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Yamaha FJR13AEV(C), Service Manual

The Yamaha FJR13AEV(C) Owner's Manual is an essential guide for all owners of this powerful motorcycle. Get a comprehensive understanding of your bike's features, maintenance procedures, and safety precautions with this free downloadable manual available exclusively at manualshive.com. Empower yourself with knowledge for an exceptional riding experience.

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ET3P66050

WIRING DIAGRAM

FJR13AEV(C) 2006

1. Main switch
2. Rectifier/regulator
3. AC magneto
4. ABS ECU fuse
5. Fuel injection system fuse
6. Backup fuse (odometer, clock, 

and windshield drive system)

7. Main fuse
8. Battery
9. ABS motor fuse
10. Starter relay
11. Starter motor
12. Diode 1
13. Coupler 1 (wire harness–front 

cowling wire harness)

14. Fuel pump
15. Fuel sender
16. Coupler 2 (wire harness–front 

cowling wire harness)

17. Neutral switch
18. ABS test coupler
19. ABS ECU (electronic control 

unit)

20. Front wheel sensor
21. Rear wheel sensor
22. ABS motor relay
23. Hydraulic unit
24. Rear brake light switch
25. Diode 2
26. Brake light relay
27. License plate light
28. Taillight assembly
29. Tail/brake light
30. Rear left turn signal light
31. Rear right turn signal light
32. Coupler 3 (wire harness–front 

cowling wire harness)

33. Sidestand switch
34. Cylinders-#1/#4 ignition coil
35. Spark plug
36. Cylinders-#2/#3 ignition coil
37. Injector #4
38. Injector #3
39. Injector #2
40. Injector #1
41. Air induction system solenoid
42. ECU (engine control unit)
43. Crankshaft position sensor
44. Intake air temperature sensor
45. Coolant temperature sensor
46. O

2

 sensor

47. Cylinder identification sensor
48. Throttle position sensor
49. Intake air pressure sensor
50. Oil level switch
51. Shift actuator motor
52. Shift actuator sensor

53. Clutch actuator sensor
54. Clutch actuator motor
55. MCU (motor control unit)
56. YCC-S test coupler
57. Coupler 4 (wire harness–front 

cowling wire harness)

58. Coupler 6 (wire harness–front 

cowling wire harness)

59. Foot shift switch
60. YCC-S speed sensor
61. Gear position sensor
62. YCC-S control relay
63. Coupler 5 (wire harness–front 

cowling wire harness)

64. Headlight (on/off)/grip warmer 

relay

65. Hazard lighting fuse
66. Signaling system fuse
67. Headlight fuse
68. Ignition fuse
69. Auxiliary DC jack fuse
70. Grip warmer control unit
71. Radiator fan motor relay
72. Left radiator fan motor fuse
73. Left radiator fan motor
74. Right radiator fan motor fuse
75. Right radiator fan motor
76. YCC-S motor control fuse
77. Auxiliary DC jack
78. Turn signal/hazard relay
79. Right handlebar switch
80. Front brake light switch
81. Engine stop switch
82. Start switch
83. Hazard switch
84. Left handlebar switch
85. Dimmer switch
86. Windshield position switch
87. Turn signal switch
88. Horn switch
89. Relay unit
90. Starting circuit cut-off relay
91. Fuel pump relay
92. Accessory box solenoid
93. Meter assembly
94. Neutral indicator light
95. ABS warning light
96. Multi-function meter
97. Oil level warning light
98. Engine trouble warning light
99. Meter light
100.High beam indicator light
101.Right turn signal indicator light
102.Left turn signal indicator light
103.Lean angle sensor
104.Thermistor
105.Hand shift switch
106.Hand shift lever switch (shift 

up)

107.Hand shift lever switch (shift 

down)

108.Hand shift select button
109.Hand shift select indicator light
110.Horn
111.Front left turn signal light
112.Front right turn signal light
113.Headlight assembly
114.Headlight
115.Headlight relay (dimmer)
116.Windshield drive unit
117.Right grip warmer
118.Left grip warmer

ET3P66066

COLOR CODE

B

Black

Br

Brown

Ch

Chocolate

Dg

Dark green

G

Green

Gy

Gray

L

Blue

Lg

Light green

O

Orange

P

Pink

R

Red

Sb

Sky blue

W

White

Y

Yellow

B/G

Black/Green

B/L

Black/Blue

B/R

Black/Red

B/W

Black/White

B/Y

Black/Yellow

Br/B

Brown/Black

Br/G

Brown/Green

Br/L

Brown/Blue

Br/R

Brown/Red

Br/W

Brown/White

Br/Y

Brown/Yellow

G/B

Green/Black

G/L

Green/Blue

G/R

Green/Red

G/W

Green/White

G/Y

Green/Yellow

Gy/R

Gray/Red

Gy/W

Gray/White

L/B

Blue/Black

L/G

Blue/Green

L/R

Blue/Red

L/W

Blue/White

L/Y

Blue/Yellow

Lg/W

Light green/White

O/B

Orange/Black

O/G

Orange/Green

O/R

Orange/Red

O/W

Orange/White

P/W

Pink/White

R/B

Red/Black

R/G

Red/Green

R/L

Red/Blue

R/W

Red/White

R/Y

Red/Yellow

Summary of Contents for FJR13AEV(C)

Page 1: ...SERVICE MANUAL FJR13AV C FJR13AEV C LIT 11616 19 83 3P6 28197 10 ...

Page 2: ...2006 by Yamaha Motor Corporation U S A First edition April 2006 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 11616 19 83 ...

Page 3: ...nded to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its 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 N...

Page 4: ...ub 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 Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a disas sembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction ch...

Page 5: ... 14 15 16 LT New T R 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 Molybdenum disulfide oil 12 Wheel bearing grease 13 Lithium soap based grease 14 Molybdenum disulfide grease 15 Apply locking agent LOCTITE 16 Replace the part ...

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: ... OPERATION 1 16 ABS SELF DIAGNOSIS FUNCTION 1 20 ABS WARNING LIGHT AND OPERATION 1 22 OUTLINE OF THE YCC S Yamaha Chip Controlled Shift SYSTEM FJR13AE 1 23 INSTRUMENT FUNCTIONS 1 26 IMPORTANT INFORMATION 1 30 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 30 REPLACEMENT PARTS 1 30 GASKETS OIL SEALS AND O RINGS 1 30 LOCK WASHERS PLATES AND COTTER PINS 1 30 BEARINGS AND OIL SEALS 1 31 CIRCLIPS 1 31 CHECK...

Page 10: ...AS20140 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 information will be needed to order spare parts ...

Page 11: ...s 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 the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to ...

Page 12: ...ed 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 intake air temperature sensor rear wheel sensor and O2 sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position se...

Page 13: ...ted The brake 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 brake system The brake fluid pressure transmitted to the rear brake caliper and part of the right front brake caliper is controlled by the proportioning valve and metering valve respectively Th...

Page 14: ...e between 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 individually and replaced if necessary ET3P61019 OUTLINE OF THE ABS 1 The Yamaha ABS anti lock brake system features an electronic control system which acts on the front and rear brakes independen...

Page 15: ...d 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 occurs when the rotation of one or both of the wheels has stopped but the vehicle continues to travel Side force The force on the tires which supports the vehicle when cornering 4 5 6 7 8 9 10 11 12 13 14 1 2 3 A ...

Page 16: ... closely 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 keeping the proper slip ratio it is possible to obtain the maximum brake force without losing much side force ABS allows full use of the tires capabilities even on slippery road surfaces or less slippery road surfac es ...

Page 17: ...ake lever and brake pedal independently NOTE When the ABS is activated a pulsating action may be felt at the brake lever or brake pedal but this does not indicate a malfunction The higher the side force on a tire the less traction there is available for braking This is true whether the vehicle is equipped with ABS or not Therefore sudden braking while cornering is not recommend ed Excessive side f...

Page 18: ...ctronic technology The ABS control is processed with good response under various vehicle travel conditions The ABS also includes a highly developed self diagnosis function The ABS detects any problem con dition and allows normal braking even if the ABS is not operating properly When this occurs the ABS warning light on the meter assembly comes on The ABS stores the malfunction codes in the memory ...

Page 19: ...nd are in stalled close to the wheel sensors As the distance changes between the top and bottom of the serra tions with the rotation of the wheels inductive electromotive force is generated in the wheel sensors Wheel speed is detected based on the frequency of this alternating voltage 1 8 7 7 6 5 4 2 5 6 7 3 13 14 15 16 12 11 10 9 1 Rear brake master cylinder 2 Hydraulic unit 3 Front brake master ...

Page 20: ... 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 The hydraulic unit 1 is composed of three hydraulic control valves each with a solenoid valve and flow control valve two buffer chambers two hydraulic pumps and an ABS motor The hydraulic unit adjusts the front and rear wheel brake fluid press...

Page 21: ...er supplied from the ABS ECU signals to decrease the brake fluid pressure and the spool 3 of the flow control valve is moved toward the solenoid valve 3 When the ABS ECU stops transmitting signals to decrease the brake fluid pressure the solenoid valve 2 closes and the brake fluid is pressurized again Pressurizing the brake fluid again while the ABS is activated limits the flow of the brake fluid ...

Page 22: ...ent To protect the ABS ECU from water damage it is protected by a cover 2 As shown in the block following diagram the ABS ECU receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits 1 Buffer chamber pressurized 2 Buffer chamber depressurized 3 Raised piston 1 2 1 ...

Page 23: ...NOTE Some types of malfunctions are not recorded in the memory of the ABS ECU e g a drop in battery voltage 7 4 5 6 2 3 1 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1 Battery 2 AC magneto 3 Rectifier regulator 4 Main fuse 5 Main switch 6 ABS fuse 7 ABS motor fuse 8 Front brake light switch 9 Brake light relay 10 Tail brake light 11 Rear brake light switch 12 ABS ECU 13 ABS motor ...

Page 24: ...r relay is activated by signals transmitted from the ABS ECU and the ABS motor oper ates when the ABS starts to reduce the hydraulic pressure of the brake fluid 2 1 3 4 5 6 7 8 A 1 Software operation flow 2 Main switch ON 3 Initialize 4 Self diagnosis when static 5 Self diagnosis when riding 6 Receive signals 7 Control operation 8 Depressurize pressurize A 8 1000th of a second 1 ...

Page 25: ... for the front wheel only excluding the unified brake system 12 14 1 11 10 2 3 4 5 6 7 8 9 13 1 ABS ECU 2 Pump motor monitor 3 Power supply 4 Pump motor relay coil 5 Power supply 6 Front brake solenoid 7 Rear brake solenoid 8 Unified brake system solenoid 9 ABS warning light 10 Battery 11 ABS motor relay 12 Hydraulic unit 13 ABS motor 14 Solenoid valves ...

Page 26: ...the inlet and outlet check valves of the hydraulic pump are closed preventing the brake fluid from flowing through the pump As a result the brake master cylinder directly pressurizes the brake caliper during normal braking When the brake lever is released the brake fluid in the brake caliper re turns to the brake master cylinder via port A and port B 1 Brake master cylinder 2 Brake light switch 3 ...

Page 27: ...and the brake fluid is sent to the brake caliper via port C 13 and to the buffer chamber via port D 11 As a result the hydraulic pressure in the brake caliper is reduced The brake fluid stored in the buffer chamber is pumped back to the brake master cylinder by the hy draulic pump linked to the ABS motor 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 F...

Page 28: ... C 13 At this time the brake is pressurized at a constant rate regardless of the brake fluid pressure level since the restriction of port A 7 chang es so that a constant pressure difference is maintained between chamber A 20 and chamber B 21 of the flow control valve 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Flow control valve 7 Port A 8 Spool 9 P...

Page 29: ...n goes off if there are no problems 2 The ABS warning light comes on while the start switch is being pushed When the engine is being started the ABS warning light comes on while the start switch is being pushed Refer to ELECTRIC STARTING SYSTEM on page 8 13 1 a e d d b c f a ABS warning light b Main switch OFF c Main switch ON d Goes off e Comes on for 2 seconds f ABS self diagnosis b c d e a f i ...

Page 30: ... adapter con nected to the ABS test coupler 5 The ABS warning light 1 flashes and a malfunction code 2 is indicated on the multi function dis play 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 panel 1 When the test coupler adapter is connected to the ABS test coupler the ...

Page 31: ...on 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 if it comes on after riding conven tional braking performance of the vehicle is maintained ABS function When hydraulic control is performed by the ABS the brake system alerts the rider that the wheels...

Page 32: ...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 user s preference the transmission can be shifted by hand after setting the hand shift select button to ON When the engine is started the MCU disengages the clutch A signal is sent to the MCU when th...

Page 33: ...abled 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 7 9 11 12 8 10 1 YCC S test coupler 2 YCC S control relay 3 YCC S indicator and warning light 4 YCC S motor control fuse 5 Hand shift switch 6 Gear position sensor 7 Neutral switch 8 MCU motor control unit 9 Shift actuator 10 Clutch actuator 11 Foot shift switch 12 YCC ...

Page 34: ...main 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 switch is turned to ON The YCC S indicator and warning light 1 come on during this self diagnosis After the self diagnosis is com pleted if there were no problems found the YCC S indicator and warning...

Page 35: ...ve 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 odometer which shows the total distance traveled two tripmeters which show the distance trav eled since they were last set to zero a fuel reserve tripmeter which shows the dis tance traveled on the fuel ...

Page 36: ... 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 flashing push the RESET button to set the hours 3 Push the SELECT button and the minute digits will start flashing 4 Push the RESET button to set the minutes 5 Push the SELECT button and then release it to start the clock Fue...

Page 37: ...emperature instantaneous fuel consumption and average fuel consumption modes Push the RESET button to switch the display between the ambient temperature mode Air the instantaneous fuel consumption mode MPG and the average fuel consumption mode AV_ _ _ MPG in the following order Air MPG AV_ _ _ MPG Air Ambient temperature mode This display shows the ambient temperature from 16 F to 122 F in 1 F inc...

Page 38: ...1 second while the display is flashing After resetting an average fuel consumption display _ _ _ will be shown for that display until the vehicle has traveled 1 km 0 6 mi CAUTION EC3P66002 If there is a malfunction will be dis played Replace the meter assembly Self diagnosis device This model is equipped with a self diagnosis de vice for various electrical circuits If any of those circuits are def...

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 for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals ...

Page 40: ...rease 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 reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned o...

Page 41: ...al 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 Check Continuity with the pocket tester NOTE If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at...

Page 42: ... 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 03149 1 21 4 61 4 62 8 175 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 32 4 20 5 42 8 132 8 133 8 156 8 157 8 215 8 216 8 217 8 221 8 223 8 224 8 225 8 226 8 227 8 228 8 229 8 230 8 231 8 232 8...

Page 43: ...ressure 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 90890 01252 3 20 Steering nut wrench 90890 01403 Spanner wrench YU 33975 3 34 4 85 Damper rod holder 90890 01447 YM 01447 4 77 4 78 Tool name Tool No Illustration Reference pages ...

Page 44: ...29 4 103 4 106 Bearing retainer wrench 90890 04050 Pinion bearing retainer remover YM 04050 4 103 4 106 Fork seal driver weight 90890 01184 Replacement hammer YM A9409 7 4 108 4 109 Fork seal driver attachment 90890 01186 Replacement 27 mm YM A9409 1 4 108 4 109 Oil seal installing tool 90890 01512 YM 01512 4 109 Pivot shaft wrench 90890 01471 Frame spanner socket YM 01471 5 8 5 9 Tool name Tool N...

Page 45: ... Yamaha bond No 1215 90890 85505 Three Bond No 1215 5 19 5 35 5 38 5 101 6 13 Valve spring compressor 90890 04019 YM 04019 5 25 5 30 Valve spring compressor attachment 90890 04114 Valve spring compressor adapter 19 5 mm YM 04114 5 25 5 30 Valve guide remover ø5 90890 04097 Valve guide remover 5 0 mm YM 04097 5 26 Valve guide installer ø5 90890 04098 Valve guide installer 5 0 mm YM 04098 5 26 Tool ...

Page 46: ...U 33270 B 5 34 Universal clutch holder 90890 04086 YM 91042 5 56 5 59 Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 5 57 Bearing retainer wrench 90890 04137 Middle drive shaft bearing retainer wrench YM 04137 5 87 5 89 Damper spring compressor 90890 04090 5 87 5 88 Bearing retainer wrench 90890 04140 Middle drive shaft bearing retainer wrench YM 04140 5 88 Tool name Tool No Illustration ...

Page 47: ...r YU 01304 5 105 Piston ring compressor 90890 05158 YM 08037 5 110 Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 5 123 Weight 90890 01084 YU 01083 3 5 123 Radiator cap tester 90890 01325 Radiator pressure tester YU 24460 01 6 3 Tool name Tool No Illustration Reference pages YU 01304 YU 01083 3 YU 24460 01 ...

Page 48: ...78 Water pump seal installer YM 33221 A 6 13 Middle driven shaft bearing driver 90890 04058 Bearing driver 40 mm YM 04058 6 13 Pressure gauge 90890 03153 YU 03153 7 8 Fuel pressure adapter 90890 03176 YM 03176 7 8 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 8 227 Tool name Tool No Illustration Reference pages YU 33984 ...

Page 49: ...RAL TIGHTENING TORQUE SPECIFICATIONS 2 16 ENGINE TIGHTENING TORQUES 2 17 CHASSIS TIGHTENING TORQUES 2 22 LUBRICATION POINTS AND LUBRICANT TYPES 2 27 ENGINE 2 27 CHASSIS 2 29 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 ENGINE OIL LUBRICATION CHART 2 31 LUBRICATION DIAGRAMS 2 33 COOLING SYSTEM DIAGRAMS 2 43 CABLE ROUTING FJR13A 2 47 CABLE ROUTING FJR13AE 2 67 ...

Page 50: ...ll height 1450 mm 57 1 in Seat height 800 mm 31 5 in Wheelbase 1545 mm 60 8 in Ground clearance 130 mm 5 12 in Minimum turning radius 3100 mm 122 0 in Weight With oil and fuel FJR13A 291 0 kg 642 lb USA FJR13A 292 0 kg 644 lb California FJR13AE 295 0 kg 650 lb USA FJR13AE 296 0 kg 653 lb California Maximum load FJR13A 212 kg 467 lb USA FJR13A 211 kg 465 lb California FJR13AE 208 kg 459 lb USA FJR1...

Page 51: ...mount 4 90 L 5 18 US qt 4 31 Imp qt Without oil filter cartridge replacement 3 80 L 4 02 US qt 3 34 Imp qt With oil filter cartridge replacement 4 00 L 4 23 US qt 3 52 Imp qt Oil pressure hot 30 0 kPa 1000 r min 4 4 psi 1000 r min 0 30 kgf cm 1000 r min Final gear oil Type Shaft drive gear oil Part No 9079E SH001 00 Quantity 0 20 L 0 21 US qt 0 18 Imp qt Oil pump Oil pump type Trochoid Inner rotor...

Page 52: ...atio 75 48 25 28 1 395 Impeller shaft tilt limit 0 15 mm 0 006 in Spark plug s Manufacturer model NGK CR8E Manufacturer model DENSO U24ESR N Spark plug gap 0 7 0 8 mm 0 028 0 031 in Cylinder head Volume 22 74 23 34 cm 1 39 1 42 cu in Warpage limit 0 10 mm 0 0039 in Camshaft Drive system Chain drive right Camshaft cap inside diameter 24 500 24 521 mm 0 9646 0 9654 in Camshaft journal diameter 24 45...

Page 53: ...A exhaust 25 90 26 10 mm 1 0197 1 0276 in Valve seat 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 50 0 90 mm 0 0197 0 0354 in Valve stem diameter intake 4 975 4 990 mm 0 1959 0 1965 in Valve stem diameter exhaust 4 965 4 980 mm 0 1955 0 1961 in V...

Page 54: ...ing rate K1 intake 21 85 N mm 124 76 lb in 2 23 kgf 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 compression spring force intake 136 00 158 00 N 30 57 35 52 lb 13 87 16 11 kgf Installed compression spring force exhaust 136 00 158 00 N 30 57 35 52 lb 13 87 ...

Page 55: ...g type Barrel Dimensions B T 1 00 2 80 mm 0 04 0 11 in End gap installed 0 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 gap installed 0 75 0 85 mm 0 0295 0 0335 in Limit 1 20 mm 0 0472 in Ring side clearance 0 020 0 060 mm 0 0008 0 0024 in Limit ...

Page 56: ...ple disc Clutch release method Hydraulic inner push Clutch lever free play FJR13A 1 9 20 7 mm 0 07 0 81 in Friction plate thickness 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 height 6 78 mm 0 27 in Minimum height 6 4 mm 0 25 in Spring quantity 1 p...

Page 57: ...mark 3P61 00 USA 3P65 10 California Throttle position sensor Resistance 4 0 6 0 kΩ Output voltage at idle 0 63 0 73 V Fuel injection sensor Crankshaft position sensor resistance 421 569 Ω 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 Coolant temper...

Page 58: ...INE SPECIFICATIONS 2 9 Ring gear to stopper bolt clearance 0 30 0 60 mm 0 0118 0 0236 in Ring gear to thrust washer clearance 0 10 0 20 mm 0 0039 0 0079 in Final gear backlash 0 22 0 45 mm 0 0087 0 0177 in ...

Page 59: ...ze 120 70 ZR17M C 58W Manufacturer model METZELER Roadtec Z6G Manufacturer model BRIDGESTONE BT020F Wear limit front 1 0 mm 0 04 in Rear tire Type Tubeless Size 180 55 ZR17M C 73W Manufacturer model METZELER Roadtec Z6C Manufacturer model BRIDGESTONE BT020R Wear limit rear 1 0 mm 0 04 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 270 kPa 39 psi 2 70 kgf cm Re...

Page 60: ...of the rider footrest Rear disc brake Disc outside diameter thickness 282 0 5 0 mm 11 10 0 20 in Brake disc thickness limit 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 Master cylinder inside diameter 15 0 mm 0 59 in Caliper cylinder inside diame...

Page 61: ...er type Coil spring gas oil damper Rear shock absorber assembly travel 60 0 mm 2 36 in 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 Spring rate K2 124 00 N mm 708 04 lb in 12 64 kgf mm Spring stroke K1 0 0 42 0 mm 0 00 1 65 in Spring stroke K2 42 0 60...

Page 62: ...gneto Model manufacturer LNX07 DENSO Standard output 14 0 V 590 W 5000 r min Stator coil resistance 0 13 0 19 Ω at 20 C 68 F Voltage regulator Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer FH012AA SHINDENGEN Regulated voltage DC 14 2 14 8 V Rectifier capacity DC 50 0 A Withstand voltage 40 0 V Battery Model GT14B 4 Voltage capacity 12 V 12 0 Ah Manufacturer GYM...

Page 63: ...in Limit 23 5 mm 0 93 in Mica undercut depth 1 50 mm 0 06 in Starter relay Model manufacturer MS5F 631 JIDECO Amperage 180 0 A Horn Horn type Plane Quantity 2 pcs Model manufacturer HF 12 NIKKO Maximum amperage 3 0 A Coil resistance 1 01 1 11 Ω at 20 C 68 F Performance 108 116 dB 2 m 6 6 ft Turn signal hazard relay Relay type Full transistor Model manufacturer FE246BH DENSO Built in self canceling...

Page 64: ...FJR13AE 0 71 0 91 V Resistance FJR13AE 4 0 6 0 kΩ Foot shift switch Output voltage FJR13AE 2 4 2 6 V Resistance FJR13AE 4 0 6 0 kΩ Grip warmer Resistance FJR13AE 1 21 1 48 Ω at 20 C 68 F Fuses Main fuse 50 0 A Headlight fuse 25 0 A Signaling system fuse 15 0 A Ignition fuse 10 0 A Radiator fan fuse 15 0 A 2 Auxiliary DC jack fuse 3 0 A Hazard fuse 10 0 A Fuel injection system fuse 15 0 A ABS motor...

Page 65: ...l 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 specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kg ft lb 10 mm 6 mm 6 0 6...

Page 66: ... 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 housing cover bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Coolant drain bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Water jacket joint bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Thermostat inlet pipe 1 bolt M6 2 10 Nm 1 0 m ...

Page 67: ... Lower crankcase plug bolt FJR13A M6 1 10 Nm 1 0 m kg 7 2 ft lb YCC S speed sensor bolt FJR13AE 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 ft lb Clutch cover bolt M6 10 12 Nm 1 2 m kg 8 7 ft lb Middle gear case cover bolt M6 9 12 Nm 1 2 m kg 8 7 ft lb Pickup rotor cover bolt M6 8 12 Nm 1 2 m kg 8 7 ft lb Rear balancer cover bolt M6 4 12 Nm 1 2 m kg 8 7 ft lb Oil ba...

Page 68: ...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 stopper bolt M8 1 22 Nm 2 2 m kg 16 ft lb Stator coil assembly bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Gear position switch bolt FJR13A M5 2 4 Nm 0 4 m kg 2 9 ft lb Crankshaft position sensor bolt M5 2 4 Nm 0 4 m kg 2 9 ft lb O2 sensor M18 1 45 Nm 4 5 m kg 3...

Page 69: ...Coolant reservoir bracket bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Clutch fluid reservoir bolt FJR13AE M6 1 7 Nm 0 7 m kg 5 1 ft lb Clutch actuator bracket bolt FJR13AE M8 2 19 Nm 1 9 m kg 13 ft lb Clutch actuator bracket bolt FJR13AE M6 3 10 Nm 1 0 m kg 7 2 ft lb Gear position sensor cover FJR13AE M6 2 10 Nm 1 0 m kg 7 2 ft lb Gear position sensor screw FJR13AE M5 2 4 Nm 0 4 m kg 2 9 ft lb Gear position...

