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PERIODIC MAINTENANCE AND MINOR REPAIR

6-26

6

EAU00713

Adjusting the rear brake light
switch

The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction

a

. To

make the brake light come on later,
turn the adjusting nut in direction

b

.

EAU00721

Checking the front and rear
brake pads

The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.

EAU00725

Front brake pads

Each front brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator groove. If a brake
pad has worn to the point that the wear
indicator groove has almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.

1. Rear brake light switch
2. Rear brake light switch adjusting nut

1. Brake pad wear indicator groove

Front

E_U5JW10.book Page 26 Wednesday, May 29, 2002 3:10 PM

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Summary of Contents for FJR1300R

Page 1: ...PRINTED IN JAPAN 2002 05 0 6 2 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 5JW 28199 10 LIT 11626 16 18 FJR1300R FJR1300RC OWNER S MANUAL ...

Page 2: ...EAU03438 ...

Page 3: ...otorcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emis sions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle To maintain these hi...

Page 4: ...e taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE _ This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product informat...

Page 5: ...T TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE AT TAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELI ABILITY OF THIS MOTORCYCLE _ E_U5JW10 book Page 2 Wednesday May 29 2002 3 10 PM ...

Page 6: ...L 2002 by Yamaha Motor Corporation U S A 1st edition April 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 16 18 E_U5JW10 book Page 3 Wednesday May 29 2002 3 10 PM ...

Page 7: ...ND CONTROL FUNCTIONS 3 4 PRE OPERATION CHECKS 4 5 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 MOTORCYCLE CARE AND STORAGE 7 8 SPECIFICATIONS 8 9 CONSUMER INFORMATION 9 INDEX EAU00009 E_U5JW10 book Page 1 Wednesday May 29 2002 3 10 PM ...

Page 8: ...NFORMATION 1 Safe riding 1 1 Protective apparel 1 3 Modifications 1 3 Loading and accessories 1 3 Gasoline and exhaust gas 1 5 Location of important labels 1 7 E_U5JW10 book Page 1 Wednesday May 29 2002 3 10 PM ...

Page 9: ...BY MECHANICAL CONDITIONS Safe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the moto...

Page 10: ...undercornering insufficient lean angle for the speed a Always obey the speed limit and never travel faster than warranted by road and traffic conditions b Always signal before turning or changing lanes Make sure that other motorists can see you 6 The posture of the operator and passenger is important for proper control a The operator should keep both hands on the handlebar and both feet on the ope...

Page 11: ...ter operation They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 A passenger should also observe the above precautions Modifications Modifications made to this motorcycle not approved by Yamaha or the removal of original equipment may render the motorcycle unsafe for use and may cause severe personal injury Modifications may also make y...

Page 12: ...fender These items in cluding such cargo as sleeping bags duffel bags or tents can create unstable handling or a slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories that may be available you must personally be responsible for the proper selection installation and use of non Yamaha ac...

Page 13: ...l ability therefore such accessories are not recommended 2 Use caution when adding electrical accessories If electrical accessories exceed the capacity of the motorcycle s electrical system an electric failure could result which could cause a dangerous loss of lights or engine power Gasoline and exhaust gas 1 GASOLINE IS HIGHLY FLAMMABLE a Always turn the engine off when refueling b Take care not ...

Page 14: ...osene heater or near an open flame otherwise it could catch fire 4 When transporting the motorcycle in another vehicle make sure that it is kept upright If the motor cycle should lean over gasoline may leak out of the fuel tank 5 If you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get into your eyes see your doctor immediately If any gasoline spills on your skin ...

Page 15: ...INFORMATION 1 2 3 4 5 6 7 8 9 1 7 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle E_U5JW10 book Page 7 Wednesday May 29 2002 3 10 PM ...

Page 16: ...SAFETY INFORMATION 1 2 3 4 5 6 7 8 9 1 8 California only 2 1 3 4 E_U5JW10 book Page 8 Wednesday May 29 2002 3 10 PM ...

