ...W B B B L GRAY P W L Y BLACK B B L Y G L P W B L BLACK L B W Dg G Y B Ch W B R B R Y G L R Y Y W L W2 L W Y G G R Br B R W G Y Y G Br G Y Br B ON P OFF R R Br W Br L Br R Br R R R G R R R R B O R L Gy...

Page 665: ...tch 36 Sidestand switch 45 ECU engine control unit 54 Shift actuator motor 55 Shift actuator sensor 56 Clutch actuator sensor 57 Clutch actuator motor 58 MCU motor control unit 59 YCC S test coupler 6...

Page 666: ...B Br L BLACK B B BLACK Br Br L BLACK L R Br G B W G Y B Dg Ch W B R B R B G Y B W W B Dg Ch B R W L W Dg Br R B B Br W Ch G Y Lg W R B BLACK G Y Dg Br W L R W Ch Br G R B B L B Y B Dg Br W P Lg Sb Ch...

Page 667: ...wire harness 66 Coupler 5 wire harness front cowling wire harness 68 Coupler 6 wire harness front cowling wire harness 89 Front brake light switch 90 Engine stop switch 91 Start switch 98 Multi funct...

Page 668: ...HECKING THE FUS ES on page 8 239 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 240 Clean the battery terminals Recharge or replace the battery 3 Check the...

Page 669: ...control unit After the engine has been stopped the lowest fault code number appears on the odometer tripmeter fuel reserve trip meter LCD Once a fault code has been displayed it remains stored in the...

Page 670: ...n When an abnormal signal is received from a sensor the MCU motor control unit processes the spec ified values that are programmed for each sensor in order to provide the YCC S system with alternate o...

Page 671: ...t signal of shift actuator sensor is ab normal Output signal of shift actuator sen sor is below 0 5 V or above 4 5 V Unable Unable Sh_ _21 Output signal of gear position sensor is ab normal Output sig...

Page 672: ...up or shift down are closed at the same time Able Able Sh_ _39 Ignition timing retard output signal is abnor mal Detected ignition retard signal from MCU motor control unit to ECU is abnormal Able Ab...

Page 673: ...eck the fault code number displayed on the meter and diagnostic code Sh_ _61 Refer to Diagnostic code table Diagnostic code No Sh_ _61 b Identify the faulty system with the fault code Refer to Self Di...

Page 674: ...emove the front cowling left inner panel 1 to access the YCC S test coupler 1 3 Remove the protective cap from the YCC S test coupler 4 Connect the test coupler adapter 2 to the YCC S test coupler 5 P...

Page 675: ...ference value Checking method Sh_ _61 Malfunction history code display No history Sh_ _61 History exists Fault code numbers Sh_ _11 Sh_ _52 First displays Sh_ _61 for 6 seconds and then displays each...

Page 676: ...op eration NOTE The checking meth od for the diagnostic code Sh_ _63 can not be performed when any of the fol lowing fault codes are detected Sh_ _11 Sh_ _12 Sh_ _13 Sh_ _15 Sh_ 16 Sh_ _17 Sh_ _25 Sh_...

Page 677: ...trol unit detects the signal from the shift actuator sensor If the signal received after upshifting is correct the hand shift select indicator light will come on If the signal received after upshiftin...

Page 678: ...is pushed 6 Shift the transmission into 4th gear us ing the hand shift lever switch shift down and then rotate the rear wheel at least 1 2 turn by hand to ensure that the dog completely engages the 4...

Page 679: ...engagement point manually The clutch engagement point while the ve hicle is starting off can be adjusted manu ally to 21 engine speed settings in this mode The initial setting of the clutch en gagemen...

Page 680: ...Refer to CHECKING AND CHARGING THE BATTERY on page 8 240 3 Malfunction in rectifier regulator Replace if detective Refer to CHARGING SYS TEM on page 8 29 4 Open or short circuit in wire harness Repai...

Page 681: ...k or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Clutch actuator motor coupler Check the coupler for any pins that may be pulled out Check the lockin...

Page 682: ...ause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Shift actuator motor coupler Check the coupler for any pins that may be pulled out Check th...

Page 683: ...tor coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main swit...

Page 684: ...t Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Clutch actuator motor coupler Shift actuator motor co...

Page 685: ...bable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Clutch actuator motor coupler Check the coupler for any pins that may be pulled out...

Page 686: ...s and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Shift actuator motor coupler Check the coupler for any pins that may be pul...

Page 687: ...put signal of shift actuator sensor is abnor mal Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Shift...