Page 70: ...TIGHTENING TORQUES 2 21 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 71: ...op 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 Nm 12 5 m kg 90 ft lb Pivot shaft locknut M28 1 115 Nm 11 5 m kg 85 ft lb Pivot shaft locknut retainer bolt FJR13A M6 1 10 Nm 1 0 m kg 7 2 ft lb Pivot shaft locknut retainer bolt FJR13AE M6 1 10 Nm ...

Page 72: ... bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Windshield upper inner bracket and windshield lower inner brack et bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Windshield upper inner bracket and windshield drive unit bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Windshield lower 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...

Page 73: ... 2 30 Nm 3 0 m kg 22 ft lb Rear wheel dust cover screw M5 3 5 Nm 0 5 m kg 3 6 ft lb Brake hose union bolt M10 14 30 Nm 3 0 m kg 22 ft lb Brake pipe flare nut M10 11 19 Nm 1 9 m kg 13 ft lb Front brake caliper bolt M10 4 40 Nm 4 0 m kg 29 ft lb Front brake hose holder bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Front brake caliper bleed screw M8 3 6 Nm 0 6 m kg 4 3 ft lb Front brake pad bolt M10 2 17 Nm 1 7 ...

Page 74: ...h bolt FJR13A M6 1 10 Nm 1 0 m kg 7 2 ft lb Shift rod locknut FJR13A 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 gear oil filler bolt M14 1 23 Nm 2 3 m kg 17 ft lb Final drive assembly nut M10 4 42 Nm 4 0 m kg 29 ft lb Final drive pinion gear bearing retainer M65 1 110 Nm 11 0 m kg 80 ft lb Left...

Page 75: ...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 a point on the outer edge of the axle with the fork making sure that the axle does not protrude past the fork 4 In the order pinch bolt 4 pinch bolt 3 pinch bolt 4 tighten each bolt to 21 Nm 2 1 m kg 15 ft lb without performing temporary tightening 1 2 3 4 ...

Page 76: ...and 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 assembly Primary driven gear Push rods and ball Transmission gears wheel and pinion Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift pedal bolt Damper drive ca...

Page 77: ...er 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 1215 Stator coil assembly lead grommet Yamaha bond No 1215 Three Bond No 1215 Lubrication point Lubricant ...

Page 78: ...hrottle grip inner surface and throttle cables Brake lever pivot bolt and metal to metal moving parts Silicon grease Clutch lever pivot bolt and metal to metal moving parts Silicon grease Rear shock absorber assembly oil seal Rear shock absorber assembly bearing Rear shock absorber assembly spacer Pivot shaft and pivot shaft thread Pivot shaft bearing Pivot shaft oil seal lip Relay arm bearing Oil...

Page 79: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 30 ...

Page 80: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 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: ...strainer 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 pipe 14 Drive axle 15 Middle drive shaft assembly ...

Page 82: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 EAS20410 LUBRICATION DIAGRAMS 5 6 7 1 2 3 4 ...

Page 83: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 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 35 1 3 2 ...

Page 85: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Main axle 2 Drive axle 3 Oil delivery pipe 1 ...

Page 86: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 6 5 4 3 2 1 ...

Page 87: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 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 39 1 2 3 4 5 6 7 8 9 ...

Page 89: ...CATION SYSTEM CHART AND DIAGRAMS 2 40 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 assembly ...

Page 90: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 41 4 5 3 2 1 9 8 6 7 ...

Page 91: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 42 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 43 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: ...r 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 joint 14 Oil cooler 15 Oil cooler inlet hose 16 Water pump outlet pipe 17 Water pump breather hose 18 Radiator outlet hose 19 Water jacket joint inlet hose ...

Page 94: ...COOLING SYSTEM DIAGRAMS 2 45 A A 7 1 2 3 4 5 5 7 8 6 8 9 10 11 12 ...

Page 95: ...1 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 pump 11 Water jacket joint 12 Water pump breather hose ...

Page 96: ...CABLE ROUTING FJR13A 2 47 EAS20430 CABLE ROUTING FJR13A B B A A B B A B C D E F G G G H I J K L 1 1 1 2 2 2 2 3 3 3 4 4 4 5 5 5 6 7 8 9 10 10 11 11 10 11 12 13 14 15 16 17 18 19 19 19 20 20 20 1 2 3 L ...

Page 97: ...he guide D Route the main switch lead to the inside of the clutch hose E Temporarily tighten the brake hose joint bolt union bolt and brake hose holder bolt in the proper tightening sequence as shown Then tighten the bolts to the specified torques making sure to tighten the brake hose joint bolt 1 last F To front cowling wire harness G Install the horn L shaped connectors so that the leads are rou...

Page 98: ...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 27 27 28 29 29 30 31 32 33 34 35 36 37 38 D F G M N S 27 29 29 18 H C C B B 5 18 18 Q R 39 41 O P 11 C 40 C B B ...

Page 99: ...rd Do not cut off the excess end of the plastic locking tie F Route the positive battery lead between the battery stay and the battery box G To front cowling wire harness H Align the rear end of the right radiator fan motor coupler with the tape on the wire harness as shown in the illustration I Fasten the wire harness right horn high leads and right radiator fan motor lead with a plastic locking ...

Page 100: ...CABLE ROUTING FJR13A 2 51 A B C D E 1 1 2 3 4 5 6 7 8 9 11 10 12 ...

Page 101: ...hydraulic unit 10 Brake pipe metering valve to right front brake caliper 11 Rear brake light switch 12 Brake hose proportioning valve 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 55 mm 1 77 2 17 in C 10 20 mm 0 39 0 79 in D Route the rear brake light switch lead under the rear wheel sensor...

Page 102: ...CABLE ROUTING FJR13A 2 53 A B C D 1 2 3 4 6 5 7 8 9 10 11 12 ...

Page 103: ... plastic locking tie Face the end of the 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 Fasten the front cowling wire harness to the radiator inlet hose with a plastic locking tie making sure to install the tie on the harness protective sleeve and ...

Page 104: ...E ROUTING FJR13A 2 55 A A B C C A A A B C D F E H I J K 1 2 9 10 12 13 G 7 3 5 4 26 27 28 29 5 5 X 6 P Q R S T U V W 22 23 24 25 15 21 14 8 L M N O 16 17 18 19 20 8 11 34 30 33 D B Y Z 15 7 32 30 31 D AA AB ...

Page 105: ...g tie G Fasten the sidestand switch lead stator coil lead and oil level switch lead with a plastic locking tie making sure to bundle and fasten the sidestand switch lead so that the coupler is positioned to the front of the tie Face the end of the plastic locking tie outward Do not cut off the excess end of the plastic locking tie H To fuel tank I Route the gear position switch lead so that the co...

Page 106: ...CABLE ROUTING FJR13A 2 57 A A B B C C B B A A A B C E D F G H I J K 2 2 1 1 4 4 4 5 5 5 6 7 8 9 10 11 12 13 3 3 3 14 15 16 17 16 17 18 19 20 21 22 ...

Page 107: ...ulator lead to the outside of the rear shock absorber spring preload adjusting cable and under the hydraulic unit breather hose D Pass the stator coil lead rectifier regulator lead and hydraulic unit breather hose through the guide on the frame making sure to route the hose to the outside of the leads E Fasten the leads to ABS wire harness and rear brake light switch that branch off from the wire ...

Page 108: ...CABLE ROUTING FJR13A 2 59 B E A C D F G H I J K L M N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 32 31 30 F ...

Page 109: ...ce the end of the plastic locking tie forward Do not cut off the excess end of the plastic 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 Route the throttle cables and brake hoses through the right opening in the frame D Route the wire harness over the spark plug leads E To cylinder identification sensor F To ...

Page 110: ...CABLE ROUTING FJR13A 2 61 D A B B C E 1 2 3 4 ...

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 light assembly lead and license plate light lead between the ribs on the rear fender D Route the intake air temperature sensor lead under the wire harness E Fasten the intake air temperature sensor le...

Page 112: ...CABLE ROUTING FJR13A 2 63 A A A B C D E P F H I J K L M N Q R 1 2 3 4 5 6 9 10 11 13 14 15 16 G 7 8 O 12 ...

Page 113: ... harness with the band after the headlight lead branches off from the harness J Secure the front cowling wire harness 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 K Fasten the leads to windshield drive unit that branch off from the front cowling wire harness to the harness with a plastic locking t...

Page 114: ...CABLE ROUTING FJR13A 2 65 C C A B A B C C A B J C D F G G I 1 1 1 1 2 2 2 3 3 3 3 4 4 4 4 4 5 5 5 6 6 6 7 7 7 8 8 8 9 9 8 9 10 10 10 10 12 11 12 17 17 13 13 17 13 14 16 15 16 E H 11 ...

Page 115: ...regulator lead 16 Rectifier regulator 17 ABS motor coupler A Install the ABS motor relay completely onto the tab on the hydraulic unit bracket B Install the hydraulic unit solenoid coupler completely onto the tab on the hydraulic unit bracket C 87 93 D 5 7 mm 0 20 0 28 in E Install the hydraulic unit breather hose so that the white paint mark on the hose is facing down F Make sure that the brake h...

Page 116: ...E ROUTING FJR13AE 2 67 ET3P66048 CABLE ROUTING FJR13AE B B A A B B A B C D E F F G G H I J K L 1 1 1 2 2 2 2 3 3 3 7 7 6 7 4 5 8 6 12 12 13 13 9 12 11 10 13 14 16 15 17 18 19 21 20 22 22 22 23 23 23 1 2 3 M ...

Page 117: ...ip warmer lead and main switch lead with a plastic locking tie E Temporarily tighten the brake hose joint bolt union bolt and brake hose holder bolt in the proper tightening sequence as shown Then tighten the bolts to the specified torque making sure to tighten the brake hose joint bolt 1 last F To front cowling wire harness G Install the horn L shaped connectors so that the leads are routed outwa...

Page 118: ...D E E A A B B F F A A CB D 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 18 19 20 21 23 24 25 26 27 27 29 28 30 30 31 32 33 34 35 36 37 38 39 D F G M N S 27 30 30 18 Q R H 22 40 41 42 41 O P 11 ...

Page 119: ...locking tie rearward Do not cut off the excess end of the plastic locking tie F Route the positive battery lead between the battery stay and the battery box G To front cowling wire harness H Align the rear end of the right radiator fan motor coupler with the tape on the wire harness as shown in the illustration I Fasten the wire harness right horn high leads and right radiator fan motor lead with ...

Page 120: ...CABLE ROUTING FJR13AE 2 71 B C 1 A D E G 1 2 3 4 5 6 7 8 9 14 13 10 11 12 15 F ...

Page 121: ...Brake hose proportioning valve 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 55 mm 1 77 2 17 in C 10 20 mm 0 39 0 79 in D Route the rear brake light switch lead under the rear wheel sensor lead E Fasten the clutch actuator motor lead and clutch actuator sensor lead to the brake hose hydraul...

Page 122: ...CABLE ROUTING FJR13AE 2 73 A B C D E 1 2 3 4 6 5 8 7 9 11 10 12 13 ...

Page 123: ...ocking tie Face the end of the 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 Route the grip warmer control unit leads to the outside of the thermostat assembly breather hose D Fasten the front cowling wire harness to the radiator inlet hose with a...

Page 124: ... FJR13AE 2 75 UP A A B D C C B D A A A B D C F G H I N O P Q R S T U X V W 1 3 2 20 20 10 12 11 13 10 15 14 16 18 19 26 27 28 29 9 30 31 32 17 33 34 11 35 36 37 38 39 E 6 8 7 4 5 36 40 41 Y 17 J K L 21 22 23 24 25 M ...

Page 125: ... 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 the sidestand switch lead stator coil lead and oil level switch lead with a plastic locking tie making sure to bundle and fasten the sidestand switch lead so that the coupler is positioned to the front of the tie Face the end of the plastic locking tie outward Do not cut ...

Page 126: ...CABLE ROUTING FJR13AE 2 77 A A B B C C B B A A A B E D C G F H I J L K M 2 2 1 1 5 5 5 6 6 6 7 8 9 16 11 12 13 15 10 17 18 19 12 3 3 4 3 20 21 11 22 11 22 23 24 25 26 27 14 ...

Page 127: ...sition the harness to the outside of the other leads Face the end of the plastic locking tie inward without cutting off the excess end D Fasten the ABS wire harness with the holder E Route the stator coil lead and rectifier regulator lead to the outside of the rear shock absorber spring preload adjusting cable and under the hydraulic unit breather hose and clutch fluid reservoir hose F Pass the st...

Page 128: ...CABLE ROUTING FJR13AE 2 79 E A C B D F F G H I J K L M N 1 2 3 4 5 6 7 8 9 10 11 13 12 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 31 30 29 ...

Page 129: ...he plastic locking tie forward Do not cut off the excess end of the plastic 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 Route the throttle cables and brake hoses through the right opening in the frame D Route the wire harness over the spark plug leads E To cylinder identification sensor F To fuel tank G Fas...

Page 130: ...CABLE ROUTING FJR13AE 2 81 D B C A E E F I 3 4 5 2 1 6 H G ...

Page 131: ...h actuator motor lead and clutch actuator sensor lead with the band that is used to secure the MCU motor control unit C Make sure that the projection on the storage compartment fits into the indentation in the MCU motor control unit The MCU should not be resting on top of the projection D Route the tail brake light assembly lead and license plate light lead between the rib and the U lock holder on...

Page 132: ...CABLE ROUTING FJR13AE 2 83 A A A B C D E P F H I J K L M N Q R 1 2 3 4 5 6 9 10 11 13 14 15 16 G 7 8 O 12 ...

Page 133: ... harness with the band after the headlight lead branches off from the harness J Secure the front cowling wire harness 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 K Fasten the leads to windshield drive unit that branch off from the front cowling wire harness to the harness with a plastic locking t...

Page 134: ...CABLE ROUTING FJR13AE 2 85 C C A B A B C C A B J C D F G G I 1 1 1 1 2 2 2 3 3 3 3 4 4 4 4 4 5 5 5 6 6 6 7 7 7 8 8 8 9 9 8 9 10 10 10 10 12 11 12 17 17 13 13 17 13 14 16 15 16 E H 11 ...

Page 135: ...regulator lead 16 Rectifier regulator 17 ABS motor coupler A Install the ABS motor relay completely onto the tab on the hydraulic unit bracket B Install the hydraulic unit solenoid coupler completely onto the tab on the hydraulic unit bracket C 87 93 D 5 7 mm 0 20 0 28 in E Install the hydraulic unit breather hose so that the white paint mark on the hose is facing down F Make sure that the brake h...

Page 136: ...CABLE ROUTING FJR13AE 2 87 ...

Page 137: ...3 13 CHECKING THE ENGINE OIL LEVEL 3 14 CHANGING THE ENGINE OIL 3 15 MEASURING THE ENGINE OIL PRESSURE 3 16 ADJUSTING THE CLUTCH LEVER FJR13A only 3 17 CHECKING THE CLUTCH FLUID LEVEL FJR13A 3 17 CHECKING THE CLUTCH FLUID LEVEL FJR13AE 3 17 BLEEDING THE HYDRAULIC CLUTCH SYSTEM FJR13A 3 18 BLEEDING THE HYDRAULIC CLUTCH SYSTEM FJR13AE 3 19 CHECKING THE VEHICLE AFTER BLEEDING THE HYDRAULIC CLUTCH SYS...

Page 138: ...KING 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 ADJUSTING THE SIDE PANELS 3 38 ADJUSTING THE RIDER SEAT HEIGHT 3 38 CHECKING THE TIRES 3 40 CHECKING THE WHEELS 3 42 CHECKING AND LUBRICATING THE CABLES 3 42 LUBRICATING THE LEVERS 3 42 LUBRICATING THE PEDALS...

Page 139: ......

Page 140: ... if necessary 2 Spark plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 3 Valve clearance Check and adjust valve clear ance when engine is cold Every 26600 mi 42000 km 4 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 5 Fuel injection Check and adjust engine idle speed and synchronization 6 Exhaust system ...

Page 141: ... Check operation Apply lithium soap based grease all purpose grease lightly 15 Sidestand switch Check operation and replace if necessary 16 Front fork Check operation and for oil leakage Replace if necessary 17 Shock absorber assembly Check operation and for oil leakage Replace if necessary 18 Rear suspension link pivots Apply lithium soap based grease lightly 19 Engine oil Change warm engine befo...

Page 142: ...if necessary Lubricate the throttle grip housing and cable 26 Lights signals and switches Check operation Adjust headlight beam No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 1 Fuel line Check fuel hoses for cracks or damage Rep...

Page 143: ...r dam age Replace if necessary 7 Tires Check tread depth and for damage Replace if necessary Check air pressure Correct if necessary 8 Wheel bearings Check bearings for smooth operation Replace if necessary 9 Swingarm pivot bearings Check bearing assemblies for looseness Moderately repack with lithi um soap based grease Repack 10 Steering bearings Check bearing assemblies for looseness Moderately ...

Page 144: ...ry 17 Shock absorber assembly Check operation and for oil leakage Replace if necessary 18 Rear suspension link pivots Apply lithium soap based grease lightly 19 Engine oil Change warm engine before draining 20 Engine oil filter cartridge Replace 21 Cooling system Check hoses for cracks or damage Replace if necessary Change with ethylene glycol anti freeze coolant every 24 months Change 22 Final ge...

Page 145: ...er 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 12 4 Remove Hose holder 1 Lead holders 2 Pickup rotor cover 3 5 Measure Valve clearance Out of specification Adjust a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres sion stroke align the TDC mark a on the pickup rotor wit...

Page 146: ... 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 the measured valve clearance Example Specified valve clearance 0 15 0 22 mm 0 0059 0 0087 in Measured valve clearance 0 25 mm 0 0098 in 0 25 mm 0 0098 in 0 22 mm 0 0087 in 0 03 mm 0 001 in c Check the...

Page 147: ...age 5 12 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 clearance again i If the valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the specified clearance is obtained 8 Install All removed parts NOTE F...

Page 148: ...tle 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 the screw 3 4 turn in and be sure to synchronize the throt tle body CAUTION ECA14900 Do not use the throttle valve adjusting screws to adjust the throttle body synchroni zation NOTE The difference in...

Page 149: ...HASSIS 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 of specification Adjust 6 Adjust Engine idling speed a Turn the engine idle speed adjustment screw 1 in direction a or b until the specified en gine idling speed is obtained 7 Adjust Throttle cable free play Refer to ADJUSTING THE...

Page 150: ...ection a or b until the specified throttle cable free play is obtained d Tighten the locknut e Slide the rubber 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 THE SPARK PLUGS The following procedure applies to all of the spark plugs 1 Remove Rider seat Re...

Page 151: ...EL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS20700 CHECKING THE IGNITION TIMING 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 NOTE Place the vehicle on the centerstand 2 Remove Right side cowling Rider seat Refer to GENER...

Page 152: ...on pressure will result in a loss of performance 1 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 6 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 Fuel tank Refer to FUEL TANK on page 7 1 T bar Refer to GENERAL CHASSIS on page 4 1 4 Disconnect the all spark plug ...

Page 153: ... 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 mark b Below the minimum level mark Add the recommended engine oil to the proper level CAUTION ECA13380 Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical add...

Page 154: ...thin coat of engine oil CAUTION ECA13390 Make sure the O ring 3 is positioned cor rectly in the groove of the oil filter cartridge c Tighten the new oil filter cartridge to specifi cation with an oil filter wrench 6 Install Engine oil drain bolt along with the gasket 7 Fill Crankcase with the specified amount of the recom mended engine oil 8 Install Engine oil filler cap 9 Start the engine warm it...

Page 155: ...3410 When the engine is cold the engine oil will have a higher viscosity causing the engine oil pressure to increase Therefore be sure to measure the engine oil pressure after warming up the engine 3 Remove Right side cowling Refer to GENERAL CHASSIS on page 4 1 4 Remove Main gallery bolt WARNING EWA12980 The engine muffler and engine oil are ex tremely hot 5 Install Oil pressure gauge set 1 Oil p...

Page 156: ... clutch fluid that is already in the system Mixing clutch flu ids may result in a harmful chemical reac tion leading to poor clutch performance When refilling be careful that water does not enter the clutch fluid reservoir Water will significantly lower the boiling point of the clutch fluid and could cause vapor lock CAUTION ECA13420 Clutch fluid may damage painted surfaces or plastic parts Theref...

Page 157: ... or allow the clutch master cylinder reservoir to over flow When bleeding the hydraulic clutch system make sure there is always enough clutch fluid before applying the clutch lever Ignoring this precaution could allow air to enter the hydraulic clutch system considerably lengthening the bleeding procedure If bleeding is difficult it may be necessary to let the clutch fluid settle for a few hours R...

Page 158: ...bles in the hose have disappeared 1 Remove Air filter case Refer to GENERAL CHASSIS on page 4 1 Rear wheel Refer to REAR WHEEL on page 4 24 Swingarm Refer to SWINGARM on page 4 91 2 Bleed Hydraulic clutch system a Fasten the clutch fluid reservoir 1 to the frame with a suitable strap etc as shown in the illustration so that it is not tilted b Turn the main switch to ON and check that the transmiss...

Page 159: ...ngage and disengage the clutch using the clutch operation bolt 3 five times each time for less than 1 second NOTE Turn the clutch operation bolt in a continuous motion without allowing the pressure plate to stop in mid stroke d Install a suitable bracket 4 the magnet base B 5 and the dial gauge stand set 6 e Disengage the clutch by turning the manual clutch operation bolt f Measure the clutch pres...

Page 160: ...13AE on page 3 19 a Place the vehicle on the centerstand b Start the engine c Shift the transmission from neutral to 1st gear and back to neutral ten times d Shift the transmission into 1st gear and then apply the rear brake NOTE If the engine stalls restart the engine let it idle for at least 90 seconds and then repeat steps c and d 3 Check Starting off performance of vehicle Abnormal vehicle vib...

Page 161: ...side cover Refer to GENERAL CHASSIS on page 4 1 Shift actuator Refer to SHIFT ACTUATOR AND SHIFT ROD FJR13AE only on page 5 67 Air filter case cover Air filter element Refer to GENERAL CHASSIS on page 4 1 2 Clean Air filter element Apply compressed air to the outer surface of the air filter element 3 Check Air filter element Damage Replace CAUTION EC3P61043 Never operate the engine without the air...

Page 162: ...el tank breather hose Fuel tank overflow hose Fuel tank breather overflow hose 2 except for California Cracks damage Replace Loose connection Connect properly CAUTION EC3P61005 Make sure the fuel tank breather overflow hose is routed correctly 3 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 EAS21070 CHECK...

Page 163: ...on page 7 1 3 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 vehicle on the centerstand Make sure the vehicle is upright 2 Remove Left side panel Refer to GENERAL CHASSIS on page 4 1 3 Check Coolant level The coolant level should be between the min imum level mark a and maximum level mark b Below ...

Page 164: ...mbly Refer to ENGINE REMOVAL on page 5 1 2 Check Radiator 1 Oil cooler outlet hose 2 Radiator inlet hose 3 Radiator outlet hose 4 Oil cooler inlet hose 5 Oil cooler 6 Water jacket joint 7 Water jacket joint inlet hose 8 Water pump outlet pipe 9 Water pump outlet hose 10 Cracks damage Replace Refer to RADIATOR on page 6 1 OIL COOLER on page 6 4 THERMOSTAT on page 6 6 and WATER PUMP on page 6 10 3 I...

Page 165: ...ir 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 system with the specified amount of the recom mended coolant Handling notes for coolant Coolant is potentially harmful and should be handled with special care WARNING EWA13040 If coolant splashes in your...

Page 166: ...y 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 recommended coolant to the maxi mum level mark a 14 Install Coolant reservoir cap 15 Start the engine warm it up for several min utes and then stop it 16 Check Coolant level Refer to CHECKING THE COOLANT ...

Page 167: ...o 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 pedal position a Loosen the locknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained WARNING EWA13070 After adjusting the brake pedal position che...

Page 168: ...ubber 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 chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause v...

Page 169: ...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 several times 4 Check Brake hoses Brake fluid leakage Replace the damaged hose Refer to FRONT BRAKE on page 4 29 REAR BRAKE on page 4 41 and ABS AN TI LOCK BRAKE SYSTEM on page 4 54 EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE The rear brake light s...

Page 170: ...ing 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 reservoir to the proper level with the recommended brake fluid b Install the diaphragm brake master cylinder reservoir or brake fluid reservoir c Connect a clear plastic hose 1 tightly to the bleed scre...

Page 171: ...center 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 position a Loosen both locknuts 1 b Turn the shift rod 2 in direction a or b to obtain the correct shift pedal position NOTE Check that the groove c in the shift pedal is be tween the projections d on ...

Page 172: ... 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 with the gasket 5 Fill Final gear case with the specified amount of the recom mended final gear oil Refer to CHECKING THE FINAL GEAR OIL LEVEL on page 3 33 EAS21510 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the vehicle on a level sur...

Page 173: ...rections If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD on page 4 83 e Install the rubber washer 3 f Install the upper ring nut 2 g Finger tighten the upper ring nut then align the slots of both ring nuts If necessary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 NOTE M...

Page 174: ...nuts 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 scratches Replace Oil seal Oil leakage Replace 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check if the front fork re...

