Yamaha FJR13AY 2009 Service Manual Download Page 417 | Manualshive

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CONNECTING RODS AND PISTONS

5-112

EAS26030

REMOVING THE CONNECTING RODS AND
PISTONS

The following procedure applies to all of the con-
necting rods and pistons.
1. Remove:

• Connecting rod cap “1”

TIP

Identify the position of each connecting rod so
that it can be reinstalled in its original place.

2. Remove:

• Big end bearings

(from the connecting rods and connecting rod
caps)

TIP

Identify the position of each big end bearing so
that it can be reinstalled in its original place.

3. Remove:

• Piston pin clips “1”
• Piston pin “2”
• Piston “3”
• Connecting rod “4”

NOTICE

ECA13810

Do not use a hammer to drive the piston pin
out.

TIP

• For 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 and lift the other side of the ring
over the piston crown.

EAS24410

CHECKING THE CYLINDERS AND PISTONS

The following procedure applies to all of the cyl-
inders and pistons.
1. Check:

• Piston wall
• Cylinder wall

Vertical scratches

→

Rebore or replace the

cylinder, and replace the piston and piston
rings as a set.

2. Measure:

• Piston-to-cylinder clearance

Piston pin puller set

90890-01304

Piston pin puller

YU-01304

1

3

2

4

1

1

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Summary of Contents for FJR13AY 2009

Page 1: ...2009 SERVICE MANUAL FJR13AY C FJR13AEY C LIT 11616 22 73 3P6 28197 12 ...

Page 2: ...08 by Yamaha Motor Corporation U S A First edition September 2008 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 11616 22 73 ...

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: ... 1 2 3 4 5 6 7 8 1 Serviceable with engine mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening torque 6 Wear limit clearance 7 Engine speed 8 Electrical data 9 Engine oil 10 Gear oil 11 Molybdenum disulfide oil 12 Brake fluid 13 Wheel bearing grease 14 Lithium soap based grease 15 Molybdenum disulfide grease 16 Silicone grease 17 Apply locking agent LOCTITE 18 Replace the part with a n...

Page 6: ......

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

Page 8: ......

Page 9: ... OPERATION 1 15 ABS SELF DIAGNOSIS FUNCTION 1 18 ABS WARNING LIGHT AND OPERATION 1 21 OUTLINE OF THE YCC S Yamaha Chip Controlled Shift SYSTEM FJR13AE 1 22 INSTRUMENT FUNCTIONS 1 25 IMPORTANT INFORMATION 1 29 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 29 REPLACEMENT PARTS 1 29 GASKETS OIL SEALS AND O RINGS 1 29 LOCK WASHERS PLATES AND COTTER PINS 1 29 BEARINGS AND OIL SEALS 1 30 CIRCLIPS 1 30 CHECK...

Page 10: ...AS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts ...

Page 11: ...s necessary to control the air fuel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to ...

Page 12: ...ed by the ECU Signals that are input from the throttle position sensor coolant temperature sensor cylinder identification sensor lean angle sensor crankshaft position sensor intake air pressure sensor intake air temperature sensor rear wheel sensor and O2 sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position se...

Page 13: ...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 14: ...ween the right front brake caliper and the rear brake caliper in the uni fied brake system is determined mechanically be sure to use the specified brake pads Each set of brake pads should be checked individually and replaced if necessary ET3P61019 OUTLINE OF THE ABS 1 The Yamaha ABS anti lock brake system features an electronic control system which acts on the front and rear brakes independently H...

Page 15: ...re reduced However the chassis travels forward by its inertia even though the wheel speed is reduced Brake force The force applied by braking to reduce the wheel speed Wheel lock A condition that occurs when the rotation of one or both of the wheels has stopped but the vehicle continues to travel Side force The force on the tires which supports the vehicle when cornering 6 5 7 11 10 12 13 14 15 1 ...

Page 16: ...closely related to wheel slippage Wheel slippage is represented by the slip ratio Side force is also closely related to wheel slippage See figure A If the brakes are applied while keep ing the proper slip ratio it is possible to obtain the maximum brake force without losing much side force ABS allows full use of the tires capabilities even on slippery road surfaces or less slippery road surfac es ...

Page 17: ...and the vehicle is approaching the limit of control To make the rider aware of this condition the ABS has been designed to generate a reaction force pulsating action in the brake lever and brake pedal independently TIP When the ABS is activated a pulsating action may be felt at the brake lever or brake pedal but this does not indicate a malfunction The higher the side force on a tire the less trac...

Page 18: ...n if the ABS is operating Electronic ABS features The Yamaha ABS anti lock brake system has been developed with the most advanced electronic technology The ABS control is processed with good response under various vehicle travel conditions The ABS also includes a highly developed self diagnosis function The ABS detects any problem con dition and allows normal braking even if the ABS is not operati...

Page 19: ... sensor rotor rotates the Hall element in the Hall IC installed in the wheel sensor generates pulses The pulse frequency which is proportional to the magnetic flux density is converted into a wave in the Hall IC so that it can be output The ABS ECU calculates the wheel rotation speed by detecting the pulse frequency 10 11 12 3 4 1 4 4 7 7 7 8 9 9 14 15 16 17 2 5 6 6 13 1 Rear brake master cylinder...

Page 20: ...lash or come on If this occurs turn the main switch to OFF then back to ON The ABS operation is normal if the ABS warning light comes on for 2 seconds then goes off Hydraulic unit assembly The hydraulic unit assembly 1 is composed of hydraulic control valves each with a outlet solenoid valve and inlet solenoid valve buffer chambers hydraulic pumps an ABS motor and ABS ECU The hydraulic unit adjust...

Page 21: ... and the outlet solenoid valve 2 is closed The brake line between the brake master cylinder and brake caliper is open 2 When the ABS is activated the inlet solenoid valve 1 closes and the outlet solenoid valve 2 opens using the power supplied from the ABS ECU signals This reduces the hydraulic pressure 3 When the ABS ECU sends a signal to stop reducing the hydraulic pressure the outlet solenoid va...

Page 22: ...ES 1 13 Buffer chamber The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating 1 Buffer chamber pressurizing phase 2 Buffer chamber depressurizing phase 3 Raised piston ...

Page 23: ...nd troubleshooting 13 7 4 5 6 2 3 1 9 10 11 12 16 14 23 19 21 22 20 25 35 26 27 28 29 30 31 32 33 17 18 15 34 24 8 1 Battery 2 AC magneto 3 Rectifier regulator 4 Main fuse 5 Main switch 6 ABS ECU fuse 7 ABS motor fuse 8 ABS solenoid fuse 9 Front brake light switch 10 Brake light relay 11 Tail brake light 12 Rear brake light switch 13 Hydraulic unit assembly 14 ABS ECU 15 Solenoid relay 16 ABS moto...

Page 24: ...em Normal braking ABS not activated When the ABS is not activated the inlet solenoid valve is open and the outlet solenoid valve is closed because a control signal has not been transmitted from the ABS ECU Therefore when the brake lever is squeezed the hydraulic pressure in the brake master cylinder increases and the brake fluid is sent to the brake caliper At this time the inlet and outlet check ...

Page 25: ...outlet solenoid valve is open the brake fluid is sent to the buffer chamber As a result the hydraulic pressure in the brake caliper is reduced The brake fluid stored in the buffer chamber is pumped back to the brake master cylinder by the hy draulic pump linked to the ABS motor 12 13 7 6 11 3 4 5 9 8 10 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Ou...

Page 26: ...e As the inlet solenoid valve opens the brake line from the brake master cylinder opens allowing the brake fluid to be sent to the brake caliper 12 13 7 6 11 3 4 5 9 8 10 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Outlet solenoid valve 7 Inlet solenoid valve 8 Brake caliper 9 Wheel sensor 10 ABS ECU 11 ABS warning light 12 Brake fluid pressure 13 T...

Page 27: ...etected by the ABS self diagnosis It is located in the meter assembly 12 13 7 6 11 3 4 5 9 8 10 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Outlet solenoid valve 7 Inlet solenoid valve 8 Brake caliper 9 Wheel sensor 10 ABS ECU 11 ABS warning light 12 Brake fluid pressure 13 Time ...

Page 28: ...fer to ELECTRIC STARTING SYSTEM on page 8 13 3 The ABS warning light comes on while riding If the ABS warning light comes on while riding a malfunction has been detected in the ABS The ABS hydraulic control will not be performed The ABS will have recourse to manual braking if this occurs 1 a e d d b c f a ABS warning light b Main switch OFF c Main switch ON d Goes off e Comes on for 2 seconds f AB...

Page 29: ... multi function display when the test coupler adapter 3 is connected to the ABS test coupler 4 for troubleshooting the ABS The ABS test coupler can be accessed by removing front cowling right inner panel 1 When the test coupler adapter is connected to the ABS test coupler the ABS warning light starts flashing and the multi function display indicates all the fault codes recorded in the ABS ECU TIP ...

Page 30: ...on is normal if the ABS warning light comes on for 2 seconds then goes off The ABS operation is normal if the ABS warning light flashes Even if the ABS warning light remains on and does not go off or if it comes on after riding conven tional braking performance of the vehicle is maintained ABS function When hydraulic control is performed by the ABS the brake system alerts the rider that the wheels...

Page 31: ...ng at traffic lights or in traffic jams YCC S operates the clutch instead of the user Basic function To shift gears after starting the engine the user must use the shift pedal However depending on the user s preference the transmission can be shifted by hand after setting the hand shift select button to ON When the engine is started the MCU disengages the clutch A signal is sent to the MCU when th...

Page 32: ...abled by pressing the hand shift select button 3 prior to being used The gear positions are shown in the illustration 1 2 3 4 5 6 8 11 12 7 10 9 1 YCC S test coupler 2 YCC S indicator and warning light 3 YCC S motor control fuse 4 Hand shift switch 5 Gear position sensor 6 Neutral switch 7 MCU motor control unit 8 Shift actuator 9 YCC S control relay 10 Clutch actuator 11 Foot shift switch 12 YCC ...

Page 33: ...main switch to LOCK when parking the vehicle YCC S indicator and warning light The YCC S system is constantly performing a self diagnosis The YCC S system also performs a self diagnosis when the main switch is turned to ON The YCC S indicator and warning light 1 come on during this self diagnosis After the self diagnosis is com pleted if there were no problems found the YCC S indicator and warning...

Page 34: ...ve Multi function display WARNING EW3P61020 Be sure to stop the vehicle before making any setting changes to the multi function display The multi function display is equipped with the following an odometer which shows the total distance traveled two tripmeters which show the distance trav eled since they were last set to zero a fuel reserve tripmeter which shows the dis tance traveled on the fuel ...

Page 35: ...return to the prior mode after refueling and traveling 5 km 3 mi Clock To set the clock 1 Push the SELECT button and RESET but ton together for at least two seconds 2 When the hour digits start flashing push the RESET button to set the hours 3 Push the SELECT button and the minute digits will start flashing 4 Push the RESET button to set the minutes 5 Push the SELECT button and then release it to ...

Page 36: ...g FJR13AE Ambient temperature instantaneous fuel consumption and average fuel consumption modes Push the RESET button to switch the display between the ambient temperature mode Air the instantaneous fuel consumption mode MPG and the average fuel consumption mode AV_ _ _ MPG in the following order Air MPG AV_ _ _ MPG Air Ambient temperature mode This display shows the ambient temperature from 16 F ...

Page 37: ...splay is flashing After resetting the average fuel consumption display _ _ _ will be shown for that display until the vehicle has traveled 1 km 0 6 mi NOTICE EC3P66002 If there is a malfunction will be dis played Replace the meter assembly Self diagnosis device This model is equipped with a self diagnosis de vice for various electrical circuits If any of those circuits are defective the engine tro...

Page 38: ... correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals ...

Page 39: ...grease Oil bearings liberally when installing if appropriate NOTICE ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfac es EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned o...

Page 40: ...ral times 3 Check All connections Loose connection Connect properly TIP If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector TIP Make sure all connections are tight 5 Check Continuity with the pocket tester TIP If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at m...

Page 41: ...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 Test coupler adapter 90890 03149 1 20 4 66 4 67 8 185 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 31 5 44 8 167 8 168 8 225 8 226 8 227 8 231 8 233 8 234 8 235 8 236 8 237 8 238 8 239 8 240 8 241 8 242 8 243 8...

Page 42: ...adapter B 90890 03124 3 16 Vacuum pressure pump gauge set 90890 06756 Mityvac brake bleeding tool YS 42423 3 19 Magnet base B 90890 06844 Magnetic base stand YU A8438 3 20 Dial gauge stand set 90890 01252 3 20 Steering nut wrench 90890 01403 Exhaust flange nut wrench YU A9472 3 34 4 91 Hexagon wrench 41 90890 01525 YM 01525 4 27 4 29 Tool name Tool No Illustration Reference pages 41 41 ...

Page 43: ...90890 01511 Middle drive gear lash tool YM 01230 4 107 Coupling gear middle shaft tool 90890 01229 Gear holder YM 01229 4 109 4 112 Bearing retainer wrench 90890 04050 Pinion bearing retainer remover YM 04050 4 109 4 112 Fork seal driver weight 90890 01184 Replacement hammer YM A9409 7 4 114 4 115 4 116 Fork seal driver attachment 90890 01186 Replacement 27 mm YM A9409 1 4 114 4 115 Tool name Tool...

Page 44: ...74 Model 88 Multimeter with tachometer YU A1927 5 11 5 76 7 9 Rotor holding tool 90890 01235 Universal magneto rotor holder YU 01235 5 15 5 18 Yamaha bond No 1215 90890 85505 Three Bond No 1215 5 20 5 37 5 40 5 108 6 13 Valve spring compressor 90890 04019 YM 04019 5 26 5 31 Valve spring compressor attachment 90890 04114 Valve spring compressor adapter 19 5 mm YM 04114 5 26 5 31 Tool name Tool No I...

Page 45: ... 5 0 mm YM 04099 5 28 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 36 5 37 5 40 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 36 Universal clutch holder 90890 04086 YM 91042 5 60 5 61 5 64 5 65 Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 5 62 Bearing retainer wrench 90890 04137 Middle drive shaft bearing retainer wrench YM 04137 5 93 5 95 Tool name Tool No ...

Page 46: ...ng retainer wrench YM 04140 5 94 Gear lash measurement tool 90890 01467 YM 01467 5 97 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 112 Piston ring compressor 90890 05158 YM 08037 5 118 Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 5 131 Tool name Tool No Illustration Reference pages YU 01304 ...

Page 47: ...3 Radiator cap tester adapter 90890 01352 Radiator pressure tester adapter YU 33984 6 3 Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A 6 13 Middle driven shaft bearing driver 90890 04058 Bearing driver 40 mm YM 04058 6 13 Tool name Tool No Illustration Reference pages YU 01083 3 YU 24460 01 YU 33984 ...

Page 48: ...S 1 39 Pressure gauge 90890 03153 YU 03153 7 8 Fuel pressure adapter 90890 03176 YM 03176 7 8 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 8 236 Tool name Tool No Illustration Reference pages ...

Page 49: ...RAL TIGHTENING TORQUE SPECIFICATIONS 2 15 ENGINE TIGHTENING TORQUES 2 16 CHASSIS TIGHTENING TORQUES 2 21 LUBRICATION POINTS AND LUBRICANT TYPES 2 26 ENGINE 2 26 CHASSIS 2 28 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 ENGINE OIL LUBRICATION CHART 2 29 LUBRICATION DIAGRAMS 2 31 COOLING SYSTEM DIAGRAMS 2 41 CABLE ROUTING FJR13A 2 45 CABLE ROUTING FJR13AE 2 65 ...

Page 50: ...ll height 1450 mm 57 1 in Seat height 805 mm 31 7 in Wheelbase 1545 mm 60 8 in Ground clearance 130 mm 5 12 in Minimum turning radius 3100 mm 122 0 in Weight With oil and fuel FJR13A 291 0 kg 642 lb USA FJR13A 292 0 kg 644 lb California FJR13AE 295 0 kg 650 lb USA FJR13AE 296 0 kg 653 lb California Maximum load FJR13A 212 kg 467 lb USA FJR13A 211 kg 465 lb California FJR13AE 208 kg 459 lb USA FJR1...

Page 51: ...r JASO standard MA Engine oil quantity Total amount 4 90 L 5 18 US qt 4 31 Imp qt Without oil filter cartridge replacement 3 80 L 4 02 US qt 3 34 Imp qt With oil filter cartridge replacement 4 00 L 4 23 US qt 3 52 Imp qt Oil pressure hot 30 0 kPa 1000 r min 4 4 psi 1000 r min 0 30 kgf cm 1000 r min Final gear oil Type Shaft drive gear oil Part No 9079E SH001 00 Quantity 0 20 L 0 21 US qt 0 18 Imp ...

Page 52: ...r pump Water pump type Single suction centrifugal pump Reduction ratio 75 48 25 28 1 395 Impeller shaft tilt limit 0 15 mm 0 006 in Spark plug s Manufacturer model NGK CR8E Manufacturer model DENSO U24ESR N Spark plug gap 0 7 0 8 mm 0 028 0 031 in Cylinder head Volume 22 74 23 34 cm 1 39 1 42 cu in Warpage limit 0 10 mm 0 0039 in Camshaft Drive system Chain drive right Camshaft cap inside diameter...

Page 53: ...at width C intake 0 90 1 10 mm 0 0354 0 0433 in Valve seat width C exhaust 0 90 1 10 mm 0 0354 0 0433 in Valve margin thickness D intake 0 80 1 20 mm 0 0315 0 0472 in Valve margin thickness D exhaust 0 50 0 90 mm 0 0197 0 0354 in Valve stem diameter intake 4 975 4 990 mm 0 1959 0 1965 in Valve stem diameter exhaust 4 965 4 980 mm 0 1955 0 1961 in Valve guide inside diameter intake 5 000 5 012 mm 0...

