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Yamaha FJR13AG, Service Manual

The Yamaha FJR13AG service manual is a comprehensive resource for owners of this powerful motorcycle. This detailed manual provides step-by-step instructions and diagrams for all maintenance and repair tasks. Download this manual for free from manualshive.com to ensure that you have all the information you need to keep your Yamaha FJR13AG running smoothly.

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EAS20005

SYMBOLS

The following symbols are used in this manual for easier understanding.

TIP

The following symbols are not relevant to every vehicle.

SYMBOL

DEFINITION

SYMBOL

DEFINITION

Serviceable with engine mounted

Gear oil

Filling fluid

Molybdenum disulfide oil

Lubricant

Brake fluid

Special tool

Wheel bearing grease

Tightening torque

Lithium-soap-based grease

Wear limit, clearance

Molybdenum disulfide grease

Engine speed

Silicone grease

Electrical data

Apply locking agent (LOCTITE®).

Engine oil

Replace the part with a new one.

G

M

BF

B

T

 

R

.

.

LS

M

S

LT

E

New

Summary of Contents for FJR13AG

Page 1: ...2016 SERVICE MANUAL FJR13AG FJR13ESG B88 28197 70 E0 ...

Page 2: ...AG FJR13ESG SERVICE MANUAL 2016 by Yamaha Motor Co Ltd First edition January 2016 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 3: ...th 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 TIP This Service Manual contains...

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: ...ITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent LOCTITE Engine oil Replace the part with a new one G M BF B T R LS M S LT E New ...

Page 6: ......

Page 7: ...EAS10003 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: ...ED BRAKE SYSTEM 1 11 OUTLINE OF THE TCS Traction Control System 1 12 MULTI FUNCTION METER UNIT 1 16 IMPORTANT INFORMATION 1 27 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 27 REPLACEMENT PARTS 1 27 GASKETS OIL SEALS AND O RINGS 1 27 LOCK WASHERS PLATES AND COTTER PINS 1 27 BEARINGS AND OIL SEALS 1 28 CIRCLIPS 1 28 RUBBER PARTS 1 28 BASIC SERVICE INFORMATION 1 29 QUICK FASTENERS 1 29 ELECTRICAL SYSTEM...

Page 10: ...S30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS30003 MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts 1 ...

Page 11: ...ble for the system to respond extremely quickly to the slightest adjustments made by the rider In par ticular optimized control of the throttle valve opening provides the optimum volume of intake air for easy to use torque even in a high revving engine Aims and advantages of using YCC T Increased engine power By shortening the air intake path higher engine speed is possible Increased engine power ...

Page 12: ... valve opening and operates the throttle servo motor to control the throttle valves Because the system allows the rider to maintain a set cruising speed without operating the throttle the system reduces the burden of maintaining a constant speed during long distance touring In addition the cruise control system is equipped with a self diagnosis function 5 6 7 8 9 3 2 1 4 1 Throttle position sensor...

Page 13: ...tally activating the cruise control system turn it off when not in use Make sure that the cruise control system indicator light is off GEAR N 25 A TEMP C Lo C TEMP C 0 06 TIME TRIP 16 15 14 13 10 11 12 9 8 7 6 5 4 3 2 1 1 Battery 2 Main switch 3 Meter assembly 4 ECU Engine Control Unit 5 Clutch switch 6 Cruise control setting switch 7 Cruise control power switch 8 Front brake light switch 9 Start ...

Page 14: ...he RES or SET side of the cruise control setting switch down will increase or de crease the speed continuously until the switch is released The traveling speed can also be increased manually using the throttle While the speed is being in creased manually or after the traveling speed has increased 4 km h or higher than the set cruising speed a new cruising speed can be set by pushing the SET side o...

Page 15: ... on If the SET side of the cruise control setting switch is pushed during the resume operation the current traveling speed will be set as the new cruising speed WARNING EWA17460 It is dangerous to use the resume function when the previously set cruising speed is too high for current conditions TIP Pushing the power switch while the system is operating will turn the system off completely and erase ...

Page 16: ... light flashes Traction control system is turned off and wheel slip or wheel spin is detected The changes in the vehicle speed signals exceed a preset value The start engine stop switch is set to the position The engine stalls The sidestand is extended SET SET SET SET RES SET RES SET A C D E F B a b d c e b f g b j h i A Operation B Indication C Speed D 160 km h 100 mph E 50 km h 31 mph or 55 km h...

Page 17: ...ng switch cannot be used to adjust the set cruising speed To reduce the traveling speed apply the brakes When the brakes are applied the cruise control system will become deactivated If the cruise control system turns off automatically while the cruising speed is not set the cruise control setting indicator light SET will not flash Automatic deactivation condi tion Vehicle condition for de tection...

Page 18: ...rol system is malfunctioning C D B A d c b a a A Cruise control system is activated cruising speed is set B Cruise control system is turned off cruise control system indicator light flashes C Cruise control system is turned off D Cruise control system is turned on cruising speed is not set a Condition for automatically deactivating cruise control system is detected b 4 seconds elapse during this t...

Page 19: ...se control system operation C E B A e d d a D D c c b b F G A Cruise control system is activated cruising speed is set B Cruise control system is turned off engine trouble warning light comes on cruise control system is deactivated and cruise control system indicator light flashes C Cruise control system is turned off engine trouble warning light goes off cruise control system is deactivated and c...

Page 20: ...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 The operat...

Page 21: ...Because the balance 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 EAS30855 OUTLINE OF THE TCS Traction Control System The traction control system controls excessive spinning slipping of the rear wheel when...

Page 22: ...et value the ECU controls the ignition timing fuel cut off and throttle valve opening of the YCC T system so that the amount of slip is less than the preset value The traction control system indicator warning light in the multi function meter center display flashes when the traction control system has activated 1 4 6 7 8 9 10 3 2 5 1 ECU Engine Control Unit 2 TCS button 3 Traction control system i...

Page 23: ...e braking and cannot prevent front wheel slip ping As with any motorcycle approach surfaces that may be slippery with caution and avoid especially slippery surfaces When the main switch is turned to ON the traction control system automatically turns on The traction control system can be turned on or off manually only when the main switch is in the ON position and the motorcycle is stopped To turn ...

Page 24: ...e traction control system indicator warning light will go off Resetting The traction control system will be disabled in the following condition The rear wheel is rotated with the centerstand down and the main switch in the ON position Either the front wheel or rear wheel comes off the ground while riding Excessive rear wheel spinning If the traction control system has been disabled both the tracti...

Page 25: ...e attempt ing to use select switch menu switch MENU RESET button or TCS button To switch the meter displays between kilome ters and miles Speedometer The speedometer shows the vehicle s traveling speed Tachometer The electric tachometer allows the rider to mon itor the engine speed and keep it within the ideal power range When the key is turned to ON the tachometer needle sweeps across the r min r...

Page 26: ...riendly fuel efficient manner The indicator goes off when the vehicle is stopped TIP Consider the following tips to reduce fuel con sumption Avoid high engine speeds during acceleration Travel at a constant speed Select the transmission gear that is appropri ate for the vehicle speed Transmission gear display This display shows the selected gear The neu tral position is indicated by and by the neu...

Page 27: ... To increase the grip warmer temperature push the side of the select switch To de crease the grip warmer temperature push the side of the select switch NOTICE ECA20750 Be sure to wear gloves when using the grip warmers If the ambient temperature is 20 C 68 F or higher do not set the grip warmer to the high setting If the handlebar grip or throttle grip be comes worn or damaged stop using the grip ...

Page 28: ...in the fuel tank the last segment of the fuel meter starts flashing In ad dition the information display will automatically change to the fuel reserve tripmeter mode TRIP F and start counting the distance trav eled from that point In this case push the select switch to switch the display in the following order TRIP F Display 1 Display 2 Display 3 TRIP F To reset a tripmeter use the select switch t...

Page 29: ...accuracy of the temperature reading may be affected when riding under 20 km h 12 mi h or when stopped at traffic signals and rail road crossings Coolant temperature display The coolant temperature display indicates the temperature of the coolant The coolant tem perature varies with changes in the weather and engine load If the message Hi flashes stop the vehicle then stop the engine and let the en...

Page 30: ... km The MPG display shows the distance that can be traveled on 1 0 Imp gal of fuel TIP If traveling at speeds under 10 km h 6 mi h _ _ _ will be displayed Adjusting the windshield position 1 To move the windshield up push the side of the select switch To move the wind shield down push the side of the select switch Setting mode TIP The transmission must be in neutral and the vehicle must be stopped...

Page 31: ...unting but are not reset The maxi mum time that can be shown is 99 59 When the time trips reach 99 59 they au tomatically reset to 0 00 and continue counting Unit This function allows you to switch the dis play units between ki lometers and miles When kilometers are selected the fuel consumption units can be switched be tween L 100km and km L Display This function allows you to change the items sh...

Page 32: ...ds 4 Push the MENU switch to return to the set ting mode menu Checking and resetting TIME 2 and TIME 3 1 Use the select switch to highlight Time Trip 2 Push the MENU switch to display TIME 2 and TIME 3 To reset a time trip push the RESET button to select the item to reset 3 While the selected item is flashing push the RESET button for at least 2 seconds 4 Push the MENU switch to return to the set ...

Page 33: ...again 7 Use the select switch to highlight and then push the MENU switch to return to the setting mode menu Selecting the display items 1 Use the select switch to highlight Display 2 Push the MENU switch use the select switch to highlight the display to change and then push the MENU switch again 3 Use the select switch to highlight the item to change and then push the MENU switch 4 Use the select ...

Page 34: ...ng mode menu Setting the clock 1 Use the select switch to highlight Clock 2 Push the MENU switch 3 When the hour digits start flashing use the select switch to set the hours 4 Push the MENU switch and the minute dig its start flashing 5 Use the select switch to set the minutes 6 Push the MENU switch to return to the set ting mode menu Resetting all of the display items 1 Use the select switch to h...

Page 35: ...ity from the low speed range to the high speed range Sports mode S This mode offers a sportier engine response in the low to mid speed range compared to the touring mode Drive mode switch MODE WARNING EWA17660 Do not change the D mode while the vehicle is moving Using this switch changes the drive mode to touring mode T or sports mode S The throttle grip must be completely closed in or der to chan...

Page 36: ... correct installation of all parts 5 Keep all parts away from any source of fire EAS30007 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 EAS30008 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals ...

Page 37: ...ed air because this will damage the bearing surfac es EAS30011 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 opposite the thrust 3 that the circlip receives EAS30012 RUBBER PARTS Check rubber parts for deterioration during i...

Page 38: ...stener push its pin so that it protrudes from the fastener head then insert the fastener into the part to be secured and push the pin in with a screwdriver Make sure that the pin is flush with the fastener s head Screw type 1 Remove Quick fastener TIP To remove the quick fastener loosen the screw with a screwdriver then pull the fastener out 2 Install Quick fastener TIP To install the quick fasten...

Page 39: ...f a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect the battery leads to the correct battery terminals Reversing the bat tery lead connections could damage the electrical components NOTICE ECA16771 When connecting the battery leads to the battery be sure to connect the positive bat tery lead first then ...

Page 40: ... ECA23620 Do not perform angle adjustment of the IMU and rear fender by pinching the washer and related parts When installing the IMU apply a thin coat of silicone grease onto the washer where con tacting the IMU grommet When installing the IMU use only a genuine bolt and washer and tighten the bolt to the specified torque Pay attention not to expose the IMU to strong shocks such as striking or dr...

Page 41: ...arness or a suitable commercially available test har ness Checking the connections Check the leads couplers and connectors for stains rust moisture etc 1 Disconnect Lead Coupler Connector NOTICE ECA16780 When disconnecting a coupler release the coupler lock hold both sections of the cou pler securely and then disconnect the cou pler There are many types of coupler locks therefore be sure to check ...

Page 42: ...cking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at most part stores 5 Check Resistance TIP The resistance values shown were obtained at the standard measuring temperature of 20 C 68 F If the measuring temperature is not 20 C 68 F the specified measuring conditions will be shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Pocket tester...

Page 43: ...o the list provided below to avoid any mistakes TIP 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 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 33 1 33 8 219 8 219 8 219 8 249 8 250 8 254 8 256 8 257 8 258 8 258 8 259 8 260 8 261 8 261 8 263 8 263 8 264 8 265 8 266 8 266 Va...

Page 44: ...flange nut wrench YU A9472 3 18 4 116 Oil filter wrench 90890 01426 Oil filter wrench YU 38411 3 26 Oil pressure gauge set 90890 03120 3 27 Oil pressure adapter B 90890 03124 3 27 Hexagon wrench 41 90890 01525 Hexagon wrench 41 YM 01525 4 41 4 43 Test coupler adapter 90890 03149 4 83 4 85 Tool name Tool No Illustration Reference pages YU 44456 41 41 ...

Page 45: ... 4 101 4 110 4 111 Fork spring compressor 90890 01441 Fork spring compressor YM 01441 4 107 4 112 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 107 4 112 Damper rod holder ø27 90890 01423 Damping rod holder YM 01423 4 108 4 110 Fork seal driver attachment 90890 01503 4 110 Rod puller 90890 01437 Universal damping rod bleeding tool set YM A8703 4 111 Tool name Tool No Illustratio...

Page 46: ...45 Coupling gear middle shaft tool 90890 01229 Gear holder YM 01229 4 147 4 150 Bearing retainer wrench 90890 04050 Pinion bearing retainer remover YM 04050 4 147 4 150 Fork seal driver weight 90890 01184 Replacement hammer YM A9409 7 4 152 4 152 Fork seal driver attachment 90890 01186 Replacement 27 mm YM A9409 1 4 152 Oil seal installing tool 90890 01512 Oil seal installing tool YM 01512 4 152 T...

Page 47: ...01471 5 9 5 10 Pivot shaft wrench adapter 90890 01476 5 9 5 10 Rotor holding tool 90890 01235 Universal magneto and rotor holder YU 01235 5 15 5 18 Yamaha bond No 1215 90890 85505 Three bond No 1215 5 20 5 34 5 37 5 83 6 13 Valve spring compressor 90890 04019 Valve spring compressor YM 04019 5 25 5 30 Tool name Tool No Illustration Reference pages 90890 03081 YU 33223 ...

Page 48: ...e installer ø5 90890 04098 Valve guide installer 5 0 mm YM 04098 5 27 Valve guide reamer ø5 90890 04099 Valve guide reamer 5 0 mm YM 04099 5 27 Rotor holding tool 90890 04166 YM 04166 5 33 5 33 5 34 5 34 5 37 5 37 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 33 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 5 41 8 260 Tool name Tool No Illustration Re...

Page 49: ...ner wrench YM 04137 5 70 5 72 Damper spring compressor 90890 04090 Middle drive gear damper spring compressor YM 33286 5 70 5 71 Bearing retainer wrench 90890 04140 Middle drive shaft bearing retainer wrench YM 04140 5 71 5 71 Gear lash measurement tool 90890 01467 Gear lash measurement tool YM 01467 5 74 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 87 Tool name Tool No Illustrat...

Page 50: ... YM 08037 5 92 Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 5 100 Weight 90890 01084 Weight YU 01083 3 5 100 Radiator cap tester 90890 01325 Mityvac cooling system tester kit YU 24460 A 6 3 Tool name Tool No Illustration Reference pages YU 01083 3 YU 24460 A ...

Page 51: ...rive bearing installer 40 50 mm YM 04058 6 13 Pressure gauge 90890 03153 Pressure gauge YU 03153 7 10 7 10 Fuel injector pressure adapter 90890 03210 Fuel injector pressure adapter YU 03210 7 10 Fuel pressure adapter 90890 03176 Fuel pressure adapter YM 03176 7 10 OBD GST Leadwire kit 90890 03249 8 62 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 258 Tool name Tool No Illus...

Page 52: ...SPECIAL TOOLS 1 43 Test harness lean angle sensor 6P 90890 03209 Test harness lean angle sensor 6P YU 03209 8 259 Tool name Tool No Illustration Reference pages ...

Page 53: ...AL TIGHTENING TORQUE SPECIFICATIONS 2 13 ENGINE TIGHTENING TORQUES 2 14 CHASSIS TIGHTENING TORQUES 2 15 LUBRICATION POINTS AND LUBRICANT TYPES 2 16 ENGINE 2 16 CHASSIS 2 18 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 19 ENGINE OIL LUBRICATION CHART 2 19 LUBRICATION DIAGRAMS 2 21 COOLING SYSTEM DIAGRAMS 2 31 CABLE ROUTING FJR13AG 2 35 CABLE ROUTING FJR13ESG 2 57 ...

Page 54: ...n Overall height 1325 1455 mm 52 2 57 3 in Seat height 805 825 mm 31 7 32 5 in Wheelbase 1545 mm 60 8 in Ground clearance 130 mm 5 12 in FJR13AG 125 mm 4 92 in FJR13ESG Minimum turning radius 3 1 m 10 17 ft FJR13AG 3 2 m 10 50 ft FJR13ESG Weight Curb weight 288 kg 635 lb FJR13AG 291 kg 642 lb FJR13ESG Loading Maximum load 216 kg 476 lb FJR13AG 213 kg 470 lb FJR13ESG ...

Page 55: ...ngine oil grade API service SG type or higher JASO standard MA Lubrication system Wet sump Engine oil quantity Oil change 3 80 L 4 02 US qt 3 34 Imp qt With oil filter removal 4 00 L 4 23 US qt 3 52 Imp qt Quantity disassembled 4 90 L 5 18 US qt 4 31 Imp qt Oil pressure 30 0 kPa 1050 r min at 100 C 4 4 psi 1050 r min at 212 F Oil filter Oil filter type Cartridge Final gear oil Type Shaft gear oil ...

Page 56: ...39 in Camshaft Camshaft cap inside diameter 24 500 24 521 mm 0 9646 0 9654 in Camshaft journal diameter 24 459 24 472 mm 0 9630 0 9635 in Camshaft journal to camshaft cap clearance 0 028 0 062 mm 0 0011 0 0024 in Limit 0 080 mm 0 0032 in Camshaft lobe dimensions Lobe height Intake 33 050 33 150 mm 1 3012 1 3051 in Limit 32 950 mm 1 2972 in Lobe height Exhaust 33 050 33 150 mm 1 3012 1 3051 in Limi...

Page 57: ...mm 0 0020 in Piston Piston to cylinder clearance 0 020 0 045 mm 0 0008 0 0018 in Diameter 78 965 78 980 mm 3 1089 3 1094 in Measuring point from piston skirt bottom 5 0 mm 0 20 in Piston pin bore inside diameter 19 004 19 015 mm 0 7482 0 7486 in Limit 19 045 mm 0 7498 in Piston pin outside diameter 18 991 19 000 mm 0 7477 0 7480 in Limit 18 971 mm 0 7469 in Piston pin to piston pin bore clearance ...

Page 58: ...83 in Limit 44 20 mm 1 74 in Spring quantity 3 pcs Push rod bending limit 0 20 mm 0 008 in Drivetrain Primary reduction ratio 1 563 75 48 Transmission type Constant mesh 6 speed Gear ratio 1st 2 500 35 14 2nd 1 722 31 18 3rd 1 350 27 20 4th 1 111 30 27 5th 0 963 26 27 6th 0 846 22 26 Main axle runout limit 0 08 mm 0 0032 in Drive axle runout limit 0 08 mm 0 0032 in Secondary reduction ratio 2 693 ...

Page 59: ... Crankshaft position sensor resistance 420 569 Ω Idling condition Engine idling speed 950 1150 r min Exhaust gas sampling point Muffler tail pipe Coolant temperature 90 110 C 194 230 F Difference in vacuum pressure between the cylinders 1 3 kPa 10 mmHg 0 4 inHg CO 0 0 2 5 Fuel line pressure at idle 300 0 390 0 kPa 3 00 3 90 kgf cm 43 5 56 6 psi Throttle grip free play 1 0 3 0 mm 0 04 0 12 in Air i...

Page 60: ...55 ZR17M C 73W Manufacturer model BRIDGESTONE BT023R F FJR13AG BRIDGESTONE BT023R E FJR13ESG Tire air pressure measured on cold tires Up to 90 kg 198 lb load Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi 90 kg 198 lb load maximum load Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi Front brake Type Hydraulic dual disc brake Disc outside diameter thickness 320 0 ...

Page 61: ...314 0 mm 12 36 in FJR13AG 273 8 mm 10 78 in FJR13ESG Limit 307 7 mm 12 11 in FJR13AG 268 3 mm 10 56 in FJR13ESG Inner tube bending limit 0 2 mm 0 01 in Recommended oil Yamaha Suspension Oil 01 Quantity left 753 0 cm 25 46 US oz 26 56 Imp oz FJR13AG 580 0 cm 19 61 US oz 20 46 Imp oz FJR13ESG Quantity right 708 0 cm 23 94 US oz 24 97 Imp oz FJR13AG 570 0 cm 19 27 US oz 20 10 Imp oz FJR13ESG Level le...

Page 62: ...orber Gas hydraulic damper Rear shock absorber assembly travel 60 0 mm 2 36 in FJR13AG 63 0 mm 2 48 in FJR13ESG Wheel travel 125 mm 4 9 in Spring preload Adjusting system Mechanical adjustable type FJR13AG Electronically adjustable type FJR13ESG Rider only SOFT FJR13AG With passenger or cargo HARD FJR13AG Rebound damping Adjusting system Mechanical adjustable type FJR13AG Electronically adjustable...

Page 63: ...ator coil resistance 0 128 0 192 Ω W W Rectifier regulator Regulator type Three phase Regulated voltage DC 14 3 14 7 V Rectifier capacity DC 50 0 A Battery Model GT14B 4 Voltage capacity 12 V 12 0 Ah 10 HR Bulb wattage quantity Headlight LED Brake tail light LED Front turn signal position light LED Rear turn signal light LED Auxiliary light LED License plate light LED Meter lighting LED Indicator ...

Page 64: ...linder identification sensor output voltage OFF 0 8 V Intake air temperature sensor resistance 5400 0 6600 0 Ω at 0 C 5400 0 6600 0 Ω at 32 F Intake air temperature sensor resistance 289 391 Ω at 80 C 289 391 Ω at 176 F Coolant temperature sensor resistance 2315 2584 Ω at 20 C 2315 2584 Ω at 68 F Coolant temperature sensor resistance 310 325 Ω at 80 C 310 325 Ω at 176 F Lean angle sensor output vo...

Page 65: ...ELECTRICAL SPECIFICATIONS 2 12 Backup fuse 7 5 A Windshield motor fuse 20 0 A Electronic throttle valve fuse 7 5 A ...

Page 66: ... To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque 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 kgf ft lbf 10 mm 6 mm 6 0 ...

Page 67: ...20 1 17 Nm 1 7 m kgf 12 ft lbf Exhaust pipe assembly nut M8 8 20 Nm 2 0 m kgf 14 ft lbf Exhaust pipe assembly and muffler bolt M8 2 20 Nm 2 0 m kgf 14 ft lbf Exhaust pipe assembly bolt M8 2 17 Nm 1 7 m kgf 12 ft lbf Muffler bolt M10 2 25 Nm 2 5 m kgf 18 ft lbf Muffler protector bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Muffler protector clamp screw 1 5 Nm 0 5 m kgf 3 6 ft lbf Generator cover bolt M6 11...

Page 68: ...e 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 kgf 15 ft lbf without performing temporary tightening Item Thread size Q ty Tightening torque Remarks Upper bracket pinch bolt M8 2 26 Nm 2 6 m kgf 19 ft lbf Lower bracket pinch bolt M8 4 23 Nm 2 3 m kgf 17 ft lbf Front wheel a...

Page 69: ...pump shaft Oil pump drive sprocket Oil filter union bolt Oil nozzle O ring Starter clutch idle gear inner surface Starter clutch and starter clutch gear Primary driven gear Push rods and ball Transmission gears wheel and pinion and collars Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift pedal bolt Damper drive cam and damper driven cam Middle driven gear...

Page 70: ... 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 71: ...to metal moving parts Sidestand spring and spring bracket contact points Tube guide throttle grip inner surface and throttle cables Brake lever pivoting point and metal to metal moving parts Swingarm bearing and oil seal lips Pivot shaft and pivot shaft thread Pivot shaft bearing Pivot shaft oil seal lip Relay arm bearing and oil seal lips Drive shaft spline final drive pinion gear side Drive shaf...

Page 72: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 19 EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 15 13 12 6 5 4 3 2 1 7 8 9 10 11 9 9 9 14 ...

Page 73: ...Oil pump 3 Relief valve assembly 4 Oil filter cartridge 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 delivery pipe 1 14 Drive axle 15 Middle drive shaft assembly ...

Page 74: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 21 EAS30021 LUBRICATION DIAGRAMS 5 6 7 1 2 3 4 ...

Page 75: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 22 1 Intake camshaft 2 Cylinder head 3 Exhaust camshaft 4 Oil check bolt 5 Main gallery bolt 6 Crankshaft 7 Oil nozzle ...

Page 76: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 1 3 2 ...

Page 77: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 24 1 Main axle 2 Drive axle 3 Oil delivery pipe 1 ...

Page 78: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 6 5 4 3 2 1 ...

Page 79: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Oil check bolt 2 Crankshaft 3 Oil cooler 4 Oil strainer 5 Oil delivery pipe 3 6 Oil pump ...

Page 80: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 1 2 3 4 5 6 7 8 9 ...

Page 81: ...CATION SYSTEM CHART AND DIAGRAMS 2 28 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 82: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 4 5 3 2 1 9 8 6 7 ...

Page 83: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 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 84: ...COOLING SYSTEM DIAGRAMS 2 31 EAS20020 COOLING SYSTEM DIAGRAMS 3 13 4 5 6 7 7 7 8 1 2 10 9 14 15 16 17 11 12 3 ...

Page 85: ...olant reservoir breather hose 6 Thermostat inlet pipe 2 7 Coolant reservoir hose 8 Radiator inlet hose 9 Thermostat inlet hose 2 10 Thermostat assembly 11 Water jacket joint 12 Oil cooler 13 Oil cooler inlet hose 14 Water pump outlet pipe 15 Water pump breather hose 16 Radiator outlet hose 17 Water jacket joint inlet hose ...

Page 86: ...COOLING SYSTEM DIAGRAMS 2 33 7 1 2 3 4 5 5 8 9 6 8 9 10 11 12 ...

Page 87: ...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 88: ...CABLE ROUTING FJR13AG 2 35 EAS20246 CABLE ROUTING FJR13AG Handlebar front view 1 2 3 4 5 6 7 7 8 8 10 10 9 1 3 13 12 17 16 A B C D E G F H 2 3 11 10 11 10 11 14 15 18 19 18 19 18 19 2 J I 20 ...

Page 89: ... right handlebar switch lead right grip warmer lead front brake light switch lead main switch lead and immobilizer unit lead with a plastic locking tie Face the end of the plastic locking tie downward angled inward and then cut off the excess end of the tie D Route the immobilizer unit lead to the inside of the clutch hose E Insert the projection on the wire harness holder completely into the hole...

Page 90: ...CABLE ROUTING FJR13AG 2 37 Radiator and battery right side view 1 3 4 5 6 7 8 13 13 13 13 18 22 23 24 25 M H L E F G C D D 2 P K 1 21 1 N A A B 10 9 12 11 14 14 O 14 15 16 14 20 19 17 I J 15 16 ...

Page 91: ...with the holder on the air guide G Route the right radiator fan motor lead between the leads starter motor lead negative battery lead and O2 sensor lead and the base of the holder that is fastening the leads H Fasten the negative battery lead starter motor lead O2 sensor lead and water pump breather hose with a plastic locking tie making sure to install the tie around the end of the hose s protect...

Page 92: ...CABLE ROUTING FJR13AG 2 39 Rear brake hose right side view 4 5 6 7 8 9 10 11 1 12 13 14 15 2 3 16 1 A B C F E D ...

Page 93: ...ly 14 Brake hose brake pipe upper joint assembly to front brake calipers 15 Rear brake light switch 16 Brake hose brake pipe to rear brake caliper A Route the rear wheel sensor lead to the inside of the swingarm making sure that the lead does not protrude above the swingarm B 45 55 mm 1 77 2 17 in C 20 30 mm 0 79 1 18 in D Fasten the rear brake light switch lead and rear wheel sensor lead with the...

Page 94: ...CABLE ROUTING FJR13AG 2 41 Horn and radiator left side view A B 1 1 2 3 4 5 5 6 C 7 7 8 ...

Page 95: ...position the coupler between the left side cowling and the left lower inner panel B Fasten the left radiator fan motor lead to the radiator inlet hose with the plastic band Be sure to position the plastic band above the radiator hose band Make sure that there is no slack in the left radiator fan motor lead and that the lead does not contact the metal hose fitting of the radiator C Face the end of ...

Page 96: ...ING FJR13AG 2 43 Front brake hose and engine left side view T U V 1 19 26 1 25 2 27 21 21 21 22 22 23 23 24 24 24 9 10 C D H M N 1 A B 2 3 E 4 F G 5 6 7 I J X W 8 9 10 13 12 11 14 15 K L 16 17 O P Q 18 19 20 R S ...

Page 97: ...pler is positioned as shown in the illustration G Pass the fuel tank breather overflow hose through the guide on the universal joint dust cover H Pass the air filter case breather hose through the guide on the muffler bracket I When installing the left side cowling make sure that the end of the coolant reservoir breather hose protrudes from the bottom of the cowling J Make sure that the paint mark...

Page 98: ...CABLE ROUTING FJR13AG 2 45 Rear fender left side view 3 4 5 B 1 2 A 6 7 C 1 11 12 8 9 10 13 D E F 15 14 15 G H ...

Page 99: ...nt couplers are positioned on top of the harness B Pass the license plate light lead through the hole in the rear fender C Route the wire harness to the inside of the seat lock cable D Securely connect the ABS ECU coupler E Secure the plastic band by inserting the projection on the band into the hole in the rear fender and then fasten the wire harness at the positioning tape with the band F Insert...