Page 175: ...d 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 direction a or b Direction a Spring preload is increased suspen sion is harder Direction b Spring preload is decreased suspen sion is softer Spring preload adjusting positions Minimum 6 Standard 4 Maxi...

Page 176: ...he maximum or minimum adjustment positions 1 Adjust Rebound damping a Turn the adjusting knob 1 in direction a or b Direction a Compression damping is increased suspension is harder Direction b Compression damping is decreased suspension is softer Compression damping adjusting positions Minimum 21 click s out Standard 12 click s out Maximum 1 click s out With the adjusting screw fully turned in Di...

Page 177: ...tener 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 NOTE Make sure that the side panel is properly in stalled ET3P61036 ADJUSTING THE RIDER SEAT HEIGHT 1 Check Rider seat height NOTE The rider seat height can be adjusted to one of two positions to suit the rider s preference The rider se...

Page 178: ...b Install the rider seat height position adjuster 2 so that the H mark a is aligned with the match mark b c Insert the projection c on the front of the rid er seat into seat holder for high position 3 as shown d Align the high position projection d on the bottom of the rider seat with the H position slot e and then push the rear of the seat down to lock it in place as shown To change to the low po...

Page 179: ...nger 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 of specification Regulate WARNING EWA13180 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature The tire pressure and the suspension must be adjusted according to the total weight inc...

Page 180: ...he front and rear tires should always be by the same manufacturer and of the same design No guarantee con cerning handling characteristics can be giv en if a tire combination other than one approved by Yamaha is used on this vehicle Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 270 kPa 39 psi 2 70 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm Loading condition FJR13A 9...

Page 181: ... 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 able lubricating device EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal to metal moving parts of the levers EAS21710 LUBRICATING THE PEDALS Lubricate the pivoting point and metal to...

Page 182: ...21740 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 soap based grease ...

Page 183: ...from 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 keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth mo...

Page 184: ...adjusting 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 right Direction b Headlight beam moves to the left 1 a b 1 a b 1 b a b a ...

Page 185: ...DISASSEMBLING THE REAR WHEEL 4 26 CHECKING THE REAR WHEEL 4 26 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR 4 26 ASSEMBLING THE REAR WHEEL 4 26 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 27 INSTALLING THE REAR WHEEL REAR BRAKE DISC 4 27 FRONT BRAKE 4 29 INTRODUCTION 4 34 CHECKING THE FRONT BRAKE DISCS 4 34 REPLACING THE FRONT BRAKE PADS 4 35 REMOVING THE FRONT BRAKE CALIPERS 4 36 DISASSEMB...

Page 186: ...NG THE HYDRAULIC UNIT 4 59 HYDRAULIC UNIT OPERATION TESTS 4 60 TRIAL RUN 4 63 HANDLEBARS 4 64 REMOVING THE HANDLEBARS 4 68 CHECKING THE HANDLEBARS 4 68 INSTALLING THE HANDLEBARS FJR13A 4 68 INSTALLING THE HANDLEBARS FJR13AE 4 70 FRONT FORK 4 73 REMOVING THE FRONT FORK LEGS 4 76 DISASSEMBLING THE FRONT FORK LEGS 4 76 CHECKING THE FRONT FORK LEGS 4 77 ASSEMBLING THE FRONT FORK LEGS 4 78 INSTALLING T...

Page 187: ... 100 ADJUSTING THE FINAL GEAR BACKLASH 4 101 MEASURING THE RING GEAR TO STOPPER BOLT CLEARANCE 4 102 ADJUSTING THE RING GEAR TO STOPPER BOLT CLEARANCE 4 102 DISASSEMBLING THE FINAL DRIVE ASSEMBLY 4 103 REMOVING AND INSTALLING THE BEARINGS 4 104 ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR 4 104 CHECKING THE DRIVE SHAFT 4 107 INSTALLING THE DRIVE SHAFT AND FINAL DRIVE ASSEMBLY FJR13A 4 108 IN...

Page 188: ...at 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 removal proce dure 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 21 Nm 2 1 m kg 15 ft Ib 3 1 4 7 2 5 9 6 8 ...

Page 189: ...ttom 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 Disconnect 13 Front cowling left inner panel 1 1 14 Front cowling left inner panel 2 1 15 Plastic band 2 Disconnect 16 Plastic holder 1 Disconnect T R 32 Nm 3 2 m kg 23 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LT LT...

Page 190: ...connect 20 Front cowling assembly 1 For installation reverse the removal proce dure Removing the front cowling assembly FJR13A Order Job Parts to remove Q ty Remarks T R 32 Nm 3 2 m kg 23 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 10 9 4 8 20 1 3 6 7 2 12 11 5 12 16 11 14 13 9 18 19 17 19 15 18 18 ...

Page 191: ...ront 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 Disconnect 13 Front cowling left inner panel 1 1 14 Grip warmer control unit coupler 2 Disconnect 15 Grip warmer control unit 1 16 Front cowling left inner panel 2 1 T R 32 Nm 3 2 m kg 23 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LT L...

Page 192: ...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 FJR13AE Order Job Parts to remove Q ty Remarks T R 32 Nm 3 2 m kg 23 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LT LT 10 9 4 8 24 1 3 6 2 12 11 5 12 18 11 16 13 15 23 23 14 14 9 21 22 19 22 20 17 21 21 T R 10 Nm 1 0 m kg 7 2 f...

Page 193: ...wer inner bracket 1 5 Rearview mirror 2 6 Accessory box solenoid coupler 1 Disconnect 7 Auxiliary DC jack coupler 1 Disconnect 8 Accessory box 1 9 Accessory box solenoid 1 10 Headlight coupler 2 Disconnect 11 Auxiliary light coupler 2 Disconnect 12 Front cowling 1 For assembly reverse the disassembly pro cedure 7 7 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 7 Nm 0 7 m kg 5 1 ft I...

Page 194: ...IS 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 proce dure 1 ...

Page 195: ...y coupler 1 Disconnect 5 Meter assembly 1 6 Relay unit coupler 1 Disconnect 7 Relay unit 1 8 Turn signal hazard relay coupler 1 Disconnect 9 Turn signal hazard relay 1 10 Headlight relay dimmer coupler 1 Disconnect 11 Headlight relay dimmer 1 12 Lean angle sensor coupler 1 Disconnect 13 Lean angle sensor 1 For installation reverse the removal proce dure T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m...

Page 196: ...ebar 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 steering stem e Fit the top and side of inner panel 2 into the front cowling assembly to the left of the meter assembly f Fit inner panel 2 under the right side of the ac cessory box NOTE Pull the fron...

Page 197: ...in 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 Fit the lower right corner of inner panel 2 into the front cowling assembly making sure to align the bolt hole in the panel with the bolt hole in the cowling f Fit the top and side of inner panel 2 i...

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

Page 199: ...arts 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 37 Nm 3 7 m kg 27 ft Ib T R 37 Nm 3 7 m kg 27 ft Ib ...

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 Disconnect 13 Air induction system hose air filter case joint assembly to 3 way joint 1 Disconnect 14 Air filter case joint clamp screw 4 Loosen T R 7 Nm 0 7 m kg 5 1 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 18 ...

Page 201: ...ilter assembly 1 For installation reverse the removal proce dure Removing the air filter case FJR13A Order Job Parts to remove Q ty Remarks T R 7 Nm 0 7 m kg 5 1 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib New T R 4 Nm 0 4 m kg 2 9 ft Ib 5 6 7 1 2 4 11 4 4 8 9 10 14 16 3 4 14 17 18 15 12 17 13 11 14 ...

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 lower fuel tank bracket 1 12 Intake air temperature sensor 1 13 Bypass air unit inlet hose 1 Disconnect T R 8 Nm 0 8 m kg 5 8 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib New T R 4 Nm 0 4 m kg 2 9 ft Ib T R 7 Nm...

Page 203: ... case 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 FJR13AE 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 T R 4 Nm 0 4 m kg 2 9 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 5 6 9 1 2 4 11 4 4 10 11 12 16 18 3 4 16 19 20 17 14 19 15 1...

Page 204: ...ont 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 installation reverse the removal proce dure T R 18 Nm 1 8 m kg 13 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 21 Nm 2 1 m kg 15 ft Ib T R 91Nm 9 1 m kg 66 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft I...

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

Page 206: ...BLING THE FRONT WHEEL 1 Remove Oil seals Wheel bearings a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flathead screwdriver NOTE To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings 3 with a gener al bearing puller EAS21920 CHECKING THE FRONT WHEEL 1 Check Wheel axle Roll the wheel axle on a flat surface B...

Page 207: ...nsor 1 Cracks bends distortion Replace Iron powder dust Clean 2 Measure Front wheel sensor resistance Out of specification Replace a Connect the pocket tester Ω 1k to the front wheel sensor coupler terminals as shown b Measure the front wheel sensor resistance 3 Check Front wheel sensor rotor 1 Cracks damage Replace the front wheel assembly NOTE The wheel sensor rotor of the vehicle is inserted un...

Page 208: ...iscs installed 1 Remove Balancing weight s 2 Find Front wheel s heavy spot NOTE Place 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 positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps...

Page 209: ...ck Front brake discs Refer to CHECKING THE FRONT BRAKE DISCS on page 4 34 3 Lubricate Oil seal lips 4 Install Collar Front wheel sensor housing Front wheel NOTE Align the slot in the front wheel sensor housing with the projection of the front fork before as sembly 5 Install Front wheel axle Front wheel axle bolt Front wheel axle pinch bolts CAUTION EC3P61022 Before tightening the wheel axle bolt p...

Page 210: ...bolt 3 pinch bolt 4 tighten each bolt to 21 Nm 2 1 m kg 15 ft lb without performing temporary tightening 6 Install Front brake calipers Front wheel sensor NOTE When installing the front wheel sensor check the wheel sensor lead for twists and the sensor electrode for foreign materials CAUTION EC3P66003 Make sure there are no foreign materials in the wheel hub Foreign materials cause damage to the i...

Page 211: ...nsor 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 disc 1 For installation reverse the removal proce dure T R 23 Nm 2 3 m kg 17 ft Ib T R 125 Nm 12 5 m kg 90 ft lb T R 30 Nm 3 0 m kg 22 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 1 4 3 5 7 9 11 6 T R 18 Nm ...

Page 212: ... remove Q ty Remarks 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 Circlip 1 8 Wheel bearing 1 9 Spacer 1 10 Spacer 1 11 Oil seal 1 12 Bearing 1 For assembly reverse the disassembly pro cedure ...

Page 213: ... CHECKING THE FRONT WHEEL on page 4 19 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 40 and CHECKING THE WHEELS on page 3 42 3 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 19 EAS22200 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR CAUTION EC3P61032 Handle the ABS components with care since they have been acc...

Page 214: ...R BRAKE DISC on page 4 47 3 Lubricate Oil seal lips 4 Install Rear wheel sensor housing Rear wheel Rear brake caliper Rear wheel axle Brake torque rod Rear wheel axle nut NOTE Align the slot a of the rear wheel sensor hous ing 1 with the projection b of the rear brake caliper bracket 2 and then assemble them After assembling the rear wheel sensor hous ing and the rear brake caliper bracket make su...

Page 215: ...13AE on page 2 67 NOTE When installing the rear wheel sensor check the rear wheel sensor lead for twists and the sensor electrode for foreign materials 7 Check Rear wheel sensor installation Check if the wheel sensor housing is installed properly T R Brake torque rod nut 30 Nm 3 0 m kg 22 ft lb Rear wheel axle nut 125 Nm 12 5 m kg 90 ft lb Rear wheel axle pinch bolt 23 Nm 2 3 m kg 17 ft lb T R Rea...

Page 216: ...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 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib LS LS LS LS T R 17 Nm 1 7 m kg 12 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib 1 2 5 4 4 5 3 3 ...

Page 217: ...ir cap 1 2 Brake master cylinder reservoir diaphragm 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 master cylinder to hy draulic unit 1 9 Front brake master cylinder holder 1 10 Front brake master cylinder 1 11 Front brake light switch 1 For installation ...

Page 218: ...mbling the front 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 reverse the disassembly pro cedure ...

Page 219: ...der 1 2 Brake hose union bolt 1 3 Copper washer 2 4 Brake hose hydraulic unit to front brake cali pers 1 5 Brake hose union bolt unified brake system 1 Right side only 6 Copper washer 2 Right side only 7 Brake hose metering valve to right front brake caliper 1 Right side only 8 Front brake caliper 1 For installation reverse the removal proce dure T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 f...

Page 220: ...ke calipers 1 Brake pad bolt 2 2 Brake pad spring 2 3 Front brake pad 4 4 Brake caliper piston 4 5 Brake caliper piston seal 8 6 Bleed screw 1 7 Bleed screw 1 Right side only For assembly reverse the disassembly pro cedure T R 17 Nm 1 7 m kg 12 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib New New New New LS 1 2 2 3 4 4 1 6 3 7 5 5 5 5 ...

Page 221: ...re 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 disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflec tion turn the handlebar to the left ...

Page 222: ...liper 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 a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper w...

Page 223: ...e caliper drain the brake fluid from the entire brake system 1 Remove Brake hose holder 1 Brake hose union bolts 2 Copper washers Brake hose hydraulic unit to front brake cali pers 3 Brake hose metering valve to right front brake caliper 4 NOTE Put the end of the brake hoses into a container and pump out the brake fluid carefully EAS22360 DISASSEMBLING THE FRONT BRAKE CALIPERS The following proced...

Page 224: ... should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston seals EAS22440 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Install Front brake caliper 1 temporarily...

Page 225: ...ormance 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 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 system Refer to BLEEDING THE HYDR...

Page 226: ... master cylinder reservoir diaphragm Damage wear Replace 4 Check Brake hose Cracks damage wear Replace EAS22520 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER WARNING EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents EAS22530 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Bra...

Page 227: ...ce Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance 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 vapor lock CAUTION ECA13540 Bra...

Page 228: ...BRAKE 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 reverse the removal proce dure ...

Page 229: ...id reservoir 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 brake light switch 1 9 Brake hose union bolt 1 10 Copper washer 2 11 Brake hose rear brake master cylinder to hy draulic unit 1 Disconnect 1 2 3 4 5 6 7 9 10 11 8 12 T R 28 Nm 2 8 m kg 20 ft Ib...

Page 230: ...tion 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 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib ...

Page 231: ...mbling the rear brake master cylinder 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 pro cedure ...

Page 232: ... 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 Rear wheel axle nut 1 7 Brake torque rod 1 8 Rear wheel axle 1 9 Rear brake caliper assembly 1 For installation reverse the removal proce dure ...

Page 233: ...Parts to remove Q ty Remarks 1 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 seal 2 8 Bleed screw 1 For assembly reverse the disassembly pro cedure ...

Page 234: ...k 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 34 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 34 5 Adjust Brake disc de...

Page 235: ...el 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 5 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 31 EAS22590 REMOVING THE REAR BRAKE CALIPER NOTE Before disassembling the brake caliper drain the brake fluid from the entire...

Page 236: ...ivery passage brake caliper body Obstruction Blow out with compressed air WARNING EWA13610 Whenever a brake caliper is disassembled replace the brake caliper piston seals 2 Check Brake caliper bracket Cracks damage Replace EAS22650 ASSEMBLING THE REAR BRAKE CALIPER WARNING EWA13620 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Nev...

Page 237: ...ning valve to rear brake caliper 1 Brake hose union bolt 2 WARNING EW3P66002 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING FJR13A on page 2 47 and CA BLE ROUTING FJR13AE on page 2 67 CAUTION EC3P61044 When installing the brake hose onto the brake caliper make sure the brake pipe a touches the projection b on the brake cali per 4 Remove Rear brake c...

Page 238: ...ngy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 31 EAS22700 REMOVING THE REAR BRAKE MASTER CYLINDER NOTE Before removing the rear brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Brake hose union bolt 1 Copper washers 2 Brake hose rear brake master cylinder to hy draulic unit 3 NOTE To collect any remaining brake flui...

Page 239: ...using 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 chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Br...

Page 240: ...REAR BRAKE 4 53 7 Adjust Brake pedal position Refer to ADJUSTING THE REAR DISC BRAKE on page 3 28 8 Adjust Rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 30 ...

Page 241: ... unit HU 5 Rear wheel sensor rotor 6 Rear wheel sensor 7 Rear brake caliper 8 Brake hose proportioning valve to rear brake caliper 9 Left front brake caliper 10 Right front brake caliper partially operated together with the rear brake 11 Front wheel sensor 12 Front wheel sensor rotor 13 Brake hose rear brake master cylinder to hydraulic unit 14 Proportioning valve 15 Brake hose hydraulic unit to p...

Page 242: ...d Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 31 Brake fluid reservoir Refer to REAR BRAKE on page 4 41 1 Tail brake light assembly coupler 1 Disconnect 2 License plate light connector 2 Disconnect 3 Tail brake light assembly 1 4 Seat lock cable assembly 1 5 Rear fender assembly 1 For installation reverse the removal proce dure T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1...

Page 243: ...n bolt Copper washer 1 2 8 Brake hose hydraulic unit to proportioning valve 1 9 Brake hose union bolt Copper washer 2 4 10 Brake hose hydraulic unit to metering valve 1 11 Hydraulic unit 1 12 Hydraulic unit solenoid coupler 1 Disconnect 13 ABS motor coupler 1 Disconnect 14 Brake hose union bolt Copper washer 1 2 15 T R 19 Nm 1 9 m kg 13 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib...

Page 244: ... the removal proce dure Removing the hydraulic unit Order Job Parts to remove Q ty Remarks 15 T R 19 Nm 1 9 m kg 13 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 16 Nm 1 6 m kg 11 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 16 Nm 1 6 m kg 11 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib 17 18 13 16 11 10 9 8 9 9 1 2 1 3 6 3 5 5 4 7 7 9 14 1...

Page 245: ...iately Do not allow any brake fluid to contact the couplers Brake fluid may damage the cou plers and cause bad contacts If the union bolts for the hydraulic unit have been removed be sure to tighten them to the specified torque and bleed the brake system 1 Remove Brake hose 1 front brake master cylinder to hydraulic unit Brake hose 2 rear brake master cylinder to hydraulic unit Brake hose 3 hydrau...

Page 246: ...1 to the metering valve Brake hose union bolt NOTE The brake hose 1 contacts the stopper a on the metering valve 4 Install Copper washers Brake hose 1 hydraulic unit to metering valve Brake hose 2 hydraulic unit to proportion ing valve Brake hose 3 hydraulic unit to front brake calipers Brake hose 4 rear brake master cylinder to hydraulic unit Brake hose 5 front brake master cylinder to hydraulic ...

Page 247: ...des Refer to D 1 DELETING THE MALFUNCTION CODES on page 8 155 9 Perform a trial run Refer to TRIAL RUN on page 4 63 EAS22800 HYDRAULIC UNIT OPERATION TESTS The reaction force pulsating action generated in the brake lever and brake pedal when the ABS is activated can be tested when the vehicle is stopped The hydraulic unit operation can be tested using the following two methods Hydraulic unit opera...

Page 248: ...e felt in the brake lever once then in the brake pedal twice The second per son should confirm that the rear brake force is released during the second pulse in the brake pedal third pulse overall by manually applying force to rotate the rear wheel If the rear brake force is released during the second pulse in the brake pedal the second person will be able to rotate the rear wheel for 0 1 second CA...

Page 249: ...wling right inner panel 1 Refer to GENERAL CHASSIS on page 4 1 4 Check Battery voltage Lower than 12 8 V Charge or replace the battery NOTE If the battery voltage is lower than 12 8 V charge the battery and then perform hydraulic unit operation test 2 If the battery voltage is lower than 10 V the ABS warning light comes on and the ABS does not operate 5 Connect the test coupler adapter 1 to the AB...

Page 250: ...ing action has stopped 12 After the pulsating action has stopped in the brake pedal it is generated in the brake lever 0 5 second later and continues for approxi mately 2 seconds NOTE The reaction force pulsating action consists of two series of quick pulses CAUTION EC3P61018 Check that the pulsating action is felt in the brake lever brake pedal and again in the brake lever in this order If the pu...

Page 251: ...ove Q ty Remarks 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 7 Left handlebar switch 1 8 Grip end 1 9 Handlebar grip 1 For installation reverse the removal proce dure ...

Page 252: ...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 9 Grip end 1 10 Handlebar grip 1 For installation reverse the removal proce dure ...

Page 253: ...r 2 Disconnect 2 Front 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 handlebar switch lead 1 10 Lead holder 1 11 Right handlebar switch 1 For installation reverse the removal proce dure ...

Page 254: ...t 2 Front 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 warmer lead 1 10 Right handlebar switch lead 1 11 Lead holder 1 12 Right handlebar switch 1 For installation reverse the removal proce dure ...

Page 255: ...urface 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 handlebar b Slide the handlebar grip onto the left handle bar c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rub ber adhesive has full...

Page 256: ...be 1 3 mm 0 04 0 12 in of clearance c between the throttle grip and the grip end 9 Install Front brake master cylinder assembly Front brake master cylinder holder 1 NOTE Install the brake master cylinder holder with the UP mark facing up Align the mating surfaces of the brake master cylinder holder with the punch mark a on the right handlebar First tighten the upper bolt then the lower bolt 10 Ins...

Page 257: ... adhesive onto the end of the left handlebar b Slide the handlebar grip onto the left handle bar c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rub ber adhesive has fully dried NOTE There should be 1 3 mm 0 04 0 12 in of clear ance a between the handlebar grip and the grip end 3 Install Right handlebar switch 1 NOTE Align the proje...

Page 258: ...lebar nuts 2 temporarily 8 Tighten Handlebar bolts Handlebar nuts NOTE First tighten the bolts then tighten the nuts 9 Install Throttle grip Throttle cables Throttle cable housing 1 Grip end 2 NOTE Make a loop in the right grip warmer lead 3 as shown in the illustration making sure that the section of the lead from the grip warmer cross es to the rear of the other section of the lead and route the...

Page 259: ...ng up Align the projection a on the front brake mas ter cylinder with hole b on the right handlebar First tighten the upper bolt then the lower bolt 11 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 10 T R Front brake master cylinder hold er bolt 10 Nm 1 0 m kg 7 2 ft lb Throttle cable free play 3 0 5 0 mm 0 12 0 20 in b a 1 ...

Page 260: ...Front 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 Battery 1 5 Upper bracket pinch bolt 1 Loosen 6 Cap bolt 1 Loosen 7 Lower bracket pinch bolt 2 Loosen 8 Front fork leg 1 For installation reverse the removal proce dure ...

Page 261: ...ocedure 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 12 Damper rod assembly bolt 1 13 Copper washer 1 14 Damper rod assembly 1 15 Spring 1 16 Oil flow stopper 1 ...

Page 262: ... 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 front fork legs Order Job Parts to remove Q ty Remarks ...

Page 263: ...NING 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 legs 1 Hold the nut 1 and loosen the cap bolt 2 2 Drain Fork oil NOTE Stroke the inner tube several times while drain ing the fork oil 3 Remove Dust seal 1 Oil seal clip 2 with a flat head screwdriver...

Page 264: ... 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 the inner tube forcefully but careful ly CAUTION EC3P61027 Excessive force will damage the bushings Damaged bushings must be replaced Avoid bottoming the inner tube into the out er tube during the abov...

Page 265: ... loss 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 front fork leg make sure all of the components are clean 1 Install Inner tube bushing 1 Oil flow stopper 2 Spring Damper rod assembly 3 CAUTION EC3P61028 Allow the damper rod assembly to slide slowly ...

Page 266: ...Before installing the oil seal lubricate its lips with lithium soap based grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation 7 Install Oil seal clip 1 NOTE Adjust the oil seal clip so that it fits into the outer tube s groove Slide metal installer 90890 ...

Page 267: ...ssembly slowly because the fork oil may spurt out 11 Slowly stroke the inner tube 1 up and down 12 Before measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed NOTE Be sure to bleed the front fork leg of any residual air 13 Measure Front fork leg oil level a from the top of the inner tube with the outer tube fully compressed and without the fork...

Page 268: ... tube NOTE Temporarily tighten the cap bolt EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts NOTE Make sure the inner tube is flush with the top of the upper bracket 2 Tighten Lower bracket pinch bolts 1 Cap bolt 2 Upper bracket pinch bolt 3 WARNING EWA13680 Ma...

Page 269: ...FRONT FORK 4 82 3 Adjust Spring preload Rebound damping Compression damping Refer to ADJUSTING THE FRONT FORK LEGS on page 3 36 ...

Page 270: ...egs Refer to FRONT FORK on page 4 73 1 Main switch coupler 2 Disconnect 2 Lower bracket cover 1 3 Brake hose joint bracket bolt 2 4 Steering stem nut 1 5 Upper bracket 1 6 Handlebar bracket 1 7 Lock washer 1 8 Upper ring nut 1 9 Rubber washer 1 10 Lower ring nut 1 11 Lower bracket 1 T R 115 Nm 11 5 m kg 85 ft lb T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 18 Nm 1 8 m kg 13 ft Ib LS LS T R 7 Nm 0 7 m kg 5 ...

Page 271: ...e 1 18 Upper bearing outer race 1 19 Lower bearing outer race 1 For installation reverse the removal proce dure Removing the lower bracket Order Job Parts to remove Q ty Remarks T R 115 Nm 11 5 m kg 85 ft lb T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 18 Nm 1 8 m kg 13 ft Ib LS LS T R 7 Nm 0 7 m kg 5 1 ft Ib 11 4 5 16 17 15 3 2 6 19 18 14 13 12 10 9 8 7 1 1 LS ...