Page 17: ...FORMATION 1 2 3 4 5 6 7 8 9 1 9 CAUTION Cleaning with alkaline or acid cleaner gasoline or solvent will damage windshield Use neutral detergent 5JW 00 8 5 6 7 9 E_U5JW10 book Page 9 Wednesday May 29 2002 3 10 PM ...

Page 18: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 E_U5JW10 book Page 1 Wednesday May 29 2002 3 10 PM ...

Page 19: ... 3 12 7 Passenger seat page 3 13 8 Carrier 9 Final gear oil filler bolt page 6 16 10 Final gear oil drain bolt page 6 16 11 Shock absorber assembly rebound damping force adjusting knob page 3 16 12 Shock absorber assembly spring preload adjusting lever page 3 16 13 Air filter element page 6 19 14 Shift pedal page 3 8 15 Engine oil filter cartridge page 6 13 16 Engine oil level check window page 6 ...

Page 20: ...rvoir page 6 17 19 Battery page 6 35 20 Windshield 21 Main fuse and Electronic fuel injection fuse page 6 36 22 Front fork compression damping force adjusting screw page 3 15 23 Brake pedal page 3 9 24 Rider footrest E_U5JW10 book Page 2 Wednesday May 29 2002 3 10 PM ...

Page 21: ...hes page 3 6 3 Tachometer page 3 4 4 Speedometer page 3 3 5 Multi function display page 3 4 6 Right handlebar switches page 3 6 7 Brake lever page 3 9 8 Throttle grip page 6 20 9 Main switch steering lock page 3 1 10 Hazard switch page 3 7 E_U5JW10 book Page 3 Wednesday May 29 2002 3 10 PM ...

Page 22: ...ft pedal 3 8 Brake lever 3 9 Brake pedal 3 9 Fuel tank cap 3 10 Fuel 3 11 Catalytic converter 3 12 Seats 3 12 Storage compartment 3 13 Adjusting the front fork 3 13 Adjusting the shock absorber assembly 3 15 Matching the front and rear suspension settings 3 17 Locks for the optional side cases and travel trunk 3 18 Sidestand 3 18 Ignition circuit cut off system 3 19 E_U5JW10 book Page 1 Wednesday ...

Page 23: ...light comes on automatically when the engine is started and stays on until the key is turned to OFF even if the engine stalls _ EAU00038 OFF All electrical systems are off The key can be removed EAU00041 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left or right 2 Push the key in from the OFF po...

Page 24: ...ht This indicator light comes on when the high beam of the headlight is switched on EAU04301 Oil level warning light This warning light comes on when the engine oil level is low The electrical circuit of the warning light can be checked according to the fol lowing procedure 1 Turn the key to ON 2 If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the ele...

Page 25: ...heck the elec trical circuit The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the elec trical circuit EAU04031 Speedometer The speedometer shows the riding speed 1 Left turn signal indicator light 2 Right turn signal indicator light 3 Neutral indicator light 4 High beam...

Page 26: ...he distance traveled since they were last set to zero a fuel reserve tripmeter which shows the distance traveled on the fuel reserve a self diagnosis device a clock NOTE _ Be sure to turn the key to ON be fore using the SELECT and RESET buttons To switch the speedometer dis play between kilometers and miles press the SELECT button for at least two seconds _ Odometer and tripmeter modes Pushing the...

Page 27: ...g and traveling 5 km 3 mi Self diagnosis device This model is equipped with a self di agnosis device for various electrical cir cuits If any of those circuits are defective the clock will indicate a two digit error code e g 11 12 13 If the clock indicates such an error code note the code number and then have a Yamaha dealer check the motorcycle ECA00100 CAUTION _ If the clock indicates an error co...

Page 28: ...urn push this switch to To signal a left hand turn push this switch to When released the switch returns to the cen ter position To cancel the turn signal lights push the switch in after it has re turned to the center position EAU00129 Horn switch Press this switch to sound the horn EAU03890 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in ca...