Page 100: ...E ROUTING FJR13AG 2 47 Throttle bodies top view 1 2 3 6 7 7 8 9 12 13 15 16 17 10 18 19 20 21 24 25 26 27 28 29 30 31 32 34 35 37 A B N O P L M 33 11 4 5 F G 14 H E I 6 22 J K 36 38 39 Q 40 S 41 D 23 R T C ...

Page 101: ...king tie 0 20 mm 0 0 79 in from the end of the protective sleeve of the front wheel sensor lead C Position the plastic locking tie 10 30 mm 0 39 1 18 in from the end of the protective sleeve of the immobilizer unit lead D Route the throttle cables and brake hoses through the right opening in the frame E Install the immobilizer unit coupler holder so that the end with the bolt is facing forward F I...

Page 102: ...CABLE ROUTING FJR13AG 2 49 Rear fender top view 1 2 3 A B 4 5 6 C C D ...

Page 103: ...e Yamaha diagnostic tool lead to the rear of the positioning ribs on the storage compartment as shown in the illustration B Install the protective cap onto the Yamaha diagnostic tool coupler and then install the coupler onto the projection on the storage compartment C Fasten the tail brake light assembly lead with the holder D Route the tail brake light assembly lead between the ribs on the rear f...

Page 104: ...LE ROUTING FJR13AG 2 51 Front cowling assembly and electrical components board 4 11 11 12 13 14 15 H I J K E A A B C D 11 D 1 F 2 3 4 1 5 6 7 8 9 10 D G M N O P Q 17 18 19 20 21 22 23 Q R S T 25 26 L 16 24 ...

Page 105: ... switch leads grip warmer leads front brake switch lead and clutch switch lead in the order listed from top to bottom H Fasten the wire harness at the white tape on both portions of the harness with a plastic locking tie Position the end of the plastic locking tie under the meter assembly facing inward Do not cut off the excess end of the plastic locking tie I Route the wire harness between the re...

Page 106: ...CABLE ROUTING FJR13AG 2 53 Hydraulic unit assembly top and side view 1 1 2 3 4 5 6 7 7 8 9 10 1 2 3 4 5 6 7 8 9 10 10 1 3 4 5 6 7 8 9 13 13 11 12 12 A 2 1 5 4 3 ...

Page 107: ...proportioning valve to rear brake hose 8 Brake hose front brake master cylinder to brake pipe lower joint assembly 9 Brake hose brake pipe upper joint assembly to front brake calipers 10 Brake hose metering valve to right front brake caliper 11 Metering valve 12 Brake hose rear brake master cylinder to brake pipe middle joint assembly 13 Proportioning valve A Position the brake pipe proportioning ...

Page 108: ...CABLE ROUTING FJR13AG 2 55 Fuel tank and canister B C 2 3 1 A A ...

Page 109: ...erflow hose 3 Fuel tank breather hose fuel tank to 3 way joint A Install each hose onto the hose fitting of the fuel tank up to the wide portion at the base of the fitting B To atmosphere C Do not install the hose clamp on the flange at the end of the 3 way joint Point the ends of the hose clamp inward ...

Page 110: ...NG FJR13ESG 2 57 EAS20235 CABLE ROUTING FJR13ESG Handlebar front view G 1 2 3 A 2 A 4 5 6 7 8 B 9 10 C D I E 11 11 12 12 13 14 15 H 22 1 1 4 4 5 5 9 10 10 4 23 23 24 24 3 3 15 15 14 14 18 17 20 16 19 21 23 24 14 F ...

Page 111: ... hose handlebar switch leads grip warmer leads front brake light switch lead clutch switch lead and left front fork stepping motor lead through the guide C Route the main switch lead to the inside of the clutch hose D Route the immobilizer unit lead to the inside of the clutch hose E Fasten the right handlebar switch lead right grip warmer lead front brake light switch lead main switch lead and im...

Page 112: ...CABLE ROUTING FJR13ESG 2 59 Radiator and battery right side view 1 3 4 5 6 7 8 13 13 13 13 18 22 23 24 25 M H L E F G C D D 2 P K 1 21 1 N A A B 10 9 12 11 14 14 O 14 15 16 14 20 19 17 I J 15 16 ...

Page 113: ...with the holder on the air guide G Route the right radiator fan motor lead between the leads starter motor lead negative battery lead and O2 sensor lead and the base of the holder that is fastening the leads H Fasten the negative battery lead starter motor lead O2 sensor lead and water pump breather hose with a plastic locking tie making sure to install the tie around the end of the hose s protect...

Page 114: ...CABLE ROUTING FJR13ESG 2 61 Rear brake hose right side view 4 5 6 7 8 9 10 11 1 12 13 14 15 2 3 16 1 A B C F E D ...

Page 115: ...bly 14 Brake hose brake pipe upper joint assembly to front brake calipers 15 Rear brake light switch 16 Brake hose brake pipe to rear brake caliper A Route the rear wheel sensor lead to the inside of the swingarm making sure that the lead does not protrude above the swingarm B 45 55 mm 1 77 2 17 in C 20 30 mm 0 79 1 18 in D Fasten the rear brake light switch lead and rear wheel sensor lead with th...

Page 116: ...CABLE ROUTING FJR13ESG 2 63 Horn and radiator left side view A B 1 1 2 3 4 5 5 6 C 7 7 8 ...

Page 117: ...position the coupler between the left side cowling and the left lower inner panel B Fasten the left radiator fan motor lead to the radiator inlet hose with the plastic band Be sure to position the plastic band above the radiator hose band Make sure that there is no slack in the left radiator fan motor lead and that the lead does not contact the metal hose fitting of the radiator C Face the end of ...

Page 118: ...TING FJR13ESG 2 65 Front brake hose and engine left side view 1 1 2 1 2 3 A B C 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 20 20 21 21 22 22 23 24 25 18 26 D E F G H I J W X K L M N O P Q R S T U V 23 23 10 9 ...

Page 119: ... shown in the illustration G Pass the fuel tank overflow hose through the guide on the universal joint dust cover H Pass the air filter case breather hose through the guide on the muffler bracket I When installing the left side cowling make sure that the end of the coolant reservoir breather hose protrudes from the bottom of the cowling J Make sure that the paint mark on the coolant reservoir brea...

Page 120: ...CABLE ROUTING FJR13ESG 2 67 Rear fender left side view 4 6 5 7 B H 10 11 12 13 14 15 16 1 D E F 1 2 3 8 13 13 19 K I 18 17 18 9 A J 12 L C G ...

Page 121: ...t lock cable D Route the rear shock absorber assembly stepping motor lead and DC motor lead between the couplers shift actuator motor coupler and shift actuator sensor coupler and the rear fender and then route the leads downward through the hole in the rear fender E Insert the projection on the wire harness holder into the hole in the rear fender F Secure the plastic band by inserting the project...

Page 122: ...OUTING FJR13ESG 2 69 Throttle bodies top view 1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 33 35 36 37 A B C D E F G H I L M N J K Q 34 32 10 20 8 9 38 39 T R S 42 43 40 41 O P ...

Page 123: ...ess 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 Position the plastic locking tie 10 30 mm 0 39 1 18 in from the end of the protective sleeve of the immobilizer unit lead D Route the throttle cables and brake hoses through the right opening in the frame E Install the immobilizer unit coupl...

Page 124: ...CABLE ROUTING FJR13ESG 2 71 Rear fender top view 7 E 6 D 5 C C 1 2 3 4 A B 8 9 10 ...

Page 125: ...nostic tool lead to the rear of the positioning ribs and under the band that is used to secure the SCU suspension control unit B Install the protective cap onto the Yamaha diagnostic tool coupler and then install the coupler onto the projection on the storage compartment C Fasten the tail brake light assembly lead and IMU sub wire harness with the holder D Route the tail brake light assembly lead ...

Page 126: ...CABLE ROUTING FJR13ESG 2 73 Front cowling assembly and electrical components board 4 11 11 12 13 14 15 H I J K E A A B C D 11 D 1 F 2 3 4 1 5 6 7 8 9 10 D G M N O P 17 18 19 20 21 P Q R S 23 24 L 16 22 ...

Page 127: ...r assembly lead and handlebar switch leads grip warmer leads front brake switch lead and clutch switch lead in the order listed from top to bottom H Fasten the wire harness at the white tape on both portions of the harness with a plastic locking tie Position the end of the plastic locking tie under the meter assembly facing inward Do not cut off the excess end of the plastic locking tie I Route th...

Page 128: ...CABLE ROUTING FJR13ESG 2 75 Hydraulic unit assembly top and side view 1 1 2 3 4 5 6 7 7 8 9 10 1 2 3 4 5 6 7 8 9 10 10 1 3 4 5 6 7 8 9 13 13 11 12 12 A 2 1 5 4 3 ...

Page 129: ... proportioning valve to rear brake hose 8 Brake hose front brake master cylinder to brake pipe lower joint assembly 9 Brake hose brake pipe upper joint assembly to front brake calipers 10 Brake hose metering valve to right front brake caliper 11 Metering valve 12 Brake hose rear brake master cylinder to brake pipe middle joint assembly 13 Proportioning valve A Position the brake pipe proportioning...

Page 130: ...CABLE ROUTING FJR13ESG 2 77 Fuel tank and canister B C 2 3 1 A A ...

Page 131: ...erflow hose 3 Fuel tank breather hose fuel tank to 3 way joint A Install each hose onto the hose fitting of the fuel tank up to the wide portion at the base of the fitting B To atmosphere C Do not install the hose clamp on the flange at the end of the 3 way joint Point the ends of the hose clamp inward ...

Page 132: ...CABLE ROUTING FJR13ESG 2 79 ...

Page 133: ...G THE BRAKE FLUID LEVEL 3 13 BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS 3 14 CHECKING THE FRONT BRAKE PADS 3 15 CHECKING THE REAR BRAKE PADS 3 15 CHECKING THE BRAKE HOSES 3 16 CHECKING THE WHEELS 3 16 CHECKING THE TIRES 3 16 CHECKING THE WHEEL BEARINGS 3 18 CHECKING THE SWINGARM PIVOT 3 18 LUBRICATING THE SWINGARM PIVOT 3 18 CHECKING AND ADJUSTING THE STEERING HEAD 3 18 LUBRICATING THE STEERING HEAD ...

Page 134: ...27 CHECKING THE COOLANT LEVEL 3 27 CHECKING THE COOLING SYSTEM 3 28 CHANGING THE COOLANT 3 29 CHECKING THE FINAL GEAR OIL LEVEL 3 30 CHANGING THE FINAL GEAR OIL 3 31 CHECKING THE BRAKE LIGHT SWITCHES 3 31 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 31 CHECKING AND LUBRICATING THE CABLES 3 32 CHECKING THE THROTTLE GRIP OPERATION 3 32 CHECKING THE SWITCHES LIGHTS AND SIGNALS 3 33 ADJUSTING THE HEADLIGHT...

Page 135: ......

Page 136: ...P From 37000 km 24000 mi or 36 months repeat the maintenance intervals starting from 13000 km 8000 mi or 12 months Items marked with an asterisk require special tools data and technical skills have a Yamaha dealer perform the service No ITEM ROUTINE INITIAL ODOMETER READINGS 1000 km 1 7 13 19 25 31 1000 mi 0 6 4 8 12 16 20 month 1 6 12 18 24 30 1 Fuel line Check fuel hoses for cracks or damage Rep...

Page 137: ...ap based grease 11 Steering bearings Check bearing assemblies for looseness Moderately repack with lithium soap based grease Every 25000 km 16000 mi 12 Chassis fasteners Check all chassis fitting and fasteners Correct if necessary 13 Brake lever pivot shaft Apply silicone grease lightly 14 Brake pedal pivot shaft Apply lithium soap based grease lightly 15 Clutch lever pivot shaft Apply silicone gr...

Page 138: ... every four years or if cracked or damaged 22 Engine oil Change warm engine before draining 23 Engine oil filter car tridge Replace 24 Cooling system Check hoses for cracks or dam age Replace if necessary Change coolant 25 Final gear oil Check oil level and for leakage Change 26 Front and rear brake switches Check operation 27 Control cables Apply Yamaha cable lubricant or other suitable cable lub...

Page 139: ...plies to all of the spark plugs 1 Remove Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 T bar Refer to GENERAL CHASSIS 6 on page 4 22 2 Remove Ignition coil 3 Remove Spark plug NOTICE ECA13320 Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders 4 Check Sp...

Page 140: ... Fuel tank Refer to FUEL TANK on page 7 1 T bar Refer to GENERAL CHASSIS 6 on page 4 22 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 13 Thermostat inlet pipe 1 Refer to THERMOSTAT on page 6 6 2 Remove Spark plugs Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS on page 5 12 3 Remove Hose holder 1 Lead holders 2 Pickup rotor cover 3 4 Measure Valve clearance Out of spe...

Page 141: ...chain with a wire to re trieve it if it falls into the crankcase 6 Adjust Valve clearance a Remove the valve lifter 1 and the valve pad 2 with the valve lapper 3 TIP Cover the timing chain opening with a rag to prevent the valve pad from falling into the 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 Valve clearance ...

Page 142: ...Valve pad number 158 Rounded value 160 New valve pad number 160 f Install the new valve pad 1 and the valve lift er 2 TIP Lubricate the valve lifter with engine oil The valve lifter must turn smoothly when rotat ed by hand Install the valve lifter and the valve pad in the correct place g Install the exhaust and intake camshafts tim ing chain and camshaft caps TIP Refer to CAMSHAFTS on page 5 12 Lu...

Page 143: ...Check the ISC idle speed control leaning value EAS30797 SYNCHRONIZING THE THROTTLE BODIES TIP Before synchronizing the throttle bodies check the following items Valve clearance Spark plugs Air filter element Throttle body joints Fuel hose Exhaust system Breather hoses Checking the throttle body synchronization 1 Stand the vehicle on a level surface TIP Place the vehicle on the centerstand 2 Remove...

Page 144: ... the bypass air screw using the carburetor angle driver After each step rev the engine two or three times each time for less than a second and check the synchronization again If a bypass air screw was removed turn the screw in fully and be sure to synchronize the throttle bodies If the throttle body synchronization can not be adjusted using the bypass air screw clean or replace the throttle bodies...

Page 145: ...HOSE 1 Remove Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 T bar Air filter case Refer to GENERAL CHASSIS 6 on page 4 22 2 Check Crankcase breather hose 1 Cracks damage Replace Loose connection Connect properly NOTICE ECA13450 Make sure the crankcase breather hose is routed correctly 3 Install Air filter case T bar Refer to GENERAL CHASSIS 6 on page 4 ...

Page 146: ...ter element Air filter case cover Side cover left Refer to GENERAL CHASSIS 7 on page 4 23 TIP When installing the air filter element into the air filter case cover make sure their sealing surfac es are aligned to prevent any air leaks EAS30889 ADJUSTING THE CLUTCH LEVER 1 Adjust Clutch lever position distance a from the handlebar grip to the clutch lever a While pushing the clutch lever forward tu...

Page 147: ...er 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 Repeat the bleeding proced...

Page 148: ...the brake system will consid erably reduce braking performance NOTICE ECA13490 After adjusting the brake lever position make sure there is no brake drag EAS30632 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on the centerstand Make sure the vehicle is upright 2 Remove Side cover right Refer to GENERAL CHASSIS 1 on page 4 1 3 Check Brake fluid level Bel...

Page 149: ...d brake system 3rd step Rear brake caliper WARNING EWA16530 Bleed the ABS whenever the system is disassembled a brake hose is loosened disconnected or replaced the brake fluid level is very low brake operation is faulty TIP Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow When bleeding the ABS make sure that there is always e...

Page 150: ...ter cylinder reservoir or brake fluid reservoir to the proper level with the specified brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 13 WARNING EWA14020 After bleeding the ABS check the brake op eration 3 Install Side cover right Refer to GENERAL CHASSIS 1 on page 4 1 EAS30633 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads NOTICE ECA23390 The...

Page 151: ...to both of the tires 1 Check Tire pressure Out of specification Regulate WARNING EWA13181 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 including cargo rider passenger and ac cessories and the anticipated riding speed Operation of an overloaded v...

Page 152: ...me 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 WARNING EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done TIP F...

Page 153: ...ly rock the front fork Binding looseness Adjust the steering head 3 Remove Upper bracket Refer to STEERING HEAD on page 4 114 4 Adjust Steering head a Remove the lock washer 1 upper ring nut 2 and rubber washer 3 b Tighten the lower ring nut 4 with the steering nut wrench 5 TIP Set a torque wrench at a right angle to the steer ing nut wrench c Loosen the lower ring nut completely and then tighten ...

Page 154: ...NG THE SIDESTAND 1 Check Sidestand operation Check that the sidestand moves smoothly Rough movement Repair or replace EAS30117 LUBRICATING THE SIDESTAND Lubricate the pivoting point metal to metal mov ing parts and spring contact points of the side stand EAS30113 CHECKING THE CENTERSTAND 1 Check Centerstand operation Check that the centerstand moves smoothly Rough movement Repair or replace EAS301...

Page 155: ...oor han dling and loss of stability NOTICE ECA13570 Grooves are provided to indicate the ad justment position Never go beyond the maximum or mini mum adjustment positions 1 Adjust Spring preload TIP The spring preload setting is determined by measuring the distance a shown in the illustra tion a Turn the adjusting bolt 1 in direction a or b Rebound damping right side only NOTICE ECA13590 Never go ...

Page 156: ...If the preload setting was not completed correct ly The damping force setting and setting level will flash 4 times and cannot be adjusted if you try to adjust them while the vehicle is stopped The preload setting pictogram will flash and the damping force cannot be adjusted if you try to adjust it while the vehicle is moving Direction a Rebound damping is increased sus pension is harder Direction ...

Page 157: ...KING THE REAR SUSPENSION 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 Rear shock absorber assembly Gas leaks oil leaks Replace the rear shock absorber assembly Refer to REAR SHOCK ABSORBER AS SEMBLY FJR13AG on page 4 118 and REAR SHOCK ABSORBER ASSEMBLY FJR13ESG on page 4 123 3 Check Rear shock absorber a...

Page 158: ...ion at ambient temperatures near or below 0 C 32 F to protect the preload adjusting function motor the electronically adjustable suspen sion system warning light may come on The suspension will still operate as normal only the preload adjusting function cannot be used To reset the electronically adjustable suspen sion system warning light wait approximately 6 minutes and then turn the key to OFF o...

Page 159: ...lete TIP While the preload is being adjusted the informa tion display may change as follows If the key is turned to OFF or the engine is stopped while the preload is being set the fol lowing preload setting pictogram will flash to alert you that the current preload setting does not match the pictogram If this occurs adjust the preload again If the vehicle starts moving the following pre load setti...

Page 160: ... any chemical additives or use engine oils with a grade of CD or higher and do not use oils labeled ENERGY CONSERVING II Do not allow foreign materials to enter the crankcase TIP Before checking the engine oil level wait a few minutes until the oil has settled 4 Start the engine warm it up for several min utes and then turn it off 5 Check the engine oil level again TIP Before checking the engine o...

Page 161: ...nkcase with the specified amount of the recom mended engine oil 8 Install Engine oil filler cap 9 Start the engine warm it up for several min utes and then turn it off 10 Check Engine for engine oil leaks 11 Check Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 25 12 Check Engine oil pressure a Remove the right side cowling Refer to GENERAL CHASSIS 2 on page 4 5 b Slightly loosen...

Page 162: ...er viscosity causing the engine oil pressure to increase Therefore be sure to measure the engine oil pressure after warming up the engine 3 Remove Side cowling right Refer to GENERAL CHASSIS 2 on page 4 5 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 pressure adapter B 2 6 Measure Engine oil pressure at the f...

Page 163: ...y be used 4 Start the engine warm it up for several min utes and then turn it off 5 Check Coolant level TIP Before checking the coolant level wait a few minutes until it settles 6 Install Side panel left Refer to GENERAL CHASSIS 2 on page 4 5 EAS30067 CHECKING THE COOLING SYSTEM 1 Remove Side cowlings Refer to GENERAL CHASSIS 2 on page 4 5 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 3 ...

Page 164: ... a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter clockwise toward the detent to allow any re sidual pressure to escape When the hissing sound has stopped press down on the radi ator cap and turn it counterclockwise to re move 3 Remove Coolant drain bolt water pump 1 along with the copper washer 4 Disconnect Radiator outlet hose 2 5 Drain Coolant from the engin...

Page 165: ...adiator 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 LEV EL on page 3 27 TIP Before checking the coolant level wait a few minutes until the coolant has settled 17 Install Side cowlings Refer to GENERAL ...

Page 166: ...control system will not op erate correctly If the brake light comes on too early the time until the cruise control system is deac tivated will be shorter If the brake light comes on too late the time until the cruise control system is deactivat ed will be longer or the cruise control sys tem may not be deactivated TIP The rear brake light switch is operated by the movement of the brake pedal Adjus...

Page 167: ...AS30861 CHECKING THE THROTTLE GRIP OPERATION 1 Check Throttle cables Damage deterioration Replace Throttle cable installation Incorrect Reinstall the throttle cables Refer to HANDLEBARS on page 4 87 2 Check Throttle grip movement Rough movement Lubricate or replace the defective part s TIP With the engine stopped turn the throttle grip slowly and release it Make sure that the throttle grip turns s...

Page 168: ...y Refer to CHECKING THE SWITCHES on page 8 247 EAS30124 ADJUSTING THE HEADLIGHT BEAMS 1 Adjust Headlight beam vertically a Turn the adjusting knobs 1 in direction a or b 2 Adjust Headlight beam horizontally a Turn the adjusting screws 1 in direction a or b Left headlight Right headlight Direction a Throttle grip free play is increased Direction b Throttle grip free play is decreased Direction a He...

Page 169: ...MOVING THE WINDSHIELD BRACKET COVERS 4 12 INSTALLING THE WINDSHIELD BRACKET COVERS 4 12 REMOVING THE CENTER COVERS 4 12 INSTALLING THE CENTER COVERS 4 12 INSTALLING THE FRONT COWLING ASSEMBLY 4 13 INSTALLING THE HEADLIGHT BEAM ADJUSTING KNOB JOINTS 4 13 GENERAL CHASSIS 4 4 14 INSTALLING THE WINDSHIELD DRIVE UNIT 4 18 GENERAL CHASSIS 5 4 19 GENERAL CHASSIS 6 4 22 GENERAL CHASSIS 7 4 23 FRONT WHEEL ...

Page 170: ...E FRONT BRAKE MASTER CYLINDER 4 58 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 58 REAR BRAKE 4 60 INTRODUCTION 4 66 CHECKING THE REAR BRAKE DISC 4 66 REPLACING THE REAR BRAKE PADS 4 66 REMOVING THE REAR BRAKE CALIPER 4 67 DISASSEMBLING THE REAR BRAKE CALIPER 4 68 CHECKING THE REAR BRAKE CALIPER 4 68 ASSEMBLING THE REAR BRAKE CALIPER 4 68 INSTALLING THE REAR BRAKE CALIPER 4 69 REMOVING THE REAR BR...

Page 171: ...STEERING HEAD 4 116 REAR SHOCK ABSORBER ASSEMBLY FJR13AG 4 118 HANDLING THE REAR SHOCK ABSORBER 4 120 DISPOSING OF A REAR SHOCK ABSORBER 4 120 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 120 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 120 CHECKING THE CONNECTING ARM AND RELAY ARM 4 121 INSTALLING THE RELAY ARM 4 121 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 121 REAR SHOCK ABSORBER ASSEMBLY FJR...

Page 172: ... 144 MEASURING THE FINAL GEAR BACKLASH 4 144 ADJUSTING THE FINAL GEAR BACKLASH 4 145 MEASURING THE RING GEAR TO STOPPER BOLT CLEARANCE 4 146 ADJUSTING THE RING GEAR TO STOPPER BOLT CLEARANCE 4 146 DISASSEMBLING THE FINAL DRIVE ASSEMBLY 4 147 REMOVING AND INSTALLING THE BEARINGS 4 147 ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR 4 148 CHECKING THE DRIVE SHAFT 4 151 INSTALLING THE DRIVE SHAFT ...

Page 173: ......

Page 174: ...ear cowling 1 5 Rear cowling left 1 6 Rear cowling right 1 7 Side cover left 1 8 Side cover right 1 9 Rider seat height position adjuster 1 3 1 5 4 7 2 6 9 8 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 21 Nm 2 1 m kgf 15 ft Ibf T R ...

Page 175: ... Remove Rear cowling 1 a Pull the rear of the rear cowling outward to re move it from the grommet on the tail brake light assembly b Slide the rear cowling rearward and remove it EAS31842 INSTALLING THE REAR COWLINGS The following procedure applies to both of the rear cowlings 1 Install Rear cowling 1 a Insert the projection on the rear cowling into the side cover b Make sure that the grommet on t...

Page 176: ...e adjusted to one of two positions to suit the rider s preference To install the rider seat in the high posi tion a Move the rider seat holder cover 1 to the lower position as shown 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 3 into seat holder d as shown d Align the projection e...

Page 177: ... front of the rid er seat 2 into seat holder d as shown c Align the projection e on the bottom of the rider seat 2 with the L position slot f and then push the rear of the seat down to lock it in place as shown 2 Install Passenger seat 1 TIP Insert the projections a on the rear of the pas senger seat into the seat holders b as shown and then push the front of the seat down to lock it in place 2 c ...

Page 178: ...de cowling right 1 7 Front turn signal position light coupler right 1 Disconnect 8 Bottom cowling 1 9 Lower inner panel left 1 10 Side panel left 1 11 Side cowling left 1 5 3 6 7 4 8 9 11 10 1 2 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm ...

Page 179: ...5 Upper inner panel 1 left 1 16 Accessory box 1 17 Accessory box solenoid 1 18 Auxiliary DC jack 1 19 Upper inner panel 2 left 1 12 19 15 16 17 13 18 14 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 4 5 Nm 0 45 m kg...

Page 180: ...tions a into the upper slots c and then slide the panel backward d Install the quick fastener 1 To close a side panel a Remove the quick fastener 1 b Slide the side panel 2 forward to unhook its projections a from the upper slots b and then pull the panel off c Insert the projections a into the lower slots c and then slide the panel backward d Install the quick fastener 1 TIP Make sure that the si...

Page 181: ...INNER PANEL 1 Install Upper inner panel right 1 TIP Place the right upper inner panel in its original position 2 Install Front cowling inner panel 1 a Fit the projections a on the bottom of the front cowling inner panel into the holes in the upper inner panels TIP Make sure to align the projections b on the headlight beam adjusting knob joint with the slots c in the front cowling inner panel b Fit...

Page 182: ...d then fas ten the front left turn signal position light lead a auxiliary DC jack lead b and accessory box solenoid lead c with a plastic locking tie TIP Make sure that the couplers are aligned as shown in the illustration b Fit the projections on the left side cowling into the holes in the front cowling 2 Install Side cowling right 1 a Connect the front right turn signal position light coupler an...

Page 183: ...1 Windshield bracket outer cover 2 2 Windshield 1 3 Windshield bracket 1 4 Windshield bracket inner cover 2 5 Center cover assembly 1 6 Upper center cover 1 7 Lower center cover 1 8 Rearview mirror 2 9 Headlight beam adjusting knob joint 2 10 Headlight beam adjusting knob shaft 2 2 3 3 3 3 4 1 3 4 5 6 7 8 5 4 9 9 10 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 184: ...ler 1 Disconnect 12 Auxiliary light coupler 1 Disconnect 13 Cornering light control unit coupler 1 Disconnect FJR13ESG 14 Lower bracket cover bolt 2 15 Front cowling assembly 1 16 Front cowling 1 17 Headlight assembly 1 3 3 3 3 4 11 15 14 14 16 17 5 4 12 13 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 185: ... windshield bracket 2 Install Windshield Windshield bracket outer cover 1 TIP Fit the projections on the windshield bracket out er cover into the holes in the windshield and then slide the cover downward EAS31094 REMOVING THE CENTER COVERS 1 Remove Center cover assembly 1 TIP Unhook the projections on the lower center cov er from the front cowling and remove the center cover assembly 2 Remove Uppe...

Page 186: ...e front cowling assembly oper ate the windshield drive unit and check that the windshield drive unit arms a do not contact the front cowling when they move up and down EAS31849 INSTALLING THE HEADLIGHT BEAM ADJUSTING KNOB JOINTS The following procedure applies to both of the headlight beam adjusting knob joints 1 Install Headlight beam adjusting knob joint 1 TIP Face the projection a on the headli...

Page 187: ...o Removing the front cowling assem bly 1 Meter assembly coupler 1 Disconnect 2 Meter assembly 1 3 Handlebar switch coupler right 2 Disconnect 4 Handlebar switch coupler left 2 Disconnect 5 Front brake light switch coupler 1 Disconnect 6 Windshield drive unit sub lead coupler 1 Disconnect 7 Air temperature sensor coupler 1 Disconnect 8 Grip warmer coupler right 1 Disconnect Gray coupler 7 Nm 0 7 m ...

Page 188: ...ctrical components board FJR13AG Order Job Parts to remove Q ty Remarks 9 Grip warmer coupler left 1 Disconnect Black coupler 10 Clutch switch coupler 1 Disconnect 11 Lean angle sensor 1 12 Electrical components board 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 12 9 10 11 ...

Page 189: ...Meter assembly 1 3 Handlebar switch coupler right 2 Disconnect 4 Handlebar switch coupler left 2 Disconnect 5 Front brake light switch coupler 1 Disconnect 6 Windshield drive unit sub lead coupler 1 Disconnect 7 Air temperature sensor coupler 1 Disconnect 8 Grip warmer coupler right 1 Disconnect Gray coupler 9 Grip warmer coupler left 1 Disconnect Black coupler 10 Clutch switch coupler 1 Disconnec...

Page 190: ...board Refer to Removing the meter assembly and electrical components board 1 Windshield drive unit relay up 1 2 Windshield drive unit relay down 1 3 Relay unit 1 4 Relay bracket 1 5 Air temperature sensor 1 6 Windshield drive unit sub lead 1 7 Windshield drive unit 1 8 Windshield drive unit bracket 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 32 Nm ...