Page 688: ...he coupler If there is a malfunction repair it and connect the coupler se curely Repairing the cause of the malfunction 2 Open or short circuit in wire harness Repair or replace if there is an open or...

Page 689: ...ed orange blue blue black black blue 3 Defective foot shift switch Adjust or replace if defective Refer to ADJUSTING THE FOOT SHIFT SWITCH on page 5 72 and CHECKING THE FOOT SHIFT SWITCH FJR1300AS onl...

Page 690: ...control unit when main switch is turned to ON Order Item components and probable cause Check or maintenance job Reinstatement method 1 Malfunction in MCU motor control unit Replace the MCU motor contr...

Page 691: ...coupler adapter is not connected Refer to DIAGNOSTIC MODE on page 8 197 Turning the main switch to OFF See NOTE 2 Short circuit in wire harness Repair or replace if there is a short circuit Between YC...

Page 692: ...it and connect the coupler se curely Turning the main switch to OFF See NOTE 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between YCC S speed sensor...

Page 693: ...hite blue white 3 Defective relay unit Check and replace relay unit Refer to CHECKING THE RE LAYS on page 8 243 4 Defective start switch Check and replace right handle bar switch Refer to CHECKING THE...

Page 694: ...and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Clutch actuator motor coupler Shift actuator motor coupler Check the coupler...

Page 695: ...er and MCU motor control unit coupler orange white orange white orange black orange black green red green red green black green black 3 Defective hand shift lever switch shift up or shift down Replace...

Page 696: ...there is an open or short circuit Between ECU coupler and MCU motor control unit cou pler yellow blue yellow blue Fault code No Sh_ _42 Symptom Communication between ECU and multi func tion meter is a...

Page 697: ...ethod 1 Connections Wire harness MCU motor control unit coupler ABS ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfuncti...

Page 698: ...diagnostic code No Sh_ _61 The fault code numbers can be confirmed in the mal function history Fault code No Sh_ _45 Symptom Shift operation and gear position do not match Order Item components and p...

Page 699: ...f the coupler If there is a malfunction repair it and connect the coupler se curely Repairing the cause of the malfunction 2 Open or short circuit in wire harness Repair or replace if there is an open...

Page 700: ...clutch stroke Refer to BLEEDING THE HY DRAULIC CLUTCH SYSTEM FJR1300AS on page 3 19 Turning the main switch to OFF See NOTE 2 Clutch slippage Check the friction plate thick ness and replace the fricti...

Page 701: ...o Sh_ _52 Symptom Main switch signal is abnormal Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Check...

Page 702: ...ELECTRICAL COMPONENTS 8 225 EAS27970 ELECTRICAL COMPONENTS FJR1300A 1 18 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17...

Page 703: ...or fuse 5 Front brake light switch 6 Clutch switch 7 Fuse box 2 8 Fuse box 1 9 Right radiator fan motor 10 Left radiator fan motor 11 Gear position switch 12 Sidestand switch 13 Oil level switch 14 Re...

Page 704: ...ELECTRICAL COMPONENTS 8 227 FJR1300A 5 1 3 2 17 8 10 11 12 13 14 15 16 7 6 4 9...

Page 705: ...ntake air temperature sensor 6 Lean angle sensor 7 Hydraulic unit assembly 8 ECU engine control unit 9 Relay unit 10 Cylinder identification sensor 11 O2 sensor 12 Crankshaft position sensor 13 Access...

Page 706: ...ELECTRICAL COMPONENTS 8 229 FJR1300AS 13 16 18 17 2 3 4 5 6 7 8 1 9 10 11 12 15 14 19...

Page 707: ...use 5 Front brake light switch 6 Fuse box 2 7 Fuse box 1 8 Right radiator fan motor 9 Left radiator fan motor 10 Neutral switch 11 Sidestand switch 12 YCC S speed sensor 13 Oil level switch 14 Rear br...

Page 708: ...ELECTRICAL COMPONENTS 8 231 FJR1300AS 1 19 3 2 5 7 9 8 12 13 14 15 16 11 10 18 17 6 4...

Page 709: ...sor 6 Lean angle sensor 7 Hydraulic unit assembly 8 MCU motor control unit 9 ECU engine control unit 10 Relay unit 11 YCC S control relay 12 Cylinder identification sensor 13 O2 sensor 14 Crankshaft p...

Page 710: ...0A L Y B Y 1 R Br L Br R ON OFF P Br LBr R R 2 BROWN B B 3 P B Lg Sb Br W L B Ch Dg B Y Y R Y L Y Lg B Sb UP DOWN 13 DgBr W Ch 14 B P 10 12 R Y Y R Y L B 11 B Br W Ch Dg R B R W G Y L W Br 8 L W B R W...