Page 272: ...g 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 races CAUTION ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged NOTE Always replace the bearings and bearing races as a set 4 Check Upper bracket Lower br...

Page 273: ...3 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 73 NOTE Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut T R Steering stem nut 115 Nm 11 5 m kg 85 ft lb ...

Page 274: ...ect 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 absorber assembly upper nut Bolt Spacer 1 1 1 8 Rear shock absorber assembly 1 9 Centerstand 1 10 Relay arm nut Bolt Spacer 1 1 1 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 ...

Page 275: ...l 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 64 Nm 6 4 m kg 46 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib 7 7 10 3 10 1 2 LS LS 8 13 15 12 17 15 15 15 5 6 1616 1514 17 11 5 5 6 15 4 4 9 LS T R 55 Nm 5 5 m kg 40 ft Ib ...

Page 276: ... 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 SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so ...

Page 277: ... 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 5JW on the relay arm faces to the left EAS23310 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Install Rear shock absorber assembly NOTE Make sure that the warning label on the rear shock absorber ass...

Page 278: ... on page 4 95 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 2 10 Bearing 2 11 Collar 1 12 Oil seal 1 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 5 m kg 90 ft lb T R 115 Nm 11 5 ...

Page 279: ...al 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 5 m kg 90 ft lb T R 115 Nm 11 5 m kg 85 ft lb New LS LS LS New LS New 3 5 6 1 4 2 LS 1 17 16 15 12 11 10 8 9 18 14 13 9 10 7 ...

Page 280: ...s 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 shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 3 Wash Pivot shaft Spacers Washer Bearings Collar 4 Check Spacers Washer Collar Oil seals Damage w...

Page 281: ...shaft 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 12 5 m kg 90 ft lb 1 3 a A 3 2 b 2 A B b 4 4 ...

Page 282: ... 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 24 1 Final drive assembly 1 For installation reverse the removal proce dure ...

Page 283: ...FJR13AE Refer to SHIFT ACTUATOR AND SHIFT ROD FJR13AE only on page 5 67 1 Shift arm 1 FJR13A 2 Left footrest assembly 1 FJR13A 3 Sidestand switch coupler 1 FJR13A Disconnect 4 Sidestand 1 FJR13A 5 Drive shaft dust cover 1 6 Universal joint dust cover 1 7 Universal joint 1 For installation reverse the removal proce dure ...

Page 284: ...l 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 Thrust washer 1 14 Coupling gear nut 1 15 Coupling gear 1 16 Bearing retainer 1 Left hand threads 17 Oil seal 1 ...

Page 285: ...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 pro cedure Disassembling the final drive assembly Order Job Parts to remove Q ty Remarks ...

Page 286: ...roken 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 injury to the rider Troubleshooting chart When causes A or B shown in the table at the beginning of the TROUBLESHOOTING section ex ist check the following points YES NO Symptom Possible cause 1 A prono...

Page 287: ...n 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 originate from EAS23580 MEASURING THE FINAL GEAR BACKLASH 1 Secure the final drive assembly in a vise 2 Remove Final gear oil drain bolt 3 Drain Final gear oil from the final drive assembly 4 Measure Fin...

Page 288: ... gear 90 h Reinstall the bolt final gear backlash 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 GEAR BACKLASH 1 Remove Ring gear bearing housing bolts 1 Ring gear bearing housing nuts 2 NOTE Working in a crisscross pattern loosen each bolt and nu...

Page 289: ...ation Adjust 3 Install Ring gear bearing housing along with the ring gear EAS23610 ADJUSTING THE RING GEAR TO STOPPER BOLT CLEARANCE 1 Remove Ring gear 1 Stopper bolt 2 Stopper bolt shim s 3 Ring gear bearing housing 4 2 Select Stopper bolt shim s 3 Install Ring gear bearing housing 1 Stopper bolt shim s 2 Stopper bolt 3 Ring gear 4 CAUTION ECA14320 The stopper bolt has left hand threads To tighte...

Page 290: ...ling gear 1 with the coupling gear middle shaft tool 2 3 Remove Bearing retainer with the bearing retainer wrench 1 CAUTION ECA14330 The bearing retainer has left hand threads To loosen the bearing retainer turn it clock wise 4 Remove Final drive pinion gear WARNING EWA13800 Always use new bearings CAUTION ECA14340 The final drive pinion gear should only be re moved if ring gear replacement is nec...

Page 291: ...aring 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 appropriate press tool 4 and press NOTE The bearing can be reused but Yamaha recom mends installing a new one EAS23640 ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR NOTE Aligning the final drive pi...

Page 292: ...r 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 Where c a numeral on the final gear case to be di vided by 100 and added to 45 d a numeral usually on the outside of the ring gear bearing housing to be divided by 100 and added to 3 e a numeral positiv...

Page 293: ...culated 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 3 Install Coupling gear 1 Coupling gear nut with the coupling gear middle shaft tool 2 Ring gear bearing thickness 13 00 mm 0 51 in B 45 51 100 3 35 100 35 40 5 100 13 45 0 51 3 0 35 35 40 0 05 13 4...

Page 294: ...nce 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 gear bear ing housing along with the ring gear g If the ring gear to thrust washer clearance is out of specification select the correct thrust washer as follows h Select the suitable thrust washer from...

Page 295: ...mbly bolt M10 3 temporarily and then tighten them to the specified torques in the proper tightening sequence as shown 8 Install Shift arm 1 NOTE Align the punch mark a in the shift shaft with the slot in the shift arm 9 Install Rear wheel Refer to REAR WHEEL on page 4 24 10 Fill Final gear case Refer to CHECKING THE FINAL GEAR OIL LEVEL on page 3 33 Recommended lubricant Molybdenum disulfide greas...

Page 296: ...rsal joint Final drive assembly NOTE Align the drive shaft splines with the driven yoke of the universal joint 7 Tighten Final drive assembly nuts 8 Install Sidestand Left footrest assembly Refer to SHIFT ACTUATOR AND SHIFT ROD FJR13AE only on page 5 67 9 Install Rear wheel Refer to REAR WHEEL on page 4 24 Recommended lubricant Molybdenum disulfide grease Recommended lubricant Lithium soap based g...

Page 297: ...SHAFT DRIVE 4 110 10 Fill Final gear case Refer to CHECKING THE FINAL GEAR OIL LEVEL on page 3 33 ...

Page 298: ...SHAFT DRIVE 4 111 ...

Page 299: ...LINDER HEAD 5 21 REMOVING THE CYLINDER HEAD 5 22 CHECKING THE CYLINDER HEAD 5 22 INSTALLING THE CYLINDER HEAD 5 22 VALVES AND VALVE SPRINGS 5 24 REMOVING THE VALVES 5 25 CHECKING THE VALVES AND VALVE GUIDES 5 25 CHECKING THE VALVE SEATS 5 27 CHECKING THE VALVE SPRINGS 5 28 CHECKING THE VALVE LIFTERS 5 29 INSTALLING THE VALVES 5 29 GENERATOR AND STARTER CLUTCH 5 31 REMOVING THE GENERATOR 5 34 REMOV...

Page 300: ... CYLINDER FJR13AE only 5 63 INSTALLING THE CLUTCH ACTUATOR FJR13AE only 5 64 REMOVING THE CLUTCH RELEASE CYLINDER 5 64 CHECKING THE CLUTCH RELEASE CYLINDER 5 65 ASSEMBLING THE CLUTCH RELEASE CYLINDER 5 65 INSTALLING THE CLUTCH RELEASE CYLINDER 5 65 SHIFT ACTUATOR AND SHIFT ROD FJR13AE only 5 67 REMOVING THE SHIFT ACTUATOR 5 69 CHECKING THE SHIFT ROD 5 69 INSTALLING THE FOOT SHIFT SWITCH 5 69 ADJUS...

Page 301: ...IPES 5 100 CHECKING THE BEARINGS AND OIL SEAL 5 100 CHECKING THE TIMING CHAIN AND OIL PUMP DRIVE CHAIN 5 100 ASSEMBLING THE CRANKCASE 5 100 CONNECTING RODS AND PISTONS 5 104 REMOVING THE CONNECTING RODS AND PISTONS 5 105 CHECKING THE CYLINDERS AND PISTONS 5 105 CHECKING THE PISTON RINGS 5 106 CHECKING THE PISTON PIN 5 107 CHECKING THE CONNECTING RODS 5 108 INSTALLING THE CONNECTING RODS AND PISTON...

Page 302: ...nt 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 Gasket 4 For installation reverse the removal proce dure T R 20 Nm 2 0 m kg 14 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib 5...

Page 303: ...ge 7 11 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 Water pump Refer to WATER PUMP on page 6 10 Starter motor Refer to ELECTRIC STARTER on page 5 40 Left footrest assembly Sidestand Refer to SHAFT DRIVE on page 4 95 1 Clutch release cylinder 1 2 Dowe...

Page 304: ... coupler 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 FJR13A Order Job Parts to remove Q ty Remarks 9 2 2 1 3 5 6 7 4 8 T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 305: ...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 Water pump Refer to WATER PUMP on page 6 10 Starter motor Refer to ELECTRIC STARTER on page 5 40 Left footrest assembly Sidestand Refer to SHIFT ACTUATOR AND SHIFT ROD FJR13AE only on page 5 67 Gear position sensor cover Refer to SHIFT ACTUATOR AND SHIFT ROD FJ...

Page 306: ...ition 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 proce dure Disconnecting the leads and hoses FJR13AE Order Job Parts to remove Q ty Remarks R 10 Nm 1 0 m kg 7 2 ft Ib LT LT T R 4 Nm 0 4 m kg 2 9 ft Ib 12 10 4 4 3 1 2 5 8 7 6 11 9 ...

Page 307: ... 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 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 32 ft Ib T R...

Page 308: ...e 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 32 ft Ib T R 49 Nm 4 9 m kg 35 ft Ib T R 49 Nm 4 9 m kg 35 ft Ib T R 49 Nm 4 9 m kg 35 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib E E 9 9 15 11 1 11 12...

Page 309: ...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 NOTE When mounting the engine to the frame be sure to align the splines on the middle driven shaft with the splines on the universal joint 2 Install Spacer bolt 1 Engine mounting bolt rear upper side 2 Spacer 3 Engine mounting ...

Page 310: ...ghten 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 Engine mounting bolts top 15 9 Tighten Pinch bolts front side 10 10 Tighten Pinch bolts rear side 11 T R Engine mounting bolt left front upper side 49 Nm 4 9 m kg 35 ft lb T R Engine mounting bolt rear lower side 45 Nm 4 5 m kg 32 ft lb T R Spacer...

Page 311: ...e 1 Engine bracket bolt 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 Install Brake pedal 1 NOTE Align the punch mark a on the brake pedal with the punch mark b on the brake pedal pivot shaft T R Engine mounting bolt top 37 Nm 3 7 m kg 27 ft lb Engine b...

Page 312: ... Refer to CHECKING THE GEAR POSITION SENSOR FJR13AE only on page 8 235 2 Adjust Gear position sensor angle a Connect the gear position sensor coupler to the gear position sensor b Connect the digital circuit tester to the gear position sensor c Turn the main switch to ON d Measure the gear position sensor voltage e Adjust the gear position sensor angle so that the voltage is within the specified r...

Page 313: ...Air cut off valve Reed valves Refer to AIR INDUCTION SYSTEM on page 7 11 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 chain guide upper side 1 For installation reverse the removal proce dure 1 New New 4 5 5 5 2 8 LT LS 6 3 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib ...

Page 314: ...CKUP ROTOR on page 5 37 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 1 8 Exhaust camshaft sprocket 1 9 Timing chain guide exhaust side 1 10 Pin 1 11 Timing chain guide intake side 1 For installation reverse the removal proce dure ...

Page 315: ... 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 to the cylinder head camshafts or camshaft caps loosen the camshaft cap bolts in stages and in a criss cross pattern working from the outside in 6 Remove Intake camshaft 1 Exhaust camshaft 2 NOTE To ...

Page 316: ...haft 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 dimensions Intake A 33 050 33 150 mm 1 3012 1 3051 in Limit 32 050 mm 1 2618 in Intake B 24 997 25 097 mm 0 9841 0 9881 in Limit 23 997 mm 0 9448 in Exhaust A 33 050 33 150 mm 1 3012 1 3051 in Limit 32 9...

Page 317: ...heck 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 chain tensioner Cracks damage rough movement Re place a Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand NOTE While pressing the timing chain tensioner rod w...

Page 318: ...aft 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 both camshaft sprockets and then install the camshafts NOTE Make sure the holes a on each camshaft fac es up When installing the timing chain start with the exhaust camshaft and be sure to keep the ti...

Page 319: ...nner 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 rotor with the crankcase mating surface b 6 Install Timing chain tensioner Timing chain tensioner gasket a While lightly pressing the timing chain ten sioner rod by hand turn the tensioner rod ful l...

Page 320: ...ation steps above 9 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 6 10 Install Cylinder head cover gasket Cylinder head cover NOTE Apply Three Bond 1514 1 onto the mating surfaces of the cylinder head cover and cylin der head cover gasket Apply Yamaha bond No 1215 2 onto the mat ing surfaces of the cylinder head cover gasket and cylinder head...

Page 321: ...CAMSHAFTS 5 20 ...

Page 322: ...OVAL on page 5 1 Camshafts Refer to CAMSHAFTS on page 5 12 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 20 Nm 2 0 m kg 14 ft Ib T R 1st 25 Nm 2 5 m kg 18 ft lb 2nd 25 Nm 2 5 m kg 18 ft lb Final Specified angle 175 185 New New 3 3 2 New 1 10 E ...

Page 323: ...c 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 ensure an even surface rotate the cylinder head several times EAS24240 INSTALLING THE CYLINDER HEAD 1 Install Cylinder head NOTE Pass the timing chain through the timing chain cavity 2 Tighten Cylind...

Page 324: ...ew 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 bolt note that the angle from one corner to another is 60 f Tighten the cylinder head bolts M6 in proper tightening sequence as shown T R Cylinder head bolt M10 2nd 25 Nm 2 5 m kg 18 ft lb T R Cylinder...

Page 325: ...inder head Refer to CYLINDER HEAD on page 5 21 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 valve 8 9 Valve stem seal 16 10 Lower spring seat 16 11 Intake valve guide 8 12 Exhaust valve guide 8 For installation reverse the removal proce dure ...

Page 326: ... 27 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 cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 4 Remove Upper spring seat 1 Valve spring 2 Valve 3 Valve stem seal 4 Lower spring...

Page 327: ...valve guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance NOTE After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clear ance exhaust 0 020 0...

Page 328: ...d 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 specification Replace the cylinder head a Apply Mechanic s blueing dye Dykem b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear imp...

Page 329: ...e back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b onto the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to...

Page 330: ...valves and related components 1 Deburr Valve stem end with an oil stone 2 Lubricate Valve stem 1 Valve stem seal 2 with the recommended lubricant 3 Lubricate Valve stem end with the recommended lubricant Installed compression spring force intake 136 00 158 00 N 30 57 35 52 lb 13 87 16 11 kgf Installed compression spring force exhaust 136 00 158 00 N 30 57 35 52 lb 13 87 16 11 kgf Installed length ...

Page 331: ...achment 2 6 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION ECA13800 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 smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stal...

Page 332: ...k 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 1 3 Generator cover gasket 1 4 Dowel pin 2 5 Starter clutch idle gear shaft 1 6 Starter clutch idle gear 1 7 Generator rotor 1 8 Woodruff key 1 9 Starter clutch gear 1 ...

Page 333: ...GENERATOR AND STARTER CLUTCH 5 32 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 334: ...OR AND STARTER CLUTCH 5 33 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 proce dure ...

Page 335: ...TARTER CLUTCH 1 Check Starter clutch rollers Damage wear Replace 2 Check Starter clutch idle gear Starter clutch gear Burrs chips roughness wear Replace the defective part s 3 Check Starter clutch gear s contacting surfaces Damage pitting wear Replace the starter clutch gear 4 Check Starter clutch operation a Install the starter clutch gear onto the starter clutch and hold the starter clutch b Whe...

Page 336: ... way of the crankshaft Lubricate the generator rotor bolt threads and washer mating surfaces with engine oil 2 Tighten Generator rotor bolt 1 NOTE While holding the generator rotor 2 with the sheave holder 3 tighten the generator rotor bolt 3 Apply Sealant onto the stator coil assembly lead grommet 4 Install Generator cover gasket Generator cover T R Starter clutch bolt 32 Nm 3 2 m kg 23 ft lb LOC...

Page 337: ...GENERATOR AND STARTER CLUTCH 5 36 NOTE Tighten the generator cover bolts in stages and in a crisscross pattern ...

Page 338: ...ator cover Refer to GENERATOR AND STARTER CLUTCH on page 5 31 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 sensor 1 6 Pickup rotor 1 For installation reverse the removal proce dure LT New New 2 1 6 3 3 5 4 LT 6 LS T R 4 Nm 0 4 m kg 2 9 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 15 Nm 1 5 m kg 11 ft Ib T R 45 ...

Page 339: ...ckup 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 tighten the pickup rotor bolt 3 Apply Sealant onto the crankshaft position sensor lead grommet Sheave holder 90890 01701 Primary clutch holder YS 01880 A 1 2 3 T R Pickup rotor bolt 45 Nm 4 5 m kg 32 ft lb...

Page 340: ...UP ROTOR 5 39 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 New ...

Page 341: ...IC STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks Throttle bodies Refer to THROTTLE BODIES on page 7 5 1 Starter motor lead 1 Disconnect 2 Starter motor assembly 1 For installation reverse the removal proce dure ...

Page 342: ...arks 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 Starter motor yoke 1 13 Armature assembly 1 For assembly reverse the disassembly pro cedure ...

Page 343: ...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 starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Limit 23 5 mm 0 93 in Mica ...

Page 344: ...ASSEMBLING 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 Starter motor rear cover 3 NOTE Align the match marks a on the starter motor yoke with the match marks b on the starter mo tor front and rear covers ...

Page 345: ...AL 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 removal proce dure LT 3 4 5 2 1 10 5 3 New 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 12 Nm 1 2 m kg 8 7 ft Ib ...

Page 346: ...h 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 diameter 135 mm 5 31 in 13 Clutch damper spring 1 14 Clutch damper spring seat 1 15 Lock washer 1 16 Clutch boss 1 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 347: ...1 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 10 Nm 1 0 m kg 7 2 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib E 9 12 11 ...

Page 348: ...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 rod pin 1 6 Clutch switch coupler 1 Disconnect 7 Clutch hose union bolt 1 8 Copper washer 2 9 Clutch hose 1 Disconnect 10 Clutch switch 1 11 Clutch master cylinder holder 1 ...

Page 349: ...CLUTCH 5 48 Apply silicon grease 12 Clutch master cylinder 1 For installation reverse the removal proce dure Removing the clutch master cylinder FJR13A Order Job Parts to remove Q ty Remarks ...

Page 350: ...ensor 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 Clutch fluid reservoir hose 1 10 Clutch hose union bolt 1 11 Copper washer 2 12 Clutch hose 1 Disconnect 13 Clutch master cylinder 1 14 Shim clutch master cylinder kit 1 T R 19 Nm 1 9 m kg 13 ft Ib T R 10...

Page 351: ...al proce dure Removing the clutch actuator and clutch master cylinder FJR13AE 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 Ib T R 30 Nm 3 0 m kg 22 ft Ib New New LS T R 7 Nm 0 7 m kg 5 1 ft Ib 1 2 4 5 7 6 8 9 10 11 12 13 14 3 16 15 ...

Page 352: ...clutch master cylinder FJR13A 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 assembly reverse the disassembly pro cedure ...

Page 353: ...ilicon grease Disassembling the clutch master cylinder FJR13AE 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 cedure 1 2 New ...

Page 354: ...remove Q ty Remarks Clutch fluid Drain Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM FJR13A on page 3 18 1 Clutch hose union bolt 1 2 Copper washer 2 3 Clutch hose 1 Disconnect 4 Clutch release cylinder 1 5 Dowel pin 2 6 Plate 1 For installation reverse the removal proce dure ...

Page 355: ...remove Q ty Remarks Clutch fluid Drain Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM FJR13AE on page 3 19 1 Clutch hose union bolt 1 2 Copper washer 2 3 Clutch hose 1 Disconnect 4 Clutch release cylinder 1 5 Dowel pin 2 6 Plate 1 For installation reverse the removal proce dure ...

Page 356: ...to 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 the disassembly pro cedure 5 2 3 1 4 New T R 6 Nm 0 6 m kg 4 3 ft Ib ...

Page 357: ...ded 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 driven gears must be aligned for installation Insert two 5 mm bolts 2 into the spacer and then remove the spacer by pulling on the bolts EAS25100 CHECKING THE FRICTION PLATES The following procedure ap...

Page 358: ...HECKING 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 clutch operation 2 Check Bearing Damage wear Replace the bearing and clutch housing EAS25160 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss NOTE Pitting o...

Page 359: ... 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 slots b in the oil pump drive sprocket Make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly Insert a cross headed screwdriver into one of the holes of the clutch housing and prima...

Page 360: ...d then alternate be tween a clutch plate and a friction plate 8 Install Clutch spring bolts NOTE Tighten the clutch spring bolts in stages and in a crisscross pattern 9 Install Rear balancer weight Refer to BALANCERS on page 5 127 10 Install Clutch cover NOTE Tighten the clutch cover bolts in the proper tight ening sequence as shown ET3P66068 BREAKING IN THE FRICTION PLATES AFTER REPLACEMENT FJR13...

Page 361: ...ly filled and bled after reas sembly Never use solvents on internal clutch com ponents Use only clean or new clutch fluid for clean ing clutch components Clutch fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt fluid immediately Avoid clutch fluid coming into contact with the eyes as it can cause serious injury First aid for clutch fluid entering the eyes Flus...

Page 362: ... 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 punch mark a on the left handlebar First tighten the upper bolt then the lower bolt 2 Install Copper washers 1 Clutch hose 2 Clutch hose union bolt 3 WARNING EW3P61017 Proper clutch hose routing is essential to in sure safe vehicle operation Refer to CAB...

Page 363: ...ch fluid to the proper level Refer to CHECKING THE CLUTCH FLUID LEVEL FJR13A on page 3 17 6 Check Clutch lever operation Soft or spongy feeling Bleed the clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM FJR13A on page 3 18 ET3P66045 INSTALLING THE CLUTCH MASTER CYLINDER FJR13AE 1 Install Copper washers 1 Clutch hose 2 Clutch hose union bolt 3 WARNING EW3P66001 Proper clutch hose routing...

Page 364: ... Check Pressure plate stroke Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM FJR13AE on page 3 19 2 Measure Shim clutch master cylinder kit 1 thickness 3 Replace Clutch master cylinder kit NOTE The thickness of the new shim 1 is 1 5 mm 0 06 in 4 Bleed Hydraulic clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM FJR13AE on page 3 19 5 Check Pressure plate stroke Refer to BLEEDING THE HYDRAUL...

Page 365: ...shift lever switch shift up until the clutch en gagement 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 5 Check Rear wheel drag torque Refer to CHECKING THE VEHICLE AFTER BLEEDING THE HYDRAULIC CLUTC...

Page 366: ...m ponents as they will cause the piston seal to swell and distort Whenever a clutch release cylinder is dis assembled replace the piston seal EAS25350 INSTALLING THE CLUTCH RELEASE CYLINDER 1 Check Copper washers 1 Clutch hose 2 Clutch hose union bolt 3 WARNING EW3P66003 Proper clutch hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING FJR13A on page 2 47 and CA BLE ...

Page 367: ... damage painted surfaces or plastic 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 Clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM FJR13A on page 3 18 and BLEEDING THE HYDRAULIC CLUTCH SYSTEM FJR13AE on page 3 19 4 Check Clutch fluid leve...

Page 368: ...r 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 Holder 1 12 Shift pedal pivot bolt 1 13 Shift pedal pivot 1 14 Wave washer 1 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 10 N...

Page 369: ...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 10 Nm 1 0 m kg 7 2 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib LS LS T R 49 Nm 4 9 m kg 35 ft Ib LT LT LT LT LT LT LS 2 1 6 8 17 18 16 19 7 12 15 14 13 5 4 3 10 11 9 ...

Page 370: ...tuator 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 1 Check Shift rod operation Rough movement Replace 2 Check Shift rod groove Groove and end of rod cover are not aligned Replace 3 Check Shift rod Bends Replace ET3P66039 INSTALLING THE FOOT SHIFT SWITCH 1 Lubric...

Page 371: ... ET3P66040 ADJUSTING THE FOOT SHIFT SWITCH 1 Check Foot shift switch Refer to CHECKING THE FOOT SHIFT SWITCH FJR13AE only on page 8 235 2 Adjust Foot shift switch angle a Connect the foot shift switch coupler to the foot shift switch b Connect the digital circuit tester to the foot shift switch coupler c Turn the main switch to ON d Measure the foot shift switch voltage e Adjust the foot shift swi...

Page 372: ...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 holes are not aligned loosen the shift rod rear locknut 5 and front locknut 6 and then turn the shift rod to adjust its length f Tighten the shift rod bolts to specification g If the shift rod front lock...

Page 373: ...SHIFT ACTUATOR AND SHIFT ROD FJR13AE only 5 72 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 374: ...LUTCH on page 5 44 Shift rod FJR13AE Refer to SHIFT ACTUATOR AND SHIFT ROD FJR13AE only on page 5 67 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 7 Stopper lever spring 1 8 Stopper lever 1 9 Circlip 1 10 Collar 1 11 Shift shaft spring stopper 1 For installation reverse the removal proce dure ...