Page 191: ...ra tion of the drive unit a Install the windshield drive unit sub lead 1 and then connect the windshield drive unit sub lead to the wire harness b Install the windshield bracket 2 c Operate the windshield drive unit and check that the windshield drive unit arms can be moved fully up and down within the specified operation time Specified operation time time re quired to move up or down 1 9 3 8 seco...

Page 192: ...moving the side cowlings 1 Negative battery lead 1 Disconnect 2 Positive battery lead 1 Disconnect 3 Battery 1 4 Main fuse 1 5 ABS test coupler 1 6 Starter relay 1 7 Radiator fan motor relay 1 8 Headlight relay on off 1 9 Radiator fan motor coupler right 1 Disconnect 10 Air guide 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 3 7 6 9 10 1 2 4 5 8 ...

Page 193: ...dshield motor fuse 1 1 3 Fuse box 2 Hazard lighting fuse 1 1 4 Cruise control system fuse Brake light fuse 1 1 5 ECU Engine Control Unit 1 6 Electrical components tray 1 7 Electrical components tray bracket 1 5 4 2 3 6 1 7 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 194: ...se box 1 Fuse box 3 1 1 3 Fuse box 2 SCU fuse 1 1 4 Cruise control system fuse Brake light fuse 1 1 5 ECU Engine Control Unit 1 6 Electrical components tray 1 7 Electrical components tray bracket 1 5 4 2 3 6 1 7 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 195: ...IS 6 Removing the T bar Order Job Parts to remove Q ty Remarks Rider seat Refer to Removing the seats and covers Fuel tank Refer to FUEL TANK on page 7 1 1 T bar 1 2 Heat protector 1 1 2 37 Nm 3 7 m kgf 27 ft Ibf T R 37 Nm 3 7 m kgf 27 ft Ibf T R ...

Page 196: ...ng the T bar 1 Air shroud 1 2 Air duct 1 3 Air filter case cover 1 4 Air filter element 1 5 Owner s tool kit 1 6 Storage compartment 1 7 Rear lower fuel tank bracket 1 8 Crankcase breather hose 1 Disconnect 9 Air induction system hose air filter case joint assembly to 3 way joint 1 Disconnect 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kg...

Page 197: ... clamp screw 4 Loosen 11 Air filter case assembly 1 12 Air filter case breather hose 2 13 Filter assembly 1 14 Air filter case joint assembly 1 15 Air filter case 1 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R New 4 11 10 10 12 13 11 15 14 12 10 4 ...

Page 198: ...er case cover 1 4 Air filter element 1 5 Owner s tool kit 1 6 SCU Suspension Control Unit 1 7 Yamaha diagnostic tool coupler 1 8 Rear lower fuel tank bracket 1 9 Storage compartment 1 10 Crankcase breather hose 1 Disconnect 11 Air induction system hose air filter case joint assembly to 3 way joint 1 Disconnect 4 11 4 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 Nm 0 8 m kgf 5 8...

Page 199: ... clamp screw 4 Loosen 13 Air filter case assembly 1 14 Air filter case breather hose 2 15 Filter assembly 1 16 Air filter case joint assembly 1 17 Air filter case 1 4 11 4 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R New 12 12 14 15 13 17 16 14 12 ...

Page 200: ...upler 1 Disconnect 3 Front wheel sensor 1 4 Front reflector 2 5 Front brake caliper 2 6 Front wheel axle pinch bolt 4 Loosen 7 Front wheel axle bolt 1 8 Front wheel axle 1 9 Front wheel 1 10 Front wheel sensor housing 1 6 Nm 0 6 m kgf 4 3 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R ...

Page 201: ... 53 in 12 Collar right side 1 l 18 0 mm 0 71 in 13 Front brake disc 2 6 Nm 0 6 m kgf 4 3 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 21 Nm 2 1 m kgf 15 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 91 Nm 9 1 m kgf 66 ft Ibf T R 12 13 13 11 LT LT LT LT 6 6 ...

Page 202: ...oupler 1 Disconnect 3 Front wheel sensor 1 4 Front reflector 2 5 Front brake caliper 2 6 Front wheel axle pinch bolt 4 Loosen 7 Front wheel axle bolt 1 8 Front wheel axle 1 9 Front wheel 1 10 Front wheel sensor housing 1 6 Nm 0 6 m kgf 4 3 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 21 Nm 2 1 m kgf 15 ft Ibf T R...

Page 203: ... l 13 5 mm 0 53 in 12 Collar right side 1 l 18 0 mm 0 71 in 13 Front brake disc 2 6 Nm 0 6 m kgf 4 3 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 21 Nm 2 1 m kgf 15 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 91 Nm 9 1 m kgf 66 ft Ibf T R 12 13 13 11 LT LT LT LT 6 6 New New ...

Page 204: ...FRONT WHEEL 4 31 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Front wheel sensor rotor 1 3 Wheel bearing 2 4 Spacer 1 8 Nm 0 8 m kgf 5 8 ft Ibf T R ...

Page 205: ...at the front wheel is elevated EAS30146 DISASSEMBLING THE FRONT WHEEL NOTICE ECA18080 Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the wheel sensor rotor Do not drop the wheel sensor rotor or sub ject it to shocks If any solvent gets on the wheel sensor ro tor wipe it off immediately 1 Remove Oil seals Wheel bearings a Clean the surface of the front wheel hub b...

Page 206: ...y replace with a new one Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the wheel sensor rotor Do not drop or shock the wheel sensor or the wheel sensor rotor 1 Check Front wheel sensor 1 Cracks bends distortion Replace Iron powder dust Clean 2 Check Front wheel sensor rotor 1 Cracks damage scratches Replace the front wheel sensor rotor Iron powder dust solvent C...

Page 207: ...e wheel sensor rotor Do not drop the wheel sensor rotor or sub ject it to shocks If any solvent gets on the wheel sensor ro tor wipe it off immediately 1 Install Wheel bearings a Install the new wheel bearing right side NOTICE ECA18110 Do not contact the wheel bearing inner race 1 or balls 2 Contact should be made only with the outer race 3 TIP Use a socket 4 that matches the diameter of the wheel...

Page 208: ...ce 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 c through e several times until all the marks come to rest at the same spot g The ...

Page 209: ...disc bolts with new ones TIP Tighten the brake disc bolts in stages and in a crisscross pattern 2 Check Front brake discs Refer to CHECKING THE FRONT BRAKE DISCS on page 4 53 3 Lubricate Oil seal lips 4 Install Collars Front wheel sensor housing Front wheel TIP 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 w...

Page 210: ... m kgf 15 ft lbf without performing temporary tightening 6 Measure TIP Measure the distance a only if the wheel bear ings wheel sensor rotor or both were replaced Distance a between the wheel sensor rotor 1 and wheel sensor housing 2 Out of specification Reinstall the bearing or replace the wheel sensor rotor 7 Install Front brake calipers Front wheel sensor TIP When installing the front wheel sen...

Page 211: ...FRONT WHEEL 4 38 TIP When installing the front fender make sure that there is no dirt between the front fender and front fork legs ...

Page 212: ...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 Collar 1 12 Rear brake disc 1 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 125...

Page 213: ...ve hub 1 3 Dust seal 1 4 Wheel bearing 1 5 Rear wheel drive hub damper 6 6 Oil seal 1 7 Bearing retainer 1 Left hand threads 8 Rear wheel sensor rotor 1 9 Wheel bearing 1 10 Spacer 1 11 Spacer 1 12 Bearing 1 4 5 Nm 0 45 m kgf 3 3 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 80 Nm 8 0 m kgf 58 ft Ibf T R LT LT LT FWD FWD ...

Page 214: ...eel sensor before removing the rear wheel sensor housing otherwise the sensor could be damaged TIP Move the rear wheel to the right to separate it from the final drive assembly EAS30158 DISASSEMBLING THE REAR WHEEL NOTICE ECA18080 Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the wheel sensor rotor Do not drop the wheel sensor rotor or sub ject it to shocks If a...

Page 215: ...p magnets including magnetic pick up tools magnetic screwdrivers etc away from the wheel sensor rotor Do not drop or shock the wheel sensor or the wheel sensor rotor 1 Check Rear wheel sensor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 33 2 Check Rear wheel sensor rotor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 33 3 Measure Rear wheel s...

Page 216: ...ise 5 Measure Wheel sensor rotor deflection Out of specification Correct the wheel sen sor rotor deflection or replace the wheel sen sor rotor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 42 EAS30164 ADJUSTING THE REAR WHEEL STATIC BALANCE TIP After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance wit...

Page 217: ...he projection c on the housing is aligned with the projection d on the bracket NOTICE ECA14470 Make sure there are no foreign materials in the wheel hub Foreign materials cause dam age to the inner sensor rotor and wheel sen sor WARNING EWA13500 Make sure the brake hose is routed properly 5 Tighten Brake torque rod nuts Rear wheel axle nut Rear wheel axle pinch bolt 6 Measure TIP Measure the dista...

Page 218: ...installing the rear wheel sensor check the rear wheel sensor lead for twists and the sensor electrode for foreign materials 8 Check Rear wheel sensor installation Check if the wheel sensor housing is installed properly Distance a between the wheel sensor rotor and wheel sensor housing 28 84 29 64 mm 1 135 1 167 in T R Rear wheel sensor bolt 7 Nm 0 7 m kgf 5 1 ft lbf a 2 1 ...

Page 219: ...ng procedure applies to both of the front brake calipers 1 Brake hose holder 1 2 Front brake caliper 1 3 Brake pad bolt 2 4 Brake pad spring 2 5 Front brake pad 4 4 6 Nm 0 6 m kgf 4 3 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 1 2 5 4 5 3 3 ...

Page 220: ...re applies to both of the front brake calipers 1 Brake hose holder 1 2 Front brake caliper 1 3 Brake pad bolt 2 4 Brake pad spring 2 5 Front brake pad 4 6 Nm 0 6 m kgf 4 3 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 1 2 3 3 5 4 5 4 ...

Page 221: ...cylinder reservoir diaphragm 1 4 Brake lever 1 5 Front brake light switch 1 6 Brake hose union bolt 1 7 Copper washer 2 8 Brake hose front brake master cylinder to brake pipe lower joint assembly 1 9 Front brake master cylinder holder 1 10 Front brake master cylinder 1 10 7 6 8 5 4 9 1 2 3 S 1 0 Nm 0 10 m kgf 0 72 ft Ibf T R 1 2 Nm 0 12 m kgf 0 87 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 30 Nm ...

Page 222: ...sembling 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 S BF 4 3 2 5 1 New New ...

Page 223: ...Brake hose holder 1 2 Brake hose union bolt 1 3 Copper washer 2 4 Brake hose brake pipe upper joint assembly to right front brake caliper 1 5 Brake hose union bolt unified brake system 1 Right side only 6 Copper washer 2 Right side only 7 Brake hose metering valve to right front brake caliper 1 Right side only 8 Front brake caliper 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 40 N...

Page 224: ... Brake hose holder 1 2 Brake hose union bolt 1 3 Copper washer 2 4 Brake hose brake pipe upper joint assembly to right front brake caliper 1 5 Brake hose union bolt unified brake system 1 Right side only 6 Copper washer 2 Right side only 7 Brake hose metering valve to right front brake caliper 1 Right side only 8 Front brake caliper 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 40 ...

Page 225: ... Brake pad bolt 2 2 Brake pad spring 2 3 Front brake pad 4 4 Brake caliper piston 4 5 Brake caliper piston dust seal 4 6 Brake caliper piston seal 4 7 Bleed screw 1 8 Bleed screw 1 Right side only 3 4 4 1 2 2 1 7 3 5 5 5 5 6 6 6 6 8 6 Nm 0 6 m kgf 4 3 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R New New New New S S BF BF S New New New New ...

Page 226: ... Front wheel Refer to FRONT WHEEL on page 4 27 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 or right to ensure that the front wheel...

Page 227: ...s as a set 2 Install Brake pads Brake pad springs TIP Always install new brake pads and new brake pad springs 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 with your finger c Tighten the bleed screw d Install new brake pads and new brake p...

Page 228: ...ring valve to right front brake caliper 4 TIP Put the end of the brake hoses into a container and pump out the brake fluid carefully EAS30172 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Remove Brake caliper pistons 1 Brake caliper piston dust seals 2 Brake caliper piston seals 3 a Blow compressed air into the brake hose joint opening a to ...

Page 229: ...isassembled replace the brake caliper piston dust seals and brake caliper piston seals EAS30175 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Install Front brake caliper 1 temporarily Copper washers Brake hose brake pipe upper joint assembly to right front brake caliper 2 Brake hose metering valve to right front brake caliper 3 Brake hose union...

Page 230: ...n up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 6 Check Brake fluid level Below the minimum level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 13 7 Check Brake lever and brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYD...

Page 231: ...ke master cylinder 1 Brake master cylinder holder 2 TIP Install the brake master cylinder holder with the UP mark facing up Fit the projection a on the brake master cylin der holder into the hole b in the right handle bar First tighten the upper bolt then the lower bolt 2 Install Copper washers Brake hose front brake master cylinder to brake pipe lower joint assembly Brake hose union bolt WARNING ...

Page 232: ...der reser voir or brake fluid reservoir Water will sig nificantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 5 Check Brake fluid level Below the minimum lev...

Page 233: ...ds 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 5 3 4 4 3 2 1 1 5 S S 6 Nm 0 6 m kgf 4 3 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R ...

Page 234: ...id reservoir cap 1 2 Brake fluid 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 Footrest assembly right 1 8 Rear brake light switch 1 1 2 3 4 5 6 7 8 New New New LT LT 18 Nm 1 8 m kgf 13 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 28 Nm 2 8 m kgf 20...

Page 235: ...t 1 10 Copper washer 2 11 Brake hose rear brake master cylinder to brake pipe middle joint assembly 1 12 Rear brake master cylinder 1 9 10 11 12 New New 10 New LT LT 18 Nm 1 8 m kgf 13 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R ...

Page 236: ...ar 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 S 16 Nm 1 6 m kgf 12 ft Ibf T R BF New New 3 2 1 4 5 ...

Page 237: ...ke hose brake pipe 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 6 5 4 9 4 2 1 3 8 7 125 Nm 12 5 m kgf 90 ft lbf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 27 Nm 2 7 m kgf...

Page 238: ...per bolt 2 2 Brake pad shim 2 3 Rear brake pad 2 4 Brake pad spring 2 5 Rear brake caliper bracket 1 6 Brake caliper piston 1 7 Brake caliper piston dust seal 1 8 Brake caliper piston seal 1 9 Bleed screw 1 7 8 New New 9 4 5 2 3 2 3 4 6 1 1 S S S S BF 6 Nm 0 6 m kgf 4 3 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R ...

Page 239: ...c 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 53 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 53 5 Adjust Brake disc deflection Re...

Page 240: ... level Below the minimum level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 13 6 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 EAS30186 REMOVING THE REAR BRAKE CALIPER TIP Before disassembling the brake caliper drain the brake fluid from the entir...

Page 241: ...ton Brake caliper cylinder 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passage brake caliper body Obstruction Blow out with compressed air WARNING EWA17300 Whenever a brake caliper is disassembled replace the brake caliper piston dust seal and brake caliper piston seal 2 Check Brake caliper bracket C...

Page 242: ...ousing is aligned with the projection d on the bracket NOTICE ECA14470 Make sure there are no foreign materials in the wheel hub Foreign materials cause dam age to the inner sensor rotor and wheel sen sor WARNING EWA13500 Make sure the brake hose is routed properly 2 Tighten Brake torque rod nuts Rear wheel axle nut Rear wheel axle pinch bolt 3 Install Copper washers Brake hose proportioning valve...

Page 243: ... fluid immediately 7 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 8 Check Brake fluid level Below the minimum level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 13 9 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14...

Page 244: ...der make sure the brake pipe touches the projection a as shown 2 Install Rear brake light switch 1 TIP Install the rear brake light switch spring as shown in the illustration 3 Fill Brake fluid reservoir with the specified amount of the specified brake fluid WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor br...

Page 245: ...mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 13 6 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 7 Adjust Rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 31 ...

Page 246: ... page 4 1 Air shroud Refer to GENERAL CHASSIS 7 on page 4 23 1 Brake fluid reservoir 1 2 License plate light connector 1 Disconnect 3 Tail brake light assembly coupler 1 Disconnect 4 Tail brake light assembly 1 5 Brake light relay 1 6 Brake switch relay 1 7 Plastic band 1 8 Seat lock cable assembly 1 9 Rear fender assembly 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 4 1 3 9 8 7 5...

Page 247: ...ct 3 Brake pipe hydraulic unit to metering valve 1 4 Metering valve 1 5 Brake hose holder 1 6 Brake pipe proportioning valve to rear brake hose 1 7 Brake pipe hydraulic unit to proportioning valve 1 1 1 1 1 3 2 5 6 7 4 New New New New New New New New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R...

Page 248: ... brake pipe lower joint assembly 1 Disconnect 14 Brake pipe upper joint assembly 1 15 Brake pipe joint assembly stay 1 16 Brake pipe middle joint assembly 1 17 Brake pipe lower joint assembly 1 9 9 11 15 16 14 17 9 9 10 13 8 12 New New New New New New New New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 f...

Page 249: ...Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 Rear fender Metering valve Proportioning valve Brake pipes Refer to ABS ANTI LOCK BRAKE SYS TEM on page 4 73 1 ABS ECU coupler 1 Disconnect 2 Cap nut 3 3 Hydraulic unit assembly bracket 1 4 Hydraulic unit assembly 1 4 3 2 2 2 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 16 Nm 1 6 m kg...

Page 250: ... Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 Rear fender Metering valve Proportioning valve Brake pipes Refer to ABS ANTI LOCK BRAKE SYS TEM on page 4 73 1 ABS ECU coupler 1 Disconnect 2 Cap nut 3 3 Hydraulic unit assembly bracket 1 4 Hydraulic unit assembly 1 4 3 2 2 2 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 16 Nm 1 6 m k...

Page 251: ...ake hose 6 Hydraulic unit assembly 7 Rear wheel sensor 8 Rear wheel sensor rotor 9 Rear brake caliper 10 Brake hose brake pipe to rear brake caliper 11 Metering valve 12 Front brake caliper left 13 Front brake caliper right partially operated together with the rear brake 14 Front wheel sensor 15 Front wheel sensor rotor 16 Brake hose rear brake master cylinder to brake pipe middle joint assembly 1...

Page 252: ...bad contacts If the union bolts for the hydraulic unit as sembly have been removed be sure to tighten them to the specified torque and bleed the brake system 1 Remove FJR13ESG Tail brake light assembly Refer to REAR SHOCK ABSORBER AS SEMBLY FJR13ESG on page 4 123 2 Remove the rear fender bolts 1 and quick fasteners 2 FJR13ESG 3 Slide the rear fender assembly 1 down FJR13ESG 4 Remove Brake pipes Br...

Page 253: ...STALLING THE HYDRAULIC UNIT ASSEMBLY 1 Install Hydraulic unit assembly TIP Do not allow any foreign materials to enter the hydraulic unit assembly or the brake hoses or brake pipes when installing the hydraulic unit as sembly NOTICE ECA18260 Do not remove the rubber plugs or bolts M10 1 0 installed in the flare nut holes be fore installing the hydraulic unit assembly 2 Remove Rubber plugs or bolts...

Page 254: ...rtioning valve 1 Brake pipe hydraulic unit to proportioning valve 2 TIP Temporarily install the brake pipe 8 Tighten Brake pipe flare nuts NOTICE ECA19290 If the brake pipe flare nut does not turn easi ly replace the hydraulic unit brake pipes and related parts as a set TIP First tighten the flare nut 3 on the hydraulic unit assembly end of the brake pipe then the flare nut 4 on the proportioning ...

Page 255: ...First tighten the brake pipe flare nut and meter ing valve bolts then the brake pipe union bolts When tightening the brake pipes onto the me tering valve make sure that the brake pipes touch the projections a on the metering valve 13 Fill Brake master cylinder reservoir Brake fluid reservoir with the specified amount of the specified brake fluid WARNING EWA13090 Use only the designated brake fluid...

Page 256: ...an be tested using the following two methods Hydraulic unit operation test 1 this test checks the function of the ABS after the system was disassembled adjusted or serviced Hydraulic unit operation test 2 this test gener ates the same reaction force pulsating action that is generated in the brake lever and brake pedal when the ABS is activated Hydraulic unit operation test 1 WARNING EWA13120 Secur...

Page 257: ...d then in the brake pedal twice If the pulse is felt in the brake pedal before it is felt in the brake lever check that the brake hoses and brake pipes are connected correctly to the hydraulic unit assembly If the rear brake force is not released during the second pulse in the brake pedal but during the pulse in the brake lever or during the first pulse in the brake pedal check that the brake hose...

Page 258: ...in switch to ON 8 Push the side of the start engine stop switch 1 for at least 4 seconds NOTICE ECA14790 Do not operate the brake lever or the brake pedal 9 After releasing the start engine stop switch operate the brake lever and the brake pedal simultaneously 10 A reaction force pulsating action is generated in the brake lever 1 0 5 second after the brake lever and the brake pedal are operated si...

Page 259: ... the pulsating action is felt in the brake pedal before it is felt in the brake lever check that the brake hoses and brake pipes are connected correctly to the hydraulic unit assembly If the pulsating action is hardly felt in either the brake lever or brake pedal check that the brake hoses and brake pipes are con nected correctly to the hydraulic unit as sembly 13 Turn the main switch to OFF 14 Re...

Page 260: ...itch left 1 6 Grip end 1 7 Handlebar grip 1 8 Lead holder 1 9 Clutch switch lead 1 10 Handlebar switch lead left 1 11 Grip warmer lead left 1 1 8 9 10 11 3 2 4 4 5 7 6 A A 8 A A 11 10 9 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 2 3 Nm 0 23 m kgf 1 7 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 65 Nm 6 5 m kgf 47 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft...

Page 261: ... right 1 8 Lead holder 1 9 Grip warmer lead right 1 10 Handlebar switch lead right 1 11 Front brake light switch lead 1 12 Handlebar switch right 1 LT LS LS LS LS A A 5 5 4 12 6 2 10 11 9 8 1 7 3 8 A A 11 9 10 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 65 Nm 6 5 m kgf 47 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T...

Page 262: ...ed in the same position e Install the handlebar bolts 3 and nuts 2 temporarily f Tighten the handlebar bolts and nuts TIP First tighten the bolts then tighten the nuts EAS30203 REMOVING THE HANDLEBARS 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 Remove Handlebar grip 1 TIP Blow compressed air between the handle...

Page 263: ...bber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rub ber adhesive has fully dried TIP 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 Handlebar switch right 1 TIP Align the projection a on the right handlebar switch with the hole b on the right handlebar 4 Install Handlebar switch left 1 TIP Align th...

Page 264: ...housing align the projection a on the housing with the hole b in the right handlebar and be sure not to pinch the right grip warmer lead There should be 1 3 mm 0 04 0 12 in of clearance c between the throttle grip and the grip end 9 Install Front brake master cylinder assembly Front brake master cylinder holder 1 TIP Install the brake master cylinder holder with the UP mark facing up Align the pro...

Page 265: ...lign the mating surfaces of the clutch master cylinder holder with the punch mark a on the left handlebar First tighten the upper bolt then the lower bolt 11 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP OPERATION on page 3 32 T R Clutch master cylinder holder bolt 10 Nm 1 0 m kgf 7 2 ft lbf Throttle grip free play 1 0 3 0 mm 0 04 0 12 in b a 1 ...

Page 266: ...plies to both of the front fork legs Lower inner panel Refer to GENERAL CHASSIS 2 on page 4 5 Front wheel Refer to FRONT WHEEL on page 4 27 1 Upper bracket pinch bolt 1 Loosen 2 Cap bolt 1 Loosen 3 Lower bracket pinch bolt 2 Loosen 4 Front fork leg 1 3 2 4 1 23 Nm 2 3 m kgf 17 ft Ibf T R 26 Nm 2 6 m kgf 19 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R ...

Page 267: ...s 1 Cap bolt 1 2 O ring 1 3 Washer 1 4 Spacer 1 5 Fork spring 1 6 Dust seal 1 7 Oil seal clip 1 8 Oil seal 1 9 Washer 1 10 Damper rod assembly bolt 1 11 Copper washer 1 12 Damper rod assembly 1 13 Inner tube 1 14 Oil flow stopper 1 New LS 13 14 12 10 11 9 8 7 6 5 4 3 2 1 23 Nm 2 3 m kgf 17 ft Ibf T R ...

Page 268: ... Order Job Parts to remove Q ty Remarks 15 Outer tube bushing 1 1 D 52 mm 2 05 in l 15 mm 0 59 in 16 Outer tube bushing 2 1 D 51 mm 2 01 in l 15 mm 0 59 in 17 Inner tube bushing 1 18 Outer tube 1 19 Protector 1 New LS 18 17 16 15 19 23 Nm 2 3 m kgf 17 ft Ibf T R ...

Page 269: ... 1 3 Nut 1 4 Damper adjusting rod 1 5 Washer 1 6 Spacer 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 Inner tube 1 15 13 14 11 10 9 8 7 3 4 1 2 5 6 12 23 Nm 2 3 m kgf 17 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R New LS ...

Page 270: ...Q ty Remarks 16 Oil flow stopper 1 17 Outer tube bushing 1 1 D 52 mm 2 05 in l 15 mm 0 59 in 18 Outer tube bushing 2 1 D 51 mm 2 01 in l 15 mm 0 59 in 19 Inner tube bushing 1 20 Outer tube 1 21 Protector 1 19 20 16 18 17 21 23 Nm 2 3 m kgf 17 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R New LS ...

Page 271: ...A13640 Before loosening the upper and lower brack et pinch bolts support the front fork leg EAS31649 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 Right side only 2 Drain Fork oil TIP 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 scr...

Page 272: ...bly Damage wear Replace Obstruction Blow out all of the oil passag es with compressed air NOTICE ECA20300 The front fork leg has a built in damper rod assembly and a very sophisticated internal construction which are particularly sensi tive to foreign material When disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork EAS31651 ASSEMBLING THE FRO...

Page 273: ... 15 mm 0 59 in 1 with the slide metal installer 2 and fork seal driver 3 5 Install Outer tube bushing 1 D 52 mm 2 05 in l 15 mm 0 59 in 1 Washer 2 with the slide metal installer 3 and fork seal driver weight 4 6 Install Oil seal 1 Suitable washer 2 ex 4SV 23115 00 with the slide metal installer 3 and fork seal driver weight 4 Recommended oil Suspension oil M1 or equivalent T R Damper rod assembly ...

Page 274: ...ce of the inner tube with fork oil 7 Remove Suitable washer 8 Install Oil seal clip 1 TIP Adjust the oil seal clip so that it fits into the outer tube s groove 9 Install Dust seal 1 with the fork seal driver 2 10 Install Protector TIP Fit the projection a on the protector into the slot b in the outer tube 11 Fill Front fork leg with the specified amount of the recom mended fork oil Slide metal ins...

Page 275: ...ubbles have dispersed TIP Be sure to bleed the front fork leg of any residual air 15 Measure Front fork leg oil level a from the top of the inner tube with the outer tube fully compressed and without the fork spring Out of specification Correct TIP While filling the front fork leg keep it upright After filling slowly pump the front fork leg up and down to distribute the fork oil 16 Install Fork sp...

Page 276: ...leg Temporarily tighten the upper and lower bracket pinch bolts TIP 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 Make sure the brake hoses are routed prop erly 3 Adjust Spring preload Rebound damping right side only Distance b 15 mm 0 59 in T R Front fork cap bolt locknut 15 Nm 1 5 m...

Page 277: ...FRONT FORK FJR13AG 4 104 Compression damping right side only Refer to ADJUSTING THE FRONT FORK LEGS FJR13AG on page 3 20 ...

Page 278: ...to GENERAL CHASSIS 2 on page 4 5 Front wheel Refer to FRONT WHEEL on page 4 27 Handlebar Refer to HANDLEBARS on page 4 87 1 Front fork stepping motor coupler 1 Disconnect 2 Upper bracket pinch bolt 1 Loosen 3 Cap bolt with front fork stepping motor 1 Loosen 4 Lower bracket pinch bolt 2 Loosen 5 Front fork leg 1 2 4 3 1 5 23 Nm 2 3 m kgf 17 ft Ibf T R 26 Nm 2 6 m kgf 19 ft Ibf T R 23 Nm 2 3 m kgf 1...

Page 279: ...Cap bolt with front fork stepping motor 1 2 O ring 1 3 Locknut 1 4 Spacer 1 5 Fork spring 1 6 Outer tube 1 7 Dust seal 1 8 Oil seal clip 1 9 Oil seal 1 10 Washer 1 11 Damper rod assembly bolt 1 12 Copper washer 1 13 Damper rod assembly 1 14 Inner tube 1 LT New New New New 15 Nm 1 5 m kgf 11 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 2 1 11 3 4 5 6 10 9 12 7 8 13 14 ...

Page 280: ... legs NOTICE ECA20260 Because the left and right damper rod as semblies are different be sure to install them in the correct positions Otherwise the elec tronically adjustable suspension could mal function 1 Remove Cap bolt with front fork stepping motor 1 from the damper rod Spacer 2 Locknut 3 NOTICE ECA20270 Do not drop the cap bolt with front fork step ping motor or subject it to shocks a Press...

Page 281: ...the compression damper rod assembly has the holes a of oil path unlike the right side EAS30208 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs NOTICE ECA20290 Do not drop the cap bolt with front fork stepping motor or subject it to shocks Do not check the operation of the front fork stepping motor assembly as an individual component 1 Check Inner tube Ou...

Page 282: ...as semblies are different be sure to install them in the correct positions Otherwise the electronically adjustable suspension could malfunction TIP When assembling the front fork leg be sure to replace the following parts Oil seal Dust seal Before assembling the front fork leg make sure all of the components are clean 1 Install Damper rod assembly 1 onto the inner tube 2 Damper rod assembly bolt C...