Page 29: ...are used in case of an emergency or to warn other drivers when your motorcycle is stopped where it might be a traffic hazard ECA00144 CAUTION _ Do not use the hazard lights for an extended length of time otherwise the battery may discharge _ EAU00153 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the c...

Page 30: ...he clutch lever is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 3 19 for an explanation of the ig nition circuit cut off system EAU00157 Shift pedal The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever when shifting the gears of the 5 speed con stant mesh transmission equipped on this motorcycle ...

Page 31: ...grip turn the adjusting dial while holding the lever pushed away from the handlebar grip Make sure that the appropriate setting on the adjusting dial is aligned with the arrow mark on the brake lever EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Brake lever 2 Arrow mark 3 Brake lever position adjusting dial a Dis...

Page 32: ...fuel tank cap 1 Push the fuel tank cap into posi tion with the key inserted in the lock 2 Remove the key and then close the lock cover NOTE _ The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked _ EWA00025 WARNING _ Make sure that the fuel tank cap is properly closed before riding _ 1 Fuel tank cap lock...

Page 33: ...de signed to use regular unleaded gaso line with a pump octane number R M 2 of 86 or higher or a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premi um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gaso hol containing ethanol and that contain ing methan...

Page 34: ...d gasoline will cause unrepairable damage to the catalytic converter Never park the motorcycle near possible fire hazards such as grass or other materials that easily burn Do not allow the engine to idle too long _ EAU03945 Seats Rider seat To remove the rider seat 1 Insert the key into the seat lock and then turn it as shown 2 Pull the rider seat off To install the rider seat 1 Insert the project...

Page 35: ...mpartment is located under the passenger seat EWA00005 WARNING _ Do not exceed the load limit of 3 kg 7 lb for the storage com partment Do not exceed the maximum load of FJR1300 202 kg 445 lb FJR1300C 201 kg 443 lb for the vehicle _ EAU03949 Adjusting the front fork This front fork is equipped with spring preload adjusting bolts rebound damp ing force adjusting knobs and compres sion damping force...

Page 36: ...crease the rebound damping force and thereby harden the rebound damping turn the adjusting knob on each fork leg in direction a To de crease the rebound damping force and thereby soften the rebound damping turn the adjusting knob on each fork leg in direction b CI 09E 1 Spring preload adjusting bolt 1 Current setting 2 Front fork cap bolt Setting Minimum soft 5 Standard 3 Maximum hard 1 1 Rebound ...

Page 37: ...l differences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the num ber of clicks of each damping force ad justing mechanism and to modify the specifications as necessary _ EAU03950 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing lev...

Page 38: ...n be fore handling the shock absorber The manufacturer cannot be held re sponsible for property damage or personal injury that may result from improper handling Do not tamper with or attempt to open the gas cylinder Do not subject the shock ab sorber to an open flame or other high heat sources otherwise it may explode due to excessive gas pressure Do not deform or damage the gas cylinder in any wa...

Page 39: ... various load conditions CI 11E EC000015 CAUTION _ Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings _ Load condition Front fork adjustment Shock absorber assembly adjustment Spring preload Compression damping force Rebound damping force Spring preload Rebound damping force Rider only 3 12 12 SOFT 10 With passenger or cargo 3 12 8 10 HARD 6 8 E_U5JW10 book Page 17...

Page 40: ...rt of the ignition circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system _ EW000044 WARNING _ The motorcycle must not be ridden with the sidestand down or if the sidestand cannot be properly moved up or does not stay up oth erwise the sidestand could contact the ground and distract the opera tor resulting in ...

Page 41: ...vents starting when the trans mission is in gear and the clutch lever is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sidestand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure EW000046 WARNING _ The vehicle must be placed on the centerstand during this in spectio...

Page 42: ...e clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle shoul...

Page 43: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 E_U5JW10 book Page 1 Wednesday May 29 2002 3 10 PM ...

Page 44: ...l leakage 6 13 Final gear oil Check vehicle for oil leakage 6 16 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 6 17 6 18 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic ...

Page 45: ...eration is smooth Lubricate pedal pivoting points if necessary 6 30 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 31 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 31 6 32 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights sign...