Page 54: ...f mm Spring rate K2 intake 28 34 N mm 161 82 lb in 2 89 kgf mm Spring rate K1 exhaust 21 85 N mm 124 76 lb in 2 23 kgf mm Spring rate K2 exhaust 28 34 N mm 161 82 lb in 2 89 kgf mm Installed compression spring force intake 136 00 158 00 N 30 57 35 52 lb 13 87 16 11 kgf Installed compression spring force exhaust 136 00 158 00 N 30 57 35 52 lb 13 87 16 11 kgf Spring tilt intake 2 5 1 7 mm 2 5 0 067 ...

Page 55: ...0 35 0 45 mm 0 0138 0 0177 in Limit 0 70 mm 0 0276 in Ring side clearance 0 030 0 070 mm 0 0012 0 0028 in Limit 0 120 mm 0 0047 in 2nd ring Ring type Taper Dimensions B T 1 00 2 90 mm 0 04 0 11 in End gap installed 0 75 0 85 mm 0 0295 0 0335 in Limit 1 20 mm 0 0472 in Ring side clearance 0 020 0 060 mm 0 0008 0 0024 in Limit 0 120 mm 0 0047 in Oil ring Dimensions B T 2 00 2 50 mm 0 08 0 10 in End ...

Page 56: ...ckness 2 90 3 10 mm 0 114 0 122 in Wear limit 2 80 mm 0 1102 in Plate quantity 9 pcs Clutch plate thickness 1 90 2 10 mm 0 075 0 083 in Plate quantity 8 pcs Warpage limit 0 10 mm 0 0039 in Clutch spring height 6 78 mm 0 27 in Minimum height 6 4 mm 0 25 in Spring quantity 1 pc Push rod bending limit 0 370 mm 0 0146 in Clutch pressure plate stroke FJR13AE 2 8 mm 0 11 in or more Transmission Transmis...

Page 57: ...ce 421 569 Ω at 20 C 68 F Cylinder identification sensor output voltage ON More than 4 8 V Cylinder identification sensor output voltage OFF Less than 0 6 V Intake air pressure sensor output voltage 3 75 4 25 V Intake air temperature sensor resistance 290 390 Ω at 80 C 176 F Coolant temperature sensor resistance 290 354 Ω at 80 C 176 F Idling condition Engine idling speed 1000 1100 r min Intake va...

Page 58: ...120 70 ZR17M C 58W Manufacturer model METZELER Roadtec Z6G Manufacturer model BRIDGESTONE BT021F F Wear limit front 1 0 mm 0 04 in Rear tire Type Tubeless Size 180 55 ZR17M C 73W Manufacturer model METZELER Roadtec Z6C Manufacturer model BRIDGESTONE BT021R F Wear limit rear 1 0 mm 0 04 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 270 kPa 39 psi 2 70 kgf cm R...

Page 59: ... the rider footrest Rear disc brake Disc outside diameter thickness 282 0 5 0 mm 11 10 0 20 in Brake disc thickness limit 4 5 mm 0 18 in Brake disc deflection limit 0 15 mm 0 0059 in Brake pad lining thickness inner 6 3 mm 0 25 in Limit 0 8 mm 0 03 in Brake pad lining thickness outer 6 3 mm 0 25 in Limit 0 8 mm 0 03 in Master cylinder inside diameter 15 0 mm 0 59 in Caliper cylinder inside diamete...

Page 60: ...er type Coil spring gas oil damper Rear shock absorber assembly travel 60 0 mm 2 36 in Spring free length 154 6 mm 6 09 in Installed length 136 2 mm 5 36 in Spring free length 73 9 mm 2 91 in Installed length 67 3 mm 2 65 in Soft Spring rate K1 91 00 N mm 519 61 lb in 9 28 kgf mm Spring rate K2 124 00 N mm 708 04 lb in 12 64 kgf mm Spring stroke K1 0 0 42 0 mm 0 00 1 65 in Spring stroke K2 42 0 60...

Page 61: ... Model manufacturer LNX07 DENSO Standard output 14 0 V 590 W at 5000 r min Stator coil resistance 0 13 0 19 Ω at 20 C 68 F Voltage regulator Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer FH012AA SHINDENGEN Regulated voltage DC 14 2 14 8 V Rectifier capacity DC 50 0 A Withstand voltage 40 0 V Battery Model GT14B 4 Voltage capacity 12 V 12 0 Ah Manufacturer GS YU...

Page 62: ...Limit 23 5 mm 0 93 in Mica undercut depth 1 50 mm 0 06 in Starter relay Model manufacturer RC19 085A MITSUBA Amperage 180 0 A Coil resistance 4 18 4 62 Ω Horn Horn type Plane Quantity 2 pcs Model manufacturer HF 12 NIKKO Maximum amperage 3 0 A Coil resistance 1 01 1 11 Ω at 20 C 68 F Performance 108 116 dB 2 m 6 6 ft Turn signal hazard relay Relay type Full transistor Model manufacturer FE246BH DE...

Page 63: ...ltage FJR13AE 2 4 2 6 V Resistance FJR13AE 4 0 6 0 kΩ Grip warmer Grip warmer resistance L FJR13AE 1 21 1 48 Ω at 20 C 68 F Grip warmer resistance R FJR13AE 1 17 1 43 Ω at 20 C 68 F Fuses Main fuse 50 0 A Headlight fuse 25 0 A Signaling system fuse 15 0 A Ignition fuse 10 0 A Radiator fan fuse 15 0 A 2 Auxiliary DC jack fuse 3 0 A Hazard fuse 10 0 A Fuel injection system fuse 15 0 A ABS motor fuse...

Page 64: ...l To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kg ft lb 10 mm 6 mm 6 0 6...

Page 65: ... Nm 1 0 m kg 7 2 ft lb Timing chain tensioner cap bolt M6 1 6 Nm 0 6 m kg 4 3 ft lb Camshaft sprocket bolt M7 4 24 Nm 2 4 m kg 17 ft lb Water pump assembly bolt M6 3 12 Nm 1 2 m kg 8 7 ft lb Water pump housing cover bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Coolant drain bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Water jacket joint bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Thermostat inlet pipe 1 bolt M6 2 10 Nm 1 0 m ...

Page 66: ... Lower crankcase plug bolt FJR13A M6 1 10 Nm 1 0 m kg 7 2 ft lb YCC S speed sensor bolt FJR13AE M6 1 10 Nm 1 0 m kg 7 2 ft lb Generator cover bolt M6 11 12 Nm 1 2 m kg 8 7 ft lb Clutch cover bolt M6 10 12 Nm 1 2 m kg 8 7 ft lb Middle gear case cover bolt M6 9 12 Nm 1 2 m kg 8 7 ft lb Pickup rotor cover bolt M6 8 12 Nm 1 2 m kg 8 7 ft lb Rear balancer cover bolt M6 4 12 Nm 1 2 m kg 8 7 ft lb Oil ba...

Page 67: ...lb Stake Middle driven shaft end cover bolt M8 3 25 Nm 2 5 m kg 18 ft lb Shift drum retainer bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Shift shaft spring stopper bolt M8 1 22 Nm 2 2 m kg 16 ft lb Stator coil assembly bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Gear position switch bolt FJR13A M5 2 4 Nm 0 4 m kg 2 9 ft lb Crankshaft position sensor bolt M5 2 4 Nm 0 4 m kg 2 9 ft lb O2 sensor M18 1 45 Nm 4 5 m kg 3...

Page 68: ...olant reservoir bracket bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Clutch fluid reservoir bolt FJR13AE M6 1 7 Nm 0 7 m kg 5 1 ft lb Clutch actuator bracket bolt FJR13AE M8 2 19 Nm 1 9 m kg 13 ft lb Clutch actuator bracket bolt FJR13AE M6 3 10 Nm 1 0 m kg 7 2 ft lb Gear position sensor cover FJR13AE M6 2 10 Nm 1 0 m kg 7 2 ft lb Gear position sensor screw FJR13AE M5 2 4 Nm 0 4 m kg 2 9 ft lb Gear position s...

Page 69: ...TIGHTENING TORQUES 2 20 Cylinder head tightening sequence Crankcase tightening sequence 17 20 16 15 19 22 3 6 9 8 23 14 24 29 30 27 26 28 31 12 11 2 1 18 5 4 21 13 7 10 25 ...

Page 70: ...op M10 2 37 Nm 3 7 m kg 27 ft lb Pinch bolt front side M8 1 24 Nm 2 4 m kg 17 ft lb Pinch bolt rear side M8 2 24 Nm 2 4 m kg 17 ft lb Pivot shaft M28 1 23 Nm 2 3 m kg 17 ft lb Pivot shaft nut M18 1 125 Nm 12 5 m kg 90 ft lb Pivot shaft locknut M28 1 115 Nm 11 5 m kg 85 ft lb Pivot shaft locknut retainer bolt FJR13A M6 1 10 Nm 1 0 m kg 7 2 ft lb Pivot shaft locknut retainer bolt FJR13AE M6 1 10 Nm ...

Page 71: ... ft lb Windshield inner bracket and windshield drive unit bolt M6 4 7 Nm 0 7 m kg 5 1 ft lb Rearview mirror nut M6 4 7 Nm 0 7 m kg 5 1 ft lb Windshield drive unit bolt M6 4 10 Nm 1 0 m kg 7 2 ft lb Windshield drive unit side rail bolt M6 6 8 Nm 0 8 m kg 5 8 ft lb Side cover bolt M6 3 7 Nm 0 7 m kg 5 1 ft lb Grab bar bolt M8 5 21 Nm 2 1 m kg 15 ft lb Grab bar bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Fuel ...

Page 72: ...8 0 m kg 58 ft lb Left hand threads Brake hose union bolt M10 11 30 Nm 3 0 m kg 22 ft lb Brake pipe flare nut M10 5 16 Nm 1 6 m kg 11 ft lb Brake pipe joint assembly flare nut M10 3 16 Nm 1 6 m kg 11 ft lb Brake pipe joint assembly bolt M6 3 7 Nm 0 7 m kg 5 1 ft lb Front brake caliper bolt M10 4 40 Nm 4 0 m kg 29 ft lb Front brake hose holder bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Front brake caliper b...

Page 73: ... 0 m kg 7 2 ft lb Shift rod locknut FJR13A M6 2 7 Nm 0 7 m kg 5 1 ft lb Drive shaft dust cover bolt M5 2 4 Nm 0 4 m kg 2 9 ft lb Final gear oil drain bolt M14 1 23 Nm 2 3 m kg 17 ft lb Final gear oil filler bolt M14 1 23 Nm 2 3 m kg 17 ft lb Final drive assembly nut M10 4 42 Nm 4 2 m kg 30 ft lb Final drive pinion gear bearing retainer M65 1 110 Nm 11 0 m kg 80 ft lb Left hand thread Coupling gear...

Page 74: ... the right end of the front axle is flush with the front fork If necessary manually push the front axle or lightly tap it with a soft hammer until its end is flush with the front fork However if the surface of the front axle end is not parallel to the surface of the front fork align a point on the outer edge of the axle with the fork making sure that the axle does not protrude past the fork 4 In t...

Page 75: ...and exhaust Water pump impeller shaft Oil pump rotors inner and outer and oil pump shaft Oil pump drive sprocket Oil strainer Oil nozzle O ring Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Push rods and ball Transmission gears wheel and pinion Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift pedal bolt Damper drive ca...

Page 76: ...er head cover gasket Yamaha bond No 1215 Three Bond No 1215 Crankcase mating surface Yamaha bond No 1215 Three Bond No 1215 Crankshaft position sensor lead grommet Yamaha bond No 1215 Three Bond No 1215 Stator coil assembly lead grommet Yamaha bond No 1215 Three Bond No 1215 Lubrication point Lubricant ...

Page 77: ...be guide throttle grip inner surface and throttle cables Brake lever pivot bolt and metal to metal moving parts Clutch lever pivot bolt and metal to metal moving parts FJR13A Rear shock absorber assembly oil seal Rear shock absorber assembly bearing Rear shock absorber assembly spacer Pivot shaft and pivot shaft thread Pivot shaft bearing Pivot shaft oil seal lip Relay arm bearing Oil seals rear s...

Page 78: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 15 14 13 12 6 5 4 3 2 1 7 8 9 10 11 9 9 9 ...

Page 79: ...strainer 2 Oil pump 3 Relief valve assembly 4 Oil filter 5 Oil cooler 6 Main gallery 7 Front balancer shaft 8 Rear balancer shaft 9 Oil nozzle 10 Intake camshaft 11 Exhaust camshaft 12 Main axle 13 Oil pipe 14 Drive axle 15 Middle drive shaft assembly ...

Page 80: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 EAS20410 LUBRICATION DIAGRAMS 5 6 7 1 2 3 4 ...

Page 81: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Intake camshaft 2 Cylinder head 3 Exhaust camshaft 4 Oil check bolt 5 Main gallery bolt 6 Crankshaft 7 Oil nozzle ...

Page 82: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 1 3 2 ...

Page 83: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Main axle 2 Drive axle 3 Oil delivery pipe 1 ...

Page 84: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 6 5 4 3 2 1 ...

Page 85: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Oil check bolt 2 Crankshaft 3 Oil cooler 4 Oil strainer 5 Oil delivery pipe 3 6 Oil pump ...

Page 86: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 1 2 3 4 5 6 7 8 9 ...

Page 87: ...CATION SYSTEM CHART AND DIAGRAMS 2 38 1 Rear balancer 2 Oil delivery pipe 2 3 Engine oil drain bolt 4 Oil level switch 5 Crankshaft 6 Front balancer 7 Crank pin 8 Oil delivery pipe 3 9 Relief valve assembly ...

Page 88: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39 4 5 3 2 1 9 8 6 7 ...

Page 89: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 40 1 Oil strainer 2 Oil delivery pipe 2 3 Oil cooler 4 Engine oil drain bolt 5 Oil level switch 6 Oil filter cartridge 7 Oil delivery pipe 3 8 Oil pan 9 Oil pump ...

Page 90: ...COOLING SYSTEM DIAGRAMS 2 41 EAS20420 COOLING SYSTEM DIAGRAMS A C D B B D A 6 5 15 6 7 8 9 9 10 1 2 3 4 12 11 16 17 18 19 13 14 5 C ...

Page 91: ...r outlet hose 6 Radiator 7 Coolant reservoir breather hose 8 Thermostat inlet pipe 2 9 Coolant reservoir hose 10 Radiator inlet hose 11 Thermostat inlet hose 2 12 Thermostat assembly 13 Water jacket joint 14 Oil cooler 15 Oil cooler inlet hose 16 Water pump outlet pipe 17 Water pump breather hose 18 Radiator outlet hose 19 Water jacket joint inlet hose ...

Page 92: ...COOLING SYSTEM DIAGRAMS 2 43 A A 7 1 2 3 4 5 5 7 8 6 8 9 10 11 12 ...

Page 93: ...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 94: ...TING FJR13A 2 45 EAS20430 CABLE ROUTING FJR13A B B C C A A B C C B A B C D E F G G H H I J K 1 2 2 2 3 4 5 6 7 3 4 5 7 3 3 4 5 7 7 8 9 10 11 12 12 13 13 14 15 16 17 18 19 20 1 2 3 21 3 12 13 L N N 20 20 21 21 M ...

Page 95: ...rmer lead and main switch 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 F Temporarily tighten the brake hose joint bolt union bolt and brake hose holder bolt in the proper tightening sequence as shown Then tighten the bolts to the specified torques making sure to tighten the brake hose joint bolt 1 last G T...

Page 96: ... D D E E A A F F A A D E D E A B C E I J K L 1 1 2 3 3 4 4 5 5 5 5 5 6 7 8 9 10 11 12 13 13 14 15 16 17 18 18 19 20 21 22 23 24 25 26 23 27 28 29 25 30 31 32 33 34 D F G M N 23 25 25 18 H C C B B 5 18 O 11 C C B B Q P 35 36 18 ...

Page 97: ...ead to the battery box with a plastic locking tie Face the end of the plastic locking tie rearward Do not cut off the excess end of the plastic locking tie F Route the positive battery lead between the battery stay and the battery box G To front cowling wire harness H Align the rear end of the right radiator fan motor coupler with the tape on the wire harness as shown in the illustration I Fasten ...

Page 98: ...CABLE ROUTING FJR13A 2 49 2 3 4 5 6 7 8 9 11 10 12 13 14 15 16 A B C D E F 1 1 ...

Page 99: ...ly 14 Brake pipe brake pipe upper joint assembly to front brake calipers 15 Rear brake light switch 16 Brake hose brake pipe to rear brake caliper A Route the rear wheel sensor lead to the inside of 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 100: ...CABLE ROUTING FJR13A 2 51 1 2 3 4 5 6 7 8 A B C D E 9 10 11 12 13 ...

Page 101: ...e plastic locking tie rearward along the side of the accessory box Do not cut off the excess end of the plastic locking tie B Fasten the wire harness and left radiator fan motor lead with the holder C Route the grip warmer control unit leads to the front of the coolant reservoir hose D Fasten the front cowling wire harness to the radiator inlet hose with a plastic locking tie making sure to instal...

Page 102: ... ROUTING FJR13A 2 53 A A B C C B D A A A D F H I N O M P K J L Q R S T U Y Z 1 2 6 6 17 19 18 17 9 11 10 15 12 13 14 16 23 22 21 20 24 25 28 29 30 31 32 33 34 G 7 8 6 3 4 36 33 35 D V 9 W X B 5 C 26 27 E 10 ...