Page 283: ...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 5 Install Outer tube onto the inner tube 6 Install Oil seal 1 with the fork seal driver 2 7 Install Oil seal clip 1 TIP Adjust the oil seal clip so that it fits into the outer tube groove Damper rod holder ø27 ...

Page 284: ...l TIP Be sure to stroke the damper rod slowly be cause the fork oil may spurt out 12 Before measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed TIP 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 outer tube with the outer tube fully compressed and without the fork spring Out of ...

Page 285: ...wn in the spacer with the fork spring compressor 1 f Pull up the rod puller and install the rod holder 2 between the locknut 3 and the spacer 4 TIP Use the side of the rod holder that is marked B g Remove the rod puller and the rod puller at tachment h Install the cap bolt with front fork stepping motor and then finger tighten it TIP Tighten the cap bolt with front fork stepping mo tor until it co...

Page 286: ...flush with the top of the upper bracket 2 Tighten Lower bracket pinch bolts 1 Cap bolt with front fork stepping motor 2 Upper bracket pinch bolt 3 WARNING EWA13680 Make sure the brake hoses are routed prop erly TIP When installing the front fork legs make sure that the front fork stepping motor couplers are positioned at the angles shown in the illustration 3 Adjust Spring preload Rebound damping ...

Page 287: ... wheel Refer to FRONT WHEEL on page 4 27 Front fork legs Refer to FRONT FORK FJR13AG on page 4 93 and FRONT FORK FJR13ESG on page 4 105 1 Immobilizer unit coupler cover holder 1 2 Immobilizer unit coupler cover 2 3 Immobilizer unit coupler 1 Disconnect 4 Main switch coupler 2 Disconnect 5 Lower bracket cover 1 LS LS 5 LS LT LT 3 1 2 2 4 4 T R 1st 52 Nm 5 2 m kgf 38 ft Ibf 2nd 18 Nm 1 8 m kgf 13 ft...

Page 288: ...ring nut 1 14 Lower bracket 1 15 Upper bearing cover 1 16 Upper bearing inner race 1 17 Upper bearing 1 18 Lower bearing 1 19 Lower bearing inner race 1 20 Dust seal 1 21 Upper bearing outer race 1 22 Lower bearing outer race 1 LS LS 14 18 6 12 LS LT LT LT 7 8 9 22 21 17 16 15 13 11 10 19 20 T R 1st 52 Nm 5 2 m kgf 38 ft Ibf 2nd 18 Nm 1 8 m kgf 13 ft Ibf 115 Nm 11 5 m kgf 83 ft lbf T R 7 Nm 0 7 m ...

Page 289: ...ces 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 NOTICE ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged TIP Always replace the bearings and bearing races as a set 4 Check Upper bracket Lower bracket ...

Page 290: ...acket Steering stem nut TIP Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK FJR13AG on page 4 93 and FRONT FORK FJR13ESG on page 4 105 TIP Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut T R Steering stem nut 115 Nm 11 5 m kgf 83 ft lbf ...

Page 291: ...ufflers Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 3 1 Rear shock absorber spring preload adjusting lever nut 3 2 Rear shock absorber assembly lower nut Wash er Bolt 1 1 1 3 Connecting arm nut Washer Bolt 2 2 2 4 Connecting arm 2 5 Rear shock absorber assembly upper nut Bolt Spacer 1 1 1 New New New New 3 40 Nm 4 0 m kgf 29 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 64 Nm 6 4 m kgf 46 f...

Page 292: ... 8 Relay arm nut Bolt Spacer 1 1 1 9 Relay arm 1 10 Spacer 1 11 Spacer 1 12 Spacer 1 13 Oil seal 6 14 Bearing 2 15 Bearing 2 New New New New 40 Nm 4 0 m kgf 29 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 64 Nm 6 4 m kgf 46 ft Ibf T R 48 Nm 4 8 m kgf 35 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 8 LS LS 6 11 13 10 15 13 14 13 14 1312 15 9 13 7 LS ...

Page 293: ...hrough 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 EAS31914 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 TIP Place the vehicle on a suitable stan...

Page 294: ...e Spacer Bearings Oil seals 2 Install Bearings 1 2 to the relay arm Oil seals 3 4 to the relay arm TIP Make sure that the oil seals do not protrude past the edges of the relay arm When installing the oil seals to the relay arm face the character stamp of the oil seals out side 3 Install Relay arm TIP Make sure that the embossed mark 5JW on the relay arm faces to the left EAS31918 INSTALLING THE RE...

Page 295: ...AR SHOCK ABSORBER ASSEMBLY FJR13AG 4 122 TIP Make sure that the warning label on the rear shock absorber assembly faces to the right When installing the rear shock absorber as sembly lift up the swingarm ...

Page 296: ...rs Refer to GENERAL CHASSIS 1 on page 4 1 Storage compartment Refer to GENERAL CHASSIS 7 on page 4 23 1 Brake fluid reservoir 1 2 License plate light coupler 1 Disconnect 3 Tail brake light assembly coupler 1 Disconnect 4 IMU coupler 1 Disconnect 5 Hose holder 1 6 Tail brake light assembly 1 7 Brake light relay 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 6 1 3 2 7 5 4 ...

Page 297: ...Remarks 8 Brake switch relay 1 9 Plastic band 1 10 Rear fender assembly 1 11 Rear shock absorber assembly stepping motor coupler 1 Disconnect 12 Rear shock absorber assembly DC motor cou pler 1 Disconnect 13 Seat lock cable assembly 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 10 13 9 8 12 11 ...

Page 298: ...nd 1 2 Rear shock absorber assembly lower nut Bolt Spacer 1 1 1 3 Connecting arm nut Washer Bolt 2 2 2 4 Connecting arm 2 5 Rear shock absorber assembly upper nut Bolt Spacer 1 1 1 6 Relay arm 1 7 Spacer 2 Length 30 0 mm 1 18 in 8 Spacer 1 New New New New 64 Nm 6 4 m kgf 46 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ib...

Page 299: ...absorber assembly stepping motor protector 1 14 Rear shock absorber assembly gas cylinder holder 1 15 Rear shock absorber assembly 1 New New New New 64 Nm 6 4 m kgf 46 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 48 Nm 4 8 m kgf 35 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R LS LS 12 13 14 15 9 11 9 9 9 10 10 9 11 9...

Page 300: ...motor 1 2 Preload adjusting pump bracket 1 3 DC motor bracket 2 4 DC motor 1 5 Sponge ring 1 6 DC motor joint 1 0 7 Nm 0 07 m kgf 0 51 ft Ibf T R 0 7 Nm 0 07 m kgf 0 51 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R New LT LT LT LT 1 4 6 3 5 2 ...

Page 301: ...ng the rear shock absorber read and make sure you understand the following information The manufacturer cannot be held responsi ble for property damage or personal injury that may result from improper handling of the rear shock absorber Do not tamper or attempt to open the rear shock absorber Do not subject the rear shock absorber to an open flame or any other source of high heat High heat can cau...

Page 302: ...t the rear of the vehicle is elevated 3 Remove Rear shock absorber assembly upper bolt 1 Spacer 2 Rear shock absorber assembly TIP Partially pull out the rear shock absorber assem bly upper bolt slide the spacer 2 towards the bolt head to create some clearance between the bolt and the frame and then remove the bolt completely EAS30220 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1 Check Rear shock ab...

Page 303: ...rn and then install the DC motor EAS30225 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Install Rear shock absorber assembly TIP Make sure that the warning label on the rear shock absorber assembly faces to the right When installing the rear shock absorber as sembly lift up the swingarm 2 Install Rear shock absorber assembly gas cylinder holder 1 Rear shock absorber assembly gas cylinder 2 TIP Ali...

Page 304: ...rarily 2 Pass the rear shock absorber assembly step ping motor coupler and rear shock absorber assembly DC motor coupler through the holes in the DC motor upper cover and rear fender assembly and then connect the cou plers TIP Move the rear shock absorber assembly slightly and then pass the couplers through the holes in the DC motor upper cover and rear fender as sembly 3 Install the rear shock ab...

Page 305: ...REAR SHOCK ABSORBER ASSEMBLY FJR13ESG 4 132 5 Install the rear fender bolts 1 and quick fas teners 2 1 1 2 2 ...

Page 306: ...EAR SHOCK ABSORBER ASSEMBLY FJR13ESG on page 4 123 Final drive assembly Universal joint Refer to SHAFT DRIVE on page 4 137 1 Footrest assembly bolt right 2 2 Pivot shaft end cover 1 3 Pivot shaft nut retainer 1 4 Pivot shaft nut 1 5 Pivot shaft nut 1 6 Pivot shaft 1 LT LT New LS LS LS New LS New 3 5 6 1 4 2 LS 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 115 Nm 11 5 m kgf 83 ft lbf T R 23 Nm 2 3 m kgf 17 ft I...

Page 307: ...al 1 15 Circlip 1 16 Bearing 1 17 Spacer 1 18 Bearing 1 LT LT New LS LS LS New LS New LS 17 16 15 12 11 10 8 9 18 14 13 9 10 7 10 Nm 1 0 m kgf 7 2 ft Ibf T R 115 Nm 11 5 m kgf 83 ft lbf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 125 Nm 12 5 m kgf 90 ft lbf T R 28 Nm 2 8 m kgf 20 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R ...

Page 308: ...e spacers bear ings washers and dust covers EAS30227 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 wear Replace Bearings Damage pitting Replace ...

Page 309: ... outside 3 Tighten Pivot shaft Pivot shaft nut Pivot shaft self lock nut 4 Swingarm 5 Connecting arm A Left side B Right side T R Pivot shaft 23 Nm 2 3 m kgf 17 ft lbf T R Pivot shaft nut 115 Nm 11 5 m kgf 83 ft lbf T R Pivot shaft self lock nut 125 Nm 12 5 m kgf 90 ft lbf 1 4 a A 4 2 2 A B b c 5 5 3 3 b c ...

Page 310: ...ly Order Job Parts to remove Q ty Remarks Final gear oil Drain Refer to CHANGING THE FINAL GEAR OIL on page 3 31 Rear wheel Refer to REAR WHEEL on page 4 39 1 Final drive assembly 1 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 42 Nm 4 2 m kgf 30 ft Ibf T R ...

Page 311: ...ft arm 1 2 Sidestand switch coupler 1 Disconnect 3 Sidestand 1 4 Footrest assembly left 1 5 Drive shaft dust cover 1 6 Universal joint dust cover 1 7 Universal joint 1 2 3 1 4 5 6 7 LT LT LT LT LT LS 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 0 Nm 0 40 m k...

Page 312: ...ng gear bearing housing 1 6 Dust cover 1 7 Oil seal 1 8 Stopper bolt 1 Left hand threads 9 Stopper bolt shim Refer to ADJUSTING THE RING GEAR TO STOPPER BOLT CLEARANCE on page 4 146 New New New 23 Nm 2 3 m kgf 17 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 110 Nm 11 m kgf 80 ft lbf ...

Page 313: ...2 Bearing 1 13 Thrust washer 1 Refer to ADJUSTING THE FINAL GEAR BACKLASH on page 4 145 and ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR on page 4 148 14 Coupling gear nut 1 15 Coupling gear 1 16 Bearing retainer 1 Left hand threads 17 Oil seal 1 18 Final drive pinion gear 1 19 Bearing 1 23 Nm 2 3 m kgf 17 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R 9 Nm 0 9 m kgf ...

Page 314: ...o ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR on page 4 148 21 Final drive pinion gear bearing 1 22 Ring gear bearing 1 23 Oil seal 1 24 Collar 1 25 Final gear case 1 23 Nm 2 3 m kgf 17 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 110 Nm 11 m kgf 80 ft lbf T R New ...

Page 315: ...bly indicates these symptoms stop riding immediately to minimize gear damage c A slight clunk evident at low speed operation not to be confused with normal vehicle operation Broken 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 Sympto...

Page 316: ...l bearings damaged Replace the wheel bearing s Refer to FRONT WHEEL on page 4 27 2 Place the vehicle on a suitable stand so that the rear wheel is ele vated and then spin the rear wheel Is the wheel bearing damaged Rear wheel bearings and shaft drive bear ings are probably not damaged Repeat the test or remove and check the compo nents 3 Remove the rear wheel Are the wheel bearings damaged Replace...

Page 317: ...g enough to locate a leak Oil leak Repair or replace the faulty part s TIP What may appear to be an oil leak on 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 EAS30240 MEASURING THE FINAL GEAR BACKLASH 1 Secure the final drive assembly i...

Page 318: ...klash EAS30241 ADJUSTING THE FINAL GEAR BACKLASH 1 Remove Ring gear bearing housing bolts 1 Ring gear bearing housing nuts 2 TIP Working in a crisscross pattern loosen each bolt and nut 1 4 of a turn After all of the bolts and nuts are fully loosened remove them 2 Remove Ring gear bearing housing 1 Dust cover 2 Ring gear 3 Ring gear shim s 4 Thrust washer 5 3 Adjust Final gear backlash a Select th...

Page 319: ...opper 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 NOTICE ECA14320 The stopper bolt has left hand threads To tighten the stopper bolt turn it counter clockwise Apply LOCTITE onto the stopper bolt 4 Measure Ring gear to stopper bolt clearance Ring gear shims Thickness mm 0 25 0 30 0 40 0...

Page 320: ...ng 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 NOTICE ECA14340 The final drive pinion gear should only be re moved if ring gear replacement is necessary TIP Lightly tap on the end of the final drive pinion gear with a soft hammer EAS30245 REMOVING AND INSTALLING THE BEARINGS 1 Check Beari...

Page 321: ... 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 TIP The bearing can be reused but Yamaha recom mends installing a new one EAS30246 ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR TIP Aligning the final drive pinion gear and ring gear is necessary when any of the following parts are replaced Final gear case Ring...

Page 322: ...m 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 surface of the ring gear bearing housing to be divided by 100 and added to 3 e a numeral positive or negative on the in si...

Page 323: ...ring retainer wrench 1 NOTICE 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 4 Stake the coupling gear nut 1 at a cutout a in the final drive pinion gear 5 Install Ring gear bearing housing along with the ring gear but without the thrust washer Ring ...

Page 324: ...ear to thrust washer clearance is out of specification select the correct thrust washer as follows h Select the suitable thrust washer from the fol lowing chart i Repeat the measurement steps until the ring gear to thrust washer clearance is within the specified limits EAS30247 CHECKING THE DRIVE SHAFT 1 Check Drive shaft splines Damage wear Replace the drive shaft EAS30918 INSTALLING THE DRIVE SH...

Page 325: ...olt M10 3 tempo rarily and then tighten them to the specified torques in the proper tightening sequence as shown Fork seal driver weight 90890 01184 Replacement hammer YM A9409 7 Fork seal driver attachment 90890 01186 Replacement 27 mm YM A9409 1 Fork seal driver weight 90890 01184 Replacement hammer YM A9409 7 Oil seal installing tool 90890 01512 Oil seal installing tool YM 01512 Installed depth...

Page 326: ... ac cording to the procedure indicated by the num bers in the illustration 10 Install Shift arm 1 TIP Align the punch mark a in the shift shaft with the slot in the shift arm 11 Fill Final gear case Refer to CHECKING THE FINAL GEAR OIL LEVEL on page 3 30 12 Check Shift pedal position Refer to ADJUSTING THE SHIFT PEDAL on page 5 59 2 1 3 1 2 ...

Page 327: ...ER 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 33 REMOVING THE STARTER CLUTCH 5 33 CHECKING THE STARTER CLUTCH 5 33 INSTALL...

Page 328: ...FT SHAFT 5 59 CHECKING THE STOPPER LEVER 5 59 INSTALLING THE SHIFT SHAFT 5 59 ADJUSTING THE SHIFT PEDAL 5 59 OIL PUMP 5 61 CHECKING THE OIL PUMP 5 64 CHECKING THE RELIEF VALVE 5 64 CHECKING THE OIL DELIVERY PIPES 5 64 CHECKING THE OIL STRAINER 5 65 ASSEMBLING THE OIL PUMP 5 65 INSTALLING THE OIL PAN 5 65 MIDDLE GEAR 5 66 REMOVING THE MIDDLE DRIVE SHAFT ASSEMBLY 5 70 DISASSEMBLING THE MIDDLE DRIVE ...

Page 329: ... 87 CHECKING THE PISTON RINGS 5 88 CHECKING THE PISTON PIN 5 89 CHECKING THE CONNECTING RODS 5 90 INSTALLING THE CONNECTING RODS AND PISTONS 5 91 CRANKSHAFT 5 94 REMOVING THE CRANKSHAFT JOURNAL BEARINGS 5 95 CHECKING THE OIL NOZZLES 5 95 CHECKING THE CRANKSHAFT 5 95 INSTALLING THE CRANKSHAFT 5 97 TRANSMISSION 5 98 REMOVING THE TRANSMISSION 5 100 CHECKING THE SHIFT FORKS 5 100 CHECKING THE SHIFT DR...

Page 330: ...nto the cylinders 7 Install Compression gauge 1 Extension 2 8 Measure Compression pressure Out of specification Refer to steps c and d a Set the main switch to ON b With the throttle wide open crank the engine until the reading on the compression gauge stabilizes WARNING EWA12940 To prevent sparking ground all spark plug leads before cranking the engine TIP The difference in compression pressure b...

Page 331: ...el tank Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Compression pressure with oil applied into the cylinder Reading Diagnosis Higher than without oil Piston ring s wear or damage Repair Same as without oil Pistons valves cylinder head gasket or piston ring s possibly defec tive Repair T R Spark plug 13 Nm 1 3 m kgf 9 4 ft lbf ...

Page 332: ...e 4 22 Fuel tank Refer to FUEL TANK on page 7 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 29 Radiator Refer to RADIATOR on page 6 1 1 O2 sensor coupler 1 Disconnect 2 Muffler left 1 3 Muffler right 1 8 2 1 3 New New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 20 Nm 2 0 m kgf ...

Page 333: ...pipe assembly 1 7 Gasket 4 8 O2 sensor 1 Remove the O2 sensor only when neces sary 6 8 4 7 8 New 5 New 5 New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 45 Nm 4 5 m kgf 33 ft Ibf T R ...

Page 334: ... AIR INDUCTION SYSTEM on page 7 13 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 25 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 39 Footrest assembly left Sidestand Refer to SHAFT DRIVE on page 4 137 1 Clut...

Page 335: ...Disconnect 5 Oil level switch coupler 1 Disconnect 6 Crankshaft position sensor coupler 1 Disconnect 7 Gear position switch coupler 1 Disconnect 8 Cylinder identification sensor coupler 1 9 Ignition coil coupler 4 10 Wire harness holder 1 11 Ground lead 1 Disconnect 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R E 9 10 9 9 2 2 3 5 4 6 7 8 11 ...

Page 336: ...racket top 2 8 Pinch bolt rear lower side 2 9 Pinch bolt front side 2 10 Engine mounting bolt right front lower side 1 11 Spacer 2 E E 8 Nm 0 8 m kgf 5 8 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R 37 Nm 3 7 m kgf 27 ft Ibf T R 37 Nm 3 7 m kgf 27 ft Ibf T R 45 Nm 4 5 m kgf 33 ft Ibf...

Page 337: ...bolt rear lower side 1 18 Spacer 1 19 Engine mounting bolt rear upper side 1 20 Engine 1 E E 8 Nm 0 8 m kgf 5 8 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R 37 Nm 3 7 m kgf 27 ft Ibf T R 37 Nm 3 7 m kgf 27 ft Ibf T R 45 Nm 4 5 m kgf 33 ft Ibf T R 45 Nm 4 5 m kgf 33 ft Ibf T R 49 Nm 4...

Page 338: ...g bolt right front lower side 9 Pinch bolts front side 10 Pinch bolts rear lower side 11 TIP Lubricate the engine mounting bolt rear lower side threads with engine oil Do not fully tighten the bolts 3 Tighten Engine mounting bolt left front upper side 5 4 Tighten Engine mounting bolt rear lower side 4 5 Tighten Spacer bolt 1 TIP Tighten the spacer bolt 1 to specification with the pivot shaft wrenc...

Page 339: ...hten TIP When temporarily tightened the bolts 13 and 14 should be flat against the engine and frame surface 12 Tighten Engine bracket and engine bolts top 13 Engine bracket bolts top 14 13 Install Engine bracket left rear side 1 Pivot shaft wrench 90890 01471 Frame spanner socket YM 01471 Pivot shaft wrench adapter 90890 01476 T R Engine mounting nut rear upper side 45 Nm 4 5 m kgf 32 ft lbf T R E...

Page 340: ...ide 2 15 Tighten Engine bracket and engine bolts left rear side 3 16 Install Brake pedal 1 TIP Align the punch mark a on the brake pedal with the punch mark b on the brake pedal pivot shaft T R Engine bracket and frame bolt left rear side 32 Nm 3 2 m kgf 23 ft lbf T R Engine bracket and engine bolt left rear side 16 Nm 1 6 m kgf 12 ft lbf T R Brake pedal pinch bolt 8 Nm 0 8 m kgf 5 8 ft lbf 3 2 1 ...

Page 341: ... cut off valve Reed valves Refer to AIR INDUCTION SYSTEM on page 7 13 1 Ignition coil coupler 4 Disconnect 2 Cylinder head cover plate 1 3 Cylinder identification sensor coupler 1 Disconnect 4 Ignition coil 4 5 Cylinder identification sensor 1 6 Spark plug 4 7 Cylinder head cover 1 New 6 New 5 3 8 7 4 2 4 1 1 4 4 LT LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 13 Nm 1 3 m kgf 9...

Page 342: ...cover Order Job Parts to remove Q ty Remarks 8 Cylinder head cover gasket 1 9 Dowel pin 4 10 Timing chain guide upper side 1 New New 8 9 9 9 8 10 LT LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R ...

Page 343: ...n 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 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R ...

Page 344: ... 1 TIP 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 NOTICE 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 TIP To pre...

Page 345: ... camshaft journal as shown c Install the dowel pins and camshaft caps TIP Tighten the camshaft cap bolts in stages and in a crisscross pattern working from the inner caps out Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance with the Plastigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 Camshaft lobe dimensions Lobe height Inta...

Page 346: ... 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 TIP While pressing the timing chain tensioner rod wind it clockwise with a thin screwdriver 1 until it stops b Remove the screwdriver and slowly release the timing chain tensioner rod c Make sure that the tim...

Page 347: ...damage or improper valve timing a Install the timing chain onto both camshaft sprockets and then install the camshafts TIP 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 tim ing chain as tight as possible on the exhaust side Make sure the match marks b and c on the camshaft sprockets are aligned with the cyl...

Page 348: ...ign 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 ly clockwise with a thin screwdriver 1 b With the timing chain tensioner rod turned all the way into the timing chain tensioner hous ing with the thin screwdriver still in...

Page 349: ...ver gasket 3 Cylinder head cover TIP Apply Three Bond 1514C 1 onto the mating surfaces of the cylinder head cover and cylin der head cover gasket Apply Yamaha bond No 1215 2 onto the mating surfaces of the cylinder head cover gasket and cylinder head Install a new cylinder head cover gasket 3 and then cut the portions a Tighten the cylinder head cover bolts in stages and in a crisscross pattern 11...

Page 350: ...efer to ENGINE REMOVAL on page 5 3 Camshafts Refer to CAMSHAFTS on page 5 12 1 Cylinder head 1 2 Cylinder head gasket 1 3 Dowel pin 2 T R 1st 25 Nm 2 5 m kgf 18 ft Ibf 25 Nm 2 5 m kgf 18 ft Ibf 1st 2nd Final Specified angle 175 185 15 Nm 1 5 m kgf 11 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R New New 3 3 2 New 1 10 E ...

Page 351: ... 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 TIP To ensure an even surface rotate the cylinder head several times EAS30282 INSTALLING THE CYLINDER HEAD 1 Install Cylinder head TIP Pass the timing chain through the timing chain cavity 2 Tighten Cylinde...

Page 352: ...w one and perform the procedure again NOTICE ECA18350 Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angle TIP 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 kgf 18 ft lbf T R Cylinder h...

Page 353: ... remove Q ty Remarks Cylinder 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 ...

Page 354: ...a clean solvent a into the intake and exhaust ports b Check that the valves properly seal TIP There should be no leakage at the valve seat 1 3 Remove Valve cotters TIP 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 seat 5 TIP I...

Page 355: ...uide with the valve guide installer 2 and valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance TIP 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 ...

Page 356: ...ng wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head a Apply blue layout fluid 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 impres sion d Measure the valve seat width TIP Where the valve seat and valve face contacted one another the blue lay...

Page 357: ... 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 blue layout fluid 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 make a clear impres ...

Page 358: ...re applies to all of the valves and related components 1 Deburr Valve stem end with an oil stone 2 Lubricate Valve stem 1 Valve stem end Valve stem seal 2 with the recommended lubricant 3 Install Lower spring seat 1 Valve stem seal 2 Valve 3 Valve spring 4 Upper spring seat 5 into the cylinder head TIP Make sure each valve is installed in its original place Install the valve springs with the large...

Page 359: ...itting the valve tip with excessive force could damage the valve 6 Lubricate Valve lifter with the recommended lubricant 7 Install Valve pad Valve lifter TIP The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in its original position b Smaller pitch Valve spring compressor 90890 04019 Valve spring compressor YM 04019 Valve spring co...

Page 360: ... 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 25 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 10 Starter clutch 1 6 12 Nm 1 2 m kgf 8 7 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R 130 Nm 13 m kgf 94 ft lbf T R ...

Page 361: ...STARTER CLUTCH 5 32 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 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 362: ...869 CHECKING THE STARTER 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 st...

Page 363: ...ted in the key way of the crankshaft Lubricate the generator rotor bolt threads and washer mating surfaces with engine oil 2 Tighten Generator rotor bolt 1 TIP While holding the generator rotor 2 with the ro tor holding tool 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 ...

Page 364: ...GENERATOR AND STARTER CLUTCH 5 35 TIP Tighten the generator cover bolts in stages and in a crisscross pattern ...

Page 365: ...n page 4 23 Fuel tank Refer to FUEL TANK on page 7 1 Generator 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 LT New 2 1 6 3 3 5 4 LT 6 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 65 Nm 6 5 m kgf 47 ft Ibf...

Page 366: ...nstalling the pickup rotor align the groove a in the crankshaft sprocket with the projection b in the pickup rotor 2 Tighten Pickup rotor bolt 1 TIP While holding the generator rotor 2 with the ro tor holding tool 3 tighten the pickup rotor bolt 3 Apply Sealant onto the crankshaft position sensor lead grommet Rotor holding tool 90890 04166 YM 04166 1 2 3 5 4 T R Pickup rotor bolt 65 Nm 6 5 m kgf 4...

Page 367: ...cification Reinstall or replace 5 Install Pickup rotor cover gasket Pickup rotor cover TIP Tighten the pickup rotor cover bolts in stages and in a crisscross pattern Gap between the crankshaft po sition sensor and pickup rotor 0 5 mm 0 02 in T R Pickup rotor cover bolt 12 Nm 1 2 m kgf 8 7 ft lbf a 1 2 New ...

Page 368: ...52 ELECTRIC STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks Throttle bodies Refer to THROTTLE BODIES on page 7 4 1 Starter motor lead 1 Disconnect 2 Starter motor assembly 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 369: ...Parts to remove Q ty Remarks 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 ...

Page 370: ...ssembly resistance Out of specification Replace the starter motor a Measure the armature assembly resistance with the digital circuit tester b If the 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 u...

Page 371: ... ASSEMBLING THE STARTER MOTOR 1 Install Brush seat 1 TIP 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 TIP 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 372: ...right Refer to GENERAL CHASSIS 2 on page 4 5 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 25 1 Clutch cover 1 2 Clutch cover gasket 1 3 Dowel pin 2 4 Damper cover 1 5 Damper 1 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R LT 3 4 5 2 1 10 5 3 New ...

Page 373: ... 1 5 Short clutch push rod 1 6 Ball 1 7 Long clutch push rod 1 8 Friction plate 1 3 9 Clutch plate 2 1 10 Clutch plate 1 7 11 Friction plate 2 6 12 Lock washer 1 13 Wire circlip 1 14 Clutch damper spring 1 8 11 E E 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 90 Nm 9 0 m kgf 65 ft Ibf T R LS 14 10 8 13 12 8 10 11 10 11 10 11 10 11 9 8 7 6 5 4 2 3 1 New New New LT 10 11 10 11 3 ...

Page 374: ...o remove Q ty Remarks 15 Clutch damper spring seat 1 16 Clutch boss 1 17 Thrust washer 1 18 Spacer 1 19 Clutch housing 1 E E 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 90 Nm 9 0 m kgf 65 ft Ibf T R LS 19 18 17 16 15 New New New LT 3 ...

Page 375: ... 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 hose union bolt 1 7 Copper washer 2 8 Clutch hose 1 Disconnect 9 Clutch switch 1 10 Clutch master cylinder holder 1 11 Clutch master cylinder 1 LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R ...

Page 376: ...sassembling the clutch master cylinder 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 BF ...

Page 377: ... Q ty Remarks Clutch fluid Drain Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 12 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 10 Nm 1 0 m kgf 7 2 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R ...

Page 378: ...3 TIP There is a built in damper between the clutch boss and the clutch plate It is not necessary to remove the wire circlip 4 and disassemble the built in damper unless there is serious clutch chattering 6 Remove Spacer 1 Clutch housing TIP Insert a cross headed screwdriver into one of the holes of the clutch housing and primary driven gear and then rotate the inner primary driven gear until both...

Page 379: ...d thickness gauge 1 Out of specification Replace the clutch plates as a set 3 Measure Assembly width a of the friction plates and clutch plates Out of specification Adjust a Adjust the assembly width by replacing the clutch plate 1 b Select the clutch plate from the following ta ble Friction plate 1 2 thickness 2 92 3 08 mm 0 115 0 121 in Wear limit 2 82 mm 0 111 in A Friction plate 1 B Friction p...