Page 46: ...tion can be accomplished in a very short time and the added safety it assures is more than worth the time involved _ EWA00033 WARNING _ If any item in the Pre operation check list is not working properly have it inspected and repaired before operating the motorcycle _ E_U5JW10 book Page 3 Wednesday May 29 2002 3 10 PM ...

Page 47: ...OPERATION AND IMPORTANT RIDING POINTS 5 Starting and warming up a cold engine 5 1 Shifting 5 3 Engine break in 5 4 Parking 5 5 E_U5JW10 book Page 1 Wednesday May 29 2002 3 10 PM ...

Page 48: ... control _ EAU00376 CAUTION _ Make sure not to store personal items near the air cleaner in take otherwise air intake will be blocked and performance will suffer Make sure not to put anything near the battery and its termi nals otherwise electrical failure and acid corrosion may result _ EAU04824 Starting and warming up a cold engine In order for the ignition circuit cut off system to enable start...

Page 49: ...uld be on otherwise have a Yamaha dealer check the electrical cir cuit _ 3 Start the engine by pushing the start switch NOTE _ If the engine fails to start release the start switch wait a few seconds and then try again Each starting attempt should be as short as possible to pre serve the battery Do not crank the en gine more than 10 seconds on any one attempt _ ECA00055 CAUTION _ For maximum engin...

Page 50: ...hile changing gears to avoid dam aging the engine transmission and drive train which are not designed to withstand the shock of forced shifting _ EAU02988 To start out and accelerate 1 Pull the clutch lever to disengage the clutch 2 Shift the transmission into first gear The neutral indicator light should go out 3 Open the throttle gradually and at the same time release the clutch lever slowly 4 A...

Page 51: ...eceleration are shown in the table below CF 04E EAU01128 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1 600 km 1 000 mi For this reason you should read the following material carefully Since the engine is brand new do not put an excessive load on it for the first 1 600 km 1 000 mi The various parts in the engine wear and polish the...

Page 52: ...ed out of the tachometer red zone If any engine trouble should oc cur during the engine break in period immediately have a Yamaha dealer check the vehicle _ EAU00461 Parking When parking stop the engine and then remove the key from the main switch EW000058 WARNING _ Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them D...

Page 53: ...n 6 25 Adjusting the rear brake light switch 6 26 Checking the front and rear brake pads 6 26 Checking the brake and clutch fluid levels 6 27 Changing the brake and clutch fluids 6 29 Checking and lubricating the cables 6 29 Checking and lubricating the throttle grip and cable 6 29 Checking and lubricating the brake and shift pedals 6 30 Checking and lubricating the brake and clutch levers 6 31 Ch...

Page 54: ...ALLY IMPORTANT ARE THE MAINTENANCE SERVICES RELAT ED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOWING PERIODIC MAINTE NANCE CHARTS THE SERVICES RELATED TO EMISSIONS CON TROL ARE GROUPED SEPARATE LY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIPMENT YAMAHA DEAL ERS ARE TRAI...

Page 55: ... particular job have a Yamaha dealer perform it for you _ EW000062 WARNING _ Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes _ E_U5JW10 book Page 2 Wednesday May 29 2002 3 10 PM ...

Page 56: ...rk plugs Check condition Adjust gap and clean Replace every 8 000 mi 13 000 km or 12 months Replace Replace 3 Crankcase ventilation system Check ventilation hose for cracks or damage Replace if necessary 4 Fuel line Check fuel hoses and vacuum hose for cracks or damage Replace if necessary 5 Muffler and exhaust pipe Check for leakage Tighten if necessary Replace gasket s if necessary 6 Electronic ...

Page 57: ...Replace at initial 600 mi 1 000 km or 1 month and thereafter every 8 000 mi 13 000 km or 12 months 3 Air filter element Check condition clean Replace 4 Cooling system Check hoses for cracks or damage Replace if necessary Replace with ethylene glycol anti freeze coolant every 24 months Replace 5 Brake system Check operation pad wear and fluid leakage See NOTE on page 6 7 Correct if necessary 6 Clut...