Page 103: ...ing tie making sure that the end of the tie faces upward Do not cut off the excess end of the plastic locking tie E Fasten the sidestand switch lead stator coil lead and oil level switch lead with a plastic locking tie making sure to bundle and fasten the sidestand switch lead so that the coupler is positioned to the front of the tie Face the end of the plastic locking tie outward Do not cut off t...

Page 104: ...CABLE ROUTING FJR13A 2 55 B B A A A A B B C C 1 2 12 13 14 15 16 17 18 E F G 3 4 3 4 H I J K L 1 2 3 4 5 6 A B C D 7 8 9 10 11 ...

Page 105: ...ctifier regulator lead through the guide on the frame E Securely connect the ABS ECU coupler F Secure the plastic band by inserting the projection on the band into the hole in the rear fender and then fasten the wire harness at the positioning tape with the band G Secure the plastic band by inserting the projection on the band into the hole in the rear fender and then fasten the wire harness with ...

Page 106: ...CABLE ROUTING FJR13A 2 57 E A C D F F G H I J K M N 1 2 4 5 6 7 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 31 29 B 3 8 9 L 30 ...

Page 107: ...arness Face the end of the plastic locking tie forward Do not cut off the excess end of the plastic locking tie B Position the plastic locking tie 0 20 mm 0 0 79 in from the end of the protective sleeve of the front wheel sensor lead C Route the throttle cables and brake hoses through the right opening in the frame D Route the wire harness over the spark plug leads E To cylinder identification sen...

Page 108: ...CABLE ROUTING FJR13A 2 59 1 2 3 4 A B B C D E ...

Page 109: ...older on the rear fender making sure that the leads are not routed on top of the holder B Fasten the tail brake light assembly lead and license plate light lead with the holder C Route the tail brake light assembly lead and license plate light lead between the ribs on the rear fender D Route the intake air temperature sensor lead under the wire harness E Fasten the intake air temperature sensor le...

Page 110: ...CABLE ROUTING FJR13A 2 61 A 1 A A B P O C D E F G H I J K L M N 2 3 4 5 6 7 8 9 10 A 11 ...

Page 111: ...tration by inserting the projection on its holder into the hole in the windshield drive unit meter assembly stay I Fasten the leads to windshield drive unit that branch off from the front cowling wire harness to the harness with a plastic locking tie making sure to position the tie 20 mm 0 79 in from the drive unit couplers J Secure the plastic band by inserting the projection on the band into the...

Page 112: ...CABLE ROUTING FJR13A 2 63 A A 1 1 2 3 4 5 6 7 7 8 9 10 1 2 3 4 5 6 7 8 9 10 10 1 3 4 5 6 7 8 9 13 13 11 12 12 A 2 1 5 4 3 ...

Page 113: ...oportioning valve to rear brake hose 8 Brake pipe front brake master cylinder to brake pipe lower joint assembly 9 Brake pipe brake pipe upper joint assembly to front brake calipers 10 Brake pipe 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 va...

Page 114: ...TING FJR13AE 2 65 ET3P66048 CABLE ROUTING FJR13AE B B A A B B A B C D E F F G G H I J K L 1 3 2 2 2 3 7 5 4 6 8 9 12 12 13 13 12 11 10 13 14 15 17 18 19 21 20 20 20 21 21 1 2 3 16 C C C C 3 4 7 3 1 1 3 4 7 7 M M ...

Page 115: ...c locking tie Face the end of the plastic locking tie downward angled inward and then cut off the excess end of the tie E Temporarily tighten the brake hose joint bolt union bolt and brake hose holder bolt in the proper tightening sequence as shown Then tighten the bolts to the specified torque making sure to tighten the brake hose joint bolt 1 last F To front cowling wire harness G Install the ho...

Page 116: ...7 C C D D E E A A B B F F A A CB E D E A B C E I J K L 1 1 2 3 3 4 4 5 5 5 5 5 5 6 7 8 9 10 11 12 13 13 14 15 16 17 18 18 18 19 20 21 22 29 23 24 25 26 27 28 30 31 32 33 34 D D F G M N 18 H 23 25 23 25 25 Q P 18 O 11 35 36 B C ...

Page 117: ...ead to the battery box with a plastic locking tie Face the end of the plastic locking tie rearward Do not cut off the excess end of the plastic locking tie F Route the positive battery lead between the battery stay and the battery box G To front cowling wire harness H Align the rear end of the right radiator fan motor coupler with the tape on the wire harness as shown in the illustration I Fasten ...

Page 118: ...CABLE ROUTING FJR13AE 2 69 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 A B C E D F 1 1 H 10 18 G ...

Page 119: ...r brake light switch 18 Brake hose brake pipe to rear brake caliper A Route the rear wheel sensor lead to the inside of the swingarm making sure that the lead does not protrude above the swingarm B 45 55 mm 1 77 2 17 in C 20 30 mm 0 79 1 18 in D Fasten the clutch actuator motor lead and clutch actuator sensor lead with the holder E Fasten the rear brake light switch lead rear wheel sensor lead clu...

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

Page 121: ...e plastic locking tie rearward along the side of the accessory box Do not cut off the excess end of the plastic locking tie B Fasten the wire harness and left radiator fan motor lead with the holder C Route the grip warmer control unit leads to the front of the coolant reservoir hose D Fasten the front cowling wire harness to the radiator inlet hose with a plastic locking tie making sure to instal...

Page 122: ...NG FJR13AE 2 73 UP A A B D C C B D A A A B D C F G H M N O P Q R S X V W 1 3 2 20 10 12 13 10 11 16 15 14 18 19 27 28 29 30 31 32 17 33 34 35 36 37 38 39 E 6 8 9 7 4 5 36 40 41 17 T U L J I K 20 22 21 26 25 24 23 ...

Page 123: ... from the wire harness to the guide on the holder with a plastic locking tie making sure that the end of the tie faces upward Do not cut off the excess end of the plastic locking tie D Fasten the sidestand switch lead stator coil lead and oil level switch lead with a plastic locking tie making sure to bundle and fasten the sidestand switch lead so that the coupler is positioned to the front of the...

Page 124: ...CABLE ROUTING FJR13AE 2 75 B B A A A A B B C C 1 2 19 15 14 13 12 18 17 F G 4 5 4 5 I J K L 1 2 3 4 5 6 7 A B C D 8 9 10 11 M H 21 22 23 24 20 E 16 ...

Page 125: ...h the guide on the frame E Fasten the shift actuator motor lead shift actuator sensor lead and foot shift switch lead with a plastic locking tie making sure to install the tie on each lead s protective sleeve Face the end of the plastic locking tie inward without cutting off the excess end F Securely connect the ABS ECU coupler G Secure the plastic band by inserting the projection on the band into...

Page 126: ...CABLE ROUTING FJR13AE 2 77 E A C D F F G H I J K M N 1 2 4 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 30 L 29 B 3 5 6 7 8 9 ...

Page 127: ...Face the end of the plastic locking tie forward Do not cut off the excess end of the plastic locking tie B Position the plastic locking tie 0 20 mm 0 0 79 in from the end of the protective sleeve of the front wheel sensor lead C Route the throttle cables and brake hoses through the right opening in the frame D Route the wire harness over the spark plug leads E To cylinder identification sensor F T...

Page 128: ...CABLE ROUTING FJR13AE 2 79 1 4 2 5 6 A B C D D E 3 F G ...

Page 129: ... on top of the storage compartment projection C Route the tail brake light assembly lead and license plate light lead between the rib and the U lock holder on the rear fender making sure that the leads are not routed on top of the holder D Fasten the tail brake light assembly lead and license plate light lead with the holder E Route the tail brake light assembly lead and license plate light lead b...

Page 130: ...CABLE ROUTING FJR13AE 2 81 A 1 A A B P O C D E F G H I J K L M N 2 3 4 5 6 7 8 9 10 A 11 ...

Page 131: ...tration by inserting the projection on its holder into the hole in the windshield drive unit meter assembly stay I Fasten the leads to windshield drive unit that branch off from the front cowling wire harness to the harness with a plastic locking tie making sure to position the tie 20 mm 0 79 in from the drive unit couplers J Secure the plastic band by inserting the projection on the band into the...

Page 132: ...CABLE ROUTING FJR13AE 2 83 A A 1 1 2 3 4 5 6 7 7 8 9 10 1 2 3 4 5 6 7 8 9 10 10 1 3 4 5 6 7 8 9 13 13 11 12 12 A 2 1 5 4 3 ...

Page 133: ...roportioning valve to rear brake hose 8 Brake pipe front brake master cylinder to brake pipe lower joint assembly 9 Brake pipe brake pipe upper joint assembly to front brake calipers 10 Brake pipe 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 v...

Page 134: ...CABLE ROUTING FJR13AE 2 85 ...

Page 135: ...3 13 CHECKING THE ENGINE OIL LEVEL 3 14 CHANGING THE ENGINE OIL 3 15 MEASURING THE ENGINE OIL PRESSURE 3 16 ADJUSTING THE CLUTCH LEVER FJR13A only 3 17 CHECKING THE CLUTCH FLUID LEVEL FJR13A 3 17 CHECKING THE CLUTCH FLUID LEVEL FJR13AE 3 18 BLEEDING THE HYDRAULIC CLUTCH SYSTEM FJR13A 3 18 BLEEDING THE HYDRAULIC CLUTCH SYSTEM FJR13AE 3 19 CHECKING THE VEHICLE AFTER BLEEDING THE HYDRAULIC CLUTCH SYS...

Page 136: ...KING AND ADJUSTING THE STEERING HEAD 3 33 ADJUSTING THE HANDLEBAR POSITION 3 34 CHECKING THE FRONT FORK 3 35 ADJUSTING THE FRONT FORK LEGS 3 36 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3 37 ADJUSTING THE SIDE PANELS 3 38 ADJUSTING THE RIDER SEAT HEIGHT 3 39 CHECKING THE TIRES 3 40 CHECKING THE WHEELS 3 42 CHECKING AND LUBRICATING THE CABLES 3 42 LUBRICATING THE LEVERS 3 42 LUBRICATING THE PEDALS...

Page 137: ......

Page 138: ... if necessary 2 Spark plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 3 Valve clearance Check and adjust valve clear ance when engine is cold Every 26600 mi 42000 km 4 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 5 Fuel injection Check and adjust engine idle speed and synchronization 6 Exhaust system ...

Page 139: ...y 16 Centerstand and sidestand pivots Check operation Apply lithium soap based grease lightly 17 Sidestand switch Check operation and replace if necessary 18 Front fork Check operation and for oil leakage Replace if necessary 19 Shock absorber assembly Check operation and for oil leakage Replace if necessary 20 Rear suspension link pivots Apply lithium soap based grease lightly 21 Engine oil Chang...

Page 140: ...f necessary Lubricate the throttle grip housing and cable 28 Lights signals and switches Check operation Adjust headlight beam No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 1 Fuel line Check fuel hoses for cracks or damage Repl...

Page 141: ...y 7 Tires Check tread depth and for damage Replace if necessary Check air pressure Correct if necessary 8 Wheel bearings Check bearings for smooth operation Replace if necessary 9 Swingarm pivot bearings Check bearing assemblies for looseness Moderately repack with lithi um soap based grease Repack 10 Steering bearings Check bearing assemblies for looseness Moderately repack with lithi um soap bas...

Page 142: ...operation and for oil leakage Replace if necessary 19 Rear suspension link pivots Apply lithium soap based grease lightly 20 Engine oil Change warm engine before draining 21 Engine oil filter cartridge Replace 22 Cooling system Check hoses for cracks or damage Replace if necessary Change with ethylene glycol anti freeze coolant every 24 months Change 23 Final gear oil Check oil level and for leak ...

Page 143: ...fer to THERMOSTAT on page 6 6 2 Disconnect Throttle cables 3 Remove Spark plugs Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS on page 5 13 4 Remove Hose holder 1 Lead holders 2 Pickup rotor cover 3 5 Measure Valve clearance Out of specification Adjust a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres sion stroke align the TDC mark a on the pickup rotor wi...

Page 144: ... crankcase Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be in stalled in the correct place b Calculate the difference between the speci fied valve clearance and the measured valve clearance Example Specified valve clearance 0 15 0 22 mm 0 0059 0 0087 in Measured valve clearance 0 25 mm 0 0098 in 0 25 mm 0 0098 in 0 22 mm 0 0087 in 0 03 mm 0 001 in c Check the...

Page 145: ...age 5 13 Lubricate the camshaft bearings camshaft lobes and camshaft journals First install the exhaust camshaft Turn the crankshaft clockwise several full turns to seat the parts h Measure the valve clearance again i If the valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the specified clearance is obtained 8 Install All removed parts TIP Fo...

Page 146: ...ttle bodies 1 2 and 4 using the air screw 1 TIP After each step rev the engine two or three times each time for less than a second and check the synchronization again If the air screw was removed turn the screw 3 4 turn in and be sure to synchronize the throt tle body NOTICE ECA14900 Do not use the throttle valve adjusting screws to adjust the throttle body synchroni zation TIP The difference in v...

Page 147: ...HASSIS on page 4 1 3 Install Digital tachometer onto the spark plug lead of cylinder 1 4 Install Fuel tank Refer to FUEL TANK on page 7 1 5 Check Engine idling speed Out of specification Adjust 6 Adjust Engine idling speed a Turn the engine idle speed adjustment screw 1 in direction a or b until the specified en gine idling speed is obtained 7 Adjust Throttle cable free play Refer to ADJUSTING THE...

Page 148: ...ection a or b until the specified throttle cable free play is obtained d Tighten the locknut e Slide the rubber covers to its original position 4 Install T bar Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS20680 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs 1 Remove Rider seat Re...

Page 149: ...EL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS20700 CHECKING THE IGNITION TIMING TIP Prior to checking the ignition timing check the wiring connections of the entire ignition system Make sure all connections are tight and free of corrosion 1 Stand the vehicle on a level surface TIP Place the vehicle on the centerstand 2 Remove Right side cowling Rider seat Refer to GENERAL...

Page 150: ...on pressure will result in a loss of performance 1 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 6 2 Start the engine warm it up for several min utes and then turn it off 3 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 T bar Refer to GENERAL CHASSIS on page 4 1 4 Disconnect the all spark plug ...

Page 151: ...vehicle is upright 2 Start the engine warm it up for several min utes and then turn it off 3 Check Engine oil level The engine oil level should be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommended engine oil to the proper level NOTICE ECA3P6D021 Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch sli...

Page 152: ...ller cap 1 Engine oil drain bolt 2 along with the gasket 4 Drain Engine oil completely from the crankcase 5 If the oil filter cartridge is also to be replaced perform the following procedure a Remove the oil filter cartridge 1 with an oil filter wrench 2 b Lubricate the O ring 3 of the new oil filter cartridge with a thin coat of engine oil NOTICE ECA13390 Make sure the O ring 3 is positioned cor ...

Page 153: ... Check Engine oil level Below the minimum level mark Add the recommended engine oil to the proper level 2 Start the engine warm it up for several min utes and then turn it off NOTICE ECA13410 When the engine is cold the engine oil will have a higher viscosity causing the engine oil pressure to increase Therefore be sure to measure the engine oil pressure after warming up the engine 3 Remove Right ...

Page 154: ...orate 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 fluid reservoir Water will significantly lower the boiling point of the clutch fluid and could cause vapor lock NOT...

Page 155: ...of the reservoir is horizontal 4 Install Left side cover Refer to GENERAL CHASSIS on page 4 1 EAS20900 BLEEDING THE HYDRAULIC CLUTCH SYSTEM FJR13A WARNING EWA13000 Bleed the hydraulic clutch system whenever the system was disassembled a clutch hose was loosened or removed the clutch fluid level is very low clutch operation is faulty TIP Be careful not to spill any clutch fluid or allow the clutch ...

Page 156: ...out the flu id using the vacuum pressure gauge set Ig noring this precaution could allow air to enter the hydraulic clutch system considerably lengthening the bleeding procedure If bleeding is difficult it may be necessary to let the clutch fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Remove Air filter case Refer to GENERAL CHASSIS...

Page 157: ...Refer to CHECKING THE CLUTCH FLUID LEVEL FJR13AE on page 3 18 3 Check Pressure plate stroke a Remove the pickup rotor cover bolts 1 b Remove the clutch cover 2 Refer to CLUTCH on page 5 46 c Manually engage and disengage the clutch using the clutch operation bolt 3 five times each time for less than 1 second TIP Turn the clutch operation bolt in a continuous motion without allowing the pressure pl...

Page 158: ...y hand 2 Check Shift operation Engine stalls Check the pressure plate stroke Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM FJR13AE on page 3 19 a Place the vehicle on the centerstand b Start the engine c Shift the transmission from neutral to 1st gear and back to neutral ten times d Shift the transmission into 1st gear and then apply the rear brake TIP If the engine stalls restart the engine let i...

Page 159: ...ASSIS on page 4 1 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 ET3P66028 CLEANING THE AIR FILTER ELEMENT FJR13AE 1 Remove Rider seat Left side cover Refer to GENERAL CHASSIS on page 4 1 Shift actuator Refer to SHIFT ACTUATOR AND SHIFT ROD FJR13AE only on page 5 73 Air filter case cover Air filter el...

Page 160: ...AS21030 CHECKING THE FUEL LINE 1 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 T bar Refer to GENERAL CHASSIS on page 4 1 2 Check Fuel hose 1 Fuel tank breather hose Fuel tank overflow hose Fuel tank breather overflow hose 2 except for California Cracks damage Replace Loose connection Connect properly NOTICE EC3P61005 Make sure the fuel tank breath...