Page 380: ...ear Replace the bearing and clutch housing EAS31970 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss TIP Pitting on the clutch boss splines will cause er ratic clutch operation EAS31971 CHECKING THE PRESSURE PLATE 1 Check Pressure plate Cracks damage Replace Bearing Damage wear Replace EAS31972 CHECKING THE CLUTCH PUSH RODS 1 Check O ring Short clutc...

Page 381: ... gear teeth and primary drive gear teeth mesh correctly Insert a cross headed 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 2 Install Spacer 1 TIP Install the spacer with the two screw holes facing towards...

Page 382: ...onnection on the hydraulic clutch system is disconnected the entire clutch system must be disassembled drained cleaned properly 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 cl...

Page 383: ... is disas sembled replace the piston seals EAS31978 INSTALLING THE CLUTCH MASTER CYLINDER 1 Install Clutch master cylinder 1 Clutch master cylinder holder 2 TIP 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 Clutc...

Page 384: ... spilt clutch fluid immediately TIP In order to ensure a correct reading of the clutch fluid level make sure the top of the clutch master cylinder reservoir is horizontal 4 Bleed Clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 12 5 Check Clutch fluid level Below the minimum level mark a Add the specified brake and clutch fluid to the proper level Refer to CHECKING THE CLUTCH ...

Page 385: ...ids may cause the rubber seals to deteriorate causing leakage and poor clutch performance Refill with the same type of clutch fluid that is already in the system Mixing clutch flu ids may result in a harmful chemical reac tion leading to poor clutch performance When refilling be careful that water does not enter the clutch master cylinder reser voir Water will significantly lower the boil ing poin...

Page 386: ...CLUTCH 5 57 5 Check Clutch lever operation Soft or spongy feeling Bleed the clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 12 ...

Page 387: ...o CLUTCH on page 5 43 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 4 6 5 8 9 7 3 1 2 10 11 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 22 Nm 2 2 m kgf 16 ft Ibf T R New New ...

Page 388: ... the shift shaft spring onto the shift shaft spring stopper 2 3 Install Shift arm 1 TIP Align the punch mark a in the shift shaft with the slot in the shift shaft arm EAS30875 ADJUSTING THE SHIFT PEDAL 1 Check Shift pedal position Check that the 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 th...

Page 389: ...SHIFT SHAFT 5 60 c Tighten both locknuts to specification T R Shift rod locknut 7 Nm 0 7 m kgf 5 1 ft lbf 1 2 c d a b ...

Page 390: ... page 4 137 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 Oil delivery pipe 2 1 6 Oil delivery pipe 3 1 7 Oil strainer 1 7 6 5 5 7 6 3 2 1 4 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m ...

Page 391: ...embly 1 11 O2 sensor lead bracket 1 11 8 8 10 9 9 10 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 43 Nm 4 3 m kgf 31 ft Ibf T R New ...

Page 392: ... 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 7 8 6 5 3 4 2 1 2 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R ...

Page 393: ...nd 2 or replace the defective part s EAS30338 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 EAS30339 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance 0 000 0 120 mm 0 0000 0 0047 in ...

Page 394: ... 2 Install Oil pump driven sprocket Oil pump housing 1 Washer 2 Pin 3 Oil pump inner rotor 4 Oil pump outer rotor TIP 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 64 EAS30345 INSTALLING THE OIL PAN 1 Install Oil pan gasket Oil pan TIP Tighten the oil pan bolts in sta...

Page 395: ...el 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 Refer to ADJUSTING THE MIDDLE GEAR BACKLASH on page 5 74 7 6 8 9 3 3 2 1 5 4 10 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R New New ...

Page 396: ...bly 1 15 Spacer 1 16 Middle driven gear 1 17 Bearing retainer 1 18 Bearing 1 19 Middle drive pinion gear shim Refer to ALIGNING THE MIDDLE GEAR on page 5 75 20 Bearing 1 11 12 13 17 18 19 14 16 15 20 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R New New 110 Nm 11 m kgf 80 ft lbf T R 160 Nm 16 m kgf 116 ft lbf T R ...

Page 397: ...R 5 68 Disassembling the 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 ...

Page 398: ...o 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 3 4 7 6 5 2 1 110 Nm 11 m kgf 80 ft lbf T R 180 Nm 18 m kgf 130 ft lbf T R New New New ...

Page 399: ...S30401 DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1 Remove Spring retainers 1 TIP While compressing the spring with the damper spring compressor 2 remove the spring retain ers EAS30402 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 nut TIP Secure the middle ...

Page 400: ...04 CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1 Check Middle driven pinion gear Galling pitting wear Replace 2 Check Bearings Damage pitting Replace EAS30405 ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1 Install Spring retainers 1 TIP While compressing the spring with the damper spring compressor 2 install the spring retain ers EAS30406 ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1 Tighten Bearing r...

Page 401: ...the threads with a drift punch EAS30408 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 T R Bearing retainer 110 Nm 11 0 m kgf 80 ft lbf T R Middle driven pinion gear nut 180 Nm 18 0 m kgf 130 ft lbf LOCTITE 1 New Bearing retai...

Page 402: ...t end cover Middle driven shaft bearing housing bolts TIP Finger tighten the middle driven shaft bearing housing bolts 2 Tighten Middle driven shaft bearing housing bolts TIP Before tightening the bolts 1 Adjust the middle gear backlash Refer to ADJUSTING THE MIDDLE GEAR BACKLASH on page 5 74 2 Check that the middle gears turns smoothly EAS31894 INSTALLING THE MIDDLE GEAR CASE COVER 1 Install Midd...

Page 403: ...14050 Do not overtighten the middle driven shaft bearing housing bolts or you may obtain too little 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 TIP Tighten the middle driven shaft bearing hous ing bolts ca...

Page 404: ...ing thickness es 8 Loosen Middle driven shaft bearing housing bolts 9 Install Middle driven pinion gear shim s 10 Tighten Middle driven shaft bearing housing bolts 11 Measure Middle gear backlash Out of specification Refer to MEASUR ING THE MIDDLE GEAR BACKLASH on page 5 74 EAS30413 ALIGNING THE MIDDLE GEAR TIP Aligning the middle gear is necessary when any of the following parts are replaced Cran...

Page 405: ...en pinion gear shim thick ness B use the following formula d a numeral on the middle driven pinion gear to be divided by 100 and either added to or subtracted from 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 ...

Page 406: ...MIDDLE GEAR 5 77 Middle driven pinion gear shim Thickness mm 0 10 0 15 0 20 0 30 0 40 0 50 ...

Page 407: ...P on page 5 61 Middle drive shaft assembly Refer to MIDDLE GEAR on page 5 66 Clutch housing Refer to CLUTCH on page 5 43 1 Timing chain 1 2 Oil pump drive chain guide 1 3 Oil pump drive chain 1 T R 1st 20 Nm 2 0 m kgf 14 ft Ibf 2nd 20 Nm 2 0 m kgf 14 ft Ibf Final Specified angle 115 125 LT LT New LS E E E E E E E E E 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 0 Nm 0 40 m kgf 2...

Page 408: ...rankcase 1 10 Dowel pin 3 T R 1st 20 Nm 2 0 m kgf 14 ft Ibf 2nd 20 Nm 2 0 m kgf 14 ft Ibf Final Specified angle 115 125 LT LT New LS E E E E E E E E E 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R LT LT LT LT 8 10 10 7 6 5 4 10 9 3 10 10 2 2 ...

Page 409: ...Oil baffle plate 2 1 2 Oil delivery pipe 1 1 3 Upper crankcase 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 LS LS 2 LT LT LT LT LT LT 4 8 3 LT 5 7 6 1 9 New New New New LS LS New E E E 3 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 N...

Page 410: ...12 Crankcase plug 1 13 Lower crankcase 1 10 LS LS LT LT LT LT LT LT LT 12 13 New New New New LS LS New E E 11 E 3 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 70 Nm 7 0 m kgf 51 ft Ibf T R ...

Page 411: ... 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 EAS30393 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 EAS31766 CHECKING THE BEARI...

Page 412: ...Set the shift drum assembly and transmission gears in the neutral position 5 Install Lower crankcase 1 onto the upper crankcase 2 NOTICE ECA13980 Before tightening the crankcase bolts make sure the transmission gears shift correctly when the shift drum assembly is turned by hand 6 Install Crankcase bolts Recommended lubricant Engine oil Yamaha bond No 1215 90890 85505 Three bond No 1215 A A Upper ...

Page 413: ...r tightening sequence as shown b Loosen and retighten the crankcase bolts in the proper tightening sequence as shown c Tighten the crankcase bolts further to reach the specified angle 115 125 in the proper tightening sequence as shown WARNING EWA16610 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 pe...

Page 414: ...ollar 2 Oil pump drive sprocket 3 Oil pump drive chain TIP Make sure that the white paint mark on the con ical spring washer is facing outward as shown in the illustration T R Crankcase bolt 11 12 24 Nm 2 4 m kgf 17 ft lbf Crankcase bolt 13 14 12 Nm 1 2 m kgf 8 7 ft lbf Crankcase bolt 15 31 10 Nm 1 0 m kgf 7 2 ft lbf 9 8 3 6 1 2 5 4 7 10 13 21 18 15 16 17 20 19 22 14 24 29 30 23 25 31 28 26 27 11 ...

Page 415: ...Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 78 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 1 2 7 6 5 4 3 3 8 9 10 New New 1st 20 Nm 2 0 m kgf 14 ft Ibf Final Specified angle 115 125 T R ...

Page 416: ... reference during installation put an identi fication mark on each piston crown Before removing the piston pin deburr the pis ton pin clip s groove and the piston s pin bore area If both areas are 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 TIP When removing a piston ring open the end gap with your fingers ...

Page 417: ... piston and piston rings as a set TIP 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 D2 D3 D4 D5 D6 Taper front to back maximum difference be tween D1 D3 D5 Taper side to side maximum difference be t...

Page 418: ...place the piston pin and then check the lubrication sys tem 2 Measure Piston pin outside diameter a Out of specification Replace the piston pin 3 Measure Piston pin bore diameter b Out of specification Replace the piston 4 Calculate Piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set b Top of cylinder Piston ring Top ring End gap limit 0 55 mm 0 ...

Page 419: ...connecting rod cap c Put a piece of Plastigauge 1 on the crank shaft pin d Assemble the connecting rod halves TIP 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 shaft Make sure the characters...

Page 420: ...is EAS30751 INSTALLING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the pis tons and connecting rods 1 Install Top ring 1 2nd ring 2 Upper oil ring rail 3 Oil ring expander 4 Lower oil ring rail 5 TIP 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 TIP A...

Page 421: ...ly 1 into the cylinder and onto the crankshaft pin Connecting rod cap onto the crankshaft pin TIP 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 th...

Page 422: ...ed 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 NOTICE ECA13950 Do not use a torque wrench to tighten the connecting rod nut to the specified angle TIP On a hexagonal nut note that the angle from one corner...

Page 423: ...Crankcase Separate Refer to CRANKCASE on page 5 78 Front balancer weight Refer to BALANCERS on page 5 103 Connecting rod caps Refer to CONNECTING RODS AND PIS TONS on page 5 86 1 Crankshaft 1 2 Crankshaft journal upper bearing 5 3 Crankshaft journal lower bearing 5 4 Oil nozzle 4 3 1 2 2 E E New 4 LS ...

Page 424: ...urnal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings NOTICE 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 bearing...

Page 425: ...width e on each crankshaft journal If the crankshaft journal to crankshaft jour nal bearing clearance is out of specification select replacement crankshaft journal bear ings 4 Select Crankshaft journal bearings J1 J5 TIP 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 ref...

Page 426: ...journal lower bearings into the lower crankcase TIP 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 Bearing color code Code 2 Black Code 3 Brown Code 4 Green Code 5 Yellow Code 6 Pink Code 7 Red Code 8 White ...

Page 427: ...KCASE on page 5 78 Stopper lever Refer to SHIFT SHAFT on page 5 58 1 Drive axle assembly 1 2 Bearing 1 3 Washer 1 4 1st pinion gear 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 8 7 2 3 1 6 9 5 4 LT LT LT LT LT LT LT E E E E E E M New E M 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R ...

Page 428: ...t forks Order Job Parts to remove Q ty Remarks 10 Spring 4 11 Shift drum assembly 1 12 Shift fork C 1 13 Main axle assembly 1 14 Middle drive gear 1 11 10 10 10 12 14 13 LT LT LT LT LT LT LT E E E E E E M New E M 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R ...

Page 429: ...e bar on a flat surface Bends Replace WARNING EWA12840 Do not attempt 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 EAS30432 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum groove Damage scratches wear Replace the shift drum assembly Shift drum segment 1 Damage wear R...

Page 430: ...semblies 5 Check Transmission gear movement Rough movement Replace the drive axle assembly and or main axle assembly EAS30438 INSTALLING THE TRANSMISSION NOTICE ECA23550 Do not disassemble the main axle assembly and drive axle assembly 1 Install Main axle assembly 1 Main axle assembly screws TIP The 1st pinion gear 2 is not press fit If the 1st pinion gear falls off install it with its chamfered s...

Page 431: ...bossed marks on the shift forks should face towards the right side of the engine and be in the following sequence R C L 4 Install Washer 1 TIP Install the washer with its chamfered side facing towards the drive axle assembly as shown in the illustration 5 Install Drive axle assembly TIP The bearing pin 1 must face towards the rear of the upper crankcase Make sure the bearing circlip 2 is inserted ...

Page 432: ...remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 78 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 10 Nm 1 0 m kgf 7 2 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R 1 2 6 3 4 7 6 5 3 ...

Page 433: ...KUP ROTOR on page 5 36 Clutch cover Refer to CLUTCH on page 5 43 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 1 2 5 6 9 8 7 5 8 4 3 New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R ...

Page 434: ...ch damper is positioned to the outside of the gear projec tions as shown in the illustration Align the punch mark b in the balancer weight with the mark c in the balancer gear 2 Align T mark on the 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 surf...

Page 435: ... the balancer gear If noise is abnormal adjust the gear lash by turning the balancer shaft TIP With each adjustment turn the balancer shaft one scale EAS31875 INSTALLING THE REAR BALANCER 1 Install Rear balancer gear 1 Dampers 2 Rear balancer weight 3 Bearings Washers TIP Install the dampers onto the balancer gear so that the middle section a of each damper is positioned to the outside of the gear...

Page 436: ...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 TIP 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 437: ...ar balancer lever bolt 1 Rear balancer shaft pinch bolt 2 TIP 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 TIP With each adjustment turn the balancer shaft one scale T R Rear balancer shaft 0 4 Nm 0 04 m kgf 0 29 ft lbf f e c 2 1 1...

Page 438: ...BALANCERS 5 109 ...

Page 439: ...TOR 6 3 OIL COOLER 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 440: ...servoir breather hose 1 2 Coolant reservoir cap 1 3 Coolant reservoir 1 4 Radiator inlet hose 1 5 Oil cooler outlet hose 1 6 Horn 1 7 Coolant reservoir bracket 1 8 Water pump breather hose 1 LT LT LT LT 2 3 4 5 1 6 7 8 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T ...

Page 441: ... 14 Radiator 1 15 Radiator cover 1 16 Radiator fan motor left 1 17 Radiator fan motor right 1 18 Radiator bracket 1 19 Thermostat assembly 1 20 Air deflector 1 LT LT LT LT 19 10 11 20 12 13 13 14 15 16 17 18 9 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 12 Nm 1...

Page 442: ...the radiator cap 3 b Apply the specified pressure for ten seconds and make sure there is no drop in pressure 4 Check Radiator fans Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 51 EAS30440 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 29 2 Check Cooling system Leaks Repair ...

Page 443: ...ANGING THE COOLANT on page 3 29 Radiator Refer to RADIATOR on page 6 1 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 3 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 6 4 7 3 1 2 5 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R New ...

Page 444: ... thinner 2 Install O ring Oil cooler TIP 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 29 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 25 4 Check Cooling system Leaks Repair or replace any faulty part 5 Measure Radiator c...

Page 445: ... 5 T bar Refer to GENERAL CHASSIS 6 on page 4 22 Fuel tank Refer to FUEL TANK on page 7 1 1 Radiator cap 1 2 Coolant reservoir hose 1 Disconnect 3 Radiator inlet hose 1 Disconnect 4 Thermostat inlet hose 2 1 5 Thermostat cover Radiator filler pipe 1 6 Thermostat housing 1 LS New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 22 Nm 2 2 m kgf 16 ft Ib...

Page 446: ...ostat inlet pipe 2 1 9 Thermostat inlet hose 1 1 10 Coolant temperature sensor coupler 1 Disconnect 11 Coolant temperature sensor 1 12 Thermostat inlet pipe 1 1 LS New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 22 Nm 2 2 m kgf 16 ft Ibf T R 12 11 10 7 3 8 9 ...

Page 447: ...mostat hoses Thermostat pipes Radiator inlet hose Thermostat cover Radiator filler pipe EAS30445 INSTALLING THE THERMOSTAT ASSEMBLY 1 Install Copper washer Coolant temperature sensor NOTICE ECA23410 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 housing 2 TIP Install the thermostat w...

Page 448: ...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 449: ...to GENERAL CHASSIS 2 on page 4 5 Coolant Drain Refer to CHANGING THE COOLANT on page 3 29 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 5 Water pump tray 1 LS New 1 2 5 4 3 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R ...

Page 450: ...s 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 1 4 2 5 8 9 9 10 6 7 3 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 451: ...er Water pump housing Impeller shaft Cracks damage wear Replace 2 Check Bearing Rough movement Replace EAS30448 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 into the water pump housing TIP 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 Mechanical seal housing side 1 NOTICE ECA20330 Ne...

Page 452: ...ion check that the impeller shaft ro tates smoothly EAS30449 INSTALLING THE WATER PUMP 1 Install Water pump tray 1 O ring 2 Water pump assembly 3 TIP Install the water pump tray completely onto the crankcase 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 0...

Page 453: ...e recom mended coolant Refer to CHANGING THE COOLANT on page 3 29 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 3 1 2 ...

Page 454: ...WATER PUMP 6 15 ...

Page 455: ...NJECTORS 7 7 CHECKING THE INJECTORS 7 7 CHECKING AND CLEANING THE THROTTLE BODIES 7 7 CHECKING THE THROTTLE BODY JOINTS 7 9 REPLACING THE THROTTLE BODIES 7 9 INSTALLING THE INJECTORS 7 9 CHECKING THE INJECTOR PRESSURE 7 9 CHECKING THE FUEL PRESSURE 7 10 ADJUSTING THE THROTTLE POSITION SENSOR 7 11 ADJUSTING THE ACCELERATOR POSITION SENSOR 7 11 AIR INDUCTION SYSTEM 7 13 CHECKING THE AIR INDUCTION SY...

Page 456: ...n page 4 1 1 Fuel tank panel 1 2 Fuel sender coupler 1 Disconnect 3 Fuel pump coupler 1 Disconnect 4 Fuel tank breather hose 1 5 Fuel tank overflow hose 1 6 Fuel hose holder 1 7 Fuel hose 1 8 Fuel tank 1 9 Fuel pump 1 New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 1 5 4 3 7 6 8 9 2 6 ...

Page 457: ...shock Do not touch the base section of the fuel sender EAS30454 CHECKING THE FUEL PUMP BODY 1 Check Fuel pump body Obstruction Clean Cracks damage Replace fuel pump as sembly EAS30456 INSTALLING THE FUEL PUMP 1 Install Fuel pump TIP Do not damage the installation surfaces of the fuel tank when installing the fuel pump Always use a new fuel pump gasket Install the fuel pump as shown in the illustra...

Page 458: ...uel hose holder is in the correct position other wise the fuel hose will not be properly in stalled TIP Install the fuel hose connector securely onto the fuel tank until a distinct click is heard and then make sure that it does not come loose After installing the fuel hose holder 1 make sure that the sections a b and c of the holder are installed securely 1 1 a b c ...

Page 459: ...HASSIS 7 on page 4 23 Fuel tank Refer to FUEL TANK on page 7 1 1 Throttle position sensor coupler 1 Disconnect 2 Injector coupler 4 Disconnect 3 Atmospheric pressure sensor coupler 1 Disconnect 4 Intake air pressure sensor coupler 1 Disconnect 5 Air cut off valve coupler 1 Disconnect 6 Grip cancel switch coupler 1 Disconnect LT 1 2 2 2 3 4 5 6 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R 3 0 Nm 0 30 m kgf 2 2...

Page 460: ...pler 1 Disconnect 9 Throttle body joint clamp screw 8 Loosen 10 Throttle bodies 1 11 Throttle cable holder 1 12 Throttle cable decelerator cable 1 Disconnect 13 Throttle cable accelerator cable 1 Disconnect 14 Throttle body joint 4 LT 9 9 9 9 9 14 9 10 8 7 11 13 12 14 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R ...

Page 461: ...ure sensor 1 4 Fuel rail 1 5 Injector 4 6 Throttle position sensor 1 7 Accelerator position sensor 1 8 Grip cancel switch 1 New New New New New 2 3 1 1 1 1 4 5 5 5 7 6 8 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R ...

Page 462: ...Replace Damage Replace 2 Check Injector resistance Refer to CHECKING THE FUEL INJEC TORS on page 8 265 EAS30769 CHECKING AND CLEANING THE THROTTLE BODIES TIP Before cleaning the throttle bodies check the following items Valve clearance Spark plugs Air filter element Throttle body joints Fuel hose Exhaust system Cylinder head breather hose WARNING EWA17340 If the throttle bodies are subjected to st...

Page 463: ...e the carbon deposits from the inside of each throttle body in a downward direction from the air filter case side of the throttle body to the engine side NOTICE ECA18470 Do not use a tool such as a wire brush to remove the carbon deposits otherwise the inside of the throttle bodies may be dam aged Do not allow carbon deposits or other for eign materials to enter any of the passages in each throttl...

Page 464: ...NG THE INJECTORS NOTICE ECA23351 Always use new O rings and seals When checking the injectors do not allow any foreign material to enter or adhere to the injectors fuel rail O rings or seals Be careful not to twist or pinch the O rings when installing the injectors If an injector is subject to strong shocks or excessive force replace it If installing the original fuel rail and screws remove the wh...

Page 465: ... Remove the fuel tank bolts 1 and lift up the fuel tank NOTICE ECA23360 When lifting up the fuel tank be careful not to pull the fuel tank breather overflow hose b Disconnect the fuel hose 2 from the fuel rail WARNING EWA17320 Cover fuel hose connections with a cloth when disconnecting them Residual pres sure in the fuel lines could cause fuel to spurt out when removing the hose NOTICE ECA20010 Be...

Page 466: ...P For information about using the Yamaha diag nostic tool refer to the operation manual that is included with the tool e Diagnostic code number 01 is selected f Adjust the position of the throttle position sen sor angle so that 12 21 can appear in the Yamaha diagnostic tool screen g After adjusting the throttle position sensor an gle tighten the throttle position sensor screws 2 EAS30486 ADJUSTING...

Page 467: ...n the throttle grip to the fully open position k Check the Yamaha diagnostic tool screen value If the Yamaha diagnostic tool screen value is not 97 107 adjust the accelerator position sensor angle l Select the diagnostic code number 15 m Turn the throttle grip to the fully closed posi tion n Check the Yamaha diagnostic tool screen value If the Yamaha diagnostic tool screen value is not 10 24 adjus...

Page 468: ...AIR INDUCTION SYSTEM 7 13 EAS20071 AIR INDUCTION SYSTEM 1 2 3 5 6 7 8 1 1 2 1 1 3 6 7 8 2 2 3 5 4 ...

Page 469: ...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 470: ... page 7 1 1 Air induction system solenoid coupler 1 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 valv...

Page 471: ...k Refer to FUEL TANK on page 7 1 Air induction system hoses 3 way joint to reed valve cover Refer to Removing the air cut off valve Thermostat 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 14 Nm 1 4 m kgf 10 ft Ibf T R LT LT LT LT 1 4 5 2 3 4 4 4 5 5 5 ...

Page 472: ...f 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 3 w...

Page 473: ... FJR13AG 8 23 CIRCUIT DIAGRAM FJR13ESG 8 25 TROUBLESHOOTING 8 27 CORNERING LIGHT SYSTEM FJR13ESG 8 29 CIRCUIT DIAGRAM 8 29 CLCU SELF DIAGNOSTIC FUNCTION 8 31 CHECKING THE CORNERING LIGHT SYSTEM 8 31 TROUBLESHOOTING DETAILS CLCU 8 31 SIGNALING SYSTEM 8 41 CIRCUIT DIAGRAM FJR13AG 8 41 CIRCUIT DIAGRAM FJR13ESG 8 43 TROUBLESHOOTING 8 45 COOLING SYSTEM 8 51 CIRCUIT DIAGRAM FJR13AG 8 51 CIRCUIT DIAGRAM ...

Page 474: ... DELETING THE FAULT CODES 8 155 C 2 FINAL CHECK 8 155 FUEL PUMP SYSTEM 8 157 CIRCUIT DIAGRAM FJR13AG 8 157 CIRCUIT DIAGRAM FJR13ESG 8 159 TROUBLESHOOTING 8 161 WINDSHIELD DRIVE SYSTEM 8 163 CIRCUIT DIAGRAM FJR13AG 8 163 CIRCUIT DIAGRAM FJR13ESG 8 165 TROUBLESHOOTING 8 167 ACCESSORY BOX SYSTEM 8 169 CIRCUIT DIAGRAM FJR13AG 8 169 CIRCUIT DIAGRAM FJR13ESG 8 171 TROUBLESHOOTING 8 173 IMMOBILIZER SYSTE...

Page 475: ... B 1 A FAULT CODE NUMBER IS NOT DISPLAYED IN THE MULTI FUNCTION METER RIGHT DISPLAY 8 199 B 2 THE ABS WARNING LIGHT REMAINS ON 8 200 B 3 DIAGNOSIS USING THE FAULT CODES 8 200 C 1 DELETING THE FAULT CODES 8 218 C 2 DELETE FUNCTION TEST 8 218 C 3 FINAL CHECK 8 220 GRIP WARMER SYSTEM 8 221 CIRCUIT DIAGRAM FJR13AG 8 221 CIRCUIT DIAGRAM FJR13ESG 8 223 TROUBLESHOOTING 8 225 ELECTRONICALLY ADJUSTABLE SUS...

Page 476: ...G THE STATOR COIL 8 260 CHECKING THE RECTIFIER REGULATOR 8 260 CHECKING THE HEADLIGHT ASSEMBLY 8 260 CHECKING THE OIL LEVEL SWITCH 8 261 CHECKING THE FUEL SENDER 8 261 CHECKING THE FUEL METER FUEL LEVEL WARNING LIGHT 8 262 CHECKING THE FRONT TURN SIGNAL POSITION LIGHT ASSEMBLY 8 262 CHECKING THE RADIATOR FAN MOTORS 8 262 CHECKING THE THROTTLE POSITION SENSOR 8 263 CHECKING THE ACCELERATOR POSITION...

Page 477: ......

Page 478: ... R G Y L Y G B O G B B O Gy P L B R B Y W Lg R Y R R L L B W O B Br R Br W R W B Y R B R B L B L B L Y L B Y Y G L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W R R R Br L Br L R W R W Br W R B B R W R W R R B B B B B R R W R W R W R B Sb W R Y W B W B W Gy W B L B Gy L W L Y W B B L L Y G B L R W B R Gy W L B L W B Y G L L L R B R B Sb B R L G B R B R...

Page 479: ...7 Sidestand switch 59 Handlebar switch right 61 Start engine stop switch 63 Gear position switch 95 Crankshaft position sensor 98 Cylinder identification sensor 99 Lean angle sensor 108 ECU Engine Control Unit 109 Ignition coil 1 110 Ignition coil 2 111 Ignition coil 3 112 Ignition coil 4 113 Spark plug A Wire harness C Negative battery sub wire harness ...

Page 480: ... O W Br L Br W G L L W L B Gy W G W L L L L L R L R L R L R L R L B L B L B L B L B B Gy B L Gy W L W B B L W L Y B L B B L R L B R W B B G B B G R W L R L B B L R R W B L B B L B L B L B L B B L B L B L Y R R R Br L Br L Br L Br L R W R W Br W R B B R W R W R W R W R W R R B B B R R R R W R W R W R B B B Sb B W B W O Gy W P W R Y W Gy W B L L W W B B L L Y R W B R Gy W L B L L B L R W B Gy B L R ...

Page 481: ...45 Handlebar switch right 47 Start engine stop switch 49 Gear position switch 103 Crankshaft position sensor 106 Cylinder identification sensor 113 ECU Engine Control Unit 114 Ignition coil 1 115 Ignition coil 2 116 Ignition coil 3 117 Ignition coil 4 118 Spark plug 127 IMU Inertial Measurement Unit A Wire harness C Negative battery sub wire harness H IMU sub wire harness ...

Page 482: ...om producing a spark However the engine continues to run under the following conditions 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 ...

Page 483: ...Refer to CHECKING AND CHARGING THE BATTERY on page 8 251 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 4 Re gap or replace the spark plug s 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 258 Ignition system is OK 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on p...

Page 484: ... 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 247 Replace the sidestand switch 12 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 256 Replace the relay unit 13 Check the lean angle sensor FJR13AG Refer to CHECKING THE LEAN ANGLE SENSOR FJR13AG on page 8 259 Replace the lean angle sensor FJR13AG 14 Check the entire ignition system wiring Refer t...

Page 485: ...IGNITION SYSTEM 8 8 ...

Page 486: ... R B R G W B W B W B W B W B W B W B B B G B B G Br Y B G Y G W Y B B Y Y W G W B B L G B W O Y W W Sb Gy W R P B P Gy L W B Y Sb B R Y W B B B B R R Br L Br L R W B B B R W R W R W R R Br R W R W B B B B B B R L W R W Y B B Y G Y G W R W R W R W R W R B W L B B B Sb W R Y W B W B W L W L W L W L W L W R B R B R B R W W L B Y Sb B R L G B Y B Y W L W L G W B R L G B B B W B W B W B B W Gy W P O Br...