Page 58: ...or looseness Moderately repack with lithium soap based grease every 12 000 mi 19 000 km or 18 months Repack 13 Brake and clutch lever pivot shafts Apply lithium soap based grease lightly 14 Brake and shift pedal pivot shafts Apply lithium soap based grease lightly 15 Final gear oil Check oil level and vehicle for oil leakage Change 16 Wheel bearings Check bearings for smooth operation No ITEM ROUT...

Page 59: ...clean or replace if necessary 19 Chassis fasteners Check all chassis fittings and fasteners Correct if necessary 20 Brake hoses Check for cracks or damage Replace See NOTE on page 6 7 21 Wheels Check runout and for damage 22 Tires Check tread depth and for damage Replace if necessary Check air pressure Correct if necessary No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1 000 km or 1 month 4 000 ...

Page 60: ...ways change the fluid Regularly check the brake and clutch fluid levels and fill the reservoirs as required Every two years replace the internal components of the brake and clutch master cylinders caliper cylinders and clutch release cylinder and change the brake and clutch fluid Replace the brake and clutch hoses every four years and if cracked or damaged Engine oil type Yamalube 4 20W 40 or engi...

Page 61: ...panels shown above need to be removed to perform some of the main tenance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed 1 Panel A 2 Panel B 3 Panel C 4 Panel D 1 Panel E 1 Panel F E_U5JW10 book Page 8 Wednesday May 29 2002 3 10 PM ...

Page 62: ...Remove panel A if removing pan el B or panel D if removing panel C 2 Remove the quick fastener by pushing the center pin 3 Remove the screws and then take the panel off To install the panel 1 Place the panel in the original po sition and then install the quick fastener and the screws 2 Install panel A to complete the in stallation of panel B or panel D to complete the installation of panel C 1 Scr...

Page 63: ...ically preferably by a Yamaha dealer Since heat and deposits will cause any spark plug to slowly erode they should be removed and checked in accordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plugs can re veal the condition of the engine The porcelain insulator around the cen ter electrode of each spark plug should be a medium to light tan the id...

Page 64: ... from the spark plug threads NOTE _ If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the speci fied torque as soon as possible _ Specified spark plug CR8E NGK or U24ESR N DENSO a Spark plug gap Spark plug gap 0 7 0 8 mm 0 027 0 031 in Tightening torque Spark plug 12...

Page 65: ...discharging of fuel vapor into the atmosphere Before operating this motorcycle make sure to check the following Check each hose connection Check each hose and canister for cracks or damage Replace if damaged Make sure that the canister breather is not blocked and if nec essary clean it E_U5JW10 book Page 12 Wednesday May 29 2002 3 10 PM ...

Page 66: ...l level through the check window located at the bottom left side of the crank case NOTE _ The engine oil should be between the minimum and maximum level marks _ 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level To change the engine oil with or without oil filter cartridge replace ment 1 Start the engine warm it up for s...

Page 67: ...e NOTE _ Make sure that the O ring is properly seated _ 6 Install the new oil filter cartridge and then tighten it to the specified torque with a torque wrench 7 Install the engine oil drain bolt and then tighten it to the specified torque 1 Oil filter cartridge 2 Oil filter wrench 1 O ring 1 Oil filter cartridge 2 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf E_U5...

Page 68: ...r oil leakage If oil is leaking immediately turn the engine off and check for the cause NOTE _ After the engine is started the engine oil level warning light should go off if the oil level is sufficient _ EC000067 CAUTION _ If the oil level warning light flickers or remains on immediately turn the engine off and have a Yamaha deal er check the vehicle _ 10 Turn the engine off and then check the oi...

Page 69: ...hecking the oil level A slight tilt to the side can result in a false read ing _ 2 Remove the oil filler bolt and then check the oil level in the final gear case NOTE _ The oil level should be at the brim of the filler hole _ 3 If the oil is below the brim of the fill er hole add sufficient oil of the rec ommended type to raise it to the correct level To change the final gear oil 1 Place an oil pa...