Page 161: ...RAL CHASSIS on page 4 1 EAS21090 CHECKING THE CANISTER for California only 1 Remove Side cowlings Refer to GENERAL CHASSIS on page 4 1 2 Check Canister Hoses Cracks damage Replace Refer to FUEL TANK on page 7 1 3 Install Side cowlings Refer to GENERAL CHASSIS on page 4 1 EAS21110 CHECKING THE COOLANT LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on the centerstand Make sure th...

Page 162: ...l it settles 6 Install Left side panel Refer to GENERAL CHASSIS on page 4 1 EAS21120 CHECKING THE COOLING SYSTEM 1 Remove Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 1 2 Check Radiator 1 Oil cooler outlet hose 2 Radiator inlet hose 3 Radiator outlet hose 4 Oil cooler inlet hose 5 Oil cooler 6 Water jacket joint 7 Water jacket joint inlet hose 8 Water pump outlet pipe 9 Water pump outle...

Page 163: ...ir cap 2 7 Drain Coolant from the coolant reservoir 8 Install Coolant reservoir 9 Connect Radiator outlet hose 10 Install Coolant drain bolt water pump along with the copper washer 11 Fill Cooling system with the specified amount of the recom mended coolant Handling notes for coolant Coolant is potentially harmful and should be handled with special care WARNING EWA13040 If coolant splashes in your...

Page 164: ...y be used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 12 Install Radiator cap 13 Fill Coolant reservoir with the recommended coolant to the maxi mum level mark a 14 Install Coolant reservoir cap 15 Start the engine warm it up for several min utes and then stop it 16 Check Coolant level Refer to CHECKING THE COOLANT ...

Page 165: ... brake drag EAS21190 ADJUSTING THE REAR DISC BRAKE 1 Check Brake pedal position distance a from the top of the rider footrest to the top of the brake pedal Out of specification Adjust 2 Adjust Brake pedal position a Loosen the locknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained WARNING EWA13070 After adjusting the brake pedal position chec...

Page 166: ...d brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the bo...

Page 167: ...l of the brake hoses and brake hose holders 1 Check Brake hoses Cracks damage wear Replace 2 Check Brake hose holders Loose Tighten the holder bolts 3 Hold the vehicle upright and apply the brake several times 4 Check Brake hoses Brake fluid leakage Replace the damaged hose Refer to FRONT BRAKE on page 4 32 REAR BRAKE on page 4 44 and ABS AN TI LOCK BRAKE SYSTEM on page 4 57 EAS21330 ADJUSTING THE...

Page 168: ...ng procedure when the tiny bubbles in the hose have disappeared 1 Remove Right side cover Refer to GENERAL CHASSIS on page 4 1 2 Bleed ABS a Fill the brake master cylinder reservoir or brake fluid reservoir to the proper level with the recommended brake fluid b Install the diaphragm brake master cylinder reservoir or brake fluid reservoir c Connect a clear plastic hose 1 tightly to the bleed screw...

Page 169: ...center of the shift pedal end 1 is aligned with the center of the middle gear case cover bolt 2 as shown in the illus tration when viewed directly from the side Incorrect Adjust 2 Adjust Shift pedal position a Loosen both locknuts 1 b Turn the shift rod 2 in direction a or b to obtain the correct shift pedal position TIP Check that the groove c in the shift pedal is be tween the projections d on t...

Page 170: ...l gear oil filler bolt 1 Final gear oil drain bolt 2 Completely drain the final gear case of its oil 3 Check Final gear oil drain bolt gasket Damage Replace 4 Install Final gear oil drain bolt along with the gasket 5 Fill Final gear case with the specified amount of the recom mended final gear oil Refer to CHECKING THE FINAL GEAR OIL LEVEL on page 3 33 EAS21510 CHECKING AND ADJUSTING THE STEERING ...

Page 171: ... front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD on page 4 89 e Install the rubber washer 3 f Install the upper ring nut 2 g Finger tighten the upper ring nut then align the slots of both ring nuts If necessary hold the lower ring nut and tighten the upper ring nut until their slots are aligned ...

Page 172: ...uts EAS21530 CHECKING THE FRONT FORK 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Check Inner tube Damage scratches Replace Oil seal Oil leakage Replace 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check if the front fork reb...

Page 173: ...d a Turn the adjusting bolt 1 in direction a or b Rebound damping NOTICE ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Rebound damping a Turn the adjusting knob 1 in direction a or b Direction a Spring preload is increased suspen sion is harder Direction b Spring preload is decreased suspen sion is softer Spring preload adjusting positions Minimum 6 Standard 4 Maxim...

Page 174: ...he adjusting lever 1 in direction a or b b Adjust the adjusting lever to HARD or SOFT Rebound damping NOTICE ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Rebound damping a Turn the adjusting knob 1 in direction a or b Direction a Compression damping is increased suspension is harder Direction b Compression damping is decreased suspension is softer Compression dampi...

Page 175: ... quick fastener screws 1 To close a side panel a Remove the quick fastener screws 1 b Push the side panel to the closed position and then install the quick fastener screws 1 Direction a Rebound damping is increased sus pension is harder Direction b Rebound damping is decreased sus pension is softer Rebound damping adjusting posi tions Minimum 20 click s out Standard 12 click s out Maximum 3 click ...

Page 176: ...TIP Remove the rider seat height position adjuster by pulling it upward 4 Adjust Rider seat height To change to the high position a Move the rider seat holder cover 1 to the lower position as shown b Install the rider seat height position adjuster 2 so that the H mark a is aligned with the match mark b c Insert the projection c on the front of the rid er seat into seat holder for high position 3 a...

Page 177: ...n to lock it in place as shown 5 Install Passenger seat Refer to GENERAL CHASSIS on page 4 1 EAS21650 CHECKING THE TIRES The following procedure applies to both of the tires 1 Check Tire pressure Out of specification Regulate WARNING EWA13180 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature The tire pressure and the suspension must...

Page 178: ...be as soon as possible with a good quality re placement Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 270 kPa 39 psi 2 70 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm Loading condition FJR13A 90 212 kg 198 467 lb USA FJR13A 90 211 kg 198 465 lb California FJR13AE 90 208 kg 198 459 lb USA FJR13AE 90 207 kg 198 456 lb California Front 270 kPa 39 psi 2 70 kgf cm Rear 290...

Page 179: ... changed or re placed always balance the wheel EAS21690 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in ner and outer cables WARNING EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement Re place damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movemen...

Page 180: ...ERSTAND Lubricate the pivoting point and metal to metal moving parts of the centerstand EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease ...

Page 181: ... from the bulb until it has cooled down 6 Install Headlight bulb Secure the new headlight bulb with the head light bulb holder NOTICE ECA13690 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth mo...

Page 182: ...adjusting screws 1 in direction a or b Left headlight Right headlight Direction a Headlight beam moves to the left Direction b Headlight beam moves to the right Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left 1 a b 1 a b 1 b a b a ...

Page 183: ...DISASSEMBLING THE REAR WHEEL 4 27 CHECKING THE REAR WHEEL 4 28 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR 4 28 ASSEMBLING THE REAR WHEEL 4 28 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 29 INSTALLING THE REAR WHEEL REAR BRAKE DISC 4 30 FRONT BRAKE 4 32 INTRODUCTION 4 37 CHECKING THE FRONT BRAKE DISCS 4 37 REPLACING THE FRONT BRAKE PADS 4 38 REMOVING THE FRONT BRAKE CALIPERS 4 39 DISASSEMB...

Page 184: ... 4 57 REMOVING THE HYDRAULIC UNIT ASSEMBLY 4 62 CHECKING THE HYDRAULIC UNIT ASSEMBLY 4 62 CHECKING THE PROPORTIONING VALVE AND METERING VALVE 4 63 CHECKING THE BRAKE PIPES 4 63 INSTALLING THE HYDRAULIC UNIT ASSEMBLY 4 63 HYDRAULIC UNIT OPERATION TESTS 4 66 TRIAL RUN 4 69 HANDLEBARS 4 70 REMOVING THE HANDLEBARS 4 74 CHECKING THE HANDLEBARS 4 74 INSTALLING THE HANDLEBARS FJR13A 4 74 INSTALLING THE H...

Page 185: ...SHAFT DRIVE 4 101 TROUBLESHOOTING 4 105 CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND CHECKING THE SHAFT DRIVE FOR LEAKS 4 106 MEASURING THE FINAL GEAR BACKLASH 4 106 ADJUSTING THE FINAL GEAR BACKLASH 4 107 MEASURING THE RING GEAR TO STOPPER BOLT CLEARANCE 4 108 ADJUSTING THE RING GEAR TO STOPPER BOLT CLEARANCE 4 108 DISASSEMBLING THE FINAL DRIVE ASSEMBLY 4 109 REMOVING AND INSTALLING THE BEA...

Page 186: ...at 1 3 Grab bar 1 4 Left rear cowling 1 5 Right rear cowling 1 6 Center rear cowling 1 7 Left side cover 1 8 Right side cover 1 9 Rider seat height position adjuster 1 For installation reverse the removal proce dure T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 21 Nm 2 1 m kg 15 ft Ib 3 1 4 7 2 5 9 6 8 ...

Page 187: ...nnect 7 Bottom cowling 1 8 Front cowling right inner panel 1 1 9 Headlight beam adjusting knob 2 10 Front cowling right inner panel 2 1 11 Adjusting knob shaft 2 12 Headlight beam adjusting cable 2 Disconnect 13 Front cowling left inner panel 1 1 14 Front cowling left inner panel 2 1 15 Plastic band 2 Disconnect 16 Plastic holder 1 Disconnect T R 32 Nm 3 2 m kg 23 ft Ib T R 10 Nm 1 0 m kg 7 2 ft I...

Page 188: ...sconnect 20 Front cowling assembly 1 For installation reverse the removal proce dure Removing the front cowling assembly FJR13A Order Job Parts to remove Q ty Remarks T R 32 Nm 3 2 m kg 23 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 10 9 4 8 20 1 3 6 7 2 12 11 5 12 16 11 14 13 9 18 19 17 19 15 18 ...

Page 189: ...ing 1 8 Front cowling right inner panel 1 1 9 Headlight beam adjusting knob 2 10 Front cowling right inner panel 2 1 11 Adjusting knob shaft 2 12 Headlight beam adjusting cable 2 Disconnect 13 Front cowling left inner panel 1 1 14 Grip warmer control unit coupler 2 Disconnect 15 Grip warmer control unit 1 16 Front cowling left inner panel 2 1 T R 32 Nm 3 2 m kg 23 ft Ib T R 10 Nm 1 0 m kg 7 2 ft I...

Page 190: ...22 Horn connector 4 Disconnect 23 Grip warmer coupler 2 Disconnect 24 Front cowling assembly 1 For installation reverse the removal proce dure Removing the front cowling assembly FJR13AE Order Job Parts to remove Q ty Remarks T R 32 Nm 3 2 m kg 23 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LT LT 10 9 4 8 24 1 3 6 2 12 11 5 12 18 11 16 13 15 23 23 14 14 9 21 22 19 22 20 17 T R 10 Nm 1 0 m kg 7 2 ft Ib 7...

Page 191: ...bracket 1 2 Windshield 1 3 Windshield inner bracket 1 4 Rearview mirror 2 5 Accessory box solenoid coupler 1 Disconnect 6 Auxiliary DC jack coupler 1 Disconnect 7 Accessory box 1 8 Accessory box solenoid 1 9 Headlight coupler 2 Disconnect 10 Front cowling 1 For assembly reverse the disassembly pro cedure 7 7 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 1 2 3 4 4 5 10 6 7 8 9 9 ...

Page 192: ...IS 4 7 Removing the headlight assembly Order Job Parts to remove Q ty Remarks Front cowling Refer to Disassembling the front cowling assembly 1 Headlight assembly 1 For installation reverse the removal proce dure 1 ...

Page 193: ... drive unit 1 3 Windshield drive unit side rail 2 4 Meter assembly coupler 1 Disconnect 5 Meter assembly 1 6 Turn signal hazard relay coupler 1 Disconnect 7 Turn signal hazard relay 1 8 Headlight relay dimmer coupler 1 Disconnect 9 Headlight relay dimmer 1 For installation reverse the removal proce dure T R 8 Nm 0 8 m kg 5 8 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib LS LS T R 10 Nm 1 0 m kg 7 2 ft Ib LS 2...

Page 194: ...ebar completely to the left c Install the adjusting knob shaft 1 onto the left headlight beam adjusting cable 2 d Place front cowling left inner panel 2 3 be tween the front cowling assembly and the steering stem e Fit the top and side of inner panel 2 into the front cowling assembly to the left of the meter assembly f Fit inner panel 2 under the right side of the ac cessory box TIP Pull the front...

Page 195: ... in front cowling right inner panel 2 3 making sure to align the projection a on the shaft s sleeve with the slot b in the panel and then install the nut d Install the headlight beam adjusting knob 4 e Fit the lower right corner of inner panel 2 into the front cowling assembly making sure to align the bolt hole in the panel with the bolt hole in the cowling f Fit the top and side of inner panel 2 ...

Page 196: ...GENERAL CHASSIS 4 11 b a 1 2 ...

Page 197: ...arts to remove Q ty Remarks Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 T bar 1 2 Heat protector 1 For installation reverse the removal proce dure 1 2 T R 37 Nm 3 7 m kg 27 ft Ib T R 37 Nm 3 7 m kg 27 ft Ib ...

Page 198: ...7 Storage compartment 1 8 ECU engine control unit 1 9 Rear lower fuel tank bracket 1 10 Intake air temperature sensor 1 11 Bypass air unit inlet hose 1 Disconnect 12 Crankcase breather hose 1 Disconnect 13 Air induction system hose air filter case joint assembly to 3 way joint 1 Disconnect 14 Air filter case joint clamp screw 4 Loosen T R 8 Nm 0 8 m kg 5 8 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib New T R...

Page 199: ...ilter assembly 1 For installation reverse the removal proce dure Removing the air filter case FJR13A Order Job Parts to remove Q ty Remarks T R 8 Nm 0 8 m kg 5 8 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib New T R 4 Nm 0 4 m kg 2 9 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 5 6 7 1 2 4 11 4 4 8 9 10 14 16 3 4 14 17 18 15 12 17 13 11 14 ...

Page 200: ...1 2 Air duct 1 3 Air filter case cover 1 4 Air filter element 1 5 Tool kit 1 6 ECU coupler 1 Disconnect 7 MCU coupler 2 Disconnect 8 MCU 1 9 Storage compartment 1 10 ECU engine control unit 1 11 Rear lower fuel tank bracket 1 12 Intake air temperature sensor 1 13 Bypass air unit inlet hose 1 Disconnect T R 8 Nm 0 8 m kg 5 8 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib New T R 4 Nm 0 4 m kg 2 9 ft Ib T R 7 Nm...

Page 201: ... case joint assembly 1 18 Air filter case 1 19 Air filter case breather hose 2 20 Filter assembly 1 For installation reverse the removal proce dure Removing the air filter case FJR13AE Order Job Parts to remove Q ty Remarks T R 8 Nm 0 8 m kg 5 8 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib New T R 4 Nm 0 4 m kg 2 9 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 5 6 9 1 2 4 11 4 4 10 11 12 16 18 3 4 16 19 20 17 14 19 15 1...

Page 202: ...nt brake caliper 2 5 Front wheel axle pinch bolt 4 Loosen 6 Front wheel axle bolt 1 7 Front wheel axle 1 8 Front wheel 1 9 Front wheel sensor housing 1 10 Collar 1 11 Front brake disc 2 For installation reverse the removal proce dure T R 18 Nm 1 8 m kg 13 ft Ib T R 21 Nm 2 1 m kg 15 ft Ib T R 91 Nm 9 1 m kg 66 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 7 Nm 0 7 m kg 5 1 ft I...

Page 203: ...RONT WHEEL 4 18 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Front wheel sensor rotor 1 3 Wheel bearing 2 4 Spacer 1 For assembly reverse the disassembly pro cedure ...

Page 204: ...t the front wheel is elevated EAS21910 DISASSEMBLING THE FRONT WHEEL NOTICE ECA3P6D003 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 ...

Page 205: ...ty 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 ...

Page 206: ...rom the wheel sensor rotor Do not drop the wheel sensor rotor or sub ject it to shocks If any solvent gets on the wheel sensor ro tor wipe it off immediately 1 Install Wheel bearings a Install the new wheel bearing right side NOTICE EC3P61021 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 th...

Page 207: ...lace the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is 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 Th...

Page 208: ...IP Tighten the brake disc bolts in stages and in a crisscross pattern 2 Check Front brake discs Refer to CHECKING THE FRONT BRAKE DISCS on page 4 37 3 Lubricate Oil seal lips 4 Install Collar Front 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 wheel axle bolt Front wheel ...

Page 209: ...ng 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 sensor check the wheel sensor lead for twists and the sen...

Page 210: ...or 1 3 Rear wheel axle pinch bolt 1 Loosen 4 Rear wheel axle nut 1 5 Brake torque rod 1 6 Rear wheel axle 1 7 Rear brake caliper 1 8 Rear wheel 1 9 Rear wheel sensor housing 1 10 Collar 1 11 Rear brake disc 1 For installation reverse the removal proce dure T R 23 Nm 2 3 m kg 17 ft Ib T R 125 Nm 12 5 m kg 90 ft lb T R 30 Nm 3 0 m kg 22 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 1...