Page 487: ...in fuse 33 Battery 34 Engine ground 36 Starter relay 37 Starter motor 40 Clutch switch 51 Relay unit 52 Starting circuit cut off relay 57 Sidestand switch 59 Handlebar switch right 61 Start engine stop switch 63 Gear position switch A Wire harness C Negative battery sub wire harness ...

Page 488: ...B B R W W L R B R W W L B Br Y B G Y G W Y B B Y Y W G W B Y B Y B Y W L W L W L B R B R G W B W B W B W B W B W B W B B G B B G R R Br L Br L Br L Br L R W B B B R W R W R W R R R W R W B B B R R R L W R W B Y G W R W R W R W R W R B W L B B B B B Sb B W B W O Gy W P W R Y W L W L W L W L W L W R B R W W L B Y Sb B R L G B Y B Y W L W L G W B R L G B W B W B W B B W R B R B B B B B Br Y B G Y 9 2...

Page 489: ...in fuse 27 Battery 28 Engine ground 30 Starter relay 31 Starter motor 34 Clutch switch 35 Relay unit 36 Starting circuit cut off relay 38 Sidestand switch 45 Handlebar switch right 47 Start engine stop switch 49 Gear position switch A Wire harness C Negative battery sub wire harness ...

Page 490: ...tarter 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 side of the start engine stop switch 12 1 11 4 6 6 6 6 a b 8 6 9 7 5 2 3 10...

Page 491: ...inals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 259 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 41 Repair or replace the starter motor 5 Check the relay unit starting circuit cut off relay Refer...

Page 492: ... CHECKING THE SWITCHES on page 8 247 Replace the sidestand switch 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 247 Replace the clutch switch 12 Check the start engine stop switch Refer to CHECKING THE SWITCHES on page 8 247 The start engine stop switch is faulty Replace the right handlebar switch 13 Check the entire starting system wiring Refer to CIRCUIT DIAGRAM FJR13AG on ...

Page 493: ...ELECTRIC STARTING SYSTEM 8 16 ...

Page 494: ...CHARGING SYSTEM 8 17 EAS20074 CHARGING SYSTEM EAS31990 CIRCUIT DIAGRAM FJR13AG B W W W B R B Gy R R B B B G B B G R R R R R B B B B B R R B B B B B R R R W W W C A 2 3 32 33 34 ...

Page 495: ...CHARGING SYSTEM 8 18 2 AC magneto 3 Rectifier regulator 32 Main fuse 33 Battery 34 Engine ground A Wire harness C Negative battery sub wire harness ...

Page 496: ...CHARGING SYSTEM 8 19 EAS31936 CIRCUIT DIAGRAM FJR13ESG B B W W W B R Gy B R R B B G B B G R R W W W R R R B B B B B R R B B B R R R B B 2 3 26 27 28 C A ...

Page 497: ...CHARGING SYSTEM 8 20 2 AC magneto 3 Rectifier regulator 26 Main fuse 27 Battery 28 Engine ground A Wire harness C Negative battery sub wire harness ...

Page 498: ... CHARGING THE BATTERY on page 8 251 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 260 Replace the stator coil 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 260 Replace the rectifier regulator 5 Check the entire charging system wiring Refer to CIRCUIT DIAGRAM FJR13AG on page 8 17...

Page 499: ...CHARGING SYSTEM 8 22 ...

Page 500: ...G B O G B B O Gy P L B R B Y W Lg R Y R R L L B W O B Br R Br W R W B Y R B R B L B L B L Y L B Y Y G L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W G G L R B Br Br L R B Br W Br B W Br W Br B Br B W Br B B B R R R R Br L Br L Br L R W R W Br Br Br W R Y R R B B B R W B R W R Y R W R W R R Br Br Br Br Br L Br G B L L R Y W R W R W BB BB B R W R W R W ...

Page 501: ...ly left 46 Headlight low beam 47 Headlight high beam 48 Headlight control unit left 49 Headlight assembly right 50 Headlight control unit right 64 Handlebar switch left 67 Dimmer pass switch 72 Auxiliary light 73 Front turn signal position light right 74 Front turn signal position light left 77 Meter assembly 78 Multi function meter 81 Meter light 91 High beam indicator light 108 ECU Engine Contro...

Page 502: ...B W O W Br L Br W G L L W L B Gy W G W B B G B B G Y W B L R L R L R L B L B L B R W R W Y B B Y W B L B L R L R L R L B L B R W R W Y B B B B B B B B Y W R W R W R W R W R W R W Y W Y W Y Y Y L B L B L R L R L B L R G G L R B Br Br L R B Br W Br B W Br W Br B Br B W Br B B B R R R R Br L Br L Br L Br L Br L Br L R W R W Br Br Br W R G R Y R R B B B R W B R W R Y R W R W R R Br Br Br Br Br Y W Y W...

Page 503: ...light assembly 62 Taillight 66 Headlight assembly left 67 Headlight low beam 68 Headlight high beam 69 Headlight control unit left 70 Headlight assembly right 71 Headlight control unit right 73 Auxiliary light 74 Front turn signal position light right 75 Front turn signal position light left 83 Meter assembly 84 Multi function meter 87 Meter light 98 High beam indicator light 113 ECU Engine Contro...

Page 504: ... ES on page 8 250 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 251 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 247 Replace the main switch immobilizer unit 4 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM FJR13AG on page 8 23 or refer to CIRCUIT DIAGRAM ...

Page 505: ...place the wire har ness Replace the ECU Refer to REPLACING THE ECU en gine control unit on page 8 250 1 Check the dimmer pass switch Refer to CHECKING THE SWITCHES on page 8 247 The dimmer pass switch is faulty Replace the left handlebar switch 2 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM FJR13AG on page 8 23 or refer to CIRCUIT DIAGRAM FJR13ESG on page 8 25 Properly connect ...

Page 506: ...B L R L R L R L B L B L B R W R W Y B B Y W B L B L R L R L R L B L B R W R W Y B B B B B B B B Y W R W R W R W R W R W R W Y W Y W Y Y Y B L B L B L R L R L B L R L R B R W Y L B B W R Y W Br W G W B Br Br L Y W B W W L O W G L Y B W Y Y B G L B W W L Br L Y W Y L R W Y W B Y B O W B Sb F Sb R R R R R B B B Br L Br L Br L R R R G R Y Br W R W B R W R Y R W R B B G B B R W W R W Br W G L R Y Y W S...

Page 507: ...Engine ground 34 Clutch switch 35 Relay unit 49 Gear position switch 52 Handlebar switch left 55 Dimmer pass switch 72 CLCU cornering light control unit 107 Yamaha diagnostic tool coupler 113 ECU Engine Control Unit 127 IMU Inertial Measurement Unit 129 ABS ECU 130 Front wheel sensor 131 Rear wheel sensor A Wire harness B Headlight sub wire harness C Negative battery sub wire harness H IMU sub wir...

Page 508: ...ted correctly during the initial display mode Some of the cornering lights LED do not come on Lighting sequence for the cornering lights when the main switch is turned to ON Immediately after turning the main switch to ON check that the cornering lights come on and go off in the following sequence EAS31942 TROUBLESHOOTING DETAILS CLCU This section describes the measures per fault code number displ...

Page 509: ...pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON and then check that the corner ing lights come on and go off in the proper sequence Lighting sequence is correct Service is finished Lighting sequence is not cor rect Go to item A 3 A 3 Wire harness continuity Open or short circuit Replace the wire harness Between CLCU coupler and joint ...

Page 510: ...efer to TROUBLESHOOT ING DETAILS ECU FAULT CODE on page 8 62 Turn the main switch to ON and then check that the corner ing lights come on and go off in the proper sequence Lighting sequence is correct Service is finished Lighting sequence is not cor rect Go to item B 3 B 3 Malfunction in CLCU Replace the headlight assem bly Turn the main switch to ON and then check that the corner ing lights come ...

Page 511: ...n execute diagnostic code No 66 in the diagnosis of function mode of the Yamaha diagnostic tool to select the fine adjustment value Fine adjustment value cannot be changed to a value other than 0 Go to item 2 Fine adjustment value can be changed to a value other than 0 Select the fine adjustment value Service is finished 2 Malfunction in CLCU Replace the headlight assem bly Turn the main switch to...

Page 512: ... the corner ing lights come on and go off in the proper sequence Lighting sequence is correct Service is finished Lighting sequence is not correct Go to item 4 4 Wire harness continuity Open or short circuit Replace the wire harness Between IMU coupler and headlight sub wire harness cou pler blue red blue red blue black blue black Turn the main switch to ON and then check that the corner ing light...

Page 513: ...m the rear wheel sensor B Neutral switch open or short circuit is detected C Clutch switch open or short circuit is detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 07 Tool display Rear wheel speed pulse 0 999 Procedure Check that the number increases when the rear wheel is rotated The number is cumulative and does not reset each time the wheel is stopped Ite...

Page 514: ...upler and joint coupler blue red blue red blue black blue black Between joint coupler and ECU coupler blue red blue red blue black blue black Turn the main switch to ON and then check that the corner ing lights come on and go off in the proper sequence Lighting sequence is correct Service is finished Lighting sequence is not correct Go to item 4 4 Headlight sub wire harness continuity Open or shor...

Page 515: ... is finished Lighting sequence is not correct Go to item 3 3 Connection of headlight assem bly coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON and then check that the corner ing lights come...

Page 516: ...e is not correct Go to item 7 7 Malfunction in IMU Replace the IMU Turn the main switch to ON and then check that the corner ing lights come on and go off in the proper sequence Lighting sequence is correct Service is finished Lighting sequence is not correct Go to item 8 8 Malfunction in CLCU Replace the headlight assem bly Turn the main switch to ON and then check that the corner ing lights come...

Page 517: ...CORNERING LIGHT SYSTEM FJR13ESG 8 40 ...

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

Page 519: ...51 Relay unit 58 Front brake light switch 59 Handlebar switch right 62 Hazard switch 63 Gear position switch 64 Handlebar switch left 68 Horn switch 71 Turn signal switch 73 Front turn signal position light right 74 Front turn signal position light left 77 Meter assembly 78 Multi function meter 80 Neutral indicator light 83 Oil level warning light 86 Turn signal indicator light left 87 Turn signal...

Page 520: ... B W B B B G B B G G G L R B Br Br L R B Br W Br B W Br W Br B Br B W Br B Y W B L R L R L R L B L B L B R W R W Y B B Y W B L B L R L R L R L B L B R W R W Y B B B L G W B L R L R L R L R L R L B L B L B L B L B B B B B B B B Y W R W R W R W R W R W R W Y W Y W Y Y Y L B L B L R L R L B L R B L B L B L B L B B L B L B L Y R R R Br R Br L L R Br R Br L Br L Br L Br L Br L Br W R W R W Br Br W R G ...

Page 521: ...switch left 56 Horn switch 59 Turn signal switch 61 Tail brake light assembly 63 Brake light 64 Rear turn signal light left 65 Rear turn signal light right 74 Front turn signal position light right 75 Front turn signal position light left 83 Meter assembly 84 Multi function meter 86 Neutral indicator light 89 Oil level warning light 92 Turn signal indicator light left 93 Turn signal indicator ligh...

Page 522: ...system hazard lighting backup fuel injec tion system brake light and ABS ECU Refer to CHECKING THE FUS ES on page 8 250 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 251 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 247 Replace the main switch immobilizer unit 4 Check the en...

Page 523: ...he horn 1 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 247 Replace the front brake light switch 2 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 247 Replace the rear brake light switch 3 Check the brake switch relay Refer to CHECKING THE RE LAYS on page 8 254 Replace the brake switch relay 4 Check the brake light relay Refer to CHECKING TH...

Page 524: ... SWITCHES on page 8 247 The hazard switch is faulty Replace the right handlebar switch 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM FJR13AG on page 8 41 or refer to CIRCUIT DIAGRAM FJR13ESG on page 8 43 Properly connect or replace the wire har ness Replace the meter assembly or tail brake light assembly 1 Check the gear position switch Refer to CHECKING THE GEAR POSITION SWI...

Page 525: ...ing system wiring Replace the meter assembly 1 Check the oil level switch Refer to CHECKING THE OIL LEVEL SWITCH on page 8 261 Replace the oil level switch 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM FJR13AG on page 8 41 or refer to CIRCUIT DIAGRAM FJR13ESG on page 8 43 Properly connect or replace the wire har ness Replace the meter assembly 1 Check the fuel sender Refer to...

Page 526: ...n sor Replace the coolant temperature sensor 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM FJR13AG on page 8 41 refer to CIRCUIT DIAGRAM FJR13ESG on page 8 43 Properly connect or replace the wiring har ness Replace the ECU or meter assembly Refer to REPLACING THE ECU en gine control unit on page 8 250 1 Check the rear wheel sensor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR...

Page 527: ...SIGNALING SYSTEM 8 50 ...

Page 528: ...Y G B O G B B O Gy P L B R B Y W Lg R Y R R L L B W O B Br R Br W R W B Y R B R B L B L B L Y L B Y Y G L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W R R R Br L Br L R W R W Y L L Br W R Br B L Y L B L B B B B B Br B G Y R R W R W R W R R B B B B B R R R W R W R W B L G W G W B L B L B L B B W B W B B Br W G Y B B B W B W Br L Br L R R C A 1 8 11 12 ...

Page 529: ... fuse left 15 Fuel injection system fuse 19 Radiator fan motor left 20 Radiator fan motor right 22 Joint coupler 24 Radiator fan motor relay 32 Main fuse 33 Battery 34 Engine ground 35 Main fuse 2 107 Coolant temperature sensor 108 ECU Engine Control Unit A Wire harness C Negative battery sub wire harness ...

Page 530: ...R W B Y R B R B L B L B L Y L B Y L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W B L G W B B B G B B G B L B L B L B L B B L B L B L Y R R R Br L Br L Br L Br L R W R W Y L L Br W R Br B L L Y L B B B B B B Br B G Y R R W R W R W R R B B B R R R R R W R W R W B L G W G W B L B L B L B B W B W B B Br W G Y B B B W B W B B 9 12 13 16 22 24 25 26 27 28 2...

Page 531: ... fuse left 16 Fuel injection system fuse 20 Joint coupler 22 Radiator fan motor relay 24 Radiator fan motor left 25 Radiator fan motor right 26 Main fuse 27 Battery 28 Engine ground 29 Main fuse 2 112 Coolant temperature sensor 113 ECU Engine Control Unit A Wire harness C Negative battery sub wire harness ...

Page 532: ...the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 251 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 247 Replace the main switch immobilizer unit 4 Check the radiator fan motors Refer to CHECKING THE RADIA TOR FAN MOTORS on page 8 262 Replace the radiator fan motor s 5 Check the radiator...

Page 533: ...re cooling system wiring Refer to CIRCUIT DIAGRAM FJR13AG on page 8 51 or refer to CIRCUIT DIAGRAM FJR13ESG on page 8 53 Properly connect or replace the wire har ness Replace the ECU Refer to REPLAC ING THE ECU engine control unit on page 8 250 ...

Page 534: ...W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W R L R L R L R L R L R L L R L R L R R B B R W W L R B R W W L B B B B B R R R R Br L Br L Br W R W R W Br W Br W R G R G R L R R B B B B R W G Y R W R W R W R R R G R G Br B G B B B B B B G B G R Y B B Y G Y G W R W R W R W R W R W R W R B B W B B B B Sb W R Y W B B W B W B W B R L R W R G R G R G L B L R Gy W B L B L L B G...

Page 535: ...Fuel pump 95 Crankshaft position sensor 96 Intake air pressure sensor 97 Atmospheric pressure sensor 98 Cylinder identification sensor 99 Lean angle sensor 100 Yamaha diagnostic tool coupler 102 ABS ECU 103 O2 sensor 104 Throttle position sensor 105 Accelerator position sensor 106 Air temperature sensor 107 Coolant temperature sensor 108 ECU Engine Control Unit 109 Ignition coil 1 110 Ignition coi...

Page 536: ... R W R W Y B B Y W B L B L R L R L R L B L B R W R W Y B B B L B L B L B L B B L B L B L Y R L R L R L R L R L R L B B B B B B Y W R W R W R W R W R W R W Y W Y W Y Y Y L B L B L R L R L B L R B B B R R R Br L Br L Br L Br L Br W R W R W Br W Br W R G R G R B B B B R W G Y R W R W R W R W R W R W R R L B L B L R L R L R L R L B L B L R L R L B L B B G B B B B G R R R B Y G W R W R W R W R W R W R ...

Page 537: ...sensor 104 Intake air pressure sensor 105 Atmospheric pressure sensor 106 Cylinder identification sensor 107 Yamaha diagnostic tool coupler 108 O2 sensor 109 Throttle position sensor 110 Accelerator position sensor 111 Air temperature sensor 112 Coolant temperature sensor 113 ECU Engine Control Unit 114 Ignition coil 1 115 Ignition coil 2 116 Ignition coil 3 117 Ignition coil 4 118 Spark plug 119 ...

Page 538: ...cified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue operating or stop operating depending on the conditions EAS30506 TROUBLESHOOTING METHOD ECU The engine operation is not normal and the engine trouble warning light comes on 1 Check Fault code number a Check the fault code numbers that have a cond...

Page 539: ...ol can also be used to identify malfunctions Connecting the Yamaha diagnostic tool Remove the protective cap and then connect the Yamaha diagnostic tool to the coupler 1 EAS30987 TROUBLESHOOTING DETAILS ECU FAULT CODE This section describes the measures per fault code number displayed on the Yamaha diagnostic tool Check and service the items or components that are the probable cause of the malfunc...

Page 540: ...owing parts beforehand Cylinder identification sensor Crankshaft position sensor Fuel injector 1 Fuel injector 2 Fuel injector 3 Fuel injector 4 Ignition coil 1 Ignition coil 2 Ignition coil 3 Ignition coil 4 Accelerator position sensor Throttle position sensor Air temperature sensor Intake air pressure sensor Atmospheric pressure sensor Coolant temperature sensor Intake air temperature sensor O2 ...

Page 541: ... pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between ECU co...

Page 542: ...ult code number P2135 first 5 Malfunction in IMU Replace the IMU Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 250 Service is...

Page 543: ... ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Start the engine and then check the condition of the fault code Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 3 TIP For this check also set the en gine stop switch...

Page 544: ...ff Confirm that the fault code has a condition of Recovered us ing the Yamaha diagnostic tool and then delete the fault code Fault code No P0030 Item O2 sensor heater defective heater controller detected Fault code No P0069 Item Intake air pressure sensor or atmospheric pressure sensor when the main switch is turned to ON the intake air pressure sensor voltage and atmospheric pressure sensor volta...

Page 545: ...ic pres sure sensor Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 4 and finish the service Condition is Detected Go to item 3 3 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 250 Service is finished 4 Delete the fault code and check th...

Page 546: ...ed Con nect the coupler securely or re place the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Turn the main switch to ON and then ch...

Page 547: ...tinuity replace the wire harness A FJR13AG B FJR13ESG Fault code No P0107 P0108 Item P0107 Intake air pressure sensor ground short circuit detected P0108 Intake air pressure sensor open or power short circuit de tected B L P W L O G G Y L Y L B Gy R B B O Gy P G B R B Y W Lg R Y R R L L B W O B Br R Br W R W Gy R G Y L Y G B O G B B Gy O P L B R B Y W Lg R Y R R L L B W O B Br R Br W R W B L P W L...

Page 548: ...he main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 Fault code No P0107 P0108 Item P0107 Intake air pressure sensor ground short circuit detected P0108 Intake air pressure sensor open or power short circuit de tected B L P W L B L ...

Page 549: ...Recovered Go to item 7 and finish the service Condition is Detected Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 250 Service is finished 7 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered us ing the Yamaha diagnostic tool and then delete the fault cod...

Page 550: ...rely or re place the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Turn the main switch to ON and then check the condition of the fau...

Page 551: ...arts that are connected to the ECU Refer to Parts connected to the ECU on page 8 63 Fault code No P0112 P0113 Item P0112 Air temperature sensor ground short circuit detected P0113 Air temperature sensor open or power short circuit detect ed B L Br W B L Br W B L Br W Y R B R B L B L B L B Y Y G L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W Y R B R B ...

Page 552: ...perature is not close to the ambient tem perature Check the air tem perature sensor Replace if defective Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engi...

Page 553: ... to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected ...

Page 554: ...e harness A FJR13AG B FJR13ESG 3 6 Disconnect the couplers from the parts that are connected to the ECU Refer to Parts connected to the ECU on page 8 63 Fault code No P0117 P0118 Item P0117 Coolant temperature sensor ground short circuit detected P0118 Coolant temperature sensor open or power short circuit de tected B L G W B L G W B L G W Y R B R B L B L B L B Y Y G L Y Gy W Y B W P W W G Lg L Lg...

Page 555: ...rature is close to the ambient temperature The displayed temperature is not close to the ambient tem perature Replace the coolant temperature sensor Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 6 6 Malfunction in ECU Rep...

Page 556: ...e pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 2 2 Connection of ECU coupler...

Page 557: ...on sensor coupler and ground white ground If there is continuity replace the wire harness 3 4 For P0222 Ground short circuit For P2135 Deviation error Between throttle position sensor coupler and ground black ground If there is continuity replace the wire harness Fault code No P0122 P0123 P0222 P0223 P2135 Item P0122 P0222 Throttle position sensor ground short circuit detect ed P0123 P0223 Throttl...

Page 558: ...cuit detect ed P0123 P0223 Throttle position sensor open or power short circuit detected P2135 Deviation error W L B L B W L B L B Y R B R B L B L B L B Y Y G L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W Y R B R B L B L B L B Y L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W A B W L B L B W L B L B Y R B...

Page 559: ...NG THE THROTTLE POSITION SEN SOR on page 7 11 Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 5 Fault code No P0122 P0123 P0222 P0223 P2135 Item P0122 P0222 Throttle position sensor ground short circuit detect ed P0123 P022...

Page 560: ...are ful ly open A value of 94 108 is indicated An indicated value is out of the specified range Replace the throttle position sensor Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 7 7 Malfunction in ECU Replace the ECU Ref...

Page 561: ...condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 4 4 Wire harness continuity Open or short circuit Properly connect or rep...

Page 562: ...pler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Execute the diagnostic mode Code No 36 Operating sound Go to item 6 No operating sound Go to item 2 2 Defective fuel injector 1 Measure the fuel injector resis tance Replace if out of specification Refer to CHECKIN...

Page 563: ... coupler Check that fuel injector 2 is actuated five times by listening for the operating sound Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of fuel injector 2 coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected C...

Page 564: ...ble to start engine depending on the number of faulty cylinders Able to drive vehicle depending on the number of faulty cylinders Diagnostic code No 38 Actuation Actuates fuel injector 3 five times at one second intervals The check indicator on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated Procedure Disconnect the fuel pump coupler Check that fuel injector 3 is...

Page 565: ...that the fault code has a condition of Recovered us ing the malfunction mode of the Yamaha diagnostic tool and then delete the fault code Fault code No P0203 Item Fuel injector 3 malfunction in fuel injector 3 Fault code No P0204 Item Fuel injector 4 malfunction in fuel injector 4 Fail safe system Able to start engine depending on the number of faulty cylinders Able to drive vehicle depending on t...

Page 566: ... fuel injector coupler and joint coupler red blue red blue Between joint coupler and relay unit coupler red blue red blue Execute the diagnostic mode Code No 39 Operating sound Go to item 6 No operating sound Go to item 5 5 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 250 6 Delete the fault code and check that the engine trouble warning light goes off...

Page 567: ...osition sensor coupler and joint cou pler black blue black blue Between joint coupler and ECU coupler black blue black blue Crank the engine and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 4 4 Installed condition of crankshaft position sensor Check for...

Page 568: ...ck the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect...

Page 569: ...ation sensor no normal signals are received from the cylinder identification sensor Fault code No P0351 Item Cylinder 1 ignition coil open or short circuit detected in the prima ry lead of the cylinder 1 ignition coil Fail safe system Able to start engine depending on the number of faulty cylinders Able to drive vehicle depending on the number of faulty cylinders Diagnostic code No 30 Actuation Ac...

Page 570: ... ignition coil Check for looseness or pinch ing Improperly installed ignition coil Reinstall or replace the igni tion coil Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Defective cylinder 1 igni...

Page 571: ...ion of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool C...

Page 572: ...ult code No P0353 Item Cylinder 3 ignition coil open or short circuit detected in the prima ry lead of the cylinder 3 ignition coil Fail safe system Able to start engine depending on the number of faulty cylinders Able to drive vehicle depending on the number of faulty cylinders Diagnostic code No 32 Actuation Actuates the cylinder 3 ignition coil five times at one second intervals The check indic...

Page 573: ...nder 3 ignition coil Check for looseness or pinch ing Improperly installed ignition coil Reinstall or replace the igni tion coil Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Defective cylinder ...

Page 574: ...nection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic to...

Page 575: ...check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered us ing the Yamaha diagnostic tool and then delete the fault code Fault code No P0354 Item Cylinder 4 ignition coil open or short circuit detected in the prima ry lead of the cylinder 4 ignition coil Fault code No P0500 Item A Rear wheel sensor no normal signals are received from the rear w...

Page 576: ...alue increases Go to item A 8 Value does not increase Go to item A 3 A 3 Connection of ABS ECU cou pler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Execute the diagnostic mode Code No 07 Rotate the rear wheel by hand and...

Page 577: ...gine trouble warning light goes off Turn the main switch to ON and then rotate the rear wheel by hand Start the engine and input the vehicle speed signals by operat ing the vehicle at 20 to 30 km h 12 to 19 mph Confirm that the fault code has a condition of Recovered us ing the malfunction mode of the Yamaha diagnostic tool and then delete the fault code Delete this fault code even if it has a con...

Page 578: ...tch lever re leased OFF Correct indication Go to item B 9 Incorrect indication Go to item B 3 B 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Execute the diagnostic mode Code No 21 When the tran...

Page 579: ...SSION on page 5 98 Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever re leased OFF Correct indication Go to item B 9 Incorrect indication Go to item B 8 B 8 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 250 Service is finished B 9 Delete the fault code and check that the...

Page 580: ...malfunction Execute the diagnostic mode Code No 07 Rotate the rear wheel by hand and check that the indicated val ue increases Value does not increase Go to item A 2 for the rear wheel sensor Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever re leased OFF Incorrect indication Go to item B 2 for the neutral switch Wh...

Page 581: ...in gear and when the sidestand is retracted OFF When the clutch lever is squeezed with the transmission in gear and when the sidestand is retracted ON Correct indication Go to item C 8 Incorrect indication Go to item C 5 C 5 Wire harness continuity Open or short circuit Replace the wire harness Between ECU coupler and joint coupler black yellow black yellow Between joint coupler and relay unit cou...

Page 582: ... warning light goes off Turn the main switch to ON and then rotate the rear wheel by hand Start the engine and input the vehicle speed signals by operat ing the vehicle at 20 to 30 km h 12 to 19 mph Confirm that the fault code has a condition of Recovered us ing the malfunction mode of the Yamaha diagnostic tool and then delete the fault code Delete this fault code even if it has a condition of De...

Page 583: ...ECU memory When this malfunction is detected in the ECU the fault code number might not appear on the tool display Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No Tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control un...

Page 584: ...lfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 250 Service is finished 3 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered us ing the Yamaha diagnostic tool and then delete the fault code Fault code No P0638 Item YCC T drive system malfunction detected Fail safe system A...

Page 585: ...tion of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 5 5 Defective throttle servo motor Check the throttle servo motor Replace the throttle bodies if defective Refer to CHECKING THE THROTTLE SERVO MOTOR on page 8 264 Turn the main switch to ON and then check the condition of the ...

Page 586: ...firmation of service com pletion 1 Connection of relay unit coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the...

Page 587: ...ace the relay unit Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Defective relay unit Execute the diagnostic mode Code No 09 Fuel system voltage is below 3 V Replace the relay unit Start the eng...

Page 588: ...n of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Set the start engine stop switch to the on position turn the main switch to ON and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Conditions is Recov...

Page 589: ...nd Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of IMU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON then to OFF and then...

Page 590: ...of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Malfunction in IMU Replace the IMU Turn the main switch to ON then to OFF and then back to ON Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 an...

Page 591: ...dition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 3 3 Connection of relay unit coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler sec...

Page 592: ...function of ECU power cut off function Fail safe system Able Unable to start engine Able Unable to drive vehicle Diagnostic code No Tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Installed condition of battery leads Check the installed con dition of the battery and battery leads loose bolts Improperly installed battery or ...

Page 593: ...witch and igni tion fuse brown blue brown blue Between ignition fuse and ECU coupler red white red white Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engi...

Page 594: ...e place the wire harness Turn the main switch to ON then to OFF and then back to ON Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Turn the main switch to ON then to OFF and then back t...

Page 595: ...For P1605 Open circuit Between lean angle sensor coupler and ECU coupler yellow green yellow green If there is no continuity replace the wire harness Fault code No P1604 P1605 Item P1604 Lean angle sensor ground short circuit detected P1605 Lean angle sensor open or power short circuit B L L Y G O G G Y L Y L B Gy R B B O Gy P G B R B Y W Lg R Y R R L L B W O B Br R Br W R W B L L Y G B L L Y G Y ...

Page 596: ...t code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 5 5 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 250 Service is finished 6 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition...

Page 597: ...firmation of service com pletion 1 Connection of accelerator posi tion sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal fu...

Page 598: ...inuity replace the wire harness 3 4 For P2127 Ground short circuit For P2138 Deviation error Between accelerator position sensor coupler and ground black ground If there is continuity replace the wire harness Fault code No P2122 P2123 P2127 P2128 P2138 Item P2122 Accelerator position sensor open or ground short circuit detected P2123 Accelerator position sensor power short circuit detected P2127 A...

Page 599: ...r position sensor power short circuit detected P2127 Accelerator position sensor ground short circuit detected P2128 Accelerator position sensor open or power short circuit de tected P2138 Deviation error B L W L B B L W L B Y R B R B L B L B L B Y Y G L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W Y R B R B L B L B L B Y L Y Gy W Y B W P W W G Lg L L...

