CLUTCH
5-61
1. Check:
• Clutch master cylinder body
Cracks/damage
→
Replace the clutch mas-
ter cylinder.
• Clutch fluid delivery passage
(clutch master cylinder body)
Obstruction
→
Blow out with compressed air.
2. Check:
• Clutch master cylinder
• Clutch master cylinder kit
Rust/scratches/wear
→
Replace the clutch
master cylinder and clutch master cylinder kit
as a set.
3. Check:
• Clutch master cylinder reservoir
Cracks/damage
→
Replace.
• Clutch master cylinder reservoir diaphragm
Damage/wear
→
Replace.
4. Check:
• Clutch hose
Cracks/damage/wear
→
Replace.
EAS25300
ASSEMBLING THE CLUTCH MASTER
CYLINDER
WARNING
EW3P61015
• Before installation, all internal clutch com-
ponents must be cleaned and lubricated
with clean or new clutch fluid.
• Never use solvents on internal clutch com-
ponents.
EAS25310
INSTALLING THE CLUTCH MASTER
CYLINDER (FJR13A)
1. Install:
• Clutch master cylinder “1”
• Clutch master cylinder holder “2”
WARNING
EW3P61016
• Install the clutch lever holder with the “UP”
mark facing up.
• Align the end of the clutch lever holder with
the 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 “CABLE
ROUTING (FJR13A)” on page 2-47.
CAUTION:
EC3P61034
When installing the clutch hose onto the
clutch master cylinder, make sure the clutch
pipe touches the projection “a” as shown.
NOTE:
Turn the handlebars to the left and to the right to
make sure the clutch hose does not touch other
parts (e.g., wire harness, cables, leads). Correct
if necessary.
3. Fill:
• Clutch master cylinder reservoir
(with the specified amount of the recom-
mended clutch fluid)
Clutch fluid
Every two years and
whenever the clutch
is disassembled
Recommended fluid
DOT 4
Recommended clutch component replace-
ment schedule
T
R
.
.
Clutch hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
Recommended fluid
DOT 4
New
Summary of Contents for FJR13AEV(C)
Page 1: ...SERVICE MANUAL FJR13AV C FJR13AEV C LIT 11616 19 83 3P6 28197 10 ...
Page 6: ......
Page 8: ......
Page 79: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 30 ...
Page 82: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 EAS20410 LUBRICATION DIAGRAMS 5 6 7 1 2 3 4 ...
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 88: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39 1 2 3 4 5 6 7 8 9 ...
Page 90: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 41 4 5 3 2 1 9 8 6 7 ...
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 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 102: ...CABLE ROUTING FJR13A 2 53 A B C D 1 2 3 4 6 5 7 8 9 10 11 12 ...
Page 110: ...CABLE ROUTING FJR13A 2 61 D A B B C E 1 2 3 4 ...
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 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 130: ...CABLE ROUTING FJR13AE 2 81 D B C A E E F I 3 4 5 2 1 6 H G ...
Page 136: ...CABLE ROUTING FJR13AE 2 87 ...
Page 139: ......
Page 198: ...GENERAL CHASSIS 4 11 b a 1 2 ...
Page 298: ...SHAFT DRIVE 4 111 ...
Page 321: ...CAMSHAFTS 5 20 ...
Page 434: ...BALANCERS 5 133 ...
Page 450: ...WATER PUMP 6 15 ...
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 471: ......
Page 483: ...IGNITION SYSTEM 8 12 ...
Page 499: ...ELECTRIC STARTING SYSTEM 8 28 ...
Page 501: ...CHARGING SYSTEM 8 30 2 Rectifier regulator 3 AC magneto 7 Main fuse 8 Battery ...
Page 503: ...CHARGING SYSTEM 8 32 ...
Page 527: ...COOLING SYSTEM 8 56 ...
Page 571: ...FUEL INJECTION SYSTEM 8 100 ...
Page 577: ...FUEL PUMP SYSTEM 8 106 ...
Page 583: ...WINDSHIELD DRIVE SYSTEM 8 112 ...
Page 589: ...ACCESSORY BOX SYSTEM 8 118 ...
Page 599: ...ABS ANTI LOCK BRAKE SYSTEM 8 128 ...
Page 629: ...ABS ANTI LOCK BRAKE SYSTEM 8 158 ...
Page 673: ...YCC S Yamaha Chip Controlled Shift SYSTEM FJR13AE only 8 202 ...
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 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 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 717: ......
Page 718: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...