Page 211: ...s 1 Dust cover 1 2 Rear wheel drive hub 1 3 Dust seal 1 4 Wheel bearing 1 5 Rear wheel drive hub damper 6 6 Oil seal 1 7 Bearing retainer 1 8 Rear wheel sensor rotor 1 9 Wheel bearing 1 10 Spacer 1 11 Spacer 1 12 Oil seal 1 13 Bearing 1 For assembly reverse the disassembly pro cedure ...

Page 212: ...el 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 ET3P6D002 DISASSEMBLING THE REAR WHEEL NOTICE ECA3P6D003 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...

Page 213: ...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 Rear wheel sensor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 20 2 Check Rear wheel sensor rotor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page...

Page 214: ... terclockwise 5 Measure Wheel sensor rotor deflection Out of specification Correct the wheel sen sor rotor deflection or replace the wheel sen sor rotor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 28 EAS22150 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 b...

Page 215: ...using 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 distance a only if the wheel b...

Page 216: ...TIP When installing the rear wheel sensor check the rear wheel sensor lead for twists and the sensor electrode for foreign materials 8 Check Rear wheel sensor installation Check if the wheel sensor housing is installed properly Distance a between the wheel sensor rotor and wheel sensor housing 28 89 29 41 mm 1 137 1 158 in T R Rear wheel sensor bolt 7 Nm 0 7 m kg 5 1 ft lb a 2 1 ...

Page 217: ... both of the front brake calipers 1 Brake hose holder 1 2 Front brake caliper 1 3 Brake pad bolt 2 4 Brake pad spring 2 5 Front brake pad 4 For installation reverse the removal proce dure 4 T R 6 Nm 0 6 m kg 4 3 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib 1 2 5 4 5 3 3 ...

Page 218: ...ragm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Brake lever 1 5 Front brake light switch connector 2 Disconnect 6 Brake hose union bolt 1 7 Copper washer 2 8 Brake hose front brake master cylinder to brake pipe lower joint assembly 1 9 Front brake master cylinder holder 1 10 Front brake master cylinder 1 11 Front brake light switch 1 For installation reverse the removal proce dure S...

Page 219: ...ront brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder push rod 1 2 Dust boot 1 3 Circlip 1 4 Brake master cylinder kit 1 5 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure S ...

Page 220: ...ke 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 For installation reverse the removal proce dure T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0...

Page 221: ...rake pad spring 2 3 Front brake pad 4 4 Brake caliper piston 4 5 Brake caliper piston dust seal 4 6 Brake caliper piston seal 4 7 Bleed screw 1 8 Bleed screw 1 Right side only For assembly reverse the disassembly pro cedure 3 4 4 1 2 2 1 7 3 5 5 5 5 6 6 6 6 8 T R 6 Nm 0 6 m kg 4 3 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib New New New New S S BF BF S New New New New ...

Page 222: ...re applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 17 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflec tion turn the handlebar to the left ...

Page 223: ...liper 1 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 2 Install Brake pads Brake pad spring TIP Always install new brake pads and a new brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper wi...

Page 224: ...ystem 1 Remove Brake hose holder 1 Brake hose union bolts 2 Copper washers Brake hose brake pipe upper joint assembly to right front brake caliper 3 Brake hose metering valve to right front brake caliper 4 TIP Put the end of the brake hoses into a container and pump out the brake fluid carefully EAS22360 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake ca...

Page 225: ...ake com ponents as they will cause the brake caliper piston dust seals and brake caliper piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston dust seals and brake caliper piston seals EAS22440 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Install Front brake caliper 1 temporarily Copper was...

Page 226: ...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 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 31 6 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE ...

Page 227: ...clean or new brake fluid Never use solvents on internal brake com ponents EAS22530 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Brake master cylinder 1 Brake master cylinder holder 2 TIP Install the brake master cylinder holder with the UP mark facing up Align the mating surfaces of the brake master cylinder holder with the punch mark a on the right handlebar First tighten the upper bolt t...

Page 228: ...ce When refilling be careful that water does not enter the brake master cylinder reser voir and brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock 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 ...

Page 229: ...AKE Removing the rear brake pads Order Job Parts to remove Q ty Remarks 1 Rear brake caliper bolt 2 2 Rear brake caliper 1 3 Brake pad shim 2 4 Rear brake pad 2 5 Brake pad spring 2 For installation reverse the removal proce dure S S ...

Page 230: ...oir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir 1 5 Brake fluid reservoir hose 1 6 Rear brake light switch coupler 1 Disconnect 7 Right footrest assembly 1 8 Rear brake light switch 1 9 Brake hose union bolt 1 10 Copper washer 2 11 Brake hose rear brake master cylinder to brake pipe middle joint assembly 1 Disconnect 1 2 3 4 5 6 7 9 10 11 8 12 T R 28 Nm 2 8 m kg ...

Page 231: ...tion reverse the removal proce dure Removing the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 2 3 4 5 6 7 9 10 11 8 12 T R 28 Nm 2 8 m kg 20 ft Ib New New T R 28 Nm 2 8 m kg 20 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib ...

Page 232: ...er Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder push rod 1 4 Brake master cylinder kit 1 5 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure S T R 16 Nm 1 6 m kg 11 ft Ib New New 3 2 1 4 5 ...

Page 233: ... SYSTEM ABS on page 3 31 1 Brake hose union bolt 1 2 Copper washer 2 3 Brake hose proportioning valve to rear brake caliper 1 4 Rear brake caliper bolt 2 Loosen 5 Rear wheel axle pinch bolt 1 Loosen 6 Rear wheel axle nut 1 7 Brake torque rod 1 8 Rear wheel axle 1 9 Rear brake caliper assembly 1 For installation reverse the removal proce dure ...

Page 234: ... Rear brake caliper bolt 2 2 Brake pad shim 2 3 Rear brake pad 2 4 Brake pad spring 2 5 Rear brake caliper bracket 1 6 Brake caliper piston 1 7 Brake caliper piston dust seal 1 8 Brake caliper piston seal 1 9 Bleed screw 1 For assembly reverse the disassembly pro cedure 7 8 New New 9 S S S S BF ...

Page 235: ...ck Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 37 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 37 5 Adjust Brake disc d...

Page 236: ...tall Rear brake caliper 5 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 29 6 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 31 EAS22590 REMOVING THE REAR BRAKE CALIPER TIP Before disassembling the brake...

Page 237: ...n 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 EWA3P6D003 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 238: ...ith 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 to rear brake cali...

Page 239: ...an up any spilt brake fluid immediately 7 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 31 8 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 29 9 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE ...

Page 240: ...ing the brake hose onto the brake master cylinder 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 recom mended brake fluid WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber...

Page 241: ...the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 29 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 31 7 Adjust Brake pedal position Refer to ADJUSTING THE REAR DISC BRAKE on page 3 28 8 Adjust Rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 30 ...

Page 242: ...ng valve to rear brake hose 6 Hydraulic unit assembly 7 Rear wheel sensor 8 Rear wheel sensor rotor 9 Rear brake caliper 10 Brake hose brake pipe to rear brake caliper 11 Metering valve 12 Left front brake caliper 13 Right front brake caliper 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 midd...

Page 243: ...ervoir 1 Refer to REAR BRAKE on page 4 44 2 Tail brake light assembly coupler 1 Disconnect 3 License plate light connector 2 Disconnect 4 Tail brake light assembly 1 5 Lean angle sensor 1 6 Brake light relay 1 7 Relay unit 1 8 YCC S control relay 1 FJR13AE 9 Plastic band 2 10 Seat lock cable assembly 1 11 Rear fender assembly 1 For installation reverse the removal proce dure T R 7 Nm 0 7 m kg 5 1 ...

Page 244: ... pipe brake pipe upper joint assembly to front brake calipers 1 Disconnect 12 Brake hose rear brake master cylinder to brake pipe middle joint assembly 1 Disconnect 13 Brake pipe front brake master cylinder to brake pipe lower joint assembly 1 Disconnect 14 Brake pipe upper joint assembly 1 9 9 11 15 16 14 17 9 9 10 13 1 1 1 1 3 2 5 8 6 7 4 12 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft I...

Page 245: ...to remove Q ty Remarks 9 9 11 15 16 14 17 9 9 10 13 1 1 1 1 3 2 5 8 6 7 4 12 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R T R 16 Nm 1 6 m kg 11 ft Ib T R 7 Nm 0 ...

Page 246: ...s 1 ABS ECU coupler 1 Disconnect 2 Cap nut 3 3 Hydraulic unit assembly bracket 1 4 Hydraulic unit assembly 1 For installation reverse the removal proce dure 4 3 2 2 2 1 T R 16 Nm 1 6 m kg 11 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib ...

Page 247: ...sembly have been removed be sure to tighten them to the specified torque and bleed the brake system 1 Remove Brake pipes Brake hoses Metering valve Proportioning valve Brake hose holder TIP Do not operate the brake lever and brake pedal while removing the brake hoses and brake pipes NOTICE ECA3P6D011 When removing the brake hoses and brake pipes cover the area around the hydraulic unit assembly to...

Page 248: ...2 Remove Rubber plugs or bolts M10 1 0 3 Connect ABS ECU coupler 1 TIP Push the coupler ejection slider down until a click is heard making sure that is installed se curely 4 Install Brake pipe lower joint assembly 1 Brake pipe middle joint assembly 2 Brake pipe joint assembly stay 3 Brake pipe upper joint assembly 4 TIP Temporarily tighten the brake pipe joint assem bly flare nuts and bolts 5 Tigh...

Page 249: ...ut 4 on the proportioning valve end 9 Install Brake pipe proportioning valve to rear brake hose 1 Brake hose holder 2 TIP Temporarily tighten the brake pipe flare nuts and brake hose holder bolt 10 Tighten Brake pipe flare nuts 3 Brake hose holder bolt 4 NOTICE ECA3P6D022 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 t...

Page 250: ...ause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and cou...

Page 251: ...alling over TIP Two people are necessary to perform hydraulic unit operation test 1 1 Place the vehicle on the centerstand 2 Turn the main switch to OFF 3 Remove Front cowling right inner panel 1 Refer to GENERAL CHASSIS on page 4 1 4 Check Battery voltage Lower than 12 8 V Charge or replace the battery TIP If the battery voltage is lower than 12 8 V charge the battery and then perform hydraulic u...

Page 252: ... the second pulse in the brake pedal but during the pulse in the brake lever or during the first pulse in the brake pedal check that the brake hoses and brake pipes are con nected correctly to the hydraulic unit as sembly If the pulse is hardly felt in either the brake lever or brake pedal check that the brake hoses and brake pipes are connected cor rectly to the hydraulic unit assembly If the ope...

Page 253: ...n force pulsating action consists of quick pulses Be sure to continue operating the brake lever and brake pedal even after the pulsating action has stopped 11 After the pulsating action has stopped in the brake lever it is generated in the brake pedal 1 0 5 second later and continues for approx imately 2 seconds TIP The reaction force pulsating action consists of quick pulses Be sure to continue o...

Page 254: ... the brake lever or brake pedal check that the brake hoses and brake pipes are con nected correctly to the hydraulic unit as sembly 13 Turn the main switch to OFF 14 Remove the test coupler adapter from the ABS test coupler 15 Turn the main switch to ON 16 Set the engine stop switch to 17 Check for brake fluid leakage around the hy draulic unit Brake fluid leakage Replace the hydraulic unit brake ...

Page 255: ...ove Q ty Remarks 1 Clutch switch coupler 1 Disconnect 2 Clutch master cylinder holder 1 3 Clutch master cylinder assembly 1 4 Left handlebar 1 5 Left handlebar switch lead 1 6 Lead holder 1 7 Left handlebar switch 1 8 Grip end 1 9 Handlebar grip 1 For installation reverse the removal proce dure ...

Page 256: ...Q ty Remarks 1 Left handlebar 1 2 Left grip warmer lead 1 3 Hand shift switch lead 1 4 Left handlebar switch lead 1 5 Lead holder 1 1 6 Hand shift switch 1 7 Lead holder 2 1 8 Left handlebar switch 1 9 Grip end 1 10 Handlebar grip 1 For installation reverse the removal proce dure ...

Page 257: ...sconnect 2 Front brake master cylinder holder 1 3 Front brake master cylinder assembly 1 4 Grip end 1 5 Throttle cable housing 2 6 Throttle cable 2 Disconnect 7 Throttle grip 1 8 Right handlebar 1 9 Right handlebar switch lead 1 10 Lead holder 1 11 Right handlebar switch 1 12 Collar 1 For installation reverse the removal proce dure ...

Page 258: ...t 2 Front brake master cylinder holder 1 3 Front brake master cylinder assembly 1 4 Grip end 1 5 Throttle cable housing 2 6 Throttle cable 2 Disconnect 7 Throttle grip 1 8 Right handlebar 1 9 Right grip warmer lead 1 10 Right handlebar switch lead 1 11 Lead holder 1 12 Right handlebar switch 1 For installation reverse the removal proce dure ...

Page 259: ...n a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Handlebar grip Grip end 1 a Apply a thin coat of rubber adhesive onto the end of the left handlebar b Slide the handlebar grip onto the left handle bar c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rub ber adhesi...

Page 260: ... with the hole b in the right handlebar 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 projection a on the front brake mas ter cylinder with hole b on the right handlebar First tighten th...

Page 261: ...ndlebar grip Grip end 1 a Apply a thin coat of rubber adhesive onto the end of the left handlebar b Slide the handlebar grip onto the left handle bar c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rub ber adhesive has 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 I...

Page 262: ...porarily 8 Tighten Handlebar bolts Handlebar nuts TIP First tighten the bolts then tighten the nuts 9 Install Throttle grip Throttle cables Throttle cable housing 1 Grip end 2 TIP Route the right grip warmer lead 3 through the throttle cable housing so that it forms a loop as shown in the illustration Make sure that the loop is formed so that the section of the lead from the handlebar grip to the ...

Page 263: ...g up Align the projection a on the front brake mas ter cylinder with hole b on the right handlebar First tighten the upper bolt then the lower bolt 11 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 10 T R Front brake master cylinder hold er bolt 10 Nm 1 0 m kg 7 2 ft lb Throttle cable free play 3 0 5 0 mm 0 12 0 20 in b a 1 ...

Page 264: ...Front cowling assembly Refer to GENERAL CHASSIS on page 4 1 Front wheel Refer to FRONT WHEEL on page 4 17 1 Battery holder 1 2 Negative battery lead 1 Disconnect 3 Positive battery lead 1 Disconnect 4 Battery 1 5 Upper bracket pinch bolt 1 Loosen 6 Cap bolt 1 Loosen 7 Lower bracket pinch bolt 2 Loosen 8 Front fork leg 1 For installation reverse the removal proce dure ...

Page 265: ...ocedure applies to both of the front fork legs 1 Cap bolt 1 2 O ring 1 3 Nut 1 4 Damper adjusting rod 1 5 Spacer 1 6 Washer 1 7 Fork spring 1 8 Dust seal 1 9 Oil seal clip 1 10 Oil seal 1 11 Washer 1 12 Damper rod assembly bolt 1 13 Copper washer 1 14 Damper rod assembly 1 15 Spring 1 16 Oil flow stopper 1 ...

Page 266: ... 1 1 D 52 mm 2 05 in l 12 mm 0 47 in 19 Outer tube bushing 2 1 D 51 mm 2 01 in l 15 mm 0 59 in 20 Inner tube bushing 1 21 Outer tube 1 For assembly reverse the disassembly pro cedure Disassembling the front fork legs Order Job Parts to remove Q ty Remarks ...

Page 267: ...RNING EWA13640 Before loosening the upper and lower brack et pinch bolts support the front fork leg EAS22980 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Hold the nut 1 and loosen the cap bolt 2 2 Drain Fork oil 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 screwdriver...

Page 268: ...assembly bolt 6 Remove Inner tube a Hold the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft jaws c Separate the inner tube from the outer tube by pulling the inner tube forcefully but careful ly NOTICE EC3P61027 Excessive force will damage the bushings Damaged bushings must be replaced Avoid bottoming the inner tube into the out er tube during the above ...

Page 269: ...a loss of stability TIP When assembling the front fork leg be sure to replace the following parts Inner tube bushing Outer tube bushing 1 Outer tube bushing 2 Oil seal Dust seal Before assembling the front fork leg make sure all of the components are clean 1 Install Inner tube bushing 1 Oil flow stopper 2 Spring Damper rod assembly 3 NOTICE EC3P61028 Allow the damper rod assembly to slide slowly d...

Page 270: ...20 Make sure the numbered side of the oil seal faces up TIP Before installing the oil seal lubricate its lips with lithium soap based grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation Slide metal installer 90890 01508 YM 01508 Fork seal driver 90890 015...

Page 271: ...eg do not allow any foreign ma terial to enter the front fork 11 After filling the front fork leg slowly stroke the damper rod assembly 1 up and down at least ten times to distribute the fork oil TIP Be sure to stroke the damper rod assembly slowly because the fork oil may spurt out 12 Slowly stroke the inner tube 1 up and down 13 Before measuring the fork oil level wait ten minutes until the oil ...

Page 272: ...nstall the damper adjusting rod 2 c Install the cap bolt 3 and finger tighten it WARNING EWA13670 Always use a new cap bolt O ring d Hold the cap bolt and tighten the nut 1 to specification 17 Install Cap bolt to the outer tube TIP Temporarily tighten the cap bolt EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg Tempora...

Page 273: ... bolt 3 WARNING EWA13680 Make sure the brake hoses are routed prop erly 3 Adjust Spring preload Rebound damping Compression damping Refer to ADJUSTING THE FRONT FORK LEGS on page 3 36 T R Upper bracket pinch bolt 26 Nm 2 6 m kg 19 ft lb ...