Page 600: ...position sensor open or ground short circuit detected P2123 Accelerator position sensor power short circuit detected P2127 Accelerator position sensor ground short circuit detected P2128 Accelerator position sensor open or power short circuit de tected P2138 Deviation error B L W L B B L W L B Y R B R B L B L B L B Y Y G L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L ...

Page 601: ... using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 5 Fault code No P2122 P2123 P2127 P2128 P2138 Item P2122 Accelerator position sensor open or ground short circuit detected P2123 Accelerator position sensor power short circuit detected P2127 Accelerator position sensor ground short circuit detecte...

Page 602: ...ed value is out of the specified range Replace the accelerator position sensor Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 7 7 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 ...

Page 603: ...eases Go to item 8 and delete the fault code Value does not increase Go to item 3 3 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Execute the diagnostic mode Code No 16 Rotate the fro...

Page 604: ...gine trouble warning light goes off Turn the main switch to ON and then rotate the front wheel by hand Start the engine and input the vehicle speed signals by operat ing the vehicle at 20 to 30 km h 12 to 19 mph Confirm that the fault code has a condition of Recovered us ing the malfunction mode of the Yamaha diagnostic tool and then delete the fault code Delete this fault code even if it has a co...

Page 605: ...d 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Start the engine and let it idle for approximately 10 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagn...

Page 606: ...ndition is Detected Go to item 7 Also delete this fault code which has a condition of De tected 7 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 250 Service is finished 8 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered us ing the Yamaha diagnostic tool and then delet...

Page 607: ...wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal...

Page 608: ...uity replace the wire harness A FJR13AG B FJR13ESG Fault code No P2228 P2229 Item P2228 Atmospheric pressure sensor ground short circuit detect ed P2229 Atmospheric pressure sensor open or power short circuit detected B L P L Gy R G Y L Y G B O G B B Gy O P L B R B Y W Lg R Y R R L L B W O B Br R Br W R W O G G Y L Y L B Gy R B B O Gy P G B R B Y W Lg R Y R R L L B W O B Br R Br W R W B L P L B L ...

Page 609: ...he main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 Fault code No P2228 P2229 Item P2228 Atmospheric pressure sensor ground short circuit detect ed P2229 Atmospheric pressure sensor open or power short circuit detected B L P L B L ...

Page 610: ... fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 250 Service is finished 7 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a co...

Page 611: ...y Open or short circuit Replace the wire harness Between ECU coupler and joint coupler blue red blue red blue black blue black Between joint coupler and IMU coupler blue red blue red blue black blue black Between IMU coupler and igni tion fuse connector red white red white Between IMU coupler and ground black black Turn the main switch to ON and then check the condition of the fault code using the...

Page 612: ...nected Con nect the coupler securely or re place the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between meter assembly cou pler an...

Page 613: ...FUEL INJECTION SYSTEM 8 136 ...

Page 614: ... B Y W Lg R Y R R L L B W O B Br R Br W R W B Y R B R B L B L B L Y L B Y Y G L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W R G R G R G R G B L R L B R G B W L B L B L B B L R L R L R Lg B B Br Y B B R R R Br L Br L Br L R W R G R W Br Br W R B B B R W R W R W R R Br Br Br Br Lg B Lg B G Y G W Lg B B G R B Y Y B Br B Lg L Y W G W G Y G Y Y B Y B Y B ...

Page 615: ...tch 41 Rear brake light switch 42 Grip cancel switch 43 Brake switch relay 44 Brake light relay 58 Front brake light switch 64 Handlebar switch left 65 Cruise control power switch 66 Cruise control setting switch 77 Meter assembly 78 Multi function meter 88 Cruise control system indicator light 89 Cruise control setting indicator light 100 Yamaha diagnostic tool coupler 108 ECU Engine Control Unit...

Page 616: ...g B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W L R L R L R L R L R L B L B L B L B L B B B G B B G Y W B L R L R L R L B L B L B R W R W Y B B Y W B L B L R L R L R L B L B R W R W Y B B B B B B B B B Y W R W R W R W R W R W R W Y W Y W Y Y Y L B L B L R L R L B L R Lg B B Br Y B R R R Br L Br L Br L Br L Br L Br L R W R W Br Br W R G R G R B B B R W R W R W R R Br Br Br L B L B ...

Page 617: ...ke light switch 43 Grip cancel switch 44 Front brake light switch 50 Brake switch relay 51 Brake light relay 52 Handlebar switch left 53 Cruise control power switch 54 Cruise control setting switch 83 Meter assembly 84 Multi function meter 94 Cruise control system indicator light 95 Cruise control setting indicator light 107 Yamaha diagnostic tool coupler 113 ECU Engine Control Unit A Wire harness...

Page 618: ...CRUISE CONTROL SYSTEM 8 141 EAS30666 CRUISE CONTROL CIRCUIT OPERATION 21 20 19 18 17 16 15 14 13 12 11 10 7 6 3 2 1 9 8 5 4 ...

Page 619: ...e 9 Cruise control system fuse 10 Cruise control power switch 11 Cruise control setting switch 12 Clutch switch 13 Front brake light switch 14 Rear brake light switch 15 Grip cancel switch 16 Brake switch relay 17 Brake light relay 18 ECU Engine Control Unit 19 Multi function meter 20 Cruise control system indicator light 21 Cruise control setting indicator light ...

Page 620: ...fficiently charged regular batteries only A Malfunction check using the cruise control system indicator light B Use the Yamaha diagnostic tool to determine the cause of the malfunction for the stored fault code from the condition and place where the malfunction occurred TIP For information about using the Yamaha diagnostic tool refer to YAMAHA DIAGNOSTIC TOOL on page 8 62 C Servicing the cruise co...

Page 621: ...re automatic deactivation history for the cruise control system Check the malfunction history using the malfunction mode of the Yamaha diagnostic tool Is there any malfunction history Diagnosis using the fault codes Yes Yes OK The cruise control power switch is defective The cruise control system fuse is blown The ECU is defective Delete the fault codes Final check Return to A Return to A If the e...

Page 622: ...2 The cruise control system indicator light flashes B 1 3 The cruise control system indicator light come on B 2 EAS30670 B 1 DIAGNOSIS USING THE FAULT CODES 1 Information for the fault codes from the cruise control system is contained in the following table Re fer to this table for troubleshooting Fault code table Fault code No P056C Fault code No Symptom Check point P056C No normal signals from t...

Page 623: ... 3 A 3 Connection of brake switch re lay coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON Operate the brake lever and then check the condition of the fault code using the malfunction mode of...

Page 624: ...short circuit Replace the wire harness Between battery and main switch coupler red red Between main switch coupler and front brake light switch cou pler brown blue green white Between front brake light switch coupler and brake switch relay coupler green white green yellow Between brake switch relay coupler and ECU coupler light green black light green black Turn the main switch to ON Operate the b...

Page 625: ...ction of rear brake light switch coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON Operate the brake pedal and then check the condition of the fault code using the malfunction mode of the Yam...

Page 626: ... finish the ser vice Condition is Detected Go to item B 6 B 6 Check the fuse main fuse sig naling system fuse brake light fuse Abnormality Replace the fuse main fuse signaling sys tem fuse brake light fuse Turn the main switch to ON Operate the brake pedal and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item B 10 ...

Page 627: ...ear brake light switch open or short circuit is detected Fault code No P0564 Item A Cruise control setting switch RES open or short circuit is de tected B Cruise control setting switch SET open or short circuit is de tected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 80 81 Tool display ON when the switch is pushed OFF when the switch is released Procedure Push an...

Page 628: ...dition is Recovered Go to item A 9 and finish the ser vice Condition is Detected Go to item A 4 A 4 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON Push and release the RE...

Page 629: ...diagnostic tool Condition is Recovered Go to item A 9 and finish the ser vice Condition is Detected Go to item A 8 A 8 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 250 A 9 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered us ing the Yamaha diagnostic tool and then de...

Page 630: ...itch cou pler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON Push and SET side of the cruise control setting switch and then check the condition of the fault code using the mal function mode of th...

Page 631: ...check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item B 9 and finish the ser vice Condition is Detected Go to item B 7 B 7 Defective cruise control setting switch Replace the left handlebar switch Turn the main switch to ON Push the RES side and SET side of the cruise con trol setting switch and then check the condition of...

Page 632: ...ation function of the cruise control system to the customer and explain that this is not a malfunction EAS30674 C 1 DELETING THE FAULT CODES 1 Delete the fault code using the malfunction of the Yamaha diagnostic tool and check that the engine trouble warning light goes off EAS30675 C 2 FINAL CHECK 1 Check the brake lever and brake pedal operation 2 Check the rear brake light switches Refer to ADJU...

Page 633: ...CRUISE CONTROL SYSTEM 8 156 ...

Page 634: ...R G Y L Y G B O G B B O Gy P L B R B Y W Lg R Y R R L L B W O B Br R Br W R W B Y R B R B L B L B L Y L B Y Y G L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W R R R Br L Br L R W R W Br W Br W R B B B R W R W R R B B B B B R R W R W R W R B B B B R L R W L Y R B R B R B Br W R L L Y B B W B W B B R L R L Br W B B B W B W Br L Br L R R C A 1 8 15 32 33...

Page 635: ...se 15 Fuel injection system fuse 32 Main fuse 33 Battery 34 Engine ground 51 Relay unit 53 Fuel pump relay 59 Handlebar switch right 61 Start engine stop switch 93 Fuel pump 108 ECU Engine Control Unit A Wire harness C Negative battery sub wire harness ...

Page 636: ...y O P G B R B Y W Lg R Y R R L L B W O B Br R Br W R W B Y R B R B L B L B L Y L B Y L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W B B G B B G R R R Br L Br L Br L Br L R W R W Br W Br W R B B B R W R W R R B B B R R R R W R W R W R B B B B R L R W L Y R B Br W R L L Y B B W B W B B R L R L Br W B B B W B W R B R B B B 9 16 26 27 28 1 35 37 45 47 100...

Page 637: ...e 16 Fuel injection system fuse 26 Main fuse 27 Battery 28 Engine ground 35 Relay unit 37 Fuel pump relay 45 Handlebar switch right 47 Start engine stop switch 100 Fuel pump 113 ECU Engine Control Unit A Wire harness C Negative battery sub wire harness ...

Page 638: ... CHECKING AND CHARGING THE BATTERY on page 8 251 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 247 Replace the main switch immobilizer unit 4 Check the start engine stop switch Refer to CHECKING THE SWITCHES on page 8 247 The start engine stop switch is faulty Replace the right handlebar switch 5 Check the relay unit fu...

Page 639: ...e entire fuel pump system wiring Refer to CIRCUIT DIAGRAM FJR13AG on page 8 157 or refer to CIRCUIT DIAGRAM FJR13ESG on page 8 159 Properly connect or replace the wire har ness Replace the ECU Refer to CIRCUIT DIAGRAM FJR13ESG on page 8 159 ...

Page 640: ... B Y P Y W L W B R Gy W G W R P W W B W G B Br B Br W Br B Br W Dg Gy B P W R W G B P W R W G W B Br Br L Y W B W W L O W G L Y B W Y Y B G L B W W L Br L Y W Y L R W Y W B Y B O W B R R Br L Br G Br L Br L Br L Br L R W Br B B R W R W R R Br Br B B B B B R R W R W W R W G B W W L B W B W B B B B B B W R W P B P W W R W G W L Br Br Br Br G Br G Br G Br G Br Br B P W Br G Br Br Br R R Br P B B Br L...

Page 641: ...fuse 33 Battery 34 Engine ground 54 Windshield drive unit 55 Windshield drive unit relay down 56 Windshield drive unit relay up 64 Handlebar switch left 69 Menu switch 70 Select switch 77 Meter assembly 78 Multi function meter A Wire harness C Negative battery sub wire harness E Windshield drive unit sub wire harness ...

Page 642: ...B Br B Br B R Br P B Br G B R B P W R W G B P W R W G W B Br Br L Y W B W W L O W G L Y B W Y Y B G L B W W L Br L Y W Y L R W Y W B Y B O W B B B G B B G R Br R Br B R R Br L Br G Br L Br L Br L Br L Br L Br L Br L R W Br B B R W R W R R Br Br B B B R R R R W R W W R W G B W W L B W B W B B B B B B W R W P B P W W R W G W L Br Br Br Br Br B P W Br G Br G Br Br Br R R R R Br P B B Br G Br G Br G B...

Page 643: ...fuse 27 Battery 28 Engine ground 39 Windshield drive unit 40 Windshield drive unit relay down 41 Windshield drive unit relay up 52 Handlebar switch left 57 Menu switch 58 Select switch 83 Meter assembly 84 Multi function meter A Wire harness C Negative battery sub wire harness E Windshield drive unit sub wire harness ...

Page 644: ...windshield motor Refer to CHECKING THE FUS ES on page 8 250 Replace the fuse s 4 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 251 Clean the battery terminals Recharge or replace the battery 5 Check the main switch Refer to CHECKING THE SWITCHES on page 8 247 Replace the main switch immobilizer unit 6 Check the menu switch Refer to CHECKING THE SWITCHES on page 8 247 The m...

Page 645: ... unit relay down 10 Check the windshield drive motor Refer to CHECKING THE WIND SHIELD DRIVE UNIT on page 8 265 Replace the windshield drive unit 11 Check the entire windshield drive system wiring Refer to CIRCUIT DIAGRAM FJR13AG on page 8 163 or refer to CIRCUIT DIAGRAM FJR13ESG on page 8 165 Properly connect or replace the wire har ness Replace the meter assembly ...

Page 646: ...20232 ACCESSORY BOX SYSTEM EAS31999 CIRCUIT DIAGRAM FJR13AG ON OFF P B C C R Br L R Br L R R Br B B B C B B G B B G B Br Br B R R Br L Br L Br B B R R Br Br B B B B B R B B Br Br B B B B Br Br Br L Br L R R C D A A 1 10 32 33 75 34 ...

Page 647: ...RY BOX SYSTEM 8 170 1 Main switch 10 Signaling system fuse 32 Main fuse 33 Battery 34 Engine ground 75 Accessory box solenoid A Wire harness C Negative battery sub wire harness D Accessory box sub wire harness ...

Page 648: ...YSTEM 8 171 EAS31954 CIRCUIT DIAGRAM FJR13ESG C C ON OFF P B B C R Br L R Br L R R Br B B B B G B B G B Br Br B R R Br L Br L Br L Br L Br B B R R Br Br B B B R R R B B Br Br B B B B Br Br B B 11 26 27 28 1 76 C D A A ...

Page 649: ...RY BOX SYSTEM 8 172 1 Main switch 11 Signaling system fuse 26 Main fuse 27 Battery 28 Engine ground 76 Accessory box solenoid A Wire harness C Negative battery sub wire harness D Accessory box sub wire harness ...

Page 650: ...ECKING AND CHARGING THE BATTERY on page 8 251 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 247 Replace the main switch immobilizer unit 4 Check the accessory box solenoid Refer to CHECKING THE ACCES SORY BOX SOLENOID on page 8 266 Replace the accessory box solenoid 5 Check the entire accessory box system wiring Refer t...

Page 651: ...ACCESSORY BOX SYSTEM 8 174 ...

Page 652: ... Dg Gy B Y L Lg R W R G B B W R G Y L G B R W B Gy R G Y L Y G B O G B B O Gy P L B R B Y W Lg R Y R R L L B W O B Br R Br W R W B Y R B R B L B L B L Y L B Y Y G L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W B B B W Y L R W G B Lg B B R G R R R Br L Br L R W R W Br W R G R G R B B B R W R W R W R W R R R G R G B B B B B R B W B B W G B R G R G R G R...

Page 653: ...15 Fuel injection system fuse 16 Backup fuse 21 Immobilizer unit 22 Joint coupler 32 Main fuse 33 Battery 34 Engine ground 77 Meter assembly 79 Immobilizer system indicator light 108 ECU Engine Control Unit A Wire harness C Negative battery sub wire harness ...

Page 654: ...B W B W B W B W B O G G Y L Y L B Gy R B B Gy O P G B R B Y W Lg R Y R R L L B W O B Br R Br W R W B Y R B R B L B L B L Y L B Y L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W B B G B B G R Br L R Br L B W Y L R W G B R G R R R B B Lg Br L Br L Br L Br L R W R W Br W R G R G R B B B R W R W R W R W R R R G B B B R R R B W B B W G B R G R G R G R W Y L...

Page 655: ...it 9 Ignition fuse 16 Fuel injection system fuse 17 Backup fuse 20 Joint coupler 26 Main fuse 27 Battery 28 Engine ground 83 Meter assembly 85 Immobilizer system indicator light 113 ECU Engine Control Unit A Wire harness C Negative battery sub wire harness ...

Page 656: ...is lost regis tering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made or all keys are lost the entire immobilizer system must be replaced Therefore it is highly rec ommended to use either standard key for driving and to keep the code re registering key in a safe place D...

Page 657: ...he ignition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours After that time the indicator light will stop flashing but the immobilizer system is still enabled Standby mode Parts to be replaced Key registration re quirement Main switch immobi lizer unit Standard key ECU Accessory lock and key Main switch Immobi...

Page 658: ...the memory when the key registration mode is activated When the key registration mode is activated the immobilizer system indicator light flashes rapidly 4 While the indicator light is flashing turn the main switch to OFF remove the key and within 5 sec onds insert the second standard key to be registered into the main switch TIP If the immobilizer system indicator light stops flashing 5 seconds a...

Page 659: ...m the memory thus disabling the lost standard key To re register refer to Standard key registration Standard key code voiding method a Main switch ON b Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g Remaining standard key h Registration mode A If the immobilizer system indicator light stops flashing 5 seconds after the first standard key is registered the second s...

Page 660: ...r to CHECKING AND CHARGING THE BATTERY on page 8 251 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 247 Replace the main switch immobilizer unit 4 Check the entire immobilizer sys tem wiring Refer to CIRCUIT DIAGRAM FJR13AG on page 8 175 or refer to CIRCUIT DIAGRAM FJR13ESG on page 8 177 Properly connect or replace the w...

Page 661: ... dard key 53 IMMOBILIZER UNIT Codes cannot be transmitted between the ECU and the im mobilizer unit Noise interference or dis connected lead cable 1 Interference due to ra dio wave noise 2 Disconnected commu nication harness 3 Immobilizer unit mal function 4 ECU malfunction 1 Check the wire harness and con nector 2 Replace the main switch immobiliz er unit 3 Replace the ECU Refer to RE PLACING THE...

Page 662: ... for 0 5 second and off for 0 5 second Example Fault code 52 56 ECU Unidentified code is received Noise interference or dis connected lead cable 1 Check the wire harness and con nector 2 Replace the main switch immobiliz er unit 3 Replace the ECU Refer to RE PLACING THE ECU engine con trol unit on page 8 250 Fault code Part Symptom Cause Action a Light on b Light off ...

Page 663: ...IMMOBILIZER SYSTEM 8 186 ...

Page 664: ... Y L Y G B O G B B O Gy P L B R B Y W Lg R Y R R L L B W O B Br R Br W R W B Y R B R B L B L B L Y L B Y Y G L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W L R L R L R B B R R R Br L Br L Br L Br W R W R W Br R L R W Br W R G R R B B B Br Br R W R W R W R R Br Br Br Br B Y Br Lg B G Y G W G Y G W Lg B B G Y Y B Br B G W G Y G Y R W R W B G B B B B B B...

Page 665: ...y 34 Engine ground 36 Starter relay 39 Brake light fuse 41 Rear brake light switch 43 Brake switch relay 44 Brake light relay 58 Front brake light switch 59 Handlebar switch right 61 Start engine stop switch 77 Meter assembly 78 Multi function meter 90 ABS warning light 101 ABS test coupler 102 ABS ECU 108 ECU Engine Control Unit 122 Front wheel sensor 123 Rear wheel sensor A Wire harness C Negati...

Page 666: ...L R W L G Y Br W Sb B W G R Gy W Y G W L W R W R L W Y W B B W B W B B B G B B G Y W B L R L R L R L B L B L B R W R W Y B B Y W B L B L R L R L R L B L B R W R W Y B B Sb B W L R L B B B B B B B Y W R W R W R W R W R W R W Y W Y W Y Y Y L B L B L R L R L B L R B B R R R Br L R R Br L Br L Br L Br L Br L Br W R W R W Br R L R W Br W R G R R B B B Br Br R W R W R W R R Br Br Br Br L B L B L R L R L...

Page 667: ...ound 30 Starter relay 33 Brake light fuse 42 Rear brake light switch 44 Front brake light switch 45 Handlebar switch right 47 Start engine stop switch 50 Brake switch relay 51 Brake light relay 83 Meter assembly 84 Multi function meter 97 ABS warning light 113 ECU Engine Control Unit 128 ABS test coupler 129 ABS ECU 130 Front wheel sensor 131 Rear wheel sensor A Wire harness B Headlight sub wire h...

Page 668: ...ight 3 ABS ECU fuse 4 ABS solenoid fuse 5 ABS motor fuse 6 Proportioning valve 7 Hydraulic unit assembly 8 Rear wheel sensor 9 Rear wheel sensor rotor 10 Rear brake caliper 11 Metering valve 12 Front brake caliper left 13 Front brake caliper right partially operated together with the rear brake 14 Front wheel sensor 15 Front wheel sensor rotor ...

Page 669: ...ABS ANTI LOCK BRAKE SYSTEM 8 192 ...

Page 670: ...HART B W L R L B Sb W B W Gy Gy W W Gy R W L R L B Br Y P B Sb W Y G R G W R G R G R G Ch W L W Y W B B Y P Y W L W B R Gy W G W R P W W B W G B Br B Br W Br B Br W Dg B W B G L Y L B L R W L G Y Br W Sb B W G R Gy W Y G W L W R W R L W Y W B 2 4 5 1 3 B B B B Gy Gy ...

Page 671: ...ABS ANTI LOCK BRAKE SYSTEM 8 194 1 Meter assembly coupler 2 ABS test coupler 3 Rear wheel sensor coupler 4 ABS ECU coupler 5 Front wheel sensor coupler ...

Page 672: ...tions by the multi function meter right display For troubleshooting items other than the following items follow the normal service method WARNING EWA16710 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 TIP To final check refer to C 3 FINAL CHECK on page 8 220 ABS operation when the ABS w...

Page 673: ...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 and hydraulic unit are united assemblies and cannot be disassembled The malfunction history is stored in the memory of the ABS ECU Delete the fault codes when the ser vice is finished This is because the past fault codes will be displayed ag...

Page 674: ...isplayed Finished The T C terminal sky blue of the ABS test coupler is grounded The meter assembly circuit is defective The hydraulic unit assembly is defective Diagnosis using the fault codes The ABS ECU fuse is blown The meter assembly circuit is defective The hydraulic unit assembly is defective There is a break in the wire harness between the ABS ECU and the meter assembly The battery voltage ...

Page 675: ...ING LIGHT FLASHES 1 Test coupler adapter confirmation Check if the test coupler adapter is connected to the ABS test coupler If the test coupler adapter is connected disconnect it and then install the protective cap onto the ABS test coupler 2 If the test coupler adapter is not connected Check that the T C terminal sky blue of the ABS test coupler is not short circuited to the ground If the T C te...

Page 676: ...nction is not detected The ABS warning light flashes every 0 5 second if a fault code for a past malfunction is not stored in the memory of the ABS ECU The ABS warning light flashes quicker if a fault code is displayed on the multi function meter right display If no fault code is displayed make sure that the customer un derstands the possible conditions that may cause the ABS warning light to come...

Page 677: ...tinuity the wire harness is defective Replace the wire harness 5 There is a break in the wire harness between the ABS ECU and the meter assembly ABS warning light Check for continuity between the green red terminal of the ABS ECU coupler and the green red terminal of the meter assembly coupler 6 The meter assembly circuit is defective Disconnect the ABS ECU coupler The green red terminal of the AB...

Page 678: ...ensor coupler and ABS ECU coupler Rear wheel sensor ABS_17 ABS_45 Missing pulses detected in the front wheel sensor signal Front wheel sensor rotor Front wheel sensor housing Front wheel ABS_18 ABS_46 Missing pulses detected in the rear wheel sensor signal Rear wheel sensor rotor Rear wheel sensor housing Rear wheel ABS_21 Hydraulic unit solenoid circuit is open or short circuited Hydraulic unit a...

Page 679: ...nuously transmitted from the ABS ECU to release the hydraulic pressure Brake dragging Brake fluid Hydraulic unit operation tests Rear wheel brake lines Hydraulic unit assembly ABS_43 Incorrect signal from the front wheel sensor is detected Installation of the front wheel sensor Front wheel sensor housing Front wheel sensor rotor ABS_44 Incorrect signal from the rear wheel sensor is detected Instal...

Page 680: ...ANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 33 4 Defective sensor rotor Check the surface of the sensor rotor for damage Re place the sensor rotor if there is visible damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 33 Fault code No ABS_12 Symptom Rear wheel sensor signal is not received properly Order Item components and probable cause Check or mainte...

Page 681: ... FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 33 5 Hydraulic unit assembly internal malfunc tion Replace the hydraulic unit assembly Fault code No ABS_14 ABS_27 Symptom Incorrect signal from the rear wheel sensor is detect ed Order Item components and probable cause Check or maintenance job 1 Installed condition of wheel sensor Check for looseness Properly install or replace the wheel sensor if n...

Page 682: ...inuity between the ground and the white terminal 1 or white terminal 3 and be tween the ground and the black terminal 2 or black terminal 4 If there is continuity the wire harness is defective Re place the wire harness Check that there is no continuity between the white terminal 1 and the black terminal 2 and between the white terminal 3 and the black terminal 4 If there is continuity the wire har...

Page 683: ...tinuity between the ground and the gray terminal 1 or gray terminal 3 and be tween the ground and the white terminal 2 or white terminal 4 If there is continuity the wire harness is defective Re place the wire harness Check that there is no continuity between the gray ter minal 1 and the white terminal 2 and between the gray terminal 3 and the white terminal 4 If there is continuity the wire harne...

Page 684: ... Item components and probable cause Check or maintenance job 1 Installed condition of wheel bearings ax le sensor housing and sensor rotor Check the components for looseness distortion and bends Refer to CHECKING THE REAR WHEEL on page 4 42 2 Foreign material inside sensor housing Check the interior of the sensor housing and the surface of the sensor rotor for foreign material such as metal partic...

Page 685: ...when main switch is turned to ON brake light circuit or front or rear brake light switch circuit Order Item components and probable cause Check or maintenance job 1 Brake light operation Defective brake switch and brake light relays Check the brake switch and brake light relays Refer to CHECKING THE RELAYS on page 8 254 2 Connections ABS ECU coupler Brake switch relay coupler Brake light relay cou...

Page 686: ...ain switch to OFF before disconnecting or connecting a coupler 3 Open or short circuit in wire harness Replace if there is an open or short circuit Between ABS ECU coupler and brake light relay cou pler yellow yellow Between rear brake light switch coupler and brake switch relay coupler green white green white Between front brake light switch coupler and brake switch relay coupler green yellow gre...

Page 687: ...ttery Refer to CHECKING AND CHARGING THE BATTERY on page 8 251 2 Blown ABS motor fuse Check the ABS motor fuse If the ABS motor fuse is blown replace the fuse and check the wire harness Refer to CHECKING THE FUSES on page 8 250 3 Connections ABS ECU coupler Starter relay coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfuncti...

Page 688: ...ing assembly the brakes will continue to operate as normal However the reduction of the hydraulic pressure for the rear brake and part of the right front brake will be reversed during the ABS operation when the final check on page C 3 FINAL CHECK on page 8 220 is performed Fault code No ABS_41 Symptom Front wheel will not recover from the locking tenden cy even though the signal is continuously tr...

Page 689: ... operate as normal However the reduction of the hydraulic pressure for the rear brake and part of the right front brake will be reversed during the ABS operation when the final check on page C 3 FINAL CHECK on page 8 220 is performed 4 Brake lines Check the brake lines for kinks and deterioration WARNING EWA16730 Only use genuine Yamaha parts Using other brake pipes hoses and union bolts may close...

Page 690: ...brake caliper when the brake pedal is op erated and that the pressure decreases when the pedal is released 4 Brake fluid Visually check the brake fluid in the brake fluid reser voir for water foreign materials solidification and con tamination Check for air in the brake lines 5 Brake lines Check the brake lines for kinks and deterioration par ticularly between the hydraulic unit and the rear brake...

Page 691: ... wheel sensor is detect ed Order Item components and probable cause Check or maintenance job 1 Installed condition of wheel sensor Check for looseness Properly install or replace the wheel sensor if necessary 2 Installed condition of wheel bearings ax le sensor housing and sensor rotor Check the components for looseness distortion and bends Refer to CHECKING THE REAR WHEEL on page 4 42 3 Foreign m...

Page 692: ...robable cause Check or maintenance job 1 Battery voltage Recharge or replace the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 251 2 Connections ABS ECU coupler Starter relay coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction replace the wire harness and connect the coupler securely TIP Turn the main swi...

Page 693: ...ay terminal 4 Check that there is no short circuit between the frame ground and the white terminal 3 If there is a short circuit the front wheel sensor is de fective Replace the front wheel sensor 5 ABS ECU 6 Front wheel sensor 3 Hydraulic unit internal malfunction Replace the hydraulic unit assembly W Gy W B W B G W L W W Y L B B W Gy W G R L R Y W L G Y Sb Br W B W B G R W R L L Y 2 3 4 1 6 5 Fa...

Page 694: ...te terminal 3 If there is a short circuit the rear wheel sensor is de fective Replace the rear wheel sensor 5 ABS ECU 6 Rear wheel sensor 3 Hydraulic unit internal malfunction Replace the hydraulic unit assembly Fault code No ABS_64 Symptom Rear wheel sensor power is abnormal Order Item components and probable cause Check or maintenance job W Gy Gy W W B G W L W W Y L B B W Gy W G R L R Y W L G Y ...