Page 375: ...s 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 Align the punch mark a in the shift shaft with the slot in the shift arm ET3P66043 INSTALLING THE SHIFT SHAFT FJR13AE 1 Install Stopper lever 1 Stopper lever spring 2 NOTE Hook the ends of the stopper l...

Page 376: ...SHIFT SHAFT 5 75 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 377: ...s Refer to THROTTLE BODIES on page 7 5 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 1 Sidestand Refer to SHAFT DRIVE on page 4 95 Water pump Refer to WATER PUMP on page 6 10 1 Oil level switch coupler 1 Disconnect 2 Oil level switch 1 3 Oil pan 1 4 Oil pan gasket 1 5 Dowel pin 2 6 Oil delivery pipe 2 1 7 Oil delivery pipe 3 1 8 Oil strainer 1 9 Dowel pin 2 10 Oil pump 1 ...

Page 378: ...OIL PUMP 5 77 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 379: ... 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 assembly reverse the disassembly pro cedure ...

Page 380: ...eck Oil pump operation Rough movement Repeat steps 1 and 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 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance Less than 0 12 mm 0 0047 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump housing ...

Page 381: ...r rotor Oil pump shaft with the recommended lubricant 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 groove a in the in ner rotor 4 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 79 EAS25050 INSTALLING THE OIL PAN 1 Install Oil p...

Page 382: ...UMP on page 5 76 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 driven shaft assembly 1 10 Middle driven pinion gear shim 11 Middle drive pinion gear nut 1 12 Lock washer 1 13 Middle drive pinion gear 1 14 Middle drive shaft assembly 1 ...

Page 383: ...r 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 FJR13A Order Job Parts to remove Q ty Remarks ...

Page 384: ... 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 driven shaft assembly 1 10 Middle driven pinion gear shim 11 Middle drive pinion gear nut 1 12 Lock washer 1 13 Middle drive pinion gear 1 14 Middle drive shaft assembly 1 15 Spacer 1 ...

Page 385: ...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 FJR13AE Order Job Parts to remove Q ty Remarks ...

Page 386: ... 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 reverse the disassembly pro cedure ...

Page 387: ...ly 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 bearing housing 1 For assembly reverse the disassembly pro cedure ...

Page 388: ...e 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 ers EAS25770 DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1 Remove Middle driven pinion gear nut a Straighten the thread on the middle driven pinion gear nut b Loosen the middle driven pinion gear ...

Page 389: ...790 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 1 Install Spring retainers 1 NOTE While compressing the spring with the damper spring compressor 2 install the spring retain ers EAS25820 ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1 Tighten Bearing...

Page 390: ...860 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 with a drift punch 2 Install Lock washer 1 Middle drive pinion gear nut 2 T R Bearing retainer 110 Nm 11 0 m kg 80 ft lb T R Middle driven pinion gear nut 110 Nm 11 0 m kg 80 ft lb LOCTITE 1 New Bearing retainer wrench...

Page 391: ...ddle 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 bolts 1 Adjust the middle gear backlash Refer to ADJUSTING THE MIDDLE GEAR BACKLASH on page 5 91 2 Check that the middle gears turns smoothly ET3P61025 INSTALLING THE MIDDLE GEAR CASE COVER 1 Install Middle gear cas...

Page 392: ...tle middle gear backlash and damage the middle gears If the bolts are overtightened loosen them until the crankcase to middle driven shaft bearing housing clearance is within specification as stated below Then repeat all of the previous steps NOTE Tighten the middle driven shaft bearing hous ing bolts carefully one thread turn at a time only Push in the middle driven shaft bearing housing and then...

Page 393: ...THE MIDDLE GEAR BACKLASH on page 5 91 EAS25930 ALIGNING THE MIDDLE GEAR NOTE Aligning the middle gear is necessary when any of the following parts are replaced Crankcase Middle drive shaft Middle driven shaft bearing housing 1 Select Middle drive pinion gear shim s 1 Middle driven pinion gear shim s 2 NOTE Select the middle driven gear shim s 2 by cal culating the middle drive gear shim thickness ...

Page 394: ... 34 e Measured value f a numeral on the lower crankcase to be divided by 100 and added to 87 Example If the middle driven pinion gear is marked 03 d is 33 97 i e 34 00 0 03 33 97 e is 54 49 If the lower crankcase is marked 95 f is 87 95 i e 87 00 0 95 87 95 B 33 97 54 49 87 95 0 51 Round off to the hundredths digit and select the appropriate shim s NOTE In the above example the calculated number i...

Page 395: ... Refer to MIDDLE GEAR on page 5 81 Clutch housing Refer to CLUTCH on page 5 44 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 Gear position switch 1 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 Spe...

Page 396: ...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 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT New LS T R 4 Nm 0 4 m kg 2 9 ft Ib E E E E E E E E LT LT LT 8 10 10 7 6 5 4 1 2 3 10 9 4 10 10 2 2 ...

Page 397: ...using Refer to CLUTCH on page 5 44 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 S speed sensor 1 10 Lower crankcase 1 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 Ib 2nd 20 Nm 2 0 m kg 14 ft Ib Final Specified...

Page 398: ...m 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 R 10 Nm 1 0 m kg 7 2 ft Ib E E E E E E E E LT LT LT 11 11 7 6 5 4 1 2 3 11 10 4 10 10 2 2 8 9 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib New LT LT ...

Page 399: ...elivery 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 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 Nm 1 0 m kg 7 2 ft Ib T R...

Page 400: ... 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 Nm 1 0 m kg 7 2 ft Ib T R 70 Nm 7 0 m kg 50 ft lb New New New New LS LS New E E T R 12 Nm 1 2 m kg 8 7 ft Ib 11 E T R 20 Nm 2 0 m kg 14 ft Ib 3 ...

Page 401: ...2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with compressed air EAS25600 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes 1 Check Oil delivery pipe Damage Replace Obstruction Wash and blow out with com pressed air ET3P61026 CHECKING THE BEA...

Page 402: ...tightening the crankcase bolts make sure the transmission gears shift correctly when the shift drum assembly is turned by hand 6 Install Crankcase bolts NOTE Lubricate the bolts 1 10 thread and wash ers with engine oil Lubricate the bolts 11 31 thread part and mating surface with engine oil Apply locking agent LOCTITE to the threads of the bolt 16 Finger tighten the crankcase bolts M9 115 mm bolts...

Page 403: ...hown WARNING EW3P61014 If the bolt is tightened more than the speci fied angle do not loosen the bolt and then re tighten it Instead replace the bolt with a new 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 bolt note that the angle from one corner to...

Page 404: ...s in the proper tight ening sequence as shown T R Crankcase bolt 11 12 24 Nm 2 4 m kg 17 ft lb Crankcase bolt 13 14 12 Nm 1 2 m kg 8 7 ft lb Crankcase bolt 15 31 10 Nm 1 0 m kg 7 2 ft lb 13 21 18 15 16 17 20 19 22 14 24 29 30 23 25 31 28 26 27 11 12 ...

Page 405: ...rder Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 94 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 4 7 Big end upper bearing 4 8 Top ring 4 9 2nd ring 4 10 Oil ring 4 For installation reverse the removal proce dure ...

Page 406: ... 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 deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 5 4 Remove Top ring 2nd ring Oil ring NOTE When removing a piston ring open the end gap with your fingers and lift the other side of th...

Page 407: ...nce Out of specification Replace the piston and piston rings as a set NOTE Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings Bore 79 000 79 010 mm 3 1102 3 1106 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in C maximum of D1 D6 T maximum of D1 or D2 maximum of D5 or D6 R maximum of D1 D3 or D5 minimum...

Page 408: ... Replace the piston pin 3 Measure Piston pin bore diameter b Out of specification Replace the piston 4 Calculate Piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set a 5 mm 0 20 in Piston ring Top ring End gap installed 0 35 0 45 mm 0 0138 0 0177 in Limit 0 70 mm 0 0276 in 2nd ring End gap installed 0 75 0 85 mm 0 0295 0 0335 in Limit 1 20 mm 0 04...

Page 409: ... in the connecting rod and connecting rod cap c Put a piece of Plastigauge 1 on the crank shaft pin d Assemble the connecting rod halves NOTE Do not move the connecting rod or crankshaft until the clearance measurement has been completed Lubricate the bolt threads and nut seats with molybdenum disulfide grease Make sure the Y mark c on the connecting rod faces towards the left side of the crank sh...

Page 410: ... Install Top ring 1 2nd ring 2 Upper oil ring rail 3 Oil ring expander 4 Lower oil ring rail 5 NOTE Be sure to install the piston rings so that the manufacturer s marks face up 2 Install Piston 1 onto the respective connecting rod 2 Piston pin 3 Piston pin clips 4 NOTE Apply engine oil onto the piston pin Make sure that the Y mark a on the connect ing rod is facing to the left when the punch mark ...

Page 411: ...Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps Be sure to reinstall each big end bearing in its original place While compressing the piston rings with piston ring compressor 2 install the connecting rod assembly 1 into the cylinder with the other hand Make sure the Y marks a on the connecting rods face towards the left side of the cran...

Page 412: ... rod nuts further to reach the specified angle 115 125 WARNING EWA13400 If the connecting rod nut is tightened more than the specified angle do not loosen the nut and then retighten it Instead replace the connecting rod bolt and nut with a new one and perform the procedure again CAUTION ECA13950 Do not use a torque wrench to tighten the connecting rod nut to the specified angle NOTE On a hexagonal...

Page 413: ... to CRANKCASE on page 5 94 Front balancer weight Refer to BALANCERS on page 5 127 Connecting rod caps Refer to CONNECTING RODS AND PIS TONS on page 5 104 1 Crankshaft 1 2 Crankshaft journal upper bearing 5 3 Crankshaft journal lower bearing 5 4 Oil nozzle 4 For installation reverse the removal proce dure 3 1 2 2 E E New 4 LS ...

Page 414: ...rankshaft 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 journal to crankshaft journal bearing clear ance and prevent engine damage the crank shaft journal bearings must be installed in their original positions a Clean the crankshaft journal bearings crank s...

Page 415: ...ication 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 are used to determine the re placement crankshaft journal bearing sizes J1 J5 refer to the bearings shown in the lower crankcase and crankshaft web illustration If J1 J5 are the same use the same si...

Page 416: ...CRANKSHAFT 5 115 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 417: ...y Remarks Crankcase Separate Refer to CRANKCASE on page 5 94 Stopper lever Refer to SHIFT SHAFT on page 5 73 1 Drive axle assembly 1 2 Bearing 1 3 Washer 1 4 Bearing 1 5 Shift drum retainer 1 6 Long shift fork guide bar 1 7 Shift fork L 1 8 Shift fork R 1 9 Short shift fork guide bar 1 10 Spring 4 11 Shift drum assembly 1 12 Shift fork C 1 ...

Page 418: ...TRANSMISSION 5 117 13 Main axle assembly 1 For installation reverse the removal proce dure Removing the transmission shift drum assembly and shift forks FJR13A Order Job Parts to remove Q ty Remarks ...

Page 419: ...to CRANKCASE on page 5 94 Stopper lever Refer to SHIFT SHAFT on page 5 73 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 1 8 Long shift fork guide bar 1 9 Shift fork L 1 10 Shift fork R 1 11 Short shift fork guide bar 1 12 Spring 4 13 Shift drum assembly 1 14 Shift fork C 1 ...

Page 420: ...TRANSMISSION 5 119 15 Main axle assembly 1 For installation reverse the removal proce dure Removing the transmission shift drum assembly and shift forks FJR13AE Order Job Parts to remove Q ty Remarks ...

Page 421: ...1 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 13 Main axle bearing housing 1 For assembly reverse the disassembly pro cedure 13 12 11 10 9 New New New New 7 8 7 6 5 4 3 2 1 6 E M M M M ...

Page 422: ...nd 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 gear 1 14 Washer 1 15 1st wheel gear 1 16 Bearing 1 17 Washer 1 1 18 17 16 15 14 8 7 12 11 10 2 3 4 6 7 8 9 13 E M M M M M M 5 New New ...

Page 423: ... 122 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 M M M 5 New New ...

Page 424: ... 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 SHIFT DRUM ASSEMBLY 1 Check Shift drum groove Damage scratches wear Replace the shift drum assembly Shift drum segment 1 Damage wear Replace the shift drum as sembly Shift drum bearing 2 Damage pitting R...

Page 425: ...30 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1 Install Toothed washer 1 Circlip 2 NOTE Be sure the circlip sharp edged corner a is positioned opposite side to the toothed washer and gear For main axle Install the circlip so that both ends b rest on the sides of a spline c with both axles aligned 2 Install Toothed lock washer retainer 1 Toothed lock washer 2 NOTE With the toothed lock washer retainer...

Page 426: ...ng bolts at a cutout a in the main axle bearing housing 2 Install Shift fork C Shift drum assembly Springs Short shift fork guide bar Shift fork R Shift fork L Long shift fork guide bar NOTE The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence R C L 3 Install Washer 1 NOTE Install the washer with its chamfered side facing towards t...

Page 427: ...g pin 1 must face towards the rear of the upper crankcase 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 1 2 ...

Page 428: ...er Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 94 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 Front balancer weight 1 For installation reverse the removal proce dure ...

Page 429: ...7 5 Pickup rotor cover Refer to PICKUP ROTOR on page 5 37 Clutch cover Refer to CLUTCH on page 5 44 1 Rear balancer cover 1 2 Rear balancer cover gasket 1 3 Rear balancer lever 1 4 Rear balancer shaft 1 5 Washer 2 6 Bearing 2 7 Rear balancer gear 1 8 Damper 4 9 Rear balancer weight 1 For installation reverse the removal proce dure ...

Page 430: ...ach 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 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 rotor with the crankcase mating sur...

Page 431: ...rom 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 Install Rear balancer gear 1 Dampers 2 Rear balancer weight 3 Bearings Washers NOTE Install the dampers onto the balancer gear so that the middle section a of each damper is positioned to the outside of th...

Page 432: ...haft 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 that the rear balancer gear teeth and the primary driven gear teeth mesh cor rectly Make sure that the balancer gear punch mark c is aligned with the projection e on the up per crankcase Make sure that...

Page 433: ... 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 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 T R Rear balancer shaft 0 4 Nm 0 04 m kg 0 29 ft lb f e c 2 ...

Page 434: ...BALANCERS 5 133 ...

Page 435: ...OOLER 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 CHECKING THE WATER PUMP 6 12 ASSEMBLING THE WATER PUMP 6 12 INSTALLING THE WATER PUMP 6 13 ...

Page 436: ...nt 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 1 13 Right horn high 1 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 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R ...

Page 437: ... 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 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 12 Nm 1 2 m kg 8 7 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 LT LT LT LT T R 7 Nm 0 7 m kg 5 1 ft Ib 1 2 4 5 6 7 8 3 9 10 11 13 14...

Page 438: ...and 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 with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 25 2 Check Cooling system Leaks Repair or replace any faulty part 3 Measure Radiator cap opening pressure ...

Page 439: ...rain 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 Water jacket joint inlet hose 1 4 Water jacket joint 1 5 Oil cooler inlet hose 1 6 Oil cooler outlet hose 1 7 Oil cooler 1 For installation reverse the removal proce dure ...

Page 440: ...r 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 3 25 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 15 4 Check Cooling system Leaks Repair or replace any faulty part 5 Measure Radiator...

Page 441: ...nect 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 1 10 Plunger control unit hose 1 1 11 Coolant temperature sensor coupler 1 Disconnect 12 Coolant temperature sensor 1 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 ...

Page 442: ...tion 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 T R 7 Nm 0 7 m kg 5 1 ft Ib New 1 10 13 12 11 2 7 5 3 4 6 8 9 3 ...

Page 443: ...at 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 temperature sensor CAUTION EC3P61019 Use extreme care when handling the coolant temperature sensor Replace any part that was dropped or subjected to a strong im pact 2 Install Thermostat 1 Thermostat ho...

Page 444: ...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 445: ...ant 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 1 Disconnect 2 Radiator outlet hose 1 Disconnect 3 Water pump outlet hose 1 Disconnect 4 Water pump assembly 1 For installation reverse the removal proce dure ...

Page 446: ...arts 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 housing 1 For assembly reverse the disassembly pro cedure ...

Page 447: ...r 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 installing the oil seal apply tap water or coolant onto its outer surface Install the oil seal with a socket that matches its outside diameter 2 Install Water pump seal 1 CAUTION ECA14080 Never lubricate the ...

Page 448: ...es 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 ring with a thin coat of lithium soap base grease Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A Middle driven shaft bearing driv er 90890 04058 Bearing driver 40 mm YM 0...

Page 449: ... 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 Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 ...

Page 450: ...WATER PUMP 6 15 ...

Page 451: ...ly 7 3 INSTALLING THE FUEL PUMP 7 3 INSTALLING THE FUEL TANK 7 4 THROTTLE BODIES 7 5 CHECKING THE INJECTORS 7 8 CHECKING THE THROTTLE BODIES 7 8 CHECKING THE FUEL PRESSURE 7 8 ADJUSTING THE THROTTLE POSITION SENSOR 7 8 AIR INDUCTION SYSTEM 7 11 CHECKING THE PRESSURE REGULATOR 7 15 CHECKING THE AIR INDUCTION SYSTEM 7 15 INSTALLING THE AIR INDUCTION SYSTEM 7 15 ...

Page 452: ...eather hose 1 Except for California 5 Fuel tank breather hose fuel tank to joint 1 For California only 6 Fuel tank overflow hose 1 Except for California 7 Fuel tank overflow hose fuel tank to joint 1 For California only 8 Fuel hose holder 1 9 Fuel hose 1 10 Fuel tank 1 11 Fuel pump 1 For installation reverse the removal proce dure T R 16 Nm 1 6 m kg 11 ft Ib New T R 4 Nm 0 4 m kg 2 9 ft Ib T R 10 ...

Page 453: ... Canister purge hose throttle body 1 to 3 way joint 1 2 3 way joint 1 3 Canister purge hose throttle body 4 to 3 way joint 1 4 Canister purge hose 3 way joint to canister 1 5 Fuel tank breather hose joint to rollover valve 1 6 Rollover valve 1 7 Fuel tank breather hose rollover valve to canis ter 1 8 Canister breather hose 1 9 Canister 1 10 Canister bracket 1 For installation reverse the removal p...

Page 454: ... wall or the like EAS26640 REMOVING THE FUEL PUMP 1 Remove Fuel pump CAUTION ECA14720 Do not drop the fuel pump or give it a strong shock 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 ET3P66071 CHECKING THE ROLLOVER VALVES for California only 1 Check Rollover valve Damage faul...

Page 455: ...il slide the fuel hose connector cover 1 on the end of the hose in the direction of the arrow shown 2 Install Fuel hose fuel pump side Fuel hose holder CAUTION EC3P61008 When installing the fuel hose make sure that it is securely connected and that the fuel 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 ...

Page 456: ... 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 5 Throttle body joint clamp screw 8 Loosen 6 Throttle bodies 1 7 Throttle cable accelerator cable 1 Disconnect 8 Throttle cable decelerator cable 1 Disconnect 9 Plunger control unit hose 1 1 Disconn...

Page 457: ...Disconnect 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 ft Ib 5 5 5 5 11 11 11 5 5 5 5 11 9 10 1 2 4 8 7 6 3 ...

Page 458: ... 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 hose 4 12 Intake air pressure sensor 1 13 Fuel rail 1 14 Injector 4 15 Throttle position sensor 1 For installation reverse the removal proce dure 12 3 4 5 6 1 7 2 8 8 8 8 9 8 8 8 14 15 11 11 11 13 1...

Page 459: ...ause 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 engine f Measure the fuel pressure Faulty Replace the fuel pump EAS27030 ADJUSTING THE THROTTLE POSITION SENSOR NOTE Before adjusting the throttle position sensor the engine idling speed should be proper...

Page 460: ...at 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 Model 88 Multimeter with ta chometer YU A1927 Output voltage at idle 0 63 0 73 V T R Throttle position sensor screw 3 5 Nm 0 35 m kg 2 53 ft lb 3 2 1 ...

Page 461: ...THROTTLE BODIES 7 10 ...

Page 462: ...AIR INDUCTION SYSTEM 7 11 EAS27040 AIR INDUCTION SYSTEM 1 2 3 4 5 1 1 1 1 2 2 5 2 3 3 4 7 8 6 ...

Page 463: ...ver 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 Air induction system hose air filter case joint assembly to 3 way joint 8 Air filter case joint assembly ...

Page 464: ... 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 valve 1 5 Air induction system hose 3 way joint to reed valve cover 4 6 Air induction system hose air cut off valve to 3 way joint 2 7 Air cut off valve 1 For installation reverse the removal proce dure...

Page 465: ...t 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 installation reverse the removal proce dure LT LT LT LT 1 4 5 2 3 4 4 4 5 5 5 T R 14 Nm 1 4 m kg 10 ft Ib ...

Page 466: ... 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 remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value 1 Check Hoses Loose connections Connect properly Cracks damage Replace Pipe...

Page 467: ...AM 2 2 FJR13AE 8 19 STARTING CIRCUIT CUT OFF SYSTEM OPERATION FJR13A 8 21 STARTING CIRCUIT CUT OFF SYSTEM OPERATION FJR13AE 8 22 TROUBLESHOOTING FJR13A 8 23 TROUBLESHOOTING FJR13AE 8 25 CHARGING SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 TROUBLESHOOTING 8 31 LIGHTING SYSTEM 8 33 CIRCUIT DIAGRAM 1 2 8 33 CIRCUIT DIAGRAM 2 2 8 35 TROUBLESHOOTING 8 37 SIGNALING SYSTEM 8 39 CIRCUIT DIAGRAM 1 2 FJR13A 8 39 CIRCU...

Page 468: ...AM 1 2 FJR13A 8 119 CIRCUIT DIAGRAM 2 2 FJR13A 8 121 CIRCUIT DIAGRAM 1 2 FJR13AE 8 123 CIRCUIT DIAGRAM 2 2 FJR13AE 8 125 ABS COMPONENTS CHART 8 127 ABS COUPLER LOCATION CHART 8 129 ABS ECU AND ABS MOTOR RELAY 8 131 MAINTENANCE OF THE ABS ECU 8 132 MAINTENANCE OF THE ABS MOTOR RELAY 8 132 MAINTENANCE OF THE HYDRAULIC UNIT 8 132 ABS TROUBLESHOOTING OUTLINE 8 133 BASIC INSTRUCTIONS FOR TROUBLESHOOTIN...

Page 469: ... FUNCTION 8 170 SELF DIAGNOSTIC FUNCTION TABLE 8 171 TROUBLESHOOTING METHOD 8 174 DIAGNOSTIC MODE 8 175 TROUBLESHOOTING DETAILS 8 179 ELECTRICAL COMPONENTS 8 203 CHECKING THE SWITCHES 8 211 CHECKING THE BULBS AND BULB SOCKETS 8 216 CHECKING THE FUSES 8 217 CHECKING AND CHARGING THE BATTERY 8 218 CHECKING THE RELAYS 8 221 CHECKING THE ABS MOTOR RELAY 8 223 CHECKING THE TURN SIGNAL HAZARD RELAY 8 22...

Page 470: ...AIR TEMPERATURE SENSOR 8 233 CHECKING THE ACCESSORY BOX SOLENOID 8 234 CHECKING THE YCC S SPEED SENSOR FJR13AE only 8 234 CHECKING THE GEAR POSITION SENSOR FJR13AE only 8 235 CHECKING THE FOOT SHIFT SWITCH FJR13AE only 8 235 CHECKING THE GRIP WARMERS FJR13AE only 8 235 CHECKING THE GRIP WARMER CONTROL UNIT FJR13AE only 8 236 CHECKING THE DIODE 2 FJR13AE only 8 236 ...

Page 471: ......

Page 472: ... R R R Br L B W R L B W R L B B W W W W GRAY B R BLACK R R L W R L R W Sb B Y B R Y W L W P W Y B G R Lg Sb W Sb Lg G R B W Y W Ch B G B R Dg B L G W B R L B DARK GREEN L Y B R R L R G G Y Sb R B B Y Br W Y G W L L W B W Br B G Y B R G R L B R L Y B Y Sb G Y R B B G R Lg Sb Br R R W G O W W W B Br B W L Br W B B B W G R G Y W Y Lg R B B W G W L W Y R L Y G Sb B2 L W R W C C B C A A A A A A A C C C...

Page 473: ...ss 16 Coupler 2 wire harness front cowling wire harness 30 Coupler 3 wire harness front cowling wire harness 31 Sidestand switch 32 Cylinders 1 4 ignition coil 33 Spark plug 34 Cylinders 2 3 ignition coil 40 ECU engine control unit 41 Crankshaft position sensor 50 Coupler 5 wire harness front cowling wire harness 55 Ignition fuse ...

Page 474: ... Ch G L R W Br Br B L R R Y R B L W Br R Br B B BLACK R B B R B R R B B B B Br Y BLACK G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G BLACK R B Br L BLACK B B B B GRAY Br Br L GRAY Ch L R B Ch B L R B L R Dg B Dg L R Lg R B L R Br G Br Br L Br L R B Br R Br B B G L Y Y G G B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Lg Sb W Dg L R L R Ch B B Dg Br G L B Ch B Dg Br G...

Page 475: ...ing wire harness wire harness 16 Coupler 2 front cowling wire harness wire harness 30 Coupler 3 front cowling wire harness wire harness 50 Coupler 5 front cowling wire harness wire harness 67 Engine stop switch 76 Relay unit 91 Lean angle sensor ...