Page 274: ...egs Refer to FRONT FORK on page 4 79 1 Main switch coupler 2 Disconnect 2 Lower bracket cover 1 3 Brake hose joint bracket bolt 2 4 Steering stem nut 1 5 Upper bracket 1 6 Handlebar bracket 1 7 Lock washer 1 8 Upper ring nut 1 9 Rubber washer 1 10 Lower ring nut 1 11 Lower bracket 1 T R 115 Nm 11 5 m kg 85 ft lb T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 18 Nm 1 8 m kg 13 ft Ib LS LS T R 7 Nm 0 7 m kg 5 ...

Page 275: ...e 1 18 Upper bearing outer race 1 19 Lower bearing outer race 1 For installation reverse the removal proce dure Removing the lower bracket Order Job Parts to remove Q ty Remarks T R 115 Nm 11 5 m kg 85 ft lb T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 18 Nm 1 8 m kg 13 ft Ib LS LS T R 7 Nm 0 7 m kg 5 1 ft Ib 11 4 5 16 17 15 3 2 6 19 18 14 13 12 10 9 8 7 1 1 LS ...

Page 276: ...es 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 a...

Page 277: ... 3 33 3 Install Upper bracket Steering stem nut TIP Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 79 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 kg 85 ft lb ...

Page 278: ...ect 3 Rear shock absorber spring preload adjusting lever nut 3 4 Rear shock absorber assembly lower nut Wash er Bolt 1 1 1 5 Connecting arm nut Washer Bolt 2 2 2 6 Connecting arm 2 7 Rear shock absorber assembly upper nut Bolt Spacer 1 1 1 8 Rear shock absorber assembly 1 9 Centerstand 1 10 Relay arm nut Bolt Spacer 1 1 1 New New New New T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R ...

Page 279: ...l proce dure Removing the rear shock absorber assembly Order Job Parts to remove Q ty Remarks New New New New T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib 5 T R 64 Nm 6 4 m kg 46 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib 7 7 10 3 10 1 2 LS LS 8 13 15 12 17 15 15 15 5 6 1616 1514 17 11 5 5 6 15 4 4 9 LS T R 55 Nm 5 5 m kg 40 ft Ib ...

Page 280: ...gh the rear shock absorber at a point 15 20 mm 0 59 0 79 in from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23230 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on a suitable stand so...

Page 281: ...e 3 Check Spacers Damage scratches Replace EAS23270 INSTALLING THE RELAY ARM 1 Lubricate Spacer Bearings 2 Install Bearing 1 2 to the relay arm 3 Install Relay arm TIP Make sure that the embossed mark 5JW on the relay arm faces to the left EAS23310 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Install Rear shock absorber assembly TIP Make sure that the warning label on the rear shock absorber asse...

Page 282: ... on page 4 101 1 Right footrest bracket bolt 2 2 Pivot shaft end cover 1 3 Pivot shaft locknut retainer 1 4 Pivot shaft nut 1 5 Pivot shaft locknut 1 6 Pivot shaft 1 7 Swingarm 1 8 Spacer 1 9 Oil seal 2 10 Bearing 2 11 Collar 1 12 Oil seal 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 125 Nm 12 5 m kg 90 ft lb T R 115 Nm 11 5...

Page 283: ...al proce dure Removing the swingarm Order Job Parts to remove Q ty Remarks T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 125 Nm 12 5 m kg 90 ft lb T R 115 Nm 11 5 m kg 85 ft lb New LS LS LS New LS New 3 5 6 1 4 2 LS 1 17 16 15 12 11 10 8 9 18 14 13 9 10 7 ...

Page 284: ...s not smooth or if there is binding check the spacers bear ings washers and dust covers EAS23360 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 3 Wash Pivot shaft Spacers Washer Bearings Collar 4 Check Spacers Washer Collar Oil seals Damage w...

Page 285: ...shaft locknut Pivot shaft nut 3 Swingarm 4 Connecting arm A Left side B Right side T R Pivot shaft 23 Nm 2 3 m kg 17 ft lb T R Pivot shaft locknut 115 Nm 11 5 m kg 85 ft lb T R Pivot shaft nut 125 Nm 12 5 m kg 90 ft lb 1 3 a A 3 2 b 2 A B b 4 4 ...

Page 286: ... the final drive assembly Order Job Parts to remove Q ty Remarks Final gear oil Drain Refer to CHANGING THE ENGINE OIL on page 3 15 Rear wheel Refer to REAR WHEEL on page 4 25 1 Final drive assembly 1 For installation reverse the removal proce dure ...

Page 287: ...FJR13AE Refer to SHIFT ACTUATOR AND SHIFT ROD FJR13AE only on page 5 73 1 Shift arm 1 FJR13A 2 Left footrest assembly 1 FJR13A 3 Sidestand switch coupler 1 FJR13A Disconnect 4 Sidestand 1 FJR13A 5 Drive shaft dust cover 1 6 Universal joint dust cover 1 7 Universal joint 1 For installation reverse the removal proce dure ...

Page 288: ...l seal 1 3 Drive shaft 1 4 Spring 1 5 Ring gear bearing housing 1 6 Dust cover 1 7 Oil seal 1 8 Stopper bolt 1 Left hand threads 9 Stopper bolt shim s 10 Ring gear shim s 11 Ring gear 1 12 Bearing 1 13 Thrust washer 1 14 Coupling gear nut 1 15 Coupling gear 1 16 Bearing retainer 1 Left hand threads 17 Oil seal 1 ...

Page 289: ...on gear 1 19 Bearing 1 20 Final drive pinion gear shim s 21 Final drive pinion gear bearing 1 22 Ring gear bearing 1 23 Oil seal 1 24 Collar 1 25 Final gear case 1 For assembly reverse the disassembly pro cedure Disassembling the final drive assembly Order Job Parts to remove Q ty Remarks ...

Page 290: ...roken gear teeth WARNING EWA13790 Stop riding immediately if broken gear teeth are suspected This condition could result in the shaft drive assembly locking up causing a loss of control and possible injury to the rider Troubleshooting chart When causes A or B shown in the table at the beginning of the TROUBLESHOOTING section ex ist check the following points YES NO Symptom Possible cause 1 A prono...

Page 291: ... a new or fairly new vehicle may result from the applica tion of a rust preventive coating or excessive seal lubrication Always clean the vehicle and recheck the area where the leak is thought to originate from EAS23580 MEASURING THE FINAL GEAR BACKLASH 1 Secure the final drive assembly in a vise 2 Remove Final gear oil drain bolt 3 Drain Final gear oil from the final drive assembly 4 Measure Fina...

Page 292: ...h band and dial gauge i Repeat steps d to h three more times for a total of four measurements j If any of the readings are over specification adjust the final gear backlash EAS23590 ADJUSTING THE FINAL GEAR BACKLASH 1 Remove Ring gear bearing housing bolts 1 Ring gear bearing housing nuts 2 TIP Working in a crisscross pattern loosen each bolt and nut 1 4 of a turn After all of the bolts and nuts a...

Page 293: ... THE FINAL GEAR BACKLASH on page 4 107 2 Measure Ring gear to stopper bolt clearance a Out of specification Adjust 3 Install Ring gear bearing housing along with the ring gear EAS23610 ADJUSTING THE RING GEAR TO STOPPER BOLT CLEARANCE 1 Remove Ring gear 1 Stopper bolt 2 Stopper bolt shim s 3 Ring gear bearing housing 4 2 Select Stopper bolt shim s 3 Install Ring gear bearing housing 1 Stopper bolt...

Page 294: ...ly loosened remove them 2 Remove Coupling gear nut Coupling gear 1 with the coupling gear middle shaft tool 2 3 Remove Bearing retainer with the bearing retainer wrench 1 NOTICE ECA14330 The bearing retainer has left hand threads To loosen the bearing retainer turn it clock wise 4 Remove Final drive pinion gear WARNING EWA13800 Always use new bearings NOTICE ECA14340 The final drive pinion gear sh...

Page 295: ...earing outer races with a socket or appropriate tool that matches the diameter of the races c Install the inner race onto the final drive pin ion gear 5 Install Collar 1 Oil seal 2 Bearing 3 with an appropriate press tool 4 and press TIP The bearing can be reused but Yamaha recom mends installing a new one EAS23640 ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR TIP Aligning the final drive pin...

Page 296: ...r shim thickness is 0 51 mm The chart instructs you to round off the 1 to 0 Thus you should use a 0 50 mm final drive pinion gear shim c To find ring gear shim thickness B use the following formula Where c a numeral on the final gear case to be di vided by 100 and added to 45 d a numeral usually on the surface of the ring gear bearing housing to be divided by 100 and added to 3 e a numeral positiv...

Page 297: ...lculated Final drive pinion gear Bearing retainer with the bearing 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 Ring gear bearing thickness 13 00 mm 0 51 in B 45 51 100 3 35 100 35 40 5 100 13 45 0 51 3 0 35 35 40 0 05 13 4...

Page 298: ...nce with Plastigauge d Remove the ring gear bearing housing e Measure the width of the flattened Plasti gauge 1 f If the ring gear to thrust washer clearance is within specification install the ring gear bear ing housing along with the ring gear g If the ring gear to thrust washer clearance is out of specification select the correct thrust washer as follows h Select the suitable thrust washer from...

Page 299: ...er weight 3 and oil seal installing tool 4 6 Install Universal joint Final drive assembly TIP Align the drive shaft splines with the driven yoke of the universal joint 7 Tighten Final drive assembly nuts 8 Install Sidestand Left footrest assembly Recommended lubricant Molybdenum disulfide grease Recommended lubricant Lithium soap based grease Fork seal driver weight 90890 01184 Replacement hammer ...

Page 300: ...Y FJR13AE 1 Lubricate Drive shaft spline final drive pinion gear side 2 Lubricate Drive shaft spline universal joint side 3 Install Oil seal 1 Washer 2 with the fork seal driver weight 3 and fork seal driver attachment 4 4 Install Circlip 5 Install Drive shaft 1 to the final drive pinion gear Oil seal 2 to the final gear case with the fork seal driver weight 3 and oil seal installing tool 4 T R Le...

Page 301: ...sembly Refer to SHIFT ACTUATOR AND SHIFT ROD FJR13AE only on page 5 73 9 Install Rear wheel Refer to REAR WHEEL on page 4 25 10 Fill Final gear case Refer to CHECKING THE FINAL GEAR OIL LEVEL on page 3 33 Fork seal driver weight 90890 01184 Replacement hammer YM A9409 7 Oil seal installing tool 90890 01512 YM 01512 Installed depth a 8 5 10 0 mm 0 33 0 39 in T R Final gear case nut 42 Nm 4 2 m kg 3...

Page 302: ...SHAFT DRIVE 4 117 ...

Page 303: ...LINDER HEAD 5 22 REMOVING THE CYLINDER HEAD 5 23 CHECKING THE CYLINDER HEAD 5 23 INSTALLING THE CYLINDER HEAD 5 23 VALVES AND VALVE SPRINGS 5 25 REMOVING THE VALVES 5 26 CHECKING THE VALVES AND VALVE GUIDES 5 26 CHECKING THE VALVE SEATS 5 28 CHECKING THE VALVE SPRINGS 5 30 CHECKING THE VALVE LIFTERS 5 30 INSTALLING THE VALVES 5 30 GENERATOR AND STARTER CLUTCH 5 33 REMOVING THE GENERATOR 5 36 REMOV...

Page 304: ... FJR13AE 5 69 REPLACING THE CLUTCH MASTER CYLINDER FJR13AE only 5 69 INSTALLING THE CLUTCH ACTUATOR FJR13AE only 5 70 REMOVING THE CLUTCH RELEASE CYLINDER 5 71 CHECKING THE CLUTCH RELEASE CYLINDER 5 71 ASSEMBLING THE CLUTCH RELEASE CYLINDER 5 71 INSTALLING THE CLUTCH RELEASE CYLINDER 5 71 SHIFT ACTUATOR AND SHIFT ROD FJR13AE only 5 73 REMOVING THE SHIFT ACTUATOR 5 75 CHECKING THE SHIFT ROD 5 75 IN...

Page 305: ...BEARINGS AND OIL SEAL 5 107 CHECKING THE TIMING CHAIN AND OIL PUMP DRIVE CHAIN 5 107 ASSEMBLING THE CRANKCASE 5 108 CONNECTING RODS AND PISTONS 5 111 REMOVING THE CONNECTING RODS AND PISTONS 5 112 CHECKING THE CYLINDERS AND PISTONS 5 112 CHECKING THE PISTON RINGS 5 113 CHECKING THE PISTON PIN 5 114 CHECKING THE CONNECTING RODS 5 115 INSTALLING THE CONNECTING RODS AND PISTONS 5 116 CRANKSHAFT 5 120...

Page 306: ...nt Drain Refer to CHANGING THE COOLANT on page 3 25 Radiator Refer to RADIATOR on page 6 1 1 O2 sensor coupler 1 Disconnect 2 O2 sensor 1 3 Left muffler 1 4 Right muffler 1 5 Exhaust pipe assembly 1 6 Gasket 4 For installation reverse the removal proce dure T R 20 Nm 2 0 m kg 14 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib 5...

Page 307: ...e 7 11 Thermostat Thermostat inlet pipe 1 Refer to THERMOSTAT on page 6 6 Engine oil Oil filter cartridge Drain Refer to CHANGING THE ENGINE OIL on page 3 15 Oil cooler Refer to OIL COOLER on page 6 4 Water pump Refer to WATER PUMP on page 6 10 Starter motor Refer to ELECTRIC STARTER on page 5 42 Left footrest assembly Sidestand Refer to SHAFT DRIVE on page 4 101 1 Clutch release cylinder 1 2 Dowe...

Page 308: ... coupler 1 Disconnect 7 Gear position switch coupler 1 Disconnect 8 Ground lead 1 Disconnect 9 Spark plug cap 4 For installation reverse the removal proce dure Disconnecting the leads and hoses FJR13A Order Job Parts to remove Q ty Remarks 9 2 2 1 3 5 6 7 4 8 T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 309: ...on page 6 6 Engine oil Oil filter cartridge Drain Refer to CHANGING THE ENGINE OIL on page 3 15 Oil cooler Refer to OIL COOLER on page 6 4 Water pump Refer to WATER PUMP on page 6 10 Starter motor Refer to ELECTRIC STARTER on page 5 42 Left footrest assembly Sidestand Refer to SHIFT ACTUATOR AND SHIFT ROD FJR13AE only on page 5 73 Gear position sensor cover Refer to SHIFT ACTUATOR AND SHIFT ROD FJ...

Page 310: ...ition sensor coupler 1 Disconnect 9 Neutral switch coupler 1 Disconnect 10 YCC S speed sensor coupler 1 Disconnect 11 Ground lead 1 Disconnect 12 Spark plug cap 4 For installation reverse the removal proce dure Disconnecting the leads and hoses FJR13AE Order Job Parts to remove Q ty Remarks R 10 Nm 1 0 m kg 7 2 ft Ib LT LT T R 4 Nm 0 4 m kg 2 9 ft Ib 12 10 4 4 3 1 2 5 8 7 6 11 9 ...

Page 311: ... 1 11 Spacer 2 12 Engine mounting bolt right front upper side 1 13 Engine mounting bolt left front lower side 1 14 Engine mounting bolt left front upper side 1 15 Engine mounting nut rear upper side 1 T R 32 Nm 3 2 m kg 23 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 37 Nm 3 7 m kg 27 ft Ib T R 37 Nm 3 7 m kg 27 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R...

Page 312: ...e Q ty Remarks T R 32 Nm 3 2 m kg 23 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 37 Nm 3 7 m kg 27 ft Ib T R 37 Nm 3 7 m kg 27 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 49 Nm 4 9 m kg 35 ft Ib T R 49 Nm 4 9 m kg 35 ft Ib T R 49 Nm 4 9 m kg 35 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib E E 9 9 15 11 1 11 12...

Page 313: ...ft wrench 1 and pivot shaft wrench adapter 2 2 Remove Engine TIP Make sure that the engine does not strike the clutch actuator 1 when removing it EAS23720 INSTALLING THE ENGINE 1 Install Engine TIP When mounting the engine to the frame be sure to align the splines on the middle driven shaft with the splines on the universal joint 2 Install Spacer bolt 1 Engine mounting bolt rear upper side 2 Space...

Page 314: ...t rear upper side threads with engine oil 7 Tighten Engine mounting bolt left front lower side 6 Engine mounting bolt right front upper side 8 Engine mounting bolt right front lower side 9 8 Install Engine mounting bolts top 15 9 Tighten Pinch bolts front side 10 10 Tighten Pinch bolts rear side 11 T R Engine mounting bolt left front upper side 49 Nm 4 9 m kg 35 ft lb T R Engine mounting bolt rear...

Page 315: ...olt left rear side 2 Engine mounting bolts left rear side 3 TIP Do not fully tighten the bolts 14 Tighten Engine bracket bolt left rear side 2 15 Tighten Engine mounting bolts left rear side 3 16 Install Brake pedal 1 TIP Align the punch mark a on the brake pedal with the punch mark b on the brake pedal pivot shaft T R Pinch bolt rear side 24 Nm 2 4 m kg 17 ft lb T R Engine mounting bolt top 37 Nm...

Page 316: ...R FJR13AE only 1 Check Gear position sensor Refer to CHECKING THE GEAR POSITION SENSOR FJR13AE only on page 8 244 2 Adjust Gear position sensor angle a Connect the gear position sensor coupler to the gear position sensor b Connect the digital circuit tester to the gear position sensor c Turn the main switch to ON d Measure the gear position sensor voltage e Adjust the gear position sensor angle so...