Page 70: ...le on the cen terstand NOTE _ The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the motorcycle is positioned straight up when checking the coolant level A slight tilt to the side can result in a false reading _ 2 Check the coolant level in the coolant reservoir NOTE _ The coolant should be between the minimum and maximum level marks _ ...

Page 71: ...ble other wise the engine may not be sufficiently cooled and the cool ing system will not be protected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced _ EW000067 WARNING _ Never attempt to remove the radia tor cap when the engine is hot ...

Page 72: ...ently if you are riding in unusually wet or dusty areas 1 Remove panel E See page 6 10 for panel removal and installation procedures 2 Remove the intake air shroud by removing the quick fastener screws 3 Remove the air filter case cover by removing the screws 4 Pull the air filter element out 1 Intake air shroud 2 Quick fastener screw 4 1 Air filter case cover 2 Screw 4 1 Air filter element E_U5JW...

Page 73: ...e should never be op erated without the air filter ele ment installed otherwise the pistons and or cylinders may become excessively worn _ 7 Install the air filter case cover by installing the screws 8 Install the intake air shroud by in stalling the quick fastener screws 9 Install the panel EAU00635 Adjusting the throttle cable free play The throttle cable free play should measure 3 5 mm 0 1 0 2 ...

Page 74: ...h ride EW000082 WARNING _ The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature The tire air pressure must be adjusted in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model _ CE 22E CE 16E Tire air pressure measured on cold tires Load Front Rear ...

Page 75: ... motorcycle Opera tion of an overloaded motorcycle could cause tire damage an acci dent or even injury _ Tire inspection Always check the tires before operating the motorcycle If a tire tread shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked con tact a Yamaha dealer immediately and have the tire replaced CE 09E EW000094 WARNING ...

Page 76: ... to make the most ef ficient use of these tires Use only the specified replace ment tires Other tires may run the danger of bursting at super high speeds Brand new tires can have a rela tively poor grip on certain road surfaces until they have been broken in Therefore it is ad visable before doing any high speed riding to ride conserva tively for approximately 100 km 60 mi after installing a new t...

Page 77: ...develop its optimal characteris tics EAU00691 Accessories and replacement parts EW000098 WARNING _ This motorcycle is not designed to pull a trailer or to be attached to a sidecar The accessories or replace ment parts you choose for your motorcycle should be designed spe cifically for this model and they must be securely mounted to main tain the inherent stability of the orig inal design Genuine Y...

Page 78: ...the system before operating the motorcycle EAU00712 Adjusting the brake pedal position The top of the brake pedal should be positioned approximately 42 mm 1 7 in below the top of the footrest as shown Periodically check the brake pedal position and if necessary have a Yamaha dealer adjust it EW000109 WARNING _ A soft or spongy feeling in the brake pedal can indicate the presence of air in the hydr...

Page 79: ...on b EAU00721 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals spec ified in the periodic maintenance and lubrication chart EAU00725 Front brake pads Each front brake pad is provided with a wear indicator groove which allows you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the we...

Page 80: ...tems pos sibly causing them to become ineffec tive Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake flu id level may indicate worn brake pads and or brake system leakage If the brake level is low be sure to check the brake pads for wear and the brake sys tem for leakage NOTE The rear brake fluid reservoir is located behind panel F See ...

Page 81: ...sure if the fluid level goes down too far Be sure to return the diaphragm to its original shape before installing it into the brake or clutch fluid reservoir Be careful that water does not en ter the brake or clutch fluid reser voir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate paint ed surfaces or plastic part...

Page 82: ...d the condition of the cables should be checked before each ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it EW000111 WARNING _ Damage to the outer housing of ca bles may result in internal rusting and cause interference with cable movement Replace damaged ca bles as soon as possible to p...

Page 83: ...the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all purpose grease E_U5JW10 book Page 30 Wednesday May 29 2002 3 10 PM ...