Page 476: ... L WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS GRAY GRAY L W W L Y Br W B Br B B W G Y L L B O B L O R Br B Br B E B G F A C D R R R Br R Br L W W W GRAY B R BLACK R Br B R W G Y B L BLACK B BLACK L B BLACK B BLACK L R Y G L R Y Y W B B G B B W R R L W R L R W BLUE BLUE B Lg W G L R B R Br R W G L L W R Y R B L R Br B G L R W ...

Page 477: ...harness front cowling wire harness 17 Neutral switch 32 Coupler 3 wire harness front cowling wire harness 33 Sidestand switch 34 Cylinders 1 4 ignition coil 35 Spark plug 36 Cylinders 2 3 ignition coil 42 ECU engine control unit 43 Crankshaft position sensor 63 Coupler 5 wire harness front cowling wire harness 68 Ignition fuse ...

Page 478: ... G L W P B R G B G R B Y Y W Y L L L W G R Y G W L G W P G B B R B W Ch Dg L G B L B Ch B W L G B L B Dg 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 Br B BLACK L Y R B B R R L R G G Y Sb R L W R B W L R L L W L Y R W L G B R Sb B R Sb W Sb B Lg Br R R Br R G Sb Lg B Sb W Br B L Y G L G L R W Br Br B L R R Y R B L Y Br R Br B B BLACK B Dg L R B Ch L R B Dg L R B Ch L R ...

Page 479: ...ng wire harness wire harness 16 Coupler 2 front cowling wire harness wire harness 32 Coupler 3 front cowling wire harness wire harness 63 Coupler 5 front cowling wire harness wire harness 81 Engine stop switch 89 Relay unit 103 Lean angle sensor ...

Page 480: ... a spark However the 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 closed The transmission is in neutral the neutral circuit of the gear position switch is closed and the side stand is down the sidestand switch circuit is open 10 11 9 1 4 5 7 2 6 3 8...

Page 481: ...ge 8 218 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 ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 227 Ignition system is OK 5 Check the spark plug caps Refer to CHECKING THE SPARK PLUG CAPS on page 8 226 Replace the spark plug cap s 6 Check...

Page 482: ...CHES on page 8 211 Replace the neutral switch 12 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 211 Replace the sidestand switch 13 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 225 Replace the relay unit 14 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 227 Replace the lean angle sensor 15 Check the entire ignition ...

Page 483: ...IGNITION SYSTEM 8 12 ...

Page 484: ... Br B B G R R R Br L B W R L B W R L B B W W W W GRAY B R BLACK R R L W R L R W Sb B Y B R Y W L W P W Y B G R Lg Sb W Sb Lg G R B W Y W Ch B G B R Dg B L G W B R L B DARK GREEN L Y B R R L R G G Y Sb R B B Y Br W Y G W L L W B W Br B G Y B R G R L B R L Y B Y Sb G Y R B B G R Lg Sb Br R R W G O W W W B Br B W L Br W B B B W G R G Y W Y Lg R B B W G W L W Y R L Y G Sb B2 L W R W C C B C A A A A A ...

Page 485: ...attery 10 Starter relay 11 Starter motor 12 Gear position switch 16 Coupler 2 wire harness front cowling wire harness 30 Coupler 3 wire harness front cowling wire harness 31 Sidestand switch 50 Coupler 5 wire harness front cowling wire harness 55 Ignition fuse ...

Page 486: ...Y B R Ch G L R W Br Br B L R R Y R B L W Br R Br B B BLACK R B B R B R R B B B B Br Y BLACK G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G BLACK R B Br L BLACK B B B B GRAY Br Br L GRAY Ch L R B Ch B L R B L R Dg B Dg L R Lg R B L R Br G Br Br L Br L R B Br R Br B B G L Y Y G G B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Lg Sb W Dg L R L R Ch B B Dg Br G L B Ch B Dg...

Page 487: ...ont cowling wire harness wire harness 30 Coupler 3 front cowling wire harness wire harness 50 Coupler 5 front cowling wire harness wire harness 67 Engine stop switch 68 Start switch 71 Clutch switch 76 Relay unit 77 Starting circuit cut off relay ...

Page 488: ...O O L L WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS GRAY GRAY L W W L Y Br W B Br B B W G Y L L B O B L O R Br B Br B E B G F A C D R R R Br R Br L W W W GRAY B R BLACK R Br B R W G Y B L BLACK B BLACK L B BLACK B BLACK L R Y G L R Y Y W B B G B B W R R L W R L R W BLUE BLUE B Lg W G L R B R Br R W G L L W R Y R B L R Br B G L...

Page 489: ...2 wire harness front cowling wire harness 17 Neutral switch 24 Rear brake light switch 26 Brake light relay 32 Coupler 3 wire harness front cowling wire harness 33 Sidestand switch 55 MCU motor control unit 62 YCC S control relay 63 Coupler 5 wire harness front cowling wire harness 66 Signaling system fuse 68 Ignition fuse ...

Page 490: ...W L Y G L W P B R G B G R B Y Y W Y L L L W G R Y G W L G W P G B B R B W Ch Dg L G B L B Ch B W L G B L B Dg 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 Br B BLACK L Y R B B R R L R G G Y Sb R L W R B W L R L L W L Y R W L G B R Sb B R Sb W Sb B Lg Br R R Br R G Sb Lg B Sb W Br B L Y G L G L R W Br Br B L R R Y R B L Y Br R Br B B BLACK B Dg L R B Ch L R B Dg L R B Ch...

Page 491: ...owling wire harness wire harness 32 Coupler 3 front cowling wire harness wire harness 63 Coupler 5 front cowling wire harness wire harness 80 Front brake light switch 81 Engine stop switch 82 Start switch 89 Relay unit 90 Starting circuit cut off relay ...

Page 492: ...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 When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engine can be started by pushing the start switch 13 1 12 4 5 7 7 a b 9 7 10 8 6 2 3 11 a WHEN...

Page 493: ...er 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 of the above conditions has been met the starting circuit cut off relay is closed and the engine can be started by pushing the start switch 19 1 18 4 6 7 12 a b 9 14 10 8 15 2 3 11 8 8 13 16 17 5 a WHEN THE...

Page 494: ...s Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 228 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 42 Repair or replace the starter motor 5 Check the relay unit starting circuit cut off relay Refer to ...

Page 495: ...ce the gear position switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 211 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 211 Replace the clutch switch 13 Check the start switch Refer to CHECKING THE SWITCHES on page 8 211 Replace the right handlebar switch 14 Check the entire starting system wiring Refer to CIRCUIT DIAG...

Page 496: ...y terminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 228 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 42 Repair or replace the starter motor 5 Check the relay unit starting circuit cut off relay...

Page 497: ...fer to CHECKING THE SWITCHES on page 8 211 Replace the right handlebar switch 12 Check the neutral switch Refer to CHECKING THE SWITCHES on page 8 211 Replace the neutral switch 13 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 211 Replace the sidestand switch 14 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 211 Replace the front brake light switc...

Page 498: ...27 NG OK 17 Check the entire starting system wiring Refer to CIRCUIT DIAGRAM 1 2 FJR13AE on page 8 17 and CIRCUIT DIAGRAM 2 2 FJR13AE on page 8 19 Properly connect or repair the starting sys tem wiring Replace the MCU or diode 1 ...

Page 499: ...ELECTRIC STARTING SYSTEM 8 28 ...

Page 500: ...Br W B W W L R R R G R W W W W B R ON OFF BLUE BLUE R Br B B G R R R Br L B B W W W W GRAY B R BLACK R R L W R L R W Sb B Y B R Y W L W P A B Lg W R Br B R W G Y R Y G L R Y Y W L G B R L B L Y RED RED G L R B B B L Gy W R L BLACK B L W B BLACK W L Y B L L W B B L L Y B L BLACK P W B L L BLACK W W W W R Br R W G L L W R Y R B L R Br B G L R W Br Br B L R R Y R B L W Br R B L BLACK B BLACK L B BLAC...

Page 501: ...CHARGING SYSTEM 8 30 2 Rectifier regulator 3 AC magneto 7 Main fuse 8 Battery ...

Page 502: ...y Refer to CHECKING AND CHARGING THE BATTERY on page 8 218 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 228 Replace the stator coil 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 229 Replace the rectifier regulator 5 Check the entire charging system wiring Refer to CIRCUIT DIAGR...

Page 503: ...CHARGING SYSTEM 8 32 ...

Page 504: ...R R Br L B W R L B W R L B B W W W W GRAY B R BLACK R R L W R L R W Sb B Y B R Y W L W P W Y B G R Lg Sb W Sb Lg G R B W Y W Ch B G B R Dg B L G W B R L B DARK GREEN L Y B R R L R G G Y Sb R B B Y Br W Y G W L L W B W Br B G Y B R G R L B R L Y B Y Sb G Y R B B G R Lg Sb Br R R W G O W W W B Br B W L Br W B B B W G R G Y W Y Lg R B B W G W L W Y R L Y G Sb B2 L W R W C C B C A A A A A A A C C C C ...

Page 505: ...5 License plate light 27 Tail brake light 30 Coupler 3 wire harness front cowling wire harness 40 ECU engine control unit 50 Coupler 5 wire harness front cowling wire harness 51 Headlight relay on off 52 Hazard lighting fuse 54 Headlight fuse 55 Ignition fuse ...

Page 506: ...Ch G L R W Br Br B L R R Y R B L W Br R Br B B BLACK R B B R B R R B B B B Br Y BLACK G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G BLACK R B Br L BLACK B B B B GRAY Br Br L GRAY Ch L R B Ch B L R B L R Dg B Dg L R Lg R B L R Br G Br Br L Br L R B Br R Br B B G L Y Y G G B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Lg Sb W Dg L R L R Ch B B Dg Br G L B Ch B Dg Br G ...

Page 507: ...ng wire harness wire harness 50 Coupler 5 front cowling wire harness wire harness 72 Dimmer switch 86 Meter light 87 High beam indicator light 93 Front left turn signal light 94 Front right turn signal light 95 Headlight relay dimmer 97 Headlight ...

Page 508: ...eck the fuses Main headlights ignition and haz ard lighting Refer to CHECKING THE FUS ES on page 8 217 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 218 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 211 Replace the main switch 5 Check the dimmer switch Refer to CHECKING THE ...

Page 509: ...SYSTEM 8 38 NG OK 8 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 Properly connect or repair the lighting sys tem wiring Replace the ECU ...

Page 510: ...G R R R Br L B W R L B W R L B B W W W W GRAY B R BLACK R R L W R L R W Sb B Y B R Y W L W P W Y B G R Lg Sb W Sb Lg G R B W Y W Ch B G B R Dg B L G W B R L B DARK GREEN L Y B R R L R G G Y Sb R B B Y Br W Y G W L L W B W Br B G Y B R G R L B R L Y B Y Sb G Y R B B G R Lg Sb Br R R W G O W W W B Br B W L Br W B B B W G R G Y W Y Lg R B B W G W L W Y R L Y G Sb B2 L W R W C C B C A A A A A A A C C ...

Page 511: ...ic control unit 20 Rear wheel sensor 23 Rear brake light switch 24 Brake light relay 27 Tail brake light 28 Rear left turn signal light 29 Rear right turn signal light 30 Coupler 3 wire harness front cowling wire harness 40 ECU engine control unit 48 Coupler 4 wire harness front cowling wire harness 49 Oil level switch 50 Coupler 5 wire harness front cowling wire harness 52 Hazard lighting fuse 53...

Page 512: ...R Ch G L R W Br Br B L R R Y R B L W Br R Br B B BLACK R B B R B R R B B B B Br Y BLACK G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G BLACK R B Br L BLACK B B B B GRAY Br Br L GRAY Ch L R B Ch B L R B L R Dg B Dg L R Lg R B L R Br G Br Br L Br L R B Br R Br B B G L Y Y G G B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Lg Sb W Dg L R L R Ch B B Dg Br G L B Ch B Dg Br ...

Page 513: ...ness 50 Coupler 5 front cowling wire harness wire harness 63 Turn signal hazard relay 66 Front brake light switch 69 Hazard switch 74 Turn signal switch 75 Horn switch 76 Relay unit 81 Neutral indicator light 83 Multi function meter 84 Oil level warning light 88 Right turn signal indicator light 89 Left turn signal indicator light 92 Horn 93 Front left turn signal light 94 Front right turn signal ...

Page 514: ...L L WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS GRAY GRAY L W W L Y Br W B Br B B W G Y L L B O B L O R Br B Br B E B G F A C D R R R Br R Br L W W W GRAY B R BLACK R Br B R W G Y B L BLACK B BLACK L B BLACK B BLACK L R Y G L R Y Y W B B G B B W R R L W R L R W BLUE BLUE B Lg W G L R B R Br R W G L L W R Y R B L R Br B G L R W...

Page 515: ...ke light switch 25 Diode 2 26 Brake light relay 29 Tail brake light 30 Rear left turn signal light 31 Rear right turn signal light 32 Coupler 3 wire harness front cowling wire harness 42 ECU engine control unit 50 Oil level switch 55 MCU motor control unit 57 Coupler 4 wire harness front cowling wire harness 61 Gear position sensor 63 Coupler 5 wire harness front cowling wire harness 65 Hazard lig...

Page 516: ...Y G L W P B R G B G R B Y Y W Y L L L W G R Y G W L G W P G B B R B W Ch Dg L G B L B Ch B W L G B L B Dg 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 Br B BLACK L Y R B B R R L R G G Y Sb R L W R B W L R L L W L Y R W L G B R Sb B R Sb W Sb B Lg Br R R Br R G Sb Lg B Sb W Br B L Y G L G L R W Br Br B L R R Y R B L Y Br R Br B B BLACK B Dg L R B Ch L R B Dg L R B Ch L R...

Page 517: ...s 63 Coupler 5 front cowling wire harness wire harness 78 Turn signal hazard relay 80 Front brake light switch 83 Hazard switch 87 Turn signal switch 88 Horn switch 89 Relay unit 94 Neutral indicator light 96 Multi function meter 97 Oil level warning light 101 Right turn signal indicator light 102 Left turn signal indicator light 110 Horn 111 Front left turn signal light 112 Front right turn signa...

Page 518: ...R13AE Refer to CHECKING THE FUS ES on page 8 217 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 218 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 211 Replace the main switch 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM 1 2 FJR13A on page 8 39 CIRCUIT DI...

Page 519: ...age 8 41 CIRCUIT DIAGRAM 1 2 FJR13AE on page 8 43 and CIRCUIT DIAGRAM 2 2 FJR13AE on page 8 45 Properly connect or repair the signaling system wiring This circuit is OK 1 Check the tail brake light bulbs and sockets Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 216 Replace the tail brake light bulb socket or both 2 Check the front brake light switch Refer to CHECKING THE SWITCHES on page ...

Page 520: ...UIT DIAGRAM 2 2 FJR13AE 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 BULB SOCKETS on page 8 216 Replace the turn signal light bulb socket or both 2 Check the turn signal switch Refer to CHECKING THE SWITCHES on page 8 211 Replace the left handlebar switch 3 Check the hazard swi...

Page 521: ...KING THE SWITCHES on page 8 211 Replace the gear position switch 2 Check the neutral switch FJR13AE Refer to CHECKING THE SWITCHES on page 8 211 Replace the neutral switch 3 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 225 Replace the relay unit 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM 1 2 FJR13A on page 8 39 CIRCUIT DIAGRAM 2 2 FJR13A on p...

Page 522: ...re signaling system wiring Refer to CIRCUIT DIAGRAM 1 2 FJR13A on page 8 39 CIRCUIT DIAGRAM 2 2 FJR13A on page 8 41 CIRCUIT DIAGRAM 1 2 FJR13AE on page 8 43 and CIRCUIT DIAGRAM 2 2 FJR13AE on page 8 45 Properly connect or repair the signaling system wiring Replace the meter assembly 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 8 230 Replace the fuel pump 2 Check the entire sig...

Page 523: ... ABS ECU coupler and ECU coupler white yellow white yellow Between ECU coupler and meter assembly yellow blue yellow blue 1 Check the rear wheel sensor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 26 Replace the rear wheel sensor 2 Check the entire speed sensor wir ing Refer to NOTE Properly connect or repair the speed sen sor wiring Replace the ABS ECU ECU or meter ass...

Page 524: ... Br L B W R L B W R L B B W W W W GRAY B R BLACK R R L W R L R W Sb B Y B R Y W L W P W Y B G R Lg Sb W Sb Lg G R B W Y W Ch B G B R Dg B L G W B R L B DARK GREEN L Y B R R L R G G Y Sb R B B Y Br W Y G W L L W B W Br B G Y B R G R L B R L Y B Y Sb G Y R B B G R Lg Sb Br R R W G O W W W B Br B W L Br W B B B W G R G Y W Y Lg R B B W G W L W Y R L Y G Sb B2 L W R W C C B C A A A A A A A C C C C C A...

Page 525: ...in fuse 8 Battery 40 ECU engine control unit 43 Coolant temperature sensor 55 Ignition fuse 58 Radiator fan motor relay 59 Left radiator fan motor fuse 60 Left radiator fan motor 61 Right radiator fan motor fuse 62 Right radiator fan motor ...

Page 526: ...y terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 211 Replace the main switch 4 Check the radiator fan motors Refer to CHECKING THE RADIA TOR FAN MOTORS on page 8 231 Replace the radiator fan motor s 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 221 Replace the radiator fan motor relay 6 Check the coolant tem...

Page 527: ...COOLING SYSTEM 8 56 ...

Page 528: ... B B G R R R Br L B W R L B W R L B B W W W W GRAY B R BLACK R R L W R L R W Sb B Y B R Y W L W P W Y B G R Lg Sb W Sb Lg G R B W Y W Ch B G B R Dg B L G W B R L B DARK GREEN L Y B R R L R G G Y Sb R B B Y Br W Y G W L L W B W Br B G Y B R G R L B R L Y B Y Sb G Y R B B G R Lg Sb Br R R W G O W W W B Br B W L Br W B B B W G R G Y W Y Lg R B B W G W L W Y R L Y G Sb B2 L W R W C C B C A A A A A A A...

Page 529: ...park plug 34 Cylinders 2 3 ignition coil 35 Injector 4 36 Injector 3 37 Injector 2 38 Injector 1 39 Air induction system solenoid 40 ECU engine control unit 41 Crankshaft position sensor 42 Intake air temperature sensor 43 Coolant temperature sensor 44 O2 sensor 45 Cylinder identification sensor 46 Throttle position sensor 47 Intake air pressure sensor 50 Coupler 5 wire harness front cowling wire ...

Page 530: ... B R Ch G L R W Br Br B L R R Y R B L W Br R Br B B BLACK R B B R B R R B B B B Br Y BLACK G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G BLACK R B Br L BLACK B B B B GRAY Br Br L GRAY Ch L R B Ch B L R B L R Dg B Dg L R Lg R B L R Br G Br Br L Br L R B Br R Br B B G L Y Y G G B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Lg Sb W Dg L R L R Ch B B Dg Br G L B Ch B Dg ...

Page 531: ...harness wire harness 30 Coupler 3 front cowling wire harness wire harness 50 Coupler 5 front cowling wire harness wire harness 67 Engine stop switch 72 Dimmer switch 76 Relay unit 78 Fuel pump relay 83 Multi function meter 85 Engine trouble warning light 91 Lean angle sensor 95 Headlight relay dimmer 97 Headlight ...

Page 532: ...O L L WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS GRAY GRAY L W W L Y Br W B Br B B W G Y L L B O B L O R Br B Br B E B G F A C D R R R Br R Br L W W W GRAY B R BLACK R Br B R W G Y B L BLACK B BLACK L B BLACK B BLACK L R Y G L R Y Y W B B G B B W R R L W R L R W BLUE BLUE B Lg W G L R B R Br R W G L L W R Y R B L R Br B G L R...

Page 533: ...2 3 ignition coil 37 Injector 4 38 Injector 3 39 Injector 2 40 Injector 1 41 Air induction system solenoid 42 ECU engine control unit 43 Crankshaft position sensor 44 Intake air temperature sensor 45 Coolant temperature sensor 46 O2 sensor 47 Cylinder identification sensor 48 Throttle position sensor 49 Intake air pressure sensor 63 Coupler 5 wire harness front cowling wire harness 64 Headlight on...

Page 534: ... L Y G L W P B R G B G R B Y Y W Y L L L W G R Y G W L G W P G B B R B W Ch Dg L G B L B Ch B W L G B L B Dg 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 Br B BLACK L Y R B B R R L R G G Y Sb R L W R B W L R L L W L Y R W L G B R Sb B R Sb W Sb B Lg Br R R Br R G Sb Lg B Sb W Br B L Y G L G L R W Br Br B L R R Y R B L Y Br R Br B B BLACK B Dg L R B Ch L R B Dg L R B Ch ...

Page 535: ...rness wire harness 32 Coupler 3 front cowling wire harness wire harness 63 Coupler 5 front cowling wire harness wire harness 81 Engine stop switch 85 Dimmer switch 89 Relay unit 91 Fuel pump relay 96 Multi function meter 98 Engine trouble warning light 103 Lean angle sensor 114 Headlight 115 Headlight relay dimmer ...

Page 536: ...ode 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 of the conditions listed below is present and the start switch is pushed Checking the engine trouble warning light The engine trouble warning light comes on for 1 4 seconds after the main switch has ...

Page 537: ...ode 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 position sensor No normal signals are received from the crankshaft position sen sor Unable Unable 13 Intake air pressure sensor open or short circuit Intake air pressure sensor open or short circuit dete...

Page 538: ...of 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 depending on the number of faulty cylin ders 41 Lean angle sensor open or short circuit Lean angle sensor open or short circuit detected Unable Unable 42 Rear wheel sensor No normal signals are rece...

Page 539: ...malfunc 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 able to drive Er 1 ECU internal malfunc tion output signal error No signals are received from the ECU Unable Unable Er 2 ECU internal malfunc tion output signal error No signals are received from the E...

Page 540: ...ore NOTE 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 the CO adjustment mode Co or the diagnostic mode dIAG 5 After selecting dIAG simultaneously press the SELECT and RESET buttons for 2 seconds or more to activate the diagnostic mode The diagno...

Page 541: ...nals 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 Improperly installed crankshaft position sensor 13 Intake air pressure sensor open or short circuit detect ed Open or short circuit in sub wire harness Open or short circuit in wire harness Defective intake air pressure sen...

Page 542: ...ed No normal signal is re ceived from the lean angle sensor The vehicle has overturned Defective lean angle sensor Malfunction in ECU Improperly installed lean angle sensor 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 or short circuit in sub wire harness Open or short circuit in front cowling wire h...

Page 543: ... wire harness Open or short circuit in wire harness Defective rear wheel sensor Malfunction in rear wheel sensor detected Defective gear position switch FJR13A Defective neutral switch FJR13AE Malfunction in the engine side of the gear position switch FJR13A Malfunction in the engine side of the neutral switch FJR13AE Malfunction in ECU Malfunction in ABS ECU 07 21 43 The ECU is unable to moni tor...

Page 544: ...d from the meter Open or short circuit in front cowling wire harness Open or short circuit in wire harness Malfunction in meter assembly Malfunction in ECU Diag nostic code No Item Meter display Checking method 01 Throttle angle Fully closed position 15 17 Check with throttle fully closed Fully opened position 97 100 Check with throttle fully open 03 Pressure difference atmospheric pressure and in...

Page 545: ...ly measured battery voltage If the bat tery voltage is lower per form recharging 20 Sidestand switch Set on off the Sidestand switch with the transmis sion in gear Stand retracted ON Stand extended OFF 21 Gear position switch FJR13A Shift the transmission Neutral switch FJR13AE Neutral ON In gear OFF 60 EEPROM fault code dis play No history 00 History exists 01 04 Cylinder fault code If more than ...

Page 546: ...erased For example if there have been three malfunctions 03 is displayed To erase the history set the engine stop switch from to 70 Control number 0 255 Diag nostic code No Item Actuation Checking method 30 Cylinders 1 4 ignition coil Actuates the cylinders 1 4 ignition coil five times at one second intervals Illuminates the engine trou ble warning light Check the spark five times Connect an ignit...

Page 547: ... the air induction system solenoid five times 50 Fuel pump relay Actuates the fuel pump relay five times at one second in tervals Illuminates the 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 pump relay five times 51 Radiator fan motor relay Actuates t...

Page 548: ...pler wire harness side and check for continuity Fault code No 11 Symptom No normal signals are received from the cylinder identifi cation sensor Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of cylinder identifi cation sensor Check for looseness or pinching Starting the en gine and oper ating it at idle 2 Connections...

Page 549: ...ns 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 connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between the crankshaft position sensor coupler and ECU cou pler gray gray b...

Page 550: ...efective intake air pressure sensor Execute the diagnostic mode Code No 03 Replace if defective Refer to CHECKING THE IN TAKE AIR PRESSURE SEN SOR on page 8 233 Fault code No 14 Symptom Intake air pressure sensor hose system malfunction clogged or detached hose Diagnostic code No 03 Intake air pressure sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 ...

Page 551: ...coupler 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 Between throttle position sen sor coupler and ECU coupler black blue black blue yellow yellow blue blue 4 Throttle position sensor lead wire open circuit output voltage check Check for open circuit and r...

Page 552: ...CU 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 curely 3 Throttle position sensor lead wire open circuit output voltage check Check for open circuit and re place the throttle position sen sor black blue yellow Open circuit item Output voltage Ground wi...