Page 695: ...tart engine stop switch is pushed without performing step 4 the starter motor gear or other parts may be damaged 5 Push the side of the start engine stop switch 1 at least 10 times in 4 seconds to delete the fault codes 6 The multi function meter right display switch es to the normal display and the ABS warning light flashes in 0 5 second intervals while the fault codes are being deleted 7 Turn th...

Page 696: ... Shift the transmission into gear and extend the sidestand c Push the side of the start engine stop switch Battery voltage Higher than 12 8 V Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe brown white 1 Negative tester probe ground Continuity is all right Pocket tester 90890 03112 Analog pocket tester YU 03112 C W B G W L W W Y L B B W Gy W G R L R Y W L G Y Sb Br ...

Page 697: ...o CHECKING THE BRAKE FLUID LEVEL on page 3 13 2 Check the wheel sensor housings and wheel sensors for proper installation Refer to INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS on page 4 36 and INSTALLING THE REAR WHEEL REAR BRAKE DISC on page 4 44 3 Perform hydraulic unit operation test 1 or 2 Refer to HYDRAULIC UNIT OPERATION TESTS on page 4 83 4 Delete the fault codes Refer to C 1 DELETING THE F...

Page 698: ...R Y R R L L B W O B Br R Br W R W B Y R B R B L B L B L Y L B Y Y G L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W L R L R L R B P W R W G B P W R W G W B Br Br L Y W B W W L O W G L Y B W Y Y B G L B W W L Br L Y W Y L R W Y W B Y B O W B B R R R Br L Br L R W R W Br W R B B B R W R W R R B B B B B R R W R W W R W G B W W L B W B W B B B W R W L B L ...

Page 699: ...use 22 Joint coupler 32 Main fuse 33 Battery 34 Engine ground 64 Handlebar switch left 69 Menu switch 70 Select switch 77 Meter assembly 78 Multi function meter 108 ECU Engine Control Unit 120 Grip warmer left 121 Grip warmer right A Wire harness C Negative battery sub wire harness ...

Page 700: ... R B R B L B L B L Y L B Y L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W B B G B B G Y W B L R L R L R L B L B L B R W R W Y B B Y W B L B L R L R L R L B L B R W R W Y B B L R L R L R L R L R L B L B L B L B L B B B B B B B B Y W R W R W R W R W R W R W Y W Y W Y Y Y L B L B L R L R L B L R R R R Br L Br L Br L Br L R W R W Br W R B B B R W R W R R ...

Page 701: ...oupler 26 Main fuse 27 Battery 28 Engine ground 52 Handlebar switch left 57 Menu switch 58 Select switch 83 Meter assembly 84 Multi function meter 113 ECU Engine Control Unit 125 Grip warmer left 126 Grip warmer right A Wire harness B Headlight sub wire harness C Negative battery sub wire harness ...

Page 702: ...off Adjust the temperature levels of the grip warmer settings 3 Check the fuses Main ignition and fuel injection system Refer to CHECKING THE FUS ES on page 8 250 Replace the fuse s 4 Check that the engine is started Start the engine 5 Check the grip warmers Refer to CHECKING THE GRIP WARMERS on page 8 266 Replace the grip warmer s 6 Check the entire grip warmer sys tem wiring Refer to CIRCUIT DIA...

Page 703: ...re levels of the grip warmer settings 2 Check that the engine trouble warn ing light is on and that fault code No P0500 is displayed in the Yamaha diagnostic tool display Perform the troubleshooting for fault code No P0500 Refer to TROUBLESHOOT ING DETAILS ECU FAULT CODE on page 8 62 Replace the ECU Refer to REPLAC ING THE ECU engine control unit on page 8 250 1 Check the menu switch Refer to CHEC...

Page 704: ...W O W Br L Br W G L L W L B Gy W G W L R L R L R L R L R L B L B L B L B L B B B G B B G B B W B G B Gy B Y B W B G B Y B Gy B P B Lg B O B Br B Lg B P B O B Br B B B B B B B B Y W R W R W R W R W R W R W Y W Y W Y Y Y L B L B L R L R L B L R Y W B L R L R L R L B L B L B R W R W Y B B Y W B L B L R L R L R L B L B R W R W Y B B R R R R W W W R R R B Br L R R R Br L Br L Br L Br L R W R W Br W R G...

Page 705: ...epping motor left 80 Front fork stepping motor right 81 Rear shock absorber assembly stepping motor 82 Rear shock absorber assembly DC motor 83 Meter assembly 84 Multi function meter 96 Electronically adjustable suspension system warning light 107 Yamaha diagnostic tool coupler 113 ECU Engine Control Unit A Wire harness B Headlight sub wire harness C Negative battery sub wire harness F Left front ...

Page 706: ...m warning light The electronically adjustable suspension system warning light come on for 2 0 seconds after the main switch has been turned to ON If the shift down indicator light electronically adjustable suspension system warning light does not come on under this condition the lights LED may be defective SCU detects an abnormal signal from a sensor If the SCU suspension control unit detects an a...

Page 707: ... malfunctioning part have been completed delete the fault codes dis played on the Yamaha diagnostic tool according to the reinstatement method Fault code No Fault code number displayed on the Yamaha diagnostic tool when the electronically adjustable suspen sion system failed to work normally Diagnostic code No Diagnostic code number to be used when the diagnostic mode is operated Refer to SELF DIA...

Page 708: ...ic mode code No 84 Service is fin ished Fault code No C1002 Item EEPROM fault code number an error is detected while reading from or writing on EEPROM Fault code No C1003 Item Stepping motor open or short circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 84 Tool display The check indicator on the Yamaha diagnostic tool screen comes on when the preload ...

Page 709: ...ion of front fork step ping motor sub lead coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to OFF and back to ON and then check the condition of the fault code using the malfunction mode of the Y...

Page 710: ...own blue brown blue Between the SCU fuse and battery red red Turn the main switch to OFF and back to ON and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Service is finished Condition is Detected Go to item 6 Fault code No C1003 Item Stepping motor open or short circuit detected ...

Page 711: ...r probe 3 Negative tester probe 4 d Measure the resistance of the stepping motor between 3 and 4 Specified resistance 43 53 Ω When the motor is cold at 20 C 68 F Out of specification Go to step e e Stepping motor is defective Replace Refer to FRONT FORK FJR13ESG on page 4 105 REAR SHOCK AB SORBER ASSEMBLY FJR13ESG on page 4 123 Turn the main switch to ON and then check the condition of the fault c...

Page 712: ...hen not completed successfully The check indicator on the Yamaha diagnostic tool screen flashes Re move the rear shock absorber assembly DC motor and adjust it by hand After adjusting the DC motor perform the procedure for diagnostic code No 84 again If the check indicator on the Yamaha diagnostic tool screen flashes again replace the rear shock absorber assembly Procedure Item Probable cause of m...

Page 713: ...on of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Service is finished Condition is Detected Go to item 5 5 Wire harness continuity Refer to REAR SHOCK AB SORBER ASSEMBLY FJR13ESG on page 4 123 Open or short circuit Replace the wire harness Between SCU coupler and rear shock absorber assembly DC motor red red white white gray gray black blue black ...

Page 714: ...otor Turn the main switch to OFF and back to ON start the en gine adjust the preload solo riding solo riding and lug gage and then check whether the motor operates Motor does not operate Go to item 8 Motor operates Go to item 10 8 Defective rear shock absorber assembly DC motor Replace the rear shock absorb er assembly DC motor Start the engine adjust the pre load solo riding solo riding and lugga...

Page 715: ...tem Able to start engine Able to drive vehicle Diagnostic code No 84 Tool display The check indicator on the Yamaha diagnostic tool screen comes on when the preload home position adjustment starts When completed successfully The check indicator on the Yamaha diagnostic tool screen goes off When not completed successfully The check indicator on the Yamaha diagnostic tool screen flashes Re move the ...

Page 716: ...screen comes on when the preload home position adjustment starts When completed successfully The check indicator on the Yamaha diagnostic tool screen goes off When not completed successfully The check indicator on the Yamaha diagnostic tool screen flashes Re move the rear shock absorber assembly DC motor and adjust it by hand After adjusting the DC motor perform the procedure for diagnostic code N...

Page 717: ...normal Fault code No U0100 Item Signals cannot be transmitted between the SCU and the ECU Fail safe system Able to start engine Able to drive vehicle Diagnostic code No Tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of ECU couplers Check the locking condition of the coupler Disconnect the coupler and check the p...

Page 718: ...Fault code No U0155 Item Signals cannot be transmitted between the SCU and the multi func tion meter Fail safe system Able to start engine Able to drive vehicle Diagnostic code No Tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of meter assembly couplers Check the locking condition of the coupler Disconnect the c...

Page 719: ... and meter assembly coupler blue black blue black blue red blue red Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Service is finished Condition is Detected Go to item 4 4 Malfunction in meter assembly Replace the meter assembly Fault code No U0155 Item Signals cannot be transmitted between ...

Page 720: ...ELECTRICAL COMPONENTS 8 243 EAS20089 ELECTRICAL COMPONENTS 1 28 27 2 3 4 5 6 13 14 16 17 19 18 20 21 22 26 25 24 23 11 12 8 7 9 10 15 ...

Page 721: ... box 1 FJR13ESG 11 Fuse box 2 12 Fuse box 4 13 Cruise control system fuse 14 Brake light fuse 15 IMU Inertial Measurement Unit FJR13ESG 16 Radiator fan motor right 17 Radiator fan motor left 18 Gear position switch 19 Sidestand switch 20 Oil level switch 21 Rear brake light switch 22 Horn 23 Ignition coil 1 24 Ignition coil 2 25 Ignition coil 3 26 Ignition coil 4 27 Lean angle sensor FJR13AG 28 Ma...

Page 722: ...ELECTRICAL COMPONENTS 8 245 6 1 3 2 17 20 19 18 7 8 11 12 13 14 15 16 4 5 10 9 ...

Page 723: ...t relay 7 SCU Suspension Control Unit FJR13ESG 8 Brake switch relay 9 Hydraulic unit assembly 10 Cylinder identification sensor 11 O2 sensor 12 Crankshaft position sensor 13 Accessory box solenoid 14 Windshield drive unit relay up 15 Windshield drive unit relay down 16 Relay unit 17 ECU Engine Control Unit 18 Radiator fan motor relay 19 Headlight relay on off 20 Air temperature sensor ...

Page 724: ...W Y B G W G Y Y B Y W PULL Br B Y G PRESS Br G B Y B B Br Y B G Y G W Br Y B G Y G W PULL B W W G MODE R B W L B R W Br L Br R L Y B R R B W Br G W G L R R B B R W W L 15 W L B W MENU W R B W W G Y Y W Y PASS G L Y B Br L RES SET Y B O W B P W R W G G L B W W L Br L Y W Y L R W Y W B Y B O W B O Y W W Sb Gy W R P B B B R Br L Br R B R L Y ...

Page 725: ...tch 4 Front brake light switch 5 Main switch 6 Rear brake light switch 7 Gear position switch 8 Sidestand switch 9 Clutch switch 10 Horn switch 11 Dimmer pass switch 12 Cruise control power switch 13 Cruise control setting switch 14 Turn signal switch 15 Menu switch 16 Select switch ...

Page 726: ...ge 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 position ...

Page 727: ...gnition systems to malfunction and could possibly cause a fire 4 Install Upper inner panel right Refer to GENERAL CHASSIS 2 on page 4 5 EAS31006 REPLACING THE ECU engine control unit 1 Turn the main switch to OFF 2 Replace the ECU engine control unit 3 Clean the throttle bodies and reset the ISC idle speed control learning value Refer to CHECKING AND CLEANING THE THROTTLE BODIES on page 7 7 4 Rese...

Page 728: ...nce will deteriorate Charging time charging amperage and charging voltage for a VRLA Valve Regu lated Lead Acid battery are different from those of conventional batteries The VRLA Valve Regulated Lead Acid battery should be charged according to the appropriate charging method If the battery is over charged the electrolyte level will drop con siderably Therefore take special care when charging the ...

Page 729: ...ull 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 time during the charging process dis connect the battery charger and let the bat tery cool before reconnecting it Hot batteries can explode As shown in the following ill...

Page 730: ...uit voltage prior to charging TIP 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 TIP If the current is lower than the standard charging current written on the battery this type of battery charger cannot charge the VR...

Page 731: ... pump relay Headlight relay 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 1 Positive battery terminal R B L W R W R 1 2 4 3 B Y Br W 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Posit...

Page 732: ...lt Continuity between 1 and 2 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe G Y G W B 1 2 3 4 Lg B Y Lg B 2 1 Br B Y Lg B 1 2 4 3 Br B 4 Negative tester probe Result No continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive tester probe 2 Negati...

Page 733: ...ative 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 probe 3 Negative tester probe Result Continuity between 1 and 2 No continuity between 1 and 3 Br B Br P W 1 2 3 5 4 Br G R B Br P B 1 3 2 Br G 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 5 Ne...

Page 734: ...nuity 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 probe sky blue white 4 No continuity Positive tester probe sky blue white 4 Negative tester probe sky blu...

Page 735: ...the start engine stop switch and gradually in crease the spark gap until a misfire occurs EAS30560 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor 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...

Page 736: ...troubleshooting starting with step 4 Refer to TROUBLESHOOTING on page 8 14 a Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 WARNING EWA13810 A wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure no flammable gas or fluid is in...

Page 737: ... CHECKING THE HEADLIGHT ASSEMBLY 1 Check Headlight assembly Faulty Replace a Disconnect the headlight sub wire harness coupler from the wire harness b Connect the battery DC 12 V as shown Stator coil resistance 0 128 0 192 Ω W W Digital circuit tester 90890 03174 Model 88 Multimeter with ta chometer YU A1927 Positive tester probe white 1 Negative tester probe white 2 Positive tester probe white 1 ...

Page 738: ... tester Ω 10 100 to the fuel sender terminals as shown A FJR13AG B FJR13ESG Oil level switch resistance Minimum level position No continuity Maximum level position Continuity Pocket tester 90890 03112 Analog pocket tester YU 03112 C Y L A Y B Y W Y Y W R W 2 1 2 2 Y L Y W B L R L R L R L B L B L B R W R W Y B 2 1 2 B Minimum level position A Positive tester probe white 1 Negative tester probe body...

Page 739: ...HECKING THE FRONT TURN SIGNAL POSITION LIGHT ASSEMBLY The following procedure applies to both of the front turn signal position light assemblies 1 Check Front turn signal position light assembly Faulty Replace a Disconnect the front turn signal position light assembly coupler from the wire harness b Connect the battery DC 12 V as shown c Check that the front turn signal position light comes on EAS...

Page 740: ...t its angle properly Refer to ADJUSTING THE THROTTLE POSITION SENSOR on page 7 11 EAS30582 CHECKING THE ACCELERATOR POSITION SENSOR 1 Remove Accelerator position sensor from the throttle bodies WARNING EWA16700 Handle the accelerator position sensor with special care Never subject the accelerator position sen sor to strong shocks If the accelerator po sition sensor is dropped replace it 2 Check Ac...

Page 741: ... throttle bodies a Connect two C size batteries to the throttle servo motor terminals 1 as shown NOTICE ECA20060 Do not use a 12 V battery to operate the throt tle servo motor TIP Do not use old batteries to operate the throttle servo motor EAS31088 CHECKING THE GEAR POSITION SWITCH 1 Remove Gear position switch from crankcase 2 Check Gear position switch Out of specification Replace the gear posi...

Page 742: ...itive tester probe sky blue 1 Negative tester probe Switch terminal a 1st position Continuity Positive tester probe pink 2 Negative tester probe Switch terminal b 2nd position Continuity Positive tester probe white 3 Negative tester probe Switch terminal c 3rd position Continuity Positive tester probe gray 4 Negative tester probe Switch terminal d 4th position Continuity Positive tester probe oran...

Page 743: ... specification Replace the grip warmer a Disconnect the grip warmer coupler from the wire harness b Connect the pocket tester Ω 1 to the grip warmer coupler as shown c Measure the grip warmer resistance A Check that the windshield drive unit arms 2 up B Check that the windshield drive unit arms 2 down Accessory box solenoid resis tance 19 21 Ω Pocket tester 90890 03112 Analog pocket tester YU 0311...

Page 744: ...ELECTRICAL COMPONENTS 8 267 ...

Page 745: ...M 9 4 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE ECU 9 5 SELF DIAGNOSTIC FUNCTION TABLE FOR FUEL INJECTION SYSTEM 9 5 SELF DIAGNOSTIC FUNCTION TABLE FOR IMMOBILIZER SYSTEM 9 15 DIAGNOSTIC CODE SENSOR OPERATION TABLE 9 15 DIAGNOSTIC CODE ACTUATOR OPERATION TABLE 9 18 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE SCU FJR13ESG 9 21 SELF DIAGNOSTIC FUNCTION TABLE 9 21 DIAGNOSTIC CODE TABL...

Page 746: ... 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 4 Ignition coil s Cracked or broken ignition coil body Broke...

Page 747: ...shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS30605 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS30849 FAULTY CLUTCH Clutch slips 1 Clutch Improp...

Page 748: ...ulic 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 or grease on the brake pad Incorrect brake fluid level EAS30610 FAULTY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high L...

Page 749: ... steering head pipe Improperly installed bearing race EAS30612 FAULTY LIGHTING OR SIGNALING SYSTEM Headlight does not come on Too many electrical accessories Hard charging Incorrect connection Improperly grounded circuit Poor contacts main switch Tail brake light does not come on Too many electrical accessories Incorrect connection Turn signal does not come on Faulty turn signal switch Faulty mete...

Page 750: ...ion in ECU Open circuit in O2 sensor heater lead When the O2 sensor does not operate be cause the exhaust temperature is low Increased exhaust emissions Fuel learning cannot be carried out If the O2 sensor does not operate O2 feed back is not carried out Cruise control system cannot be operated P0069 Intake air pressure sensor or atmospher ic pressure sensor When the main switch is turned to ON th...

Page 751: ... 3 kPa O2 feedback is not carried out ISC feedback is not carried out ISC learning is not carried out Cruise control system cannot be operated P0112 P0113 P0112 Air tempera ture sensor ground short circuit detected P0113 Air tempera ture sensor open or power short circuit de tected P0112 Low voltage of the air temperature sensor circuit 0 1 V or less P0113 High voltage of the air temperature senso...

Page 752: ...und short circuit detected P0123 P0223 Throt tle position sensor open or power short circuit detected P2135 Deviation er ror P0122 P0222 Low voltage of the throttle position sensor circuit 0 25 V or less P0123 P0223 High voltage of the throttle position sensor circuit 4 75 V or more Defective coupler between throttle po sition sensor and ECU Open or short cir cuit in wire harness between throttle ...

Page 753: ...njector and ECU Defective injector Malfunction in ECU Improperly installed injector Loss of engine power Engine is difficult to start Engine cannot be started Engine stops Engine idling speed is unstable Increased exhaust emissions O2 feedback is not carried out Power is constantly supplied to the air in duction system sole noid air induction system air is cut off ISC feedback is not carried out I...

Page 754: ...ected in the primary lead of the cylinder 2 igni tion coil P0353 Cylinder 3 ignition coil open or short circuit detected in the primary lead of the cylinder 3 igni tion coil P0354 Cylinder 4 ignition coil open or short circuit detected in the primary lead of the cylinder 4 igni tion coil Defective coupler between ignition coil and ECU Open or short cir cuit in wire harness between ignition coil an...

Page 755: ...rol when the rear wheel sensor or neutral switch malfunctions is carried out ISC feedback is not carried out ISC learning is not carried out Cruise control system cannot be operated Traction control sys tem does not operate P0560 Charging voltage is abnormal Battery overcharg ing defective rectifi er regulator Battery overcharg ing broken or dis connected rectifier regulator lead Battery over dis ...

Page 756: ...ot properly written ISC learning value is not properly written OBD memory value is not properly writ ten Malfunction in ECU Increased exhaust emissions Engine cannot be started or is difficult to start Engine idling speed is unstable OBD memory value is not correct CO adjustment value for the faulty cylinder 0 default value ISC learning values Default values OBD memory value is initialized O2 feed...

Page 757: ...on in IMU Malfunction in ECU Engine cannot be started Engine cannot be started P1601 Sidestand switch open or short circuit of the black red lead of the ECU is detect ed Defective coupler between relay unit and ECU Open or short cir cuit in wire harness between relay unit and ECU Defective coupler between sidestand switch and relay unit Open or short cir cuit in wire harness between sidestand swit...

Page 758: ...ion sensor and ECU Open or short cir cuit in wire harness between accelera tor position sensor and ECU Improperly installed accelerator position sensor Defective accelera tor position sensor Malfunction in ECU Engine response is poor Loss of engine power Engine idling speed is unstable Change in the accel erator angle is 0 tran sient control is not carried out Accelerator angle is fixed to 0 O2 fe...

Page 759: ... Defective atmo spheric pressure sensor Malfunction in ECU Engine is difficult to start Increased exhaust emissions Insufficient power at high altitudes Engine idling speed is unstable α N is fixed Intake air pressure difference is fixed to 0 kPa Atmospheric pres sure is fixed to 101 3 kPa Atmospheric pres sure sensor output correction value is fixed to 0 Fuel is not cut off due to the intake air ...

Page 760: ...ition 97 106 Check with throttle valves ful ly open 02 Atmospheric pressure Displays the atmospheric pressure Compare the actually mea sured atmospheric pressure with the tool display value 03 Intake air pressure Displays the intake air pres sure Operate the throttle while pushing the side of the start engine stop switch If the display value changes the performance is OK 05 Air temperature Display...

Page 761: ...ition Fully open position 95 109 Check with throttle grip fully open position 16 Front wheel vehicle speed pulses Front wheel speed pulse 0 999 Check that the number in creases when the front wheel is rotated The number is cu mulative and does not reset each time the wheel is stopped 17 FJR13ESG Bank angle display 0 5 Upright Less than approximately 30 On the sidestand Hold the vehicle upright and...

Page 762: ...ntrol learning val ues 12 O2 feedback learning val ue 13 OBD memory value 67 ISC idle speed control learning condition display ISC idle speed control learning data erasure 00 ISC idle speed control learning data has been erased 01 It is not necessary to erase the ISC idle speed control learning data 02 It is necessary to erase the ISC idle speed control learning data To erase the ISC idle speed co...

Page 763: ...o erase the O2 feedback learning data set the start engine stop switch from to 3 times in 5 sec onds Diagnostic code No Item Actuation Procedure 30 Cylinder 1 ignition coil Actuates the cylinder 1 igni tion coil five times at one second intervals The check indicator on the Yamaha diagnostic tool screen come on each time the ignition coil is actuated Check that a spark is gener ated five times Conn...

Page 764: ...at one second inter vals The check indicator on the Yamaha diagnostic tool screen come on each time the fuel injector is actuated Disconnect the fuel pump coupler Check that injector 3 is ac tuated five times by listening for the operating sound 39 Injector 4 Actuates the injector 4 five times at one second inter vals The check indicator on the Yamaha diagnostic tool screen come on each time the f...

Page 765: ...n motor relay is actuated five times by listening for the op erating sound 52 Headlight relay Actuates the headlight relay five times at five second in tervals The check indicator on the Yamaha diagnostic tool screen come on each time the relay is actuated Check that the headlight re lay is actuated five times by listening for the operating sound 57 Grip warmer Turns on the grip warmers for 2 minu...

Page 766: ...efective connec tion of stepping mo tor and SCU couplers Defective connec tion of sub wire har ness coupler Short circuit in wire harness or wire har ness continuity Defective stepping motor Malfunction in SCU The following adjust ments cannot be per formed Damping force ad justment Damping force fine adjustment Preload adjustment C1004 Preload adjusting mo tor rear shock ab sorber assembly DC mot...

Page 767: ...ed Damping force ad justment Damping force fine adjustment Preload adjustment Stepping motor ini tialization home po sition adjustment when the main switch is turned to ON Execute the diag nostic mode Code No 84 U0100 Signals cannot be transmitted between the SCU and the ECU Defective connec tion of wire harness ECU and SCU cou plers Wire harness conti nuity Malfunction in SCU Malfunction in ECU T...

Page 768: ...y Procedure 09 Monitor voltage Displays the monitor voltage Approximately 12 0 Compare the actually mea sured battery voltage with the tool display value If the actually measured battery voltage is low recharge the battery 84 Preload home position ad justment The check indicator on the Yamaha diagnostic tool screen comes on when the preload home position ad justment starts When completed successfu...

Page 769: ...IMU Defective coupler between IMU and CLCU Open or short cir cuit in wire harness between IMU and CLCU Improperly installed IMU Malfunction in IMU Malfunction in CL CU Cornering lights go off Cornering lights do not come on Lighting sequence for the cornering lights is not complet ed correctly Cornering lights go off P0500 Refer to the informa tion for fuel injection system fault code No P0500 Ref...

Page 770: ... Cornering lights do not come on Cornering lights do not come on and go off in the proper se quence Cornering lights go off Diagnostic code No Item Tool display Procedure 66 Bank angle fine adjustment Displays the fine adjustment value for the bank angle 0 2 4 2 4 0 Right bank angle Positive value Left bank angle Negative value Click the Actuator Check button and adjust the activa tion timing for ...

Page 771: ...n in put lead of ECU Same as for fault code number P1601 Perform the checks and maintenance jobs for fault code number P1601 196 Coolant temperature sensor Brief abnormality de tected in coolant tem perature sensor Same as for fault code number P0117 and P0118 Perform the checks and maintenance jobs for fault code number P0117 and P0118 197 Air temperature sensor Brief abnormality de tected in air...

Page 772: ...engine idling speed Clogged throttle body Improperly adjusted throttle cable Defective fuel injec tion system Dirty or worn spark plug Defective battery Defective ECU Execute the diagnos tic mode diagnostic code number 67 and check the ISC main tenance require ments If a fault code is indi cated perform the checks and mainte nance jobs for the fault code first Event code number 242 may be indicate...

Page 773: ...e indicated even if the system is normal 246 Cruise control Automatic turning off of the cruise control system detected The cruise control sys tem will automatically turn off under the fol lowing conditions Unable to maintain the set cruising speed when travel ing up a steep slope Wheel slip detected Engine stalls Sidestand is extend ed Start engine stop switch is set to the position The automatic...

Page 774: ... warning light comes on Go to item 2 2 Installed condition of lean angle sensor Check the installed direction and condition of the sensor Turn the main switch to ON then to OFF and then back to ON Engine trouble warning light does not come on Service is finished Engine trouble warning light comes on Go to item 3 3 Defective lean angle sensor Execute the diagnostic mode Code No 08 Replace if defect...

Page 775: ...lled direction and condition of the IMU Check the rubber components for deterioration Turn the main switch to ON then to OFF and then back to ON Engine trouble warning light does not come on Service is finished Engine trouble warning light comes on Go to item 3 3 Defective IMU Execute the diagnostic mode Code No 17 Replace if defective Turn the main switch to ON then to OFF and then back to ON Eng...

Page 776: ...4 Handlebar switch left 65 Cruise control power switch 66 Cruise control setting switch 67 Dimmer pass switch 68 Horn switch 69 Menu switch 70 Select switch 71 Turn signal switch 72 Auxiliary light 73 Front turn signal position light right 74 Front turn signal position light left 75 Accessory box solenoid 76 Auxiliary DC jack 77 Meter assembly 78 Multi function meter 79 Immobilizer system indicato...

Page 777: ...4 Front turn signal position light right 75 Front turn signal position light left 76 Accessory box solenoid 77 Auxiliary DC jack 78 SCU Suspension Control Unit 79 Front fork stepping motor left 80 Front fork stepping motor right 81 Rear shock absorber assembly stepping motor 82 Rear shock absorber assembly DC motor 83 Meter assembly 84 Multi function meter 85 Immobilizer system indicator light 86 ...

Page 778: ...W Green White G Y Green Yellow Gy B Gray Black 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 B Light green Black Lg L Light green Blue Lg R Light green Red O B Orange Black O G Orange Green O R Orange Red O W Orange White P B Pink Black P W Pink White R B Red Black R G Red Green R L Red Blue R W Red White R Y Red Yellow Sb W Sky blue Whi...

Page 779: ......

Page 780: ......

Page 781: ... W W W B R Gy Br R R Br L R Br L Br R B Y L Lg R W R G B B W R G Y L G B R W R R R L W R W B B L B B B L B L B B B Y L Br Ch Dg B Y Y B L G Br L B B L R R Y R W B R W R R W G Y Br B R W R W R W R W R W L W L W L W L W L W R G R G R G R G B R W L R L B Br Y P B Sb W Y G R G W R G R G R G Ch W L W Y B Y P Y W L W B R Gy W B W G W R P W W B W G B Br B Br W Br B Br W Dg Gy R L B Dg G W B W W W Br L Br...

Page 782: ...Y B B B B B B B 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 20 20 20 20 21 22 23 24 25 26 27 28 29 30 31 20 20 20 20 20 20 20 20 20 1 60 61 62 63 64 32 33 58 59 65 66 67 69 68 67 68 70 71 72 73 96 97 98 120 121 122 123 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 101 102 103 104 105 107 106 108 109 110 99 1...

Page 783: ...r W R G R G R L R Y R R R Br B L Y L B L B B B B B B B B B R W B R W R Y Br B G Y R R W P Br Br Br Br R W R W R W R W R W R W R W R W R R R G R G R G R G R G Br Br Br Br Br Br Br Br L Br G Y Ch Dg B L L R Y W R W R W BB BB B R W R W R W R W R W Y W Y W Y W Y W Y W Y W Y Y Y Y Y Y B Y Y B BB Y W R W R W Y B B Y W R W R W Y B Lg B Y Y Br Lg B G Y G W G Y G W Lg B B B G R B Y Y B Br B Lg L Y W G W G ...

Page 784: ...B B B B B A B C D A A E A 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 30 31 32 33 58 59 60 61 62 63 64 65 66 67 69 68 70 71 72 96 97 98 120 121 122 123 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 34 35 36 37 38 39 40 41 42 43 44 45 46 47 46 47 48 49 50 51 52 53 54 55 56 57 101 102 103 104 105 107 106 108 109 110 99 100 111 112 113 113 113 113 11...

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