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

Page 318: ...Air cut off valve Reed valves Refer to AIR INDUCTION SYSTEM on page 7 11 1 Spark plug 4 2 Cylinder identification sensor 1 3 Cylinder head cover 1 4 Cylinder head cover gasket 1 5 Dowel pin 4 6 Timing chain guide upper side 1 For installation reverse the removal proce dure 1 New New 4 5 5 5 2 8 LT LS 6 3 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib ...

Page 319: ...CKUP ROTOR on page 5 39 1 Timing chain tensioner 1 2 Timing chain tensioner gasket 1 3 Intake camshaft cap 4 4 Exhaust camshaft cap 4 5 Intake camshaft 1 6 Exhaust camshaft 1 7 Intake camshaft sprocket 1 8 Exhaust camshaft sprocket 1 9 Timing chain guide exhaust side 1 10 Pin 1 11 Timing chain guide intake side 1 For installation reverse the removal proce dure ...

Page 320: ...er 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 p...

Page 321: ...haft into the cylinder head without the dowel pins and camshaft caps b Position a strip of Plastigauge 1 onto the camshaft journal as shown c Install the dowel pins and camshaft caps Camshaft lobe dimensions Intake A 33 050 33 150 mm 1 3012 1 3051 in Limit 32 050 mm 1 2618 in Intake B 24 997 25 097 mm 0 9841 0 9881 in Limit 23 997 mm 0 9448 in Exhaust A 33 050 33 150 mm 1 3012 1 3051 in Limit 32 9...

Page 322: ...heck Timing chain guide exhaust side Timing chain guide intake side Timing chain guide upper side Damage wear Replace the defective part s EAS23970 CHECKING THE TIMING CHAIN TENSIONER 1 Check Timing chain tensioner Cracks damage rough movement Re place a Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand TIP While pressing the timing chain tensioner rod wi...

Page 323: ...haft 2 Intake camshaft 3 with the camshaft sprockets NOTICE ECA13740 Do not turn the crankshaft when installing the camshaft s to avoid damage or improper valve timing a Install the timing chain onto both camshaft sprockets and then install the camshafts 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...

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

Page 325: ...ation steps above 9 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 6 10 Install Cylinder head cover gasket Cylinder head cover TIP Apply Three Bond 1514 1 onto the mating surfaces of the cylinder head cover and cylin der head cover gasket Apply Yamaha bond No 1215 2 onto the mat ing surfaces of the cylinder head cover gasket and cylinder head ...

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

Page 327: ...OVAL on page 5 1 Camshafts Refer to CAMSHAFTS on page 5 13 1 Cylinder head 1 2 Cylinder head gasket 1 3 Dowel pin 2 For installation reverse the removal proce dure T R 12 Nm 1 2 m kg 8 7 ft Ib T R 1st 25 Nm 2 5 m kg 18 ft lb 2nd 25 Nm 2 5 m kg 18 ft lb Final Specified angle 175 185 T R 15 Nm 1 5 m kg 11 ft Ib New New 3 3 2 New 1 10 E ...

Page 328: ... 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 EAS24240 INSTALLING THE CYLINDER HEAD 1 Install Cylinder head TIP Pass the timing chain through the timing chain cavity 2 Tighten Cylinde...

Page 329: ...new one and perform the procedure again NOTICE EC3P61033 Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angle 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 kg 18 ft lb T R Cylinder ...

Page 330: ...inder head Refer to CYLINDER HEAD on page 5 22 1 Valve lifter 16 2 Valve pad 16 3 Valve cotter 32 4 Upper spring seat 16 5 Intake valve spring 8 6 Exhaust valve spring 8 7 Intake valve 8 8 Exhaust valve 8 9 Valve stem seal 16 10 Lower spring seat 16 11 Intake valve guide 8 12 Exhaust valve guide 8 For installation reverse the removal proce dure ...

Page 331: ...5 28 a Pour 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 ...

Page 332: ...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 333: ...es to all of the valves and valve seats 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width C a Out of specification Replace the cylinder head a Apply Mechanic s blueing dye Dykem b onto the valve face Valve guide remover ø5 90890 04097 Valve guide remover 5 0 mm YM 04097 Valve guide installer ø5 90890 ...

Page 334: ...enum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound TIP For the best lapping results lightly tap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f Aft...

Page 335: ...age scratches Replace the valve lift ers and cylinder head EAS24340 INSTALLING THE VALVES The following procedure applies to all of the valves and related components 1 Deburr Valve stem end with an oil stone Free length intake 39 73 mm 1 56 in Limit 37 74 mm 1 49 in Free length exhaust 39 73 mm 1 56 in Limit 37 74 mm 1 49 in Installed compression spring force intake 136 00 158 00 N 30 57 35 52 lb ...

Page 336: ...is installed in its original place Install the valve springs with the larger pitch a facing up 5 Install Valve cotters TIP Install the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 Recommended lubricant Molybdenum disulfide oil Recommended lubricant Engine oil New b Smaller pitch Valve spring compressor 90890 04019 YM ...

Page 337: ...A13800 Hitting the valve tip with excessive force could damage the valve 7 Lubricate Valve lifter with the recommended lubricant 8 Install Valve pad Valve lifter 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 Recommended lubricant Engine oil ...

Page 338: ...k Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 15 1 Stator coil coupler 1 Disconnect 2 Generator cover 1 3 Generator cover gasket 1 4 Dowel pin 2 5 Starter clutch idle gear shaft 1 6 Starter clutch idle gear 1 7 Generator rotor 1 8 Woodruff key 1 9 Starter clutch gear 1 ...

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

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

Page 341: ... CLUTCH 1 Remove Starter clutch bolts 1 TIP While holding the generator rotor with the sheave holder remove the starter clutch bolts EAS24570 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 ...

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

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

Page 344: ...ator cover Refer to GENERATOR AND STARTER CLUTCH on page 5 33 1 Pickup rotor cover 1 2 Pickup rotor cover gasket 1 3 Dowel pin 2 4 Crankshaft position sensor coupler 1 Disconnect 5 Crankshaft position sensor 1 6 Pickup rotor 1 For installation reverse the removal proce dure LT New New 2 1 6 3 3 5 4 LT 6 LS T R 4 Nm 0 4 m kg 2 9 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 15 Nm 1 5 m kg 11 ft Ib T R 45 ...

Page 345: ...ckup 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 sheave holder 3 tighten the pickup rotor bolt 3 Apply Sealant onto the crankshaft position sensor lead grommet Sheave holder 90890 01701 Primary clutch holder YS 01880 A 1 2 3 T R Pickup rotor bolt 45 Nm 4 5 m kg 32 ft lb ...

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

Page 347: ...IC STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks Throttle bodies Refer to THROTTLE BODIES on page 7 5 1 Starter motor lead 1 Disconnect 2 Starter motor assembly 1 For installation reverse the removal proce dure ...

Page 348: ...arks 1 O ring 1 2 Starter motor front cover 1 3 Brush 2 4 Brush seat along with brushes 1 5 Washer 1 6 Lock washer 1 7 Oil seal 1 8 Bearing 1 9 Starter motor rear cover 1 10 Collar 1 11 O ring 2 12 Starter motor yoke 1 13 Armature assembly 1 For assembly reverse the disassembly pro cedure ...

Page 349: ... commutator and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Limit 23 5 mm 0 93 in Mica u...

Page 350: ... 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 351: ...AL CHASSIS on page 4 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 15 1 Clutch cover 1 2 Clutch cover gasket 1 3 Dowel pin 2 4 Damper cover 1 5 Damper 1 For installation reverse the removal proce dure LT 3 4 5 2 1 10 5 3 New T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib ...

Page 352: ... push rod 1 7 Ball 1 8 Long clutch push rod 1 9 Friction plate 1 1 Inside diameter 124 mm 4 88 in 10 Clutch plate 7 11 Friction plate 2 7 Inside diameter 124 mm 4 88 in 12 Lock washer 1 13 Wire circlip 1 14 Clutch plate 1 15 Friction plate 3 1 Inside diameter 135 mm 5 31 in 16 Clutch damper spring 1 21 20 19 18 17 16 15 14 13 12 1110 9 8 7 6 5 4 3 2 1 6 New New New LT T R 90 Nm 9 0 m kg 65 ft Ib T...

Page 353: ...Clutch housing 1 For installation reverse the removal proce dure Removing the clutch FJR13A Order Job Parts to remove Q ty Remarks 21 20 19 18 17 16 15 14 13 12 1110 9 8 7 6 5 4 3 2 1 6 New New New LT T R 90 Nm 9 0 m kg 65 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib E 9 15 11 ...

Page 354: ... push rod 1 7 Ball 1 8 Long clutch push rod 1 9 Friction plate 1 1 Inside diameter 124 mm 4 88 in 10 Clutch plate 8 11 Friction plate 2 7 Inside diameter 124 mm 4 88 in 12 Friction plate 3 1 Inside diameter 135 mm 5 31 in 13 Clutch damper spring 1 14 Clutch damper spring seat 1 15 Lock washer 1 16 Clutch boss 1 19 18 17 16 14 15 12 1110 9 8 7 6 5 4 3 2 1 13 6 New New LT T R 90 Nm 9 0 m kg 65 ft Ib...

Page 355: ...r installation reverse the removal proce dure Removing the clutch FJR13AE Order Job Parts to remove Q ty Remarks 19 18 17 16 14 15 12 1110 9 8 7 6 5 4 3 2 1 13 6 New New LT T R 90 Nm 9 0 m kg 65 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib E 9 12 11 ...

Page 356: ...page 3 18 1 Clutch master cylinder reservoir cap 1 2 Clutch master cylinder reservoir diaphragm holder 1 3 Clutch master cylinder reservoir diaphragm 1 4 Clutch lever 1 5 Clutch master cylinder push rod pin 1 6 Clutch switch coupler 1 Disconnect 7 Clutch hose union bolt 1 8 Copper washer 2 9 Clutch hose 1 Disconnect 10 Clutch switch 1 11 Clutch master cylinder holder 1 ...

Page 357: ...CLUTCH 5 52 12 Clutch master cylinder 1 For installation reverse the removal proce dure Removing the clutch master cylinder FJR13A Order Job Parts to remove Q ty Remarks ...

Page 358: ...ect 3 Clutch actuator sensor coupler 1 Disconnect 4 Clutch actuator bracket 1 5 Clutch fluid reservoir cap 1 6 Clutch fluid reservoir diaphragm holder 1 7 Clutch fluid reservoir diaphragm 1 8 Clutch fluid reservoir 1 9 Clutch fluid reservoir hose 1 10 Clutch hose union bolt 1 11 Copper washer 2 12 Clutch hose 1 Disconnect 13 Clutch master cylinder 1 T R 19 Nm 1 9 m kg 13 ft Ib T R 10 Nm 1 0 m kg 7...

Page 359: ...emoving the clutch actuator and clutch master cylinder FJR13AE Order Job Parts to remove Q ty Remarks T R 19 Nm 1 9 m kg 13 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib New T R 7 Nm 0 7 m kg 5 1 ft Ib 1 2 4 5 7 6 8 9 10 11 12 13 3 14 LS ...

Page 360: ...ter cylinder FJR13A Order Job Parts to remove Q ty Remarks 1 Clutch master cylinder push rod 1 2 Dust boot 1 3 Circlip 1 4 Washer 1 5 Clutch master cylinder kit 1 6 Clutch master cylinder body 1 For assembly reverse the disassembly pro cedure ...

Page 361: ...2 This kit part is used for all models after 2009 Disassembling the clutch master cylinder FJR13AE Order Job Parts to remove Q ty Remarks 1 Clutch master cylinder kit 1 2 Clutch master cylinder body 1 For assembly reverse the disassembly pro cedure S 1 2 1 1 New 2 LS ...

Page 362: ...remove Q ty Remarks Clutch fluid Drain Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM FJR13A on page 3 18 1 Clutch hose union bolt 1 2 Copper washer 2 3 Clutch hose 1 Disconnect 4 Clutch release cylinder 1 5 Dowel pin 2 6 Plate 1 For installation reverse the removal proce dure ...

Page 363: ...remove Q ty Remarks Clutch fluid Drain Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM FJR13AE on page 3 19 1 Clutch hose union bolt 1 2 Copper washer 2 3 Clutch hose 1 Disconnect 4 Clutch release cylinder 1 5 Dowel pin 2 6 Plate 1 For installation reverse the removal proce dure ...

Page 364: ... remove Q ty Remarks 1 Clutch release cylinder piston 1 2 Clutch release cylinder spring 1 3 Clutch release cylinder piston seal 1 4 Bleed screw 1 5 Clutch release cylinder body 1 For assembly reverse the disassembly pro cedure 5 2 3 1 4 New S S T R 6 Nm 0 6 m kg 4 3 ft Ib ...

Page 365: ...boss nut 6 Remove Clutch boss nut 1 Washer 2 Clutch boss assembly 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 7 Remove Spacer 1 Clutch housing TIP Insert a cross headed screwdriver into one of the holes of the clutch housing and primary dr...

Page 366: ...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 Insert two 5 mm bolts 2 into the spacer and then remove the spacer by pulling on the bolts EAS25100 CHECKING THE FRICTION PLATES The following procedure...

Page 367: ...CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing TIP Pitting on the clutch housing dogs will cause er ratic clutch operation 2 Check Bearing Damage wear Replace the bearing and clutch housing EAS25160 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss TIP Pitting on...

Page 368: ...operation Replace the clutch housing and crankshaft as a set EAS25250 INSTALLING THE CLUTCH FJR13A 1 Install Clutch housing 1 TIP Make sure that the projections a in the clutch housing align with the slots b in the oil pump drive sprocket Make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly Insert a cross headed screwdriver into one of the holes of the clutch ho...

Page 369: ...tes TIP First install a friction plate and then alternate be tween a clutch plate and a friction plate 8 Install Clutch spring bolts TIP Tighten the clutch spring bolts in stages and in a crisscross pattern 9 Install Rear balancer weight Refer to BALANCERS on page 5 136 10 Install Clutch cover TIP Tighten the clutch cover bolts in the proper tight ening sequence as shown EAS3P6N002 INSTALLING THE ...

Page 370: ...h boss nut 3 TIP Install the clutch boss nut with its large inner di ameter side facing inward as shown in the illus tration While holding the clutch boss with the univer sal clutch holder 4 tighten the clutch boss nut 4 Bend the lock washer tab along a flat side of the nut 5 Install Clutch damper spring seat 1 Clutch damper spring 2 TIP Install the clutch damper spring seat with the white paint m...

Page 371: ...the transmission into 1st gear d Turn the throttle grip to 1 4 a of the fully open position ten times each time for less than 0 5 second TIP It is not unusual for the engine to stall when per forming this procedure If the engine stalls re start the engine let it idle for at least 90 seconds and then repeat steps b to d EAS25280 DISASSEMBLING THE CLUTCH MASTER CYLINDER NOTICE ECA13840 Clutch compon...

Page 372: ... clutch master cylinder body Obstruction Blow out with compressed air 2 Check Clutch master cylinder Clutch master cylinder kit Rust scratches wear Replace the clutch master cylinder and clutch master cylinder kit as a set 3 Check Clutch master cylinder reservoir Cracks damage Replace Clutch master cylinder reservoir diaphragm Damage wear Replace 4 Check Clutch hose Cracks damage wear Replace EAS2...

Page 373: ...nated clutch fluid Other clutch fluids 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 fluid reservoir Water will significantly...

Page 374: ...akage 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 fluid reservoir Water will significantly lower the boiling point of the clutch fluid and could cause vapor lock NOTICE ECA13420 Clu...

Page 375: ... FJR13AE on page 3 19 4 Adjust Clutch engagement point Refer to Diagnostic code table Diagnostic code No Sh_ _66 TIP Adjust the clutch engagement point if the clutch actuator was replaced a Select diagnostic code No Sh_ _66 in the di agnostic mode and operate the hand shift le ver switch shift up until the clutch engagement point is at the maximum setting TIP The hand shift select indicator light ...

Page 376: ...lutch com ponents must be cleaned and lubricated with clean or new clutch fluid Never use solvents on internal clutch com ponents as they will cause the piston seal to swell and distort Whenever a clutch release cylinder is dis assembled replace the piston seal EAS25350 INSTALLING THE CLUTCH RELEASE CYLINDER 1 Check Copper washers 1 Clutch hose 2 Clutch hose union bolt 3 WARNING EW3P66003 Proper c...

Page 377: ...ces or plastic parts Therefore always clean up any spilt clutch fluid immediately TIP In order to ensure a correct reading of the clutch fluid level make sure that the top of the reservoir is horizontal 3 Bleed Clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM FJR13A on page 3 18 and BLEEDING THE HYDRAULIC CLUTCH SYSTEM FJR13AE on page 3 19 4 Check Clutch fluid level Below the minimum le...

Page 378: ...r motor coupler 1 Disconnect 5 Shift actuator 1 6 Sidestand switch coupler 1 Disconnect 7 Left footrest assembly 1 8 Sidestand 1 9 Foot shift switch coupler 1 Disconnect 10 Foot shift switch 1 11 Holder 1 12 Shift pedal pivot bolt 1 13 Shift pedal pivot 1 14 Wave washer 1 LT LT T R 65 Nm 6 5 m kg 47 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 N...

Page 379: ...ator shift rod and foot shift switch Order Job Parts to remove Q ty Remarks LT LT T R 65 Nm 6 5 m kg 47 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib LS LS T R 49 Nm 4 9 m kg 35 ft Ib LT LT LT LT LT LT LS 2 1 6 8 17 18 16 19 7 12 15 14 13 5 4 3 10 11 9 ...