Page 553: ... may be pulled out Check the locking condition 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 wiring 2 Open or short circuit in wire harness and or front cowling wire harness Repair or replace if there is an open or short circuit Between ECU and black ...

Page 554: ...t 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 the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between coolant temperature sensor coupler and ECU cou pler black blue black blue gr...

Page 555: ...r 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 the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between intake air temperature sensor coupler and ECU cou pler black blue black blu...

Page 556: ...CU coupler Sub wire harness coupler Front cowling 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 curely 3 Open or short circuit in wire harness sub wire harness and or front cowling wire harness Repair or replace if there is an open or short circuit Between O2 senso...

Page 557: ...e 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 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 the coupler se ...

Page 558: ...is a malfunction repair it and connect the coupler se curely Starting the en gine warming it up until the coolant temper ature is 60 C or more and then running it between 2000 3000 r min un til the engine trouble warn ing light turns off 2 Open or short circuit in wire harness sub wire harness and or front cowling wire harness Repair or replace if there is an open or short circuit Between O2 senso...

Page 559: ...efer to CHECKING THE FUEL PRESSURE on page 7 8 Check the throttle position sen sor Execute the diagnostic mode Code No 01 Replace if defective Check the fuel system discon nection etc Repair or replace if there is a malfunction Check the intake system im proper sealing etc Repair or replace if there is a malfunction Fault code No 31 Symptom The amount of air fuel ratio feedback compensation is mai...

Page 560: ...and connect the coupler se curely Starting the en gine warming it up until the coolant temper ature is 60 C or more and then running it between 2000 3000 r min un til the engine trouble warn ing light turns off 2 Open or short circuit in wire harness sub wire harness and or front cowling wire harness Repair or replace if there is an open or short circuit Between O2 sensor coupler and ECU coupler b...

Page 561: ... 7 8 Checking the throttle position sensor Execute the diagnostic mode Code No 01 Replace if defective Checking the fuel system clog ging etc Repair or replace if there is a malfunction Fault code No 32 Symptom The amount of air fuel ratio feedback compensation is maintained continuously in the vicinity of the lower limit rich air fuel ratio Diagnostic code No 01 Throttle position sensor Order Ite...

Page 562: ...locking 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 cowling wire harness Repair or replace if there is an open or short circuit Between cylinders 1 4 igni tion coil connector and ECU coupler orange orange Between cylinders 1 4 igni tion coil connect...

Page 563: ...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 front cowling wire harness Repair or replace if there is an open or short circuit Between cylinders 2 3 igni tion coil connector and ECU coupler gray red gray red Between cylinders 2 3 igni tion coil conn...

Page 564: ...y 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 wire harness and or front cowling wire harness Repair or replace if there is an open or short circuit Between lean angle sensor coupler and ECU coupler black blue black blue yellow green yellow green ...

Page 565: ...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 speed signals by operating the vehicle at a 20 to 30 km h A 2 Open or short circuit in wire harness and or ABS wire harness Repair or replace if there is an open or short circuit Between rear wheel senso...

Page 566: ... switch coupler and relay unit coupler sky blue sky blue FJR13AE Between relay unit coupler and ECU coupler black red black red FJR13AE Between neutral switch coupler and ECU coupler sky blue sky blue FJR13AE B 3 Faulty shift drum neutral detection ar ea Replace if defective Refer to TRANSMISSION on page 5 116 B 4 Defective gear position switch neutral circuit FJR13A Defective neutral switch FJR13...

Page 567: ...and main switch coupler red brown 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 09 Replace if defective If there is no malfunction with the fuel pump relay replace the ECU Fault code No 44 Symptom An error is detected while reading or writing on EEPROM CO adjustment value Diagn...

Page 568: ...n page 8 218 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 circuit Between battery and main switch coupler red red Between main switch coupler and ignition fuse brown blue brown blue Between ignition fuse and ECU coupler red white red white Fault code No 50 Symp...

Page 569: ...lue 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 Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Meter assembly coupler Wire harness ECU coupler Front cowling wire harness coupler Che...

Page 570: ...lue 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 Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Meter assembly coupler Wire harness ECU coupler Front cowling wire harness coupler Check...

Page 571: ...FUEL INJECTION SYSTEM 8 100 ...

Page 572: ... R R Br L B W R L B W R L B B W W W W GRAY B R BLACK R R L W R L R W Sb B Y B R Y W L W P W Y B G R Lg Sb W Sb Lg G R B W Y W Ch B G B R Dg B L G W B R L B DARK GREEN L Y B R R L R G G Y Sb R B B Y Br W Y G W L L W B W Br B G Y B R G R L B R L Y B Y Sb G Y R B B G R Lg Sb Br R R W G O W W W B Br B W L Br W B B B W G R G Y W Y Lg R B B W G W L W Y R L Y G Sb B2 L W R W C C B C A A A A A A A C C C C...

Page 573: ... Main switch 5 Fuel injection system fuse 7 Main fuse 8 Battery 14 Fuel pump 16 Coupler 2 wire harness front cowling wire harness 40 ECU engine control unit 50 Coupler 5 wire harness front cowling wire harness 55 Ignition fuse ...

Page 574: ...h G L R W Br Br B L R R Y R B L W Br R Br B B BLACK R B B R B R R B B B B Br Y BLACK G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G BLACK R B Br L BLACK B B B B GRAY Br Br L GRAY Ch L R B Ch B L R B L R Dg B Dg L R Lg R B L R Br G Br Br L Br L R B Br R Br B B G L Y Y G G B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Lg Sb W Dg L R L R Ch B B Dg Br G L B Ch B Dg Br G C...

Page 575: ...FUEL PUMP SYSTEM 8 104 16 Coupler 2 front cowling wire harness wire harness 50 Coupler 5 front cowling wire harness wire harness 67 Engine stop switch 76 Relay unit 78 Fuel pump relay ...

Page 576: ...inals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 211 Replace the main switch 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 211 Replace the right handlebar switch 5 Check the relay unit fuel pump re lay Refer to CHECKING THE RE LAYS on page 8 221 Replace the relay unit 6 Check the fuel pump Refer to CHECKING THE FUEL PU...

Page 577: ...FUEL PUMP SYSTEM 8 106 ...

Page 578: ...B B G R R R Br L B W R L B W R L B B W W W W GRAY B R BLACK R R L W R L R W Sb B Y B R Y W L W P W Y B G R Lg Sb W Sb Lg G R B W Y W Ch B G B R Dg B L G W B R L B DARK GREEN L Y B R R L R G G Y Sb R B B Y Br W Y G W L L W B W Br B G Y B R G R L B R L Y B Y Sb G Y R B B G R Lg Sb Br R R W G O W W W B Br B W L Br W B B B W G R G Y W Y Lg R B B W G W L W Y R L Y G Sb B2 L W R W C C B C A A A A A A A ...

Page 579: ...108 1 Main switch 6 Backup fuse odometer clock and windshield drive system 7 Main fuse 8 Battery 16 Coupler 2 wire harness front cowling wire harness 50 Coupler 5 wire harness front cowling wire harness 53 Signaling system fuse ...

Page 580: ... R Ch G L R W Br Br B L R R Y R B L W Br R Br B B BLACK R B B R B R R B B B B Br Y BLACK G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G BLACK R B Br L BLACK B B B B GRAY Br Br L GRAY Ch L R B Ch B L R B L R Dg B Dg L R Lg R B L R Br G Br Br L Br L R B Br R Br B B G L Y Y G G B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Lg Sb W Dg L R L R Ch B B Dg Br G L B Ch B Dg Br...

Page 581: ...WINDSHIELD DRIVE SYSTEM 8 110 16 Coupler 2 front cowling wire harness wire harness 50 Coupler 5 front cowling wire harness wire harness 73 Windshield position switch 100 Windshield drive unit ...

Page 582: ...efer to CHECKING AND CHARGING THE BATTERY on page 8 218 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 211 Replace the main switch 4 Check the windshield position switch Refer to CHECKING THE SWITCHES on page 8 211 Replace the left handlebar switch 5 Check the entire windshield drive system wiring Refer to CIRCUIT DIAGRA...

Page 583: ...WINDSHIELD DRIVE SYSTEM 8 112 ...

Page 584: ...L L B L P W Y L Y G G W Br R Br L Br L Br W B W W R R R G R W W W W B R ON OFF BLUE BLUE R Br B B G R R R Br L B B W W W W GRAY B R BLACK R R L W R L R W Sb B Y B R Y W L W P A B Lg W R Br B R W G Y R Y G L R Y Y W L G B R L B L Y RED RED G L R B B B L Gy W R L BLACK B L W B BLACK W L Y B L L W B B L L Y B L BLACK P W B L L BLACK W W W W R Br R W G L L W R Y R B L R Br B G L R W Br Br B L R R Y R ...

Page 585: ...ACCESSORY BOX SYSTEM 8 114 1 Main switch 7 Main fuse 8 Battery 50 Coupler 5 wire harness front cowling wire harness 53 Signaling system fuse ...

Page 586: ... Ch G L R W Br Br B L R R Y R B L W Br R Br B B BLACK R B B R B R R B B B B Br Y BLACK G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G BLACK R B Br L BLACK B B B B GRAY Br Br L GRAY Ch L R B Ch B L R B L R Dg B Dg L R Lg R B L R Br G Br Br L Br L R B Br R Br B B G L Y Y G G B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Lg Sb W Dg L R L R Ch B B Dg Br G L B Ch B Dg Br G...

Page 587: ...ACCESSORY BOX SYSTEM 8 116 50 Coupler 5 front cowling wire harness wire harness 79 Accessory box solenoid ...

Page 588: ...D CHARGING THE BATTERY on page 8 218 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 211 Replace the main switch 4 Check the accessory box solenoid Refer to CHECKING THE ACCES SORY BOX SOLENOID on page 8 234 Replace the accessory box solenoid 5 Check the entire accessory box system wiring Refer to CIRCUIT DIAGRAM 1 2 on p...

Page 589: ...ACCESSORY BOX SYSTEM 8 118 ...

Page 590: ...E R Br B B G R R R Br L B W R L B W R L B B W W W W GRAY B R BLACK R R L W R L R W Sb B Y B R Y W L W P W Y B G R Lg Sb W Sb Lg G R B W Y W Ch B G B R Dg B L G W B R L B DARK GREEN L Y B R R L R G G Y Sb R B B Y Br W Y G W L L W B W Br B G Y B R G R L B R L Y B Y Sb G Y R B B G R Lg Sb Br R R W G O W W W B Br B W L Br W B B B W G R G Y W Y Lg R B B W G W L W Y R L Y G Sb B2 L W R W C C B C A A A A...

Page 591: ...nt cowling wire harness 17 ABS test coupler 18 ABS ECU electronic control unit 19 Front wheel sensor 20 Rear wheel sensor 21 ABS motor relay 22 Hydraulic unit 23 Rear brake light switch 24 Brake light relay 27 Tail brake light 30 Coupler 3 wire harness front cowling wire harness 40 ECU engine control unit 50 Coupler 5 wire harness front cowling wire harness 53 Signaling system fuse 55 Ignition fus...

Page 592: ...B Y B R Ch G L R W Br Br B L R R Y R B L W Br R Br B B BLACK R B B R B R R B B B B Br Y BLACK G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G BLACK R B Br L BLACK B B B B GRAY Br Br L GRAY Ch L R B Ch B L R B L R Dg B Dg L R Lg R B L R Br G Br Br L Br L R B Br R Br B B G L Y Y G G B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Lg Sb W Dg L R L R Ch B B Dg Br G L B Ch B ...

Page 593: ...ont cowling wire harness wire harness 30 Coupler 3 front cowling wire harness wire harness 50 Coupler 5 front cowling wire harness wire harness 66 Front brake light switch 67 Engine stop switch 68 Start switch 76 Relay unit 77 Starting circuit cut off relay 82 ABS warning light 83 Multi function meter ...

Page 594: ... O O L L WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS GRAY GRAY L W W L Y Br W B Br B B W G Y L L B O B L O R Br B Br B E B G F A C D R R R Br R Br L W W W GRAY B R BLACK R Br B R W G Y B L BLACK B BLACK L B BLACK B BLACK L R Y G L R Y Y W B B G B B W R R L W R L R W BLUE BLUE B Lg W G L R B R Br R W G L L W R Y R B L R Br B G ...

Page 595: ...nt cowling wire harness 18 ABS test coupler 19 ABS ECU electronic control unit 20 Front wheel sensor 21 Rear wheel sensor 22 ABS motor relay 23 Hydraulic unit 24 Rear brake light switch 25 Diode 2 26 Brake light relay 29 Tail brake light 32 Coupler 3 wire harness front cowling wire harness 42 ECU engine control unit 63 Coupler 5 wire harness front cowling wire harness 66 Signaling system fuse 68 I...

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

Page 597: ...ont cowling wire harness wire harness 32 Coupler 3 front cowling wire harness wire harness 63 Coupler 5 front cowling wire harness wire harness 80 Front brake light switch 81 Engine stop switch 82 Start switch 89 Relay unit 90 Starting circuit cut off relay 95 ABS warning light 96 Multi function meter ...

Page 598: ...U fuse 4 ABS motor fuse 5 ABS motor relay 6 ABS ECU electronic control unit 7 Hydraulic unit HU 8 Rear wheel sensor 9 Rear wheel sensor rotor 10 Rear brake caliper 11 Left front brake caliper 12 Right front brake caliper partially operated together with the rear brake 13 Front wheel sensor 14 Front wheel sensor rotor 15 Proportioning valve 16 Metering valve ...

Page 599: ...ABS ANTI LOCK BRAKE SYSTEM 8 128 ...

Page 600: ... W W G B B R L W Y W P B Y R W G W Y L Sb W Y 6 5 W B Gy W R R W G G W B W R B R B B W R L B W R L W Y B G R Lg Sb W Sb Lg G R B W Y W Br W Y G W L L W B W Br B G Y B L W W L Y G Br W B Br B B W G Y L Y L Y W B Y G W W L Y G L W P B R G B G R B Y Y W Y L L L W Y G W L G W P G R G B B R L Y B R R L R G G Y Sb R B B Y R G R L B R L Y B Y Sb G Y R B R Br R W G L L W R Y R B L R Br B G L R W Br Br B L...

Page 601: ...ABS test coupler 3 ABS motor relay coupler 4 Hydraulic unit solenoid coupler 5 ABS motor coupler 6 Rear wheel sensor coupler 7 ABS ECU coupler 8 Wire harness ABS wire harness coupler 9 Front wheel sensor coupler 10 Wire harness front cowling wire harness coupler ...

Page 602: ...b Parts to remove Q ty Remarks Rear side cover Refer to GENERAL CHASSIS on page 4 1 Storage compartment Refer to GENERAL CHASSIS on page 4 1 1 ABS ECU cover 1 2 ABS ECU coupler 2 Disconnect 3 ABS ECU 1 4 ABS motor relay coupler 1 Disconnect 5 ABS motor relay 1 For installation reverse the removal proce dure 4 5 3 2 2 1 ...

Page 603: ...hoses 1 Check Solenoid valve resistance Out of specification Replace the hydraulic unit NOTE Measure the resistance of the front brake rear brake and unified brake system solenoid valves a Connect the pocket tester Ω 1 to the sole noid valve terminals as shown b Measure the solenoid valve resistance 2 Check Solenoid valve insulation Continuity Replace the hydraulic unit a Connect the pocket tester...

Page 604: ...G EW3P61011 When maintenance or checks have been performed on components related to the ABS be sure to perform a final check before delivering the vehicle to the customer Refer to D 3 FINAL CHECK on page 8 157 ABS operation when the ABS warning light comes on 1 The ABS warning light remains on ABS operates as a normal brake system A malfunction was detected using the ABS self diagnosis function 2 ...

Page 605: ...are should be taken not to damage components by subjecting them to shocks or pulling on them with too much force since the ABS components are precisely adjusted The ABS ECU hydraulic unit wheel sensors and ABS motor relay are united assemblies and cannot be disassembled The malfunction history is stored in the memory of the ABS ECU Delete the malfunction codes when the service is finished This is ...

Page 606: ...d C 5 The ABS warning light flashes every 0 5 second C 1 Only the ABS warn ing light does not come on C 3 The ABS warning light does not come on when pushing the start switch Check the test coupler adapter B 1 The ABS warning light does not come on B 3 The ABS warning light flashes B 2 The ABS warning light remains on B 5 Present malfunction B 4 Past malfunction A Check the ABS warning light C 2 A...

Page 607: ...4 ET3P61061 B 1 THE ABS WARNING LIGHT DOES NOT COME ON 1 Only the ABS warning light fails to come on when the main switch is turned to ON C 1 2 The ABS warning light and all other indicator lights fail to come on C 2 3 The ABS warning light fails to come on while the start switch is being pushed C 3 ET3P61062 B 2 THE ABS WARNING LIGHT REMAINS ON 1 A present malfunction is detected B 5 2 The ABS wa...

Page 608: ...lfunction codes delete the fuel injection system fault codes and then start the check again The test coupler adapter must be connected to the ABS test coupler to display the malfunction codes If the adapter is not connected the ABS warning light will come on or flash but no malfunction codes will be displayed EAS27870 B 5 MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS PRESENT MALFUNCTION Remove front...

Page 609: ...test coupler 2 Lock plate 3 Protective cap 4 Ground terminal black 5 T C terminal sky blue 6 T F terminal light green 7 ABS warning light terminal green red 8 Test coupler adapter 9 Light green lead 10 Black lead 11 White red lead A This example is the pattern for malfunction code 12 B This example is the pattern for malfunction code 21 C Time seconds ...

Page 610: ...ECKING AND CHARGING THE BATTERY on page 8 218 If the battery is defective clean the battery terminals and recharge it or replace the battery 3 Main fuse Check the main fuse for continuity Refer to CHECKING THE FUSES on page 8 217 If the main fuse is blown replace the fuse 4 Wiring Check the entire multi function meter wiring Refer to CIRCUIT DIAGRAM 1 2 FJR13A on page 8 119 CIRCUIT DIAGRAM 2 2 FJR...

Page 611: ...omes on The ABS wire harness front cowling wire harness and the wire harness couplers may be discon nected Refer to ABS COUPLER LOCATION CHART on page 8 129 ET3P61067 C 5 THE ABS WARNING LIGHT FLASHES EVERY 0 5 SECOND The ABS warning light flashes every 0 5 second if a malfunction code for a past malfunction is not stored in the memory of the ABS ECU The ABS warning light flashes quicker if a malf...

Page 612: ...e ABS wire harness front cowling wire harness and wire harness for continuity Refer to CIRCUIT DIAGRAM 1 2 FJR13A on page 8 119 CIRCUIT DIAGRAM 2 2 FJR13A on page 8 121 CIRCUIT DIAGRAM 1 2 FJR13AE on page 8 123 and CIRCUIT DIAGRAM 2 2 FJR13AE on page 8 125 If the anti lock brake system wiring is defective properly connect or replace the ABS ECU couplers ABS wire harness front cowling wire harness ...

Page 613: ...he check points Malfunc tion code Problem Check point Reference 11 Front wheel sensor signal is not re ceived properly Installation of the front wheel sensor Front wheel sensor lead and coupler Wire harness and ABS wire harness front wheel sensor circuit Front wheel sensor rotor Malfunction code 11 See page 8 145 12 Rear wheel sensor signal is not re ceived properly Installation of the rear wheel ...

Page 614: ...Malfunction code 23 See page 8 149 24 Brake light is defective Brake light relay Brake light bulbs Wire harness and ABS wire harness brake light circuit Malfunction code 24 See page 8 149 25 No signal is received from the front wheel sensor when the vehicle starts moving Rear wheel was rotated when the vehicle was on the centerstand Slippage of the rear wheel The vehicle wheelies Installation of t...

Page 615: ...ll not rotate ABS motor fuse Wire harness and ABS wire harness ABS circuit ABS motor coupler ABS motor relay ABS motor circuit Malfunction code 33 See page 8 153 34 ABS motor is defective ABS motor keeps rotating and will not stop ABS motor relay Wire harness and ABS wire harness ABS circuit ABS motor circuit Malfunction code 34 See page 8 154 35 Disconnection is detected in the ABS ECU and hydrau...

Page 616: ...CIRCUIT DIAGRAM 2 2 FJR13AE on page 8 125 ABS ECU coupler terminal is disconnected Refer to MAINTENANCE OF THE ABS ECU on page 8 132 2 The ABS warning light comes on for 2 0 seconds then goes off a With the front wheel stopped the rear wheel was rotated for longer than about 20 seconds This is not a malfunction b No signal is generated at the front wheel sensor Front wheel sensor is not installed ...

Page 617: ...ected Refer to CIRCUIT DIAGRAM 1 2 FJR13A on page 8 119 CIRCUIT DIAGRAM 2 2 FJR13A on page 8 121 CIRCUIT DIAGRAM 1 2 FJR13AE on page 8 123 and CIRCUIT DIAGRAM 2 2 FJR13AE on page 8 125 ABS ECU coupler terminal is disconnected Refer to MAINTENANCE OF THE ABS ECU on page 8 132 2 The ABS warning light comes on for 2 0 seconds then goes off a With the rear wheel stopped the front wheel was rotated at ...

Page 618: ...OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 26 and IN STALLING THE REAR WHEEL REAR BRAKE DISC on page 4 27 Check the rotor and inside the rotor housing for foreign materials Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 20 INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS on page 4 22 MAINTE NANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 26 and IN STALLING...

Page 619: ...solenoid coupler Check if a hydraulic unit solenoid coupler terminal is disconnected Refer to ABS COUPLER LOCATION CHART on page 8 129 2 Hydraulic unit solenoids Check the solenoids front brake rear brake and unified brake system for continuity Refer to MAINTENANCE OF THE HYDRAULIC UNIT on page 8 132 Check the insulation between each solenoid terminal and the negative battery terminal Refer to MAI...

Page 620: ...brake light switch monitor circuits Check the green yellow lead for continuity between 1 and 2 of the front brake light switch monitor circuit Check the brown black lead for continuity between 3 and 4 of the rear brake light switch monitor circuit Malfunction code 24 Brake light is defective 1 Wire harness and ABS wire harness Check the entire anti lock brake system wiring Refer to CIRCUIT DIAGRAM...

Page 621: ... ABS wire harness and wire harness are short circuited Refer to CIRCUIT DIAGRAM 1 2 FJR13A on page 8 119 CIRCUIT DIAGRAM 2 2 FJR13A on page 8 121 CIRCUIT DIAGRAM 1 2 FJR13AE on page 8 123 and CIRCUIT DIAGRAM 2 2 FJR13AE on page 8 125 Malfunction code 41 Front wheel will not recover from the locking tendency even though the signal is continuously transmitted from the ABS ECU to release the hydrauli...

Page 622: ...re reversed on the hydraulic unit the pulsating action in the brake lever and brake pedal will be performed in the reverse order when the final check on page D 3 FINAL CHECK on page 8 157 is performed If the brake hoses to the proportioning valve and the metering valve are switched during assembly the brakes will continue to operate as normal However the reduction of the hydraulic pressure for the...

Page 623: ...the proportioning valve are correct WARNING EW3P61007 The rear brake will not function properly if the connections are reversed Brake hose 1 inlet from the rear brake master cylinder to the hydraulic unit Brake hose 2 outlet from the hydraulic unit to the proportioning valve NOTE If the rear brake hose inlet and outlet connections are reversed on the hydraulic unit the brake pedal will be pressed ...

Page 624: ...onnect the ABS ECU coupler and battery leads Check for continuity between the positive battery terminal and the red white terminal of the ABS ECU coupler Refer to CIRCUIT DIAGRAM 1 2 FJR13A on page 8 119 CIRCUIT DIAGRAM 2 2 FJR13A on page 8 121 CIRCUIT DIAGRAM 1 2 FJR13AE on page 8 123 and CIRCUIT DIAGRAM 2 2 FJR13AE on page 8 125 If there is continuity repair or replace the defective harness 2 AB...

Page 625: ...aulic unit is connected properly Check the ABS motor for continuity Refer to MAINTENANCE OF THE HYDRAULIC UNIT on page 8 132 2 ABS wire harness Disconnect the ABS motor coupler and then check for continuity between the black white terminal of the ABS motor coupler of ABS wire harness and the negative battery terminal Disconnect the ABS ECU couplers and then check for continuity between the red bla...

Page 626: ...2 Battery voltage Measure the battery output voltage EAS22830 D 1 DELETING THE MALFUNCTION CODES 1 Connect the test coupler adapter 1 to the ABS test coupler 2 Refer to B 5 MAL FUNCTION CHECK BY THE ABS SELF DI AGNOSIS PRESENT MALFUNCTION on page 8 137 2 Turn the main switch to ON Previously recorded malfunction codes will be displayed in the multi function display 3 Set the engine stop switch 1 t...

Page 627: ...tion codes af ter the service has been completed ET3P61020 D 2 DELETE FUNCTION TEST 1 Place the vehicle on the centerstand 2 Turn the main switch to OFF 3 Connect the test coupler adapter to the ABS test coupler 4 Turn the main switch to ON 5 Check ABS ECU voltage Lower than 12 8 V Charge or replace the battery a Connect the pocket tester DC 20 V to the ABS ECU couplers b Measure the ABS ECU volta...

Page 628: ...NG THE FRONT WHEEL FRONT BRAKE DISCS on page 4 22 and IN STALLING THE REAR WHEEL REAR BRAKE DISC on page 4 27 3 Perform hydraulic unit operation test 1 or 2 Refer to HYDRAULIC UNIT OPERATION TESTS on page 4 60 4 Delete the malfunction codes Refer to D 1 DELETING THE MALFUNCTION CODES on page 8 155 5 Perform a trial run Refer to TRIAL RUN on page 4 63 Pocket tester 90890 03112 Analog pocket tester ...