Page 711: ...ch 2 Main switch 3 Rear brake light switch 4 Gear position switch 5 Sidestand switch 6 Clutch switch 7 Hazard switch 8 Start switch 9 Engine stop switch 10 Horn switch 11 Dimmer switch 12 Pass switch...

Page 712: ...ACK B B 3 Lg B Sb UP DOWN 15 DgBr W Ch 16 B P 12 14 R Y Y R Y L B 13 B Br W Ch Dg R B R W G Y L W Br 7 L W B R W R B 8 Ch Dg Br W 6 BLUE B B 5 4 G Y Br Sb 10 Shift up Shift down G R G B B L 11 O W O B...

Page 713: ...tch 4 Neutral switch 5 Sidestand switch 6 Hazard switch 7 Start switch 8 Engine stop switch 9 Hand shift select button 10 Hand shift lever switch shift up 11 Hand shift lever switch shift down 12 Horn...

Page 714: ...ange When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main swi...

Page 715: ...ulbs 1 Remove Bulb WARNING EW3P61001 Since headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down CAUTION EC3P61002 Be sure to hold the soc...

Page 716: ...ket tester selector to 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Turn the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches...

Page 717: ...lance between cells will not be maintained and battery per formance will deteriorate Charging time charging amperage and charging voltage for an MF battery are dif ferent from those of conventional ba...

Page 718: ...ery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process dis connect the batt...

Page 719: ...30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the bat t...

Page 720: ...2 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 FJR1300A B Y FJR1300AS B R 1...

Page 721: ...l 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 5 Negative tester probe Result No continuity between 3 and 4 Continuity between 3 and 5 G L Y L B B 1 3 2 G G L Y L B B 1...

Page 722: ...Turn signal hazard relay output voltage Out of specification Replace 1 Positive tester probe 2 Negative tester probe Result No continuity between 1 and 2 1 Positive battery terminal 2 Negative batter...

Page 723: ...U 03112 C Continuity Positive tester probe sky blue 1 Negative tester probe FJR1300A black yellow 2 FJR1300AS black red 2 No continuity Positive tester probe FJR1300A black yellow 2 FJR1300AS black re...

Page 724: ...ck Primary coil resistance Out of specification Replace a Disconnect the ignition coil connectors from the ignition coil terminals b Connect the pocket tester 1 to the igni tion coil as shown c Measur...

Page 725: ...un til a misfire occurs EAS28120 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness 2 Check Crankshaft position sensor resistance Out of spec...

Page 726: ...e at least the same capacity of the bat tery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the...

Page 727: ...cification Replace a Disconnect the horn connectors from the horn terminals b Connect the pocket tester 1 to the horn terminals c Measure the horn resistance 2 Check Horn sound Faulty sound Adjust or...

Page 728: ...tance Out of specification Replace the fuel pump assembly a Connect the pocket tester 10 to the fuel sender terminals as shown Oil level switch resistance Minimum level position No continuity Maximum...

Page 729: ...coolant temperature sen sor to strong shocks If the coolant temper ature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification Replace a Connect the pocket t...

Page 730: ...isconnect the air induction system solenoid coupler from the wire harness b Connect the pocket tester 1 to the air in duction system solenoid terminals as shown c Measure the air induction system sole...

Page 731: ...ove Intake air temperature sensor from the air filter case WARNING EWA14110 Handle the intake air temperature sensor with special care Never subject the intake air temperature sensor to strong shocks...

Page 732: ...als as shown c Measure the accessory box solenoid resis tance ET3P66023 CHECKING THE GRIP WARMERS The following procedure applies to both of the grip warmers 1 Check Grip warmer resistance Out of spec...

Page 733: ...he rear wheel and slowly rotate it d Measure the voltage of white yellow and black blue With each full rotation of the rear wheel the voltage reading should cycle from 0 6 V to 4 8 V to 0 6 V to 4 8 V...

Page 734: ...e pocket tester 1k to the foot shift switch terminals as shown b Measure the foot shift switch maximum resis tance 3 Install Foot shift switch Refer to INSTALLING THE FOOT SHIFT SWITCH on page 5 71 ET...

Page 735: ...et tester 1 to the diode 2 terminals as shown c Check the diode for continuity d Check the diode for no continuity Continuity Positive tester probe yellow 1 Negative tester probe yel low green 2 No co...

Page 736: ...ELECTRICAL COMPONENTS 8 259...