Page 84: ... and lubricating the centerstand and sidestand The operation of the centerstand and sidestand should be checked before each ride and the pivots and metal to metal contact surfaces should be lubri cated if necessary EW000114 WARNING _ If the centerstand or sidestand does not move up and down smoothly have a Yamaha dealer check or re pair it _ Recommended lubricant Lithium soap based grease all purp...

Page 85: ...ing points of the rear suspen sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Recommended lubricant Lithium soap based grease all purpose grease Recommended lubricant Lithium soap based grease E_U5JW10 book Page 32 Wednesday May 29 2002 3 10 PM ...

Page 86: ... 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and re bounds smoothly EC000098 CAUTION _ If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it _ EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be ...

Page 87: ...ha dealer check or repair the steer ing EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings E_U5JW10 book Page 34 Wednesday May 29 2002 3 10 PM ...

Page 88: ...clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc aw...

Page 89: ...ed un der panel A Both the electronic fuel in jection fuse and the main fuse are located under panel D The main fuse is located beside the battery See pag es 6 9 and 6 10 for panel removal and installation procedures If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amp...

Page 90: ... headlights If a headlight bulb burns out replace it as follows 1 Remove panel B if replacing the left headlight bulb or panel C if replacing the right headlight bulb See page 6 9 for panel removal and installation procedures 2 Disconnect the headlight coupler and then remove the headlight bulb cover 1 Main fuse Specified fuses Main fuse 50 A Headlight fuse 25 A Signaling system fuse 10 A Ignition...

Page 91: ...ight bulb to keep it free from oil otherwise the transpar ency of the glass the luminosi ty of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the head light lens Do not use a headlight bulb of a wattage hig...

Page 92: ...until it stops 4 Install the lens by installing the screw ECA00065 CAUTION _ Do not overtighten the screw other wise the lens may break _ EAU03087 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power ...

Page 93: ...compression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery...

Page 94: ...ss ing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap _ NOTE _ If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible _ Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Che...

Page 95: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 E_U5JW10 book Page 1 Wednesday May 29 2002 3 10 PM ...

Page 96: ...ll as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 CAUTION _ Avoid using strong acidic wheel cleaners especially on...

Page 97: ...eld is scratched use a quali ty plastic polishing compound after washing _ After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding i...

Page 98: ... surfaces 7 Let the motorcycle dry completely before storing or covering it EWA00031 WARNING _ Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or ac etone and wash the tires with warm water and a mild deter gent Before riding at higher speeds test the motorcycle s braking performance and cor nering ...

Page 99: ... plug caps and spark plugs b Pour a teaspoonful of engine oil into each spark plug bore c Install the spark plug caps onto the spark plugs and then place the spark plugs on the cylinder head so that the electrodes are grounded This will limit spark ing during the next step d Turn the engine over several times with the starter This will coat the cylinder walls with oil e Remove the spark plug caps ...

Page 100: ...ly charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more informa tion on storing the battery see page 6 35 NOTE _ Make any necessary repairs before storing the motorcycle _ E_U5JW10 book Page 5 Wednesday May 29 2002 3 10 PM ...

Page 101: ...SPECIFICATIONS 8 Specifications 8 1 E_U5JW10 book Page 1 Wednesday May 29 2002 3 10 PM ...

Page 102: ...tio 10 8 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG or higher Quantity Without oil filter cartridge replacement 3 8 L 3 34 Imp qt 4 02 US qt With oil filter cartridge replacement 4 L 3 52 Imp qt 4 23 US qt Total amount dry engine 4 9 L 4 31 Imp qt 5 18 US qt 0 10 30 50 70 90 110 130 F 20 10 0 10 20 30 40...

Page 103: ...ap 0 7 0 8 mm 0 027 0 031 in Clutch type Wet multiple disc Transmission Primary reduction system Helical gear Primary reduction ratio 1 563 Secondary reduction system Shaft drive Secondary reduction ratio 2 773 Transmission type Constant mesh 5 speed Operation Left foot Gear ratio 1st 2 529 2nd 1 773 3rd 1 348 4th 1 077 5th 0 929 Chassis Frame type Diamond Caster angle 26 Trail 109 mm 42 9 in Tire...