Page 629: ...ABS ANTI LOCK BRAKE SYSTEM 8 158 ...

Page 630: ...NESS O G O G B L B L O O L L WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS GRAY GRAY L W W L Y Br W B Br B B W G Y L L B O B L O R Br B Br B E B G F A C D R R R Br R Br L W W W GRAY B R BLACK R Br B R W G Y B L BLACK B BLACK L B BLACK B BLACK L R Y G L R Y Y W B B G B B W R R L W R L R W BLUE BLUE B Lg W G L R B R Br R W G L L W...

Page 631: ...y 8 160 1 Main switch 7 Main fuse 8 Battery 42 ECU engine control unit 63 Coupler 5 wire harness front cowling wire harness 64 Headlight on off grip warmer relay 66 Signaling system fuse 67 Headlight fuse 70 Grip warmer control unit ...

Page 632: ... R B B R R Br R W G L L W R Y R B L R Br B G L Y L B G BLACK B Sb B Lg Br R R Br R G Sb Lg B Sb W Br G L R W Br Br B L R R Y R B L Y Br R Br B B BLACK Dg B R B B R B R R B B B Br Y B BLACK G Y Dg W L R W Ch Br Br G B R B Dg Dg Ch Sb Ch Lg Lg L B L B R W L W Dg R B B Br Br W Ch G Y B B P P Sb W Br G Br W R Y R Y L R Br G BLACK R B Br L BLACK B B B B GRAY Br Br L GRAY G Y B G Y B 63 78 77 79 80 81 8...

Page 633: ...GRIP WARMER SYSTEM FJR13AE only 8 162 63 Coupler 5 front cowling wire harness wire harness 117 Right grip warmer 118 Left grip warmer ...

Page 634: ...ng system and head light Refer to CHECKING THE FUS ES on page 8 217 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 grip warmer relay 4 Check the grip warmers Refer to CHECKING THE GRIP WARMERS FJR13AE only on page 8 235 Replace the grip warmer s 5 Check the entire grip warmer sys tem wiring Refer to CIRCUIT DIAGR...

Page 635: ... light green 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 coupler to the grip warmer control unit coupler black and light green white is faulty and must be repaired 2 Check that the grip warmer adjust ing knob is set to the HI position Adjust the grip wa...

Page 636: ...ESS ABS WIRE HARNESS WIRE HARNESS O G O G B L B L O O L L WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS GRAY GRAY L W W L Y Br W B Br B B W G Y L L B O B L O R Br B Br B E B G F A C D R R R Br R Br L W W W GRAY B R BLACK R Br B R W G Y B L BLACK B BLACK L B BLACK B BLACK L R Y G L R Y Y W B B G B B W R R L W R L R W BLUE BLUE B ...

Page 637: ... wire harness 33 Sidestand switch 42 ECU engine control unit 51 Shift actuator motor 52 Shift actuator sensor 53 Clutch actuator sensor 54 Clutch actuator motor 55 MCU motor control unit 56 YCC S test coupler 57 Coupler 4 wire harness front cowling wire harness 58 Coupler 6 wire harness front cowling wire harness 59 Foot shift switch 60 YCC S speed sensor 61 Gear position sensor 62 YCC S control r...

Page 638: ...Y W B Y G W W L Y G L W P B R G B G R B Y Y W Y L L L W G R Y G W L G W P G B B R B W Ch Dg L G B L B Ch B W L G B L B Dg 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 Br B BLACK L Y R B B R R L R G G Y Sb R L W R B W L R L L W L Y R W L G B R Sb B R Sb W Sb B Lg Br R R Br R G Sb Lg B Sb W Br B L Y G L G L R W Br Br B L R R Y R B L Y Br R Br B B BLACK B Dg L R B Ch L R B...

Page 639: ...ess wire harness 58 Coupler 6 front cowling wire harness wire harness 63 Coupler 5 front cowling wire harness wire harness 80 Front brake light switch 81 Engine stop switch 82 Start switch 89 Relay unit 90 Starting circuit cut off relay 96 Multi function meter 98 Engine trouble warning light 105 Hand shift switch 106 Hand shift lever switch shift up 107 Hand shift lever switch shift down 108 Hand ...

Page 640: ...HECKING THE FUS ES on page 8 217 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 218 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 211 Replace the main switch 4 Check the entire YCC S system wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 165 and CIRCUIT DIA GRAM 2 2 on page 8 1...

Page 641: ...or 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 memory of the MCU motor control unit until it is deleted NOTE If the engine trouble indicator 1 YCC S indicator 2 and engine trouble warning light 3 all come on malfunctions have been detected in b...

Page 642: ...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 operating instructions that enable the system to continue operating or stop operating depending on the conditions Self Diagnostic Function table SHIFT 3 1 2 a b c c d a Main switch OFF b Main switch ON...

Page 643: ...ut 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 signal of gear position sen sor is below 0 3 V or above 4 7 V Unable Unable Sh_ _22 Output signal of foot shift switch is abnor mal Output signal of foot shift switch is below 0 9 V or above 4 1 V Able ...

Page 644: ... 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 Able Sh_ _41 Coolant temperature sensor signal is ab normal Coolant temperature sensor signal is too high or too low Able Able Sh_ _42 Communication be tween ECU and multi function meter is ab normal Er...

Page 645: ...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 Diagnostic Function table 2 Check and repair the probable cause of the malfunction Refer to TROUBLESHOOTING DETAILS on page 8 179 3 Perform the reinstatement action for the YCC system Refer to Reinstate...

Page 646: ...C S test coupler 4 Connect the test coupler adapter 2 to the YCC S test coupler 5 Push and hold the hand shift select button 1 turn the main switch 2 to ON and continue to push the button for 8 seconds or more NOTE All displays on the meter disappear except the odometer tripmeter fuel reserve tripmeter displays Sh_ _61 appears on the odometer tripmeter fuel reserve tripmeter LCD 6 Select the diagn...

Page 647: ...s have been shown the display re peats the same process If fault codes are stored in the malfunction history the hand shift select indicator light will come on Sh_ _62 Malfunction history code erasure No history Sh_ _62 History exists 01 09 First displays Sh_ _62 for 6 seconds and then displays the total number of malfunctions including the cur rent malfunction that have oc curred since the histor...

Page 648: ...Sh_ _15 Sh_ 16 Sh_ _18 Sh_ _19 Sh_ _25 Sh_ _37 and Sh_ _51 Sh_ _64 The shift actuator can be operated in this mode 1 Make sure that the transmission is in neutral 2 Set the engine stop switch to and operate the hand shift lever switch shift up simultaneously The MCU motor control unit operates the shift actuator once The shift actuator is operated once each time two switches are operated 3 The MCU...

Page 649: ... 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 4th gear 7 Push the start switch If the gear position sensor output signal is correct for the 4th gear position the hand shift select indicator light will come on for 0 5 second 8 Repeat steps 6 and 7 ...

Page 650: ...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 gagement point varies according to the ve hicle Hand shift lever switch operation shift up To increase the clutch engagement point by approximately 100 150 r min oper ate the hand shift lever switch shift up...

Page 651: ... Refer to CHECKING AND CHARGING THE BATTERY on page 8 218 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 Repair or replace if there is an open or short circuit Between battery and main switch coupler red red Between main switch coupler and signaling system fuse brown blue brown blue Between signaling system f...

Page 652: ...d probable 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 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 OFF See NOTE 2 Open or short circuit in wire harness Re...

Page 653: ...onents 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 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 OFF See NOTE 2 Open or short circuit in wire ha...

Page 654: ...ler Shift actuator motor 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 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 clutch actuator motor coupler and MCU motor con trol unit...

Page 655: ...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 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 switch to ...

Page 656: ...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 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 OFF See NOTE 2 Open or short circuit in wire harness Repair ...

Page 657: ...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 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 OFF See NOTE 2 Open or short circuit in wire harness...

Page 658: ...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 actuator sensor 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 t...

Page 659: ... 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 or short circuit Between gear position sensor coupler and MCU motor con trol unit coupler yellow yellow blue blue black blue black blue 3 Defective gear position sensor Adjust or replace if defective ...

Page 660: ...range black blue blue black blue black blue 3 Defective foot shift switch Adjust or replace if defective Refer to ADJUSTING THE FOOT SHIFT SWITCH on page 5 70 and CHECKING THE FOOT SHIFT SWITCH FJR13AE only on page 8 235 Fault code No Sh_ _23 Symptom No input signal from sidestand switch Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harne...

Page 661: ...r 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 control unit Replacing the MCU motor control unit Fault code No Sh_ _26 Symptom Abnormal clutch movement is detected during check when main switch is turned to ON Order Item components and probable cause...

Page 662: ...coupler adapter is not connected Refer to DIAGNOSTIC MODE on page 8 175 Turning the main switch to OFF See NOTE 2 Short circuit in wire harness Repair or replace if there is a short circuit Between YCC S test coupler and MCU motor control unit coupler blue yellow blue yellow Fault code No Sh_ _31 Symptom Engine speed signal is abnormal Order Item components and probable cause Check or maintenance ...

Page 663: ...r 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 coupler and MCU motor con trol unit coupler white yellow white yellow blue blue black blue black blue 3 Defective YCC S speed sensor Replace if detective Refer to CHECKING THE YCC S SPEED SENSOR FJR1...

Page 664: ...hite blue white 3 Defective relay unit Check and replace relay unit Refer to CHECKING THE RE LAYS on page 8 221 4 Defective start switch Check and replace right handle bar switch Refer to CHECKING THE SWITCHES on page 8 211 Fault code No Sh_ _36 Symptom Output signal of clutch actuator sensor is ab normal Order Item components and probable cause Check or maintenance job Reinstatement method 1 Conn...

Page 665: ... 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 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 switch to OFF See NOTE 2 Open or ...

Page 666: ...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 hand shift switch Refer to CHECKING THE SWITCHES on page 8 211 Fault code No Sh_ _39 Symptom Ignition timing retard output signal is abnormal Order Item components and probable cause Check or maintenance job Reinstat...

Page 667: ...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 abnormal Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler YCC S speed sensor coupler Check the coupler fo...

Page 668: ...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 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 short circuit Between ABS ECU cou...

Page 669: ... 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 probable cause Check or maintenance job Reinstatement method 1 Shift rod Check the shift rod pin hole lo cation Check the shift rod groove loca tion Adjust or replace if defective Refer to CHECKING THE...

Page 670: ...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 or short circuit Between battery and main switch coupler red red Between main switch coupler and signaling system fuse brown blue brown blue Between signaling system fuse and brake light relay couple...

Page 671: ... clutch stroke Refer to BLEEDING THE HY DRAULIC CLUTCH SYSTEM FJR13AE on page 3 19 Turning the main switch to OFF See NOTE 2 Clutch slippage Check the friction plate thick ness and replace the friction plates if necessary Refer to CHECKING THE FRICTION PLATES on page 5 56 Fault code No Sh_ _51 Symptom Shift actuator sensor signal is abnormal Order Item components and probable cause Check or mainte...

Page 672: ...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 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 switch to OFF See NOTE...

Page 673: ...YCC S Yamaha Chip Controlled Shift SYSTEM FJR13AE only 8 202 ...

Page 674: ...ELECTRICAL COMPONENTS 8 203 EAS27970 ELECTRICAL COMPONENTS FJR13A 1 18 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 ...

Page 675: ...tor 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 Rear brake light switch 15 Left horn low 16 Right horn high 17 Ignition coil 18 Main fuse ...

Page 676: ...ELECTRICAL COMPONENTS 8 205 FJR13A 1 17 16 18 19 3 2 4 5 6 7 8 9 10 11 12 13 14 15 ...

Page 677: ...nsor 5 ABS motor relay 6 Hydraulic unit 7 ECU engine control unit 8 ABS ECU 9 Cylinder identification sensor 10 O2 sensor 11 Crankshaft position sensor 12 Accessory box solenoid 13 Headlight relay dimmer 14 Radiator fan motor relay 15 Headlight relay on off 16 Brake light relay 17 Turn signal hazard relay 18 Relay unit 19 Lean angle sensor ...

Page 678: ...ELECTRICAL COMPONENTS 8 207 FJR13AE 1 2 3 4 5 6 7 8 9 10 11 12 13 15 14 16 18 19 20 17 ...

Page 679: ...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 brake light switch 15 Left horn low 16 Right horn high 17 Ignition coil 18 Main fuse 19 Diode 1 20 Diode 2 ...

Page 680: ...ELECTRICAL COMPONENTS 8 209 FJR13AE 1 19 18 17 20 21 3 2 4 5 6 8 7 9 10 11 12 13 14 15 16 ...

Page 681: ...ulic unit 7 MCU motor control unit 8 ECU engine control unit 9 ABS ECU 10 Cylinder identification sensor 11 O2 sensor 12 Crankshaft position sensor 13 Accessory box solenoid 14 Headlight relay dimmer 15 Radiator fan motor relay 16 Headlight on off grip warmer relay 17 Brake light relay 18 YCC S control relay 19 Turn signal hazard relay 20 Relay unit 21 Lean angle sensor ...

Page 682: ...JR13A 1 R Br ON OFF Br L B L Y R 2 BROWN B B 3 P B Lg Sb Br W L B Ch Dg B Y R Y L Y Lg B Sb UP DOWN 12 DgBr W Ch 13 B P 10 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 R B 9 Ch Dg Br W 7 B Y L Y BLACK 6 BLUE B B 5 L B Ch B R Dg B G 4 G Y Br RED L B L Y ...

Page 683: ...ight switch 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 Windshield position switch 13 Turn signal switch ...

Page 684: ...W Ch 15 B P 12 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 Shift down G R G B B L 11 10 Shift up O W O B B L Br L B L 9 PUSH B R B G R B L G B O W Br L O B Dg Sb Ch Lg L B B P Br W R Y R Br ON OFF Br L B L Y R 2 RED L B L Y ...

Page 685: ...ight switch 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 switch 13 Dimmer switch 14 Windshield position switch 15 Turn signal switch ...

Page 686: ... range 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 switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch posit...

Page 687: ...ition of the bulbs The following procedure applies to all of the bulbs 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 socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching t...

Page 688: ...nel 1 Refer to GENERAL CHASSIS on page 4 1 2 Check Fuse a Connect the pocket tester to the fuse and check the continuity NOTE Set the pocket tester selector to Ω 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 to verify if the electrical circuit is operational d If the f...

Page 689: ...ediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion CAUTION EC3P61004 This is a sealed battery Never remove the sealing caps because the balance between cells will not be maintained and battery per formance will deteriorate Charging time charging amperage and charging voltage for an M...

Page 690: ...attery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded bat tery 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...

Page 691: ...han 30 minutes Charging method using a constant volt age charger a Measure the open circuit voltage prior to charging NOTE Voltage should be measured 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 tery NOTE If the current is lower than the standard...

Page 692: ...fication Replace Starter relay Relay unit starting circuit cut off relay Relay unit fuel pump relay Recommended lubricant Dielectric grease Pocket tester 90890 03112 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 R B L W R W R L 1 2 4 3 1 Positive battery terminal 2 Negative b...

Page 693: ...r probe 2 Negative tester probe 3 Negative tester probe Result Continuity between 1 and 2 No continuity between 1 and 3 R Y G L R Y Y W 1 2 3 4 G L Y L B B 1 3 2 G 1 Positive battery terminal 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 1 Positive tester probe 2 Negative tester pr...

Page 694: ...tinuity between 3 and 4 1 Positive tester probe 2 Negative tester probe Result No continuity between 1 and 2 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Y G G Y Br 1 2 4 3 Br B G L W L Y Y G 1 2 1 2 3 4 G L W L Y Y G Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negativ...

Page 695: ... relay input voltage 2 Check Turn signal hazard relay output voltage Out of specification Replace a Connect the pocket tester DC 20 V to the turn signal hazard relay terminal as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Turn signal hazard relay input voltage DC 12 V L R W R...

Page 696: ...er YU 03112 C Continuity Positive tester probe sky blue 1 Negative tester probe black yellow 2 No continuity Positive tester probe black yellow 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe black red 3 No continuity Positive tester probe black red 3 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester pr...

Page 697: ...nect the ignition coil connectors from the ignition coil terminals b Connect the pocket tester Ω 1 to the igni tion coil as shown c Measure the primary coil resistance 2 Check Secondary coil resistance Out of specification Replace a Disconnect the spark plug cap from the igni tion coil b Connect the pocket tester Ω 1k to the ig nition coil as shown Resistance 10 0 kΩ Pocket tester 90890 03112 Anal...

Page 698: ...or coupler from the wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace the crank shaft position sensor a Connect the pocket tester Ω 100 to the crankshaft position sensor coupler as shown b Measure the crankshaft position sensor re sistance EAS28130 CHECKING THE LEAN ANGLE SENSOR 1 Remove Lean angle sensor 2 Check Lean angle sensor output voltage Out of specifi...

Page 699: ... 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 starter motor operation EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the stator coil a Connect the pocket tester Ω 1 to the stator coil coupler as shown Pocke...

Page 700: ...ck Horn resistance Out of specification Replace a Disconnect the horn connectors from the horn terminals b Connect the pocket tester Ω 1 to the horn terminals c Measure the horn resistance 2 Check Horn sound Faulty sound Adjust or replace a Connect a battery 12 V to the horn b Turn the adjusting screw in direction a or b until the horn sound is obtained Charging voltage 14 V at 5000 r min Pocket t...

Page 701: ...ance Out of specification Replace the fuel pump assembly a Connect the pocket tester Ω 10 to the fuel sender terminals as shown Oil level switch resistance Minimum level position No continuity Maximum level position Continuity Pocket tester 90890 03112 Analog pocket tester YU 03112 C Minimum level position A Positive tester probe white 1 Negative tester probe body ground 2 Maximum level position B...

Page 702: ...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 tester Ω 100 to the coolant temperature sensor terminals as shown b Immerse the coolant temperature sensor 1 in a container filled with coolant 2 NOTE Make sure that the coolant temperature sensor termi...

Page 703: ...Disconnect the air induction system solenoid coupler from the wire harness b Connect the pocket tester Ω 1 to the air in duction system solenoid terminals as shown c Measure the air induction system solenoid re sistance EAS28390 CHECKING THE CYLINDER IDENTIFICATION SENSOR 1 Remove Timing plate cover 2 Check Cylinder identification sensor output voltage Out of specification Replace T R Coolant temp...

Page 704: ...ve 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 If the intake air temperature sensor is dropped replace it 2 Check Intake air temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 100 to the in take air temperature...

Page 705: ...nce ET3P66020 CHECKING THE YCC S SPEED SENSOR FJR13AE only 1 Check YCC S speed sensor output voltage Out of specification Replace a Connect the pocket tester DC 20 V to the YCC S speed sensor coupler wire harness side as shown b Turn the main switch to ON c Elevate the 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...

Page 706: ...TCH FJR13AE only 1 Remove Foot shift switch 2 Check Foot shift switch maximum resistance Out of specification Replace the foot shift switch a Connect the pocket tester Ω 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 69 ET3P66023 CHECKING THE GRIP WARMERS FJR13AE only...

Page 707: ...l unit resis tance ET3P66025 CHECKING THE DIODE 2 FJR13AE only 1 Check Diode 2 Out of specification Replace NOTE The pocket tester and the analog pocket tester readings are shown in the following table Grip warmer resistance FJR13AE 1 21 1 48 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe black 1 Negative tester probe black 2 Grip warmer control unit...

Page 708: ...L COMPONENTS 8 237 a Remove the diode 2 from the wire harness b Connect the pocket tester Ω 1 to the diode 2 terminals as shown c Check the diode 2 for continuity d Check the diode 2 for no continuity Y Y G 1 2 ...

Page 709: ...DLING 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 PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 ...

Page 710: ...fuel 2 Fuel pump Faulty fuel pump Faulty fuel pump 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 fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Faul...

Page 711: ...S28530 FAULTY GEAR SHIFTING 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 drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JU...

Page 712: ...lug s Incorrect spark 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 brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper kit Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil...

Page 713: ...ht 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 brake light bulb Too many electrical accessories Incorrect connection Burnt out tail brake light bulb Tail brake light bulb burnt out Wrong tail brake light bulb Faulty battery Incorrectly adjusted r...

Page 714: ... radiator fan motor 61 Right radiator fan motor fuse 62 Right radiator fan motor 63 Turn signal hazard relay 64 Auxiliary DC jack 65 Right handlebar switch 66 Front brake light switch 67 Engine stop switch 68 Start switch 69 Hazard switch 70 Left handlebar switch 71 Clutch switch 72 Dimmer switch 73 Windshield position switch 74 Turn signal switch 75 Horn switch 76 Relay unit 77 Starting circuit c...

Page 715: ... Auxiliary DC jack fuse 70 Grip warmer control unit 71 Radiator fan motor relay 72 Left radiator fan motor fuse 73 Left radiator fan motor 74 Right radiator fan motor fuse 75 Right radiator fan motor 76 YCC S motor control fuse 77 Auxiliary DC jack 78 Turn signal hazard relay 79 Right handlebar switch 80 Front brake light switch 81 Engine stop switch 82 Start switch 83 Hazard switch 84 Left handle...

Page 716: ...Sb W Sky blue White W B White Black W G White Green W L White Blue W Y White Yellow Y B Yellow Black Y G Yellow Green Y L Yellow Blue Y R Yellow Red Y W Yellow White ...

Page 717: ......

Page 718: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 719: ...R L B B W W W W GRAY B R BLACK R R L W R L R W Sb B Y B R Y W L W P W Y B G R Lg Sb W Sb Lg G R B W Y W Ch B G B R Dg B L G W B R L B DARK GREEN L Y B R R L R G G Y Sb R B B Y Br W Y G W L L W B W Br B G Y B R G R L B R L Y B Y Sb G Y R B B G R Lg Sb Br R R W G O W W W B Br B W L Br W B B B W G R G Y W Y Lg R B B W G W L W Y R L Y G Sb B2 L W R W C C B C A A A A A A A C C C C C A A A A A D B B B A...

Page 720: ... Y R B L W Br R Br B B BLACK R B B R B R R B B B B Br Y BLACK G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G BLACK R B Br L BLACK B B B B GRAY Br Br L GRAY Ch L R B Ch B L R B L R Dg B Dg L R Lg R B L R Br G Br Br L Br L R B Br R Br B B G L Y Y G G B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Lg Sb W Dg L R L R Ch B B Dg Br G L B Ch B Dg Br G Ch W L B Y L W L W R B R...

Page 721: ...RAY GRAY GRAY BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK WIRE HARNESS B WIRE HARNESS C WIRE HARNESS D WIRE HARNESS B BLACK GRAY GRAY BLACK GRAY GRAY BROWN BROWN ABS WIRE HARNESS ABS WIRE HARNESS ABS WIRE HARNESS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 27 28 29 30 31 32 33 33 33 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 ...

Page 722: ...AGRAM 2 2 BLACK BLACK UP DOWN BLACK BLACK BLACK BLACK BLACK GRAY GRAY GRAY GRAY GRAY GRAY 48 30 13 16 50 63 64 65 66 67 69 70 71 72 73 74 75 76 68 78 79 80 81 82 83 84 85 77 87 88 89 90 91 92 92 93 94 97 97 96 95 86 98 99 100 ...

Page 723: ...ESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS GRAY GRAY L W W L Y Br W B Br B B W G Y L L B O B L O R Br B Br B E B G F A C D R R R Br R Br L W W W GRAY B R BLACK R Br B R W G Y B L BLACK B BLACK L B BLACK B BLACK L R Y G L R Y Y W B B G B B W R R L W R L R W BLUE BLUE B Lg W G L R B R Br R W G L L W R Y R B L R Br B G L R W Br Br B L R ...

Page 724: ...Y W Y L L L W G R Y G W L G W P G B B R B W Ch Dg L G B L B Ch B W L G B L B Dg 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 Br B BLACK L Y R B B R R L R G G Y Sb R L W R B W L R L L W L Y R W L G B R Sb B R Sb W Sb B Lg Br R R Br R G Sb Lg B Sb W Br B L Y G L G L R W Br Br B L R R Y R B L Y Br R Br B B BLACK B Dg L R B Ch L R B Dg L R B Ch L R R B B R B R R B B B Br Y ...

Page 725: ...S WIRE HARNESS GRAY GRAY E B G F A C D GRAY BLACK BLACK BLACK BLACK BLACK BLUE BLUE GRAY GRAY DARK GREEN GRAY GRAY GRAY GRAY BLACK BLACK BLACK BLACK BLACK BLACK BROWN BLACK BLACK BLACK BLACK BLACK BLACK GREEN BROWN BLUE BLUE RED RED GRAY GRAY GRAY GRAY GRAY BLACK BLACK BLACK BLACK 1 2 3 4 5 6 7 64 62 65 66 67 68 69 71 72 73 75 74 8 9 10 11 12 70 63 15 14 16 17 18 60 55 59 58 44 45 49 24 26 25 37 3...

Page 726: ...GRAY GRAY BLACK BLACK BLACK BLACK BLACK GRAY GRAY Shift down Shift up PUSH UP DOWN 57 32 13 16 63 78 77 79 80 81 83 84 85 86 87 88 89 82 91 92 93 94 95 96 97 98 90 100 101 102 58 104 103 110 110 111 112 115 99 114 114 113 117 118 116 106 107 108 109 105 ...

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