Page 737: ...LING SPEED 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 3 OVERCOOLING 9 3 POOR BRAKING PE...

Page 738: ...relay 3 Throttle body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fu...

Page 739: ...IFTING Shifting is difficult Refer to Clutch drags EAS28540 SHIFT PEDAL DOES NOT MOVE Shift shaft Improperly adjusted shift rod Bent shift shaft Shift drum and shift forks Foreign object in a shift dr...

Page 740: ...plug gap Incorrect spark plug heat range 2 Ignition system Faulty ECU EAS28610 OVERCOOLING Cooling system 1 Thermostat Thermostat stays open EAS28620 POOR BRAKING PERFORMANCE Worn brake pad Worn brak...

Page 741: ...t bulb burnt out Wrong headlight bulb Faulty battery Faulty rectifier regulator Improperly grounded circuit Faulty main switch Headlight bulb life expired Tail brake light does not come on Wrong tail...

Page 742: ...l unit 62 Radiator fan motor relay 63 Left radiator fan motor fuse 64 Left radiator fan motor 65 Right radiator fan motor fuse 66 Right radiator fan motor 67 Turn signal hazard relay 68 Right handleba...

Page 743: ...re harness 69 Hazard lighting fuse 70 Signaling system fuse 71 Headlight fuse 72 Ignition fuse 73 Auxiliary DC jack fuse 74 Grip warmer control unit 75 Radiator fan motor relay 76 Left radiator fan mo...

Page 744: ...R G Red Green R L Red Blue R W Red White R Y Red Yellow Sb W Sky blue White W B White Black W L White Blue W Y White Yellow Y B Yellow Black Y G Yellow Green Y L Yellow Blue Y W Yellow White...

Page 745: ......

Page 746: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN...

Page 747: ...Y W BLACK L W Y W Y P W R W Br W B W W B Gy W L Y L G W Gy R B G B R L L B Lg W O B Br R B3 O Gy R P W B L BLACK L B L Y L B2 B1 Sb W W B Br B L W W Y L B B W Gy W G R L R Y G W L G Y Sb Br W B W B G...

Page 748: ...L W W W L G W G R G B B R GRAY P B B BLACK W B Br L BLACK B B BLACK Br Br L BLACK L R Br G L Y BLACK B Y L Y BLACK B Y R W L W Dg Br R B B Br W Ch G Y G Y Dg Br W L R W Ch Br G R B B B Ch B W B R R B...

Page 749: ...K BLACK BLACK BLUE BROWN BLUE BROWN BLUE BLUE BLACK BLACK BLACK GREEN BLACK BLACK BLACK BLACK BLACK GRAY GRAY A WIRE HARNESS SUB WIRE HARNESS GRAY GRAY GRAY GRAY GRAY GRAY BLACK BLACK ON P OFF A A A A...

Page 750: ...s Kabelbaum FJR1300A X 2008 SCHEMA ELETTRICO 2 2 Cablaggio elettrico del cupolino FJR1300A X 2008 DIAGRAMA EL CTRICO 2 2 Mazo decables delcarenado delantero GRAY GRAY BLACK BLACK BLACK BLACK GRAY GRAY...

Page 751: ...Y W B B B L GRAY P W L Y BLACK B B L Y G L P W B L BLACK L B W Dg G Y B Ch W B R B R Y G L R Y Y W L W2 L W Y G G R Br B R W G Y Y G Br G Y Br B B W B G R R L W B Br B L W W Y L B B W Gy W G R L R Br...

Page 752: ...Br Br BLACK B G Y B G Y B Sb W Y L Y W B Y G W W L W L W P B R G B GRAY G R B Y Y W Y L Sb W L W W W L G W G R G B B R GRAY P R B B B R B B B BLACK W B Br L BLACK B B BLACK Br Br L BLACK L R Br G B W...

Page 753: ...N BLACK BLACK BLACK BLACK BLACK BLACK GRAY GRAY GRAY GRAY BLACK BLACK BLACK GRAY A WIRE HARNESS SUB LEAD1 BLACK BLACK C WIRE HARNESS SUB LEAD2 B WIRE HARNESS SUB WIRE HARNESS GRAY GRAY BLACK BLACK ON...

Page 754: ...TTRICO 2 2 Cablaggio elettrico del cupolino FJR1300AS X 2008 DIAGRAMA EL CTRICO 2 2 Mazo decables delcarenado delantero BLACK BLACK BLACK GRAY GRAY BLACK BLACK B B BLACK BLACK GRAY GRAY BLACK BLACK BL...

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