Page 104: ... cargo and accessories Wheels Front Type Cast wheel Size 17 M C MT 3 50 Rear Type Cast wheel Size 17 M C MT 5 50 Brakes Front Type Dual disc brake Operation Right hand Fluid DOT 4 Rear Type Single disc brake Operation Right foot Fluid DOT 4 Suspension Front Telescopic fork Rear Swingarm link suspension Spring shock absorber Front Coil spring oil damper Rear Coil spring gas oil damper Wheel travel ...

Page 105: ...utral indicator light 14 V 1 12 W 1 High beam indicator light 14 V 1 12 W 1 Turn signal indicator light 14 V 2 W 2 Engine trouble warning light 14 V 1 12 W 1 Oil level warning light 14 V 1 12 W 1 Fuses Main fuse 50 A Electronic fuel injection fuse 15 A Headlight fuse 25 A Signaling system fuse 10 A Radiator fan fuse 15 A Ignition fuse 10 A Odometer and clock fuse backup fuse 10 A Hazard fuse 10 A ...

Page 106: ...dentification number 9 1 Model label 9 2 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 9 7 YAMAHA EXTENDED SERVICE Y E S 9 9 E_U5JW10 book Page 1 Wednesday May 29 2002 3 10 PM ...

Page 107: ... EAU01041 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space provided NOTE _ The vehicle identification number is used to identify yo...

Page 108: ...under the rider seat See page 3 12 for rider seat removal and installation pro cedures Record the information on this label in the space provided This in formation will be needed when ordering spare parts from a Yamaha dealer 1 Model label E_U5JW10 book Page 2 Wednesday May 29 2002 3 10 PM ...

Page 109: ...stigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Tra...

Page 110: ... for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc CL 01...

Page 111: ...printed only as a reminder that maintenance work is required It is not acceptable proof of maintenance work CL 04E Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1 000 km or 1 month 4 000 mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 km or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 km or 30 months 24 000 mi ...

Page 112: ...or 42 months 32 000 mi 49 000 km or 48 months 36 000 mi 55 000 km or 54 months 40 000 mi 61 000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks E_U5JW10 book Page 6 Wednesday May 29 2002 3 10 PM ...

Page 113: ...CONSUMER INFORMATION 9 7 9 EAU02918 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY E_U5JW10 book Page 7 Wednesday May 29 2002 3 10 PM ...

Page 114: ...CONSUMER INFORMATION 9 8 9 E_U5JW10 book Page 8 Wednesday May 29 2002 3 10 PM ...

Page 115: ...CONSUMER INFORMATION 9 9 9 EAU01063 YAMAHA EXTENDED SERVICE Y E S E_U5JW10 book Page 9 Wednesday May 29 2002 3 10 PM ...

Page 116: ...CONSUMER INFORMATION 9 10 9 E_U5JW10 book Page 10 Wednesday May 29 2002 3 10 PM ...

Page 117: ...on settings 3 17 Front fork adjusting 3 13 Front fork checking 6 33 Fuel 3 11 Fuel tank cap 3 10 Fuses replacing 6 36 H Handlebar switches 3 6 Hazard switch 3 7 Headlight bulb replacing 6 37 High beam indicator light 3 2 Horn switch 3 6 I Identification numbers 9 1 Ignition circuit cut off system 3 19 Indicator and warning lights 3 2 K Key identification number 9 1 L Labels location 1 7 Locks for ...

Page 118: ...39 Throttle cable free play adjusting 6 20 Throttle grip and cable checking and lubricating 6 29 Tires 6 21 Tool kit 6 1 Troubleshooting 6 39 Troubleshooting charts 6 40 Turn signal indicator lights 3 2 Turn signal light bulb replacing 6 39 Turn signal switch 3 6 V Valve clearance adjusting 6 21 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking ...

Page 119: ...PRINTED IN JAPAN 2002 05 0 6 2 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 5JW 28199 10 LIT 11626 16 18 FJR1300R FJR1300RC OWNER S MANUAL ...

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