Page 380: ...he shift actuator sensor coupler and shift actuator motor coupler e Remove the shift actuator front bolt 4 and then remove the rear bolt 5 f Remove the shift actuator ET2D21008 CHECKING THE SHIFT ROD 1 Check Shift rod operation Rough movement Replace 2 Check Shift rod groove Groove and end of rod cover are not aligned Replace 3 Check Shift rod Bends Replace ET3P66039 INSTALLING THE FOOT SHIFT SWIT...

Page 381: ... page 5 76 ET3P66040 ADJUSTING THE FOOT SHIFT SWITCH 1 Check Foot shift switch Refer to CHECKING THE FOOT SHIFT SWITCH FJR13AE only on page 8 245 2 Adjust Foot shift switch angle a Connect the foot shift switch coupler to the foot shift switch b Connect the digital circuit tester to the foot shift switch coupler c Turn the main switch to ON d Measure the foot shift switch voltage e Adjust the foot...

Page 382: ...oles in the rear shift arm and shift actuator to secure the shift rod e Install the shift rod 4 TIP Check that the hole a in the shift rod is aligned with the hole b in the front shift arm If the holes are not aligned loosen the shift rod rear locknut 5 and front locknut 6 and then turn the shift rod to adjust its length f Tighten the shift rod bolts to specification g If the shift rod front lockn...

Page 383: ...SHIFT ACTUATOR AND SHIFT ROD FJR13AE only 5 78 h Pull out the rod from the holes T R Shift rod front locknut 7 Nm 0 7 m kg 5 1 ft lb Shift rod rear locknut 10 Nm 1 0 m kg 7 2 ft lb ...

Page 384: ...LUTCH on page 5 46 Shift rod FJR13AE Refer to SHIFT ACTUATOR AND SHIFT ROD FJR13AE only on page 5 73 1 Oil baffle plate 1 1 2 Shift arm 1 3 Circlip 1 4 Shift shaft 1 5 Shift shaft spring 1 6 Spacer 1 7 Stopper lever spring 1 8 Stopper lever 1 9 Circlip 1 10 Collar 1 11 Shift shaft spring stopper 1 For installation reverse the removal proce dure ...

Page 385: ...ss 3 Mesh the stopper lever with the shift drum seg ment assembly 2 Install Shift shaft 1 TIP Hook the end of 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 arm ET3P66043 INSTALLING THE SHIFT SHAFT FJR13AE 1 Install Stopper lever 1 Stopper lever spring 2 TIP Hook the ends of the stopper lev...

Page 386: ...SHIFT SHAFT 5 81 3 Install Front shift arm 1 TIP Align the punch mark a on the front shift arm with the punch mark b on the shift shaft T R Front shift arm bolt 10 Nm 1 0 m kg 7 2 ft lb 2 1 b a 1 ...

Page 387: ...s Refer to THROTTLE BODIES on page 7 5 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 1 Sidestand Refer to SHAFT DRIVE on page 4 101 Water pump Refer to WATER PUMP on page 6 10 1 Oil level switch coupler 1 Disconnect 2 Oil level switch 1 3 Oil pan 1 4 Oil pan gasket 1 5 Dowel pin 2 6 Oil delivery pipe 2 1 7 Oil delivery pipe 3 1 8 Oil strainer 1 9 Dowel pin 2 10 Oil pump 1 ...

Page 388: ...OIL PUMP 5 83 11 Relief valve assembly 1 For installation reverse the removal proce dure Removing the oil pan and oil pump Order Job Parts to remove Q ty Remarks ...

Page 389: ... Order Job Parts to remove Q ty Remarks 1 Oil pump housing cover 1 2 Pin 2 3 Oil pump inner rotor 1 4 Oil pump outer rotor 1 5 Pin 1 6 Washer 1 7 Oil pump driven sprocket 1 8 Oil pump housing 1 For assembly reverse the disassembly pro cedure ...

Page 390: ...and 2 or replace the defective part s EAS24970 CHECKING THE RELIEF VALVE 1 Check Relief valve body 1 Relief valve 2 Spring 3 O ring 4 Damage wear Replace the defective part s EAS24980 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 Less than 0 12 mm 0 0047 in Lim...

Page 391: ...t 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 85 EAS25050 INSTALLING THE OIL PAN 1 Install Oil pan gasket Oil pan TIP Tighten the oil pan bolts in st...

Page 392: ...UMP on page 5 82 1 Middle gear case cover 1 2 Middle gear case cover gasket 1 3 Dowel pin 2 4 Damper cover 1 5 Damper 1 6 Middle drive shaft bearing housing 1 7 Bearing 1 8 Middle driven shaft end cover 1 9 Middle driven shaft assembly 1 10 Middle driven pinion gear shim 11 Middle drive pinion gear nut 1 12 Lock washer 1 13 Middle drive pinion gear 1 14 Middle drive shaft assembly 1 ...

Page 393: ...r 1 16 Middle driven gear 1 17 Bearing retainer 1 18 Bearing 1 19 Middle drive pinion gear shim 20 Bearing 1 For installation reverse the removal proce dure Removing the middle gear FJR13A Order Job Parts to remove Q ty Remarks ...

Page 394: ... 1 Middle gear case cover 1 2 Middle gear case cover gasket 1 3 Dowel pin 2 4 Damper cover 1 5 Damper 1 6 Middle drive shaft bearing housing 1 7 Bearing 1 8 Middle driven shaft end cover 1 9 Middle driven shaft assembly 1 10 Middle driven pinion gear shim 11 Middle drive pinion gear nut 1 12 Lock washer 1 13 Middle drive pinion gear 1 14 Middle drive shaft assembly 1 15 Spacer 1 ...

Page 395: ...Middle driven gear 1 17 Bearing retainer 1 18 Bearing 1 19 Middle drive pinion gear shim 20 Bearing 1 For installation reverse the removal proce dure Removing the middle gear FJR13AE Order Job Parts to remove Q ty Remarks ...

Page 396: ... middle drive shaft assembly Order Job Parts to remove Q ty Remarks 1 Spring retainer 2 2 Spring seat 1 3 Damper spring 1 4 Damper driven cam 1 5 Damper drive cam 1 6 Middle drive shaft 1 For assembly reverse the disassembly pro cedure ...

Page 397: ...ly Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Middle driven pinion gear nut 1 3 Middle driven shaft 1 4 Middle driven pinion gear 1 5 Bearing retainer 1 6 Bearing 1 7 Middle driven shaft bearing housing 1 For assembly reverse the disassembly pro cedure ...

Page 398: ...ve the bearing retainer EAS25750 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 EAS25770 DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1 Remove Middle driven pinion gear nut a Straighten the thread on the middle driven pinion gear nut b Loosen the middle driven pinion gear ...

Page 399: ...5790 CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1 Check Middle driven pinion gear Galling pitting wear Replace 2 Check Bearings Damage pitting Replace EAS25800 ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1 Install Spring retainers 1 TIP While compressing the spring with the damper spring compressor 2 install the spring retain ers EAS25820 ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1 Tighten Bearing...

Page 400: ...ift punch EAS25860 INSTALLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1 Tighten Bearing retainer 1 a Attach the bearing retainer wrench 2 b Tighten the bearing retainer to specification c Lock the threads with a drift punch 2 Install Lock washer 1 T R Bearing retainer 110 Nm 11 0 m kg 80 ft lb T R Middle driven pinion gear nut 110 Nm 11 0 m kg 80 ft lb LOCTITE 1 New Bearing retainer wrench 90890 04137 Mid...

Page 401: ...shaft 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 97 2 Check that the middle gears turns smoothly ET3P61025 INSTALLING THE MIDDLE GEAR CASE COVER 1 Install...

Page 402: ...le driven shaft bearing housing bolts 2 Remove Middle driven pinion gear shim s 3 Tighten Middle driven shaft bearing housing bolts NOTICE ECA14050 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 clearan...

Page 403: ...and the middle driven shaft bear ing housing is 0 42 mm Therefore the chart instructs you to round off the 2 to 0 Thus you should use one 0 40 mm shim Shims are supplied in the following thickness es 8 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 ...

Page 404: ...ed number is 0 51 The chart instructs you to round off the 1 to 0 Thus the shim thickness is 0 50 mm Shims are supplied in the following thickness es c To find middle driven pinion gear shim thick 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 divi...

Page 405: ... the hundredths digit and select the appropriate shim s TIP In the above example the calculated number is 0 51 The chart instructs you to round off the 1 to 0 Thus the shim thickness is 0 50 mm Shims are supplied in the following thickness es Hundredth Rounded value 0 1 2 0 3 4 5 6 7 5 8 9 10 Middle driven pinion gear shim Thickness mm 0 10 0 15 0 20 0 30 0 40 0 50 ...

Page 406: ...y Refer to MIDDLE GEAR on page 5 87 Clutch housing Refer to CLUTCH on page 5 46 1 Timing chain 1 2 Oil pump drive chain guide 1 3 Oil pump drive chain 1 4 Oil pump drive sprocket 1 5 Spacer 1 6 Collar 1 7 Spring washer 1 8 Gear position switch 1 T R 24 Nm 2 4 m kg 17 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 1st 20 Nm 2 0 m kg 14 ft lb 2nd 20 Nm 2 0 m kg 14 ft lb Final Sp...

Page 407: ...move Q ty Remarks T R 24 Nm 2 4 m kg 17 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 1st 20 Nm 2 0 m kg 14 ft lb 2nd 20 Nm 2 0 m kg 14 ft lb Final Specified angle 115 125 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT New LS T R 4 Nm 0 4 m kg 2 9 ft Ib E E E E E E E E LT LT LT 8 10 10 7 6 5 4 1 2 3 10 9 4 10 10 2 2 ...

Page 408: ...ousing Refer to CLUTCH on page 5 46 1 Timing chain 1 2 Oil pump drive chain guide 1 3 Oil pump drive chain 1 4 Oil pump drive sprocket 1 5 Spacer 1 6 Collar 1 7 Spring washer 1 8 Neutral switch 1 9 YCC S speed sensor 1 10 Lower crankcase 1 T R 24 Nm 2 4 m kg 17 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 1st 20 Nm 2 0 m kg 14 ft Ib 2nd 20 Nm 2 0 m kg 14 ft Ib Final Specifie...

Page 409: ...Nm 2 4 m kg 17 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 1st 20 Nm 2 0 m kg 14 ft Ib 2nd 20 Nm 2 0 m kg 14 ft Ib Final Specified angle 115 125 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib E E E E E E E E LT LT LT 11 11 7 6 5 4 1 2 3 11 10 4 10 10 2 2 8 9 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib New LT LT ...

Page 410: ...elivery pipe 1 1 3 Plate 1 4 Oil baffle plate 3 1 5 Bearing 1 6 Oil seal 1 7 Bearing 1 8 Upper crankcase 1 9 Bearing 1 10 Oil filter cartridge bolt 1 11 Upper crankcase damper 1 12 Crankcase plug 1 10 LS LS 2 LT LT LT LT LT LT 4 8 3 LT 5 7 6 12 1 9 13 T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R...

Page 411: ... to remove Q ty Remarks 10 LS LS 2 LT LT LT LT LT LT 4 8 3 LT 5 7 6 12 1 9 13 T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 70 Nm 7 0 m kg 50 ft lb New New New New LS LS New E E T R 12 Nm 1 2 m kg 8 7 ft Ib 11 E T R 20 Nm 2 0 m kg 14 ft Ib 3 ...

Page 412: ...oughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with compressed air EAS25600 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes 1 Check Oil delivery pipe Damage Replace Obstruction Wash and blow ...

Page 413: ...me into contact with the oil gallery or crankshaft journal bear ings Do not apply sealant to within 2 3 mm 0 08 0 12 in of the crankshaft journal bearings 3 Install Dowel pins 4 Set the shift drum assembly and transmission gears in the neutral position 5 Install Lower crankcase 1 onto the upper crankcase 2 Recommended lubricant Engine oil Yamaha bond No 1215 90890 85505 Three Bond No 1215 A Upper ...

Page 414: ...0 21 27 30 M6 45 mm bolt 31 7 Tighten Crankcase bolts M9 115 mm 1 10 WARNING EW3P61013 Replace the bolts with new ones TIP The tightening procedure of crankcase bolts 1 10 is angle controlled therefore tighten the bolts using the following procedure a Tighten the crankcase bolts in the proper tightening sequence as shown b Loosen and retighten the crankcase bolts in the proper tightening sequence ...

Page 415: ...e 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 8 Tighten Crankcase bolts 11 31 TIP Tighten the crankcase bolts in the proper tight ening sequence as shown 9 8 3 6 1 2 5 4 7 10 T R Crankcase bolt 11 12 24 Nm 2 4 m kg 17 ft lb Crankcase bolt 13 14 12 Nm 1 2 m kg 8 7 ft lb Crankcase bolt 15 31 10 Nm 1 ...

Page 416: ...der Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 101 1 Connecting rod cap 4 2 Big end lower bearing 4 3 Piston pin clip 8 4 Piston pin 4 5 Piston 4 6 Connecting rod 4 7 Big end upper bearing 4 8 Top ring 4 9 2nd ring 4 10 Oil ring 4 For installation reverse the removal proce dure ...

Page 417: ...erence during installation put an identi fication mark on each piston crown Before removing the piston pin deburr the pis ton pin clip s groove and the piston s pin bore area If both areas are 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 and ...

Page 418: ...er and replace the piston and piston rings as a set EAS24430 CHECKING THE PISTON RINGS 1 Measure Piston ring side clearance Out of specification Replace the piston and piston rings as a set 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...

Page 419: ... 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 Piston ring Top ring Ring side clearance 0 030 0 070 mm 0 0012 0 0028 in Limit 0 120 mm 0 0047 in 2nd ring Ring side clearance 0 020 0 060 mm 0 0008 0 0024 in Limit 0 120 mm 0 0047 in a 5 mm 0 20 in Pist...

Page 420: ... the big end lower bearing into the connecting rod cap TIP Align the projections a on the big end bearings with the notches b in the connecting rod and connecting rod cap c Put a piece of Plastigauge 1 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 sea...

Page 421: ...on the connecting rods are used to determine the replacement big end bearing sizes P1 P4 refer to the bearings shown in the crank shaft illustration For example if the connecting rod P1 and the crankshaft web P1 numbers are 6 and 1 re spectively then the bearing size for P1 is EAS26170 INSTALLING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the pis tons and connecting ...

Page 422: ...ps 4 Lubricate Piston Piston rings Cylinder with the recommended lubricant 5 Lubricate Bolt threads Nut seats with the recommended lubricant 6 Lubricate Crankshaft pins Big end bearings Connecting rod inner surface with the recommended lubricant 7 Install Big end bearings Connecting rod assembly 1 into the cylinder and onto the crankshaft pin Connecting rod cap onto the crankshaft pin TIP Align th...

Page 423: ...ing rod nuts with a torque wrench b Put a mark 1 on the corner of the connecting rod nut 2 and the connecting rod 3 c Tighten the connecting rod nuts further to reach the specified angle 115 125 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 ...

Page 424: ...CONNECTING RODS AND PISTONS 5 119 ...

Page 425: ...to CRANKCASE on page 5 101 Front balancer weight Refer to BALANCERS on page 5 136 Connecting rod caps Refer to CONNECTING RODS AND PIS TONS on page 5 111 1 Crankshaft 1 2 Crankshaft journal upper bearing 5 3 Crankshaft journal lower bearing 5 4 Oil nozzle 4 For installation reverse the removal proce dure 3 1 2 2 E E New 4 LS ...

Page 426: ...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 bearings crank s...

Page 427: ...fication 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 refer to the bearings shown in the lower crankcase and crankshaft web illustration If J1 J5 are the same use the same si...

Page 428: ...CRANKSHAFT 5 123 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 ...

Page 429: ... Remarks Crankcase Separate Refer to CRANKCASE on page 5 101 Stopper lever Refer to SHIFT SHAFT on page 5 79 1 Drive axle assembly 1 2 Bearing 1 3 Washer 1 4 Bearing 1 5 Shift drum retainer 1 6 Long shift fork guide bar 1 7 Shift fork L 1 8 Shift fork R 1 9 Short shift fork guide bar 1 10 Spring 4 11 Shift drum assembly 1 12 Shift fork C 1 ...

Page 430: ...TRANSMISSION 5 125 13 Main axle assembly 1 For installation reverse the removal proce dure Removing the transmission shift drum assembly and shift forks FJR13A Order Job Parts to remove Q ty Remarks ...

Page 431: ...to CRANKCASE on page 5 101 Stopper lever Refer to SHIFT SHAFT on page 5 79 1 Gear position sensor bracket 1 2 Oil seal 1 3 Drive axle assembly 1 4 Bearing 1 5 Washer 1 6 Bearing 1 7 Shift drum retainer 1 8 Long shift fork guide bar 1 9 Shift fork L 1 10 Shift fork R 1 11 Short shift fork guide bar 1 12 Spring 4 13 Shift drum assembly 1 14 Shift fork C 1 ...

Page 432: ...TRANSMISSION 5 127 15 Main axle assembly 1 For installation reverse the removal proce dure Removing the transmission shift drum assembly and shift forks FJR13AE Order Job Parts to remove Q ty Remarks ...

Page 433: ...1 3 Toothed lock washer retainer 1 4 5th pinion gear 1 5 Toothed spacer 1 6 Toothed washer 2 7 Circlip 2 8 3rd pinion gear 1 9 4th pinion gear 1 10 Collar 1 11 Main axle 1st pinion gear 1 12 Bearing 1 13 Main axle bearing housing 1 For assembly reverse the disassembly pro cedure 13 12 11 10 9 New New New New 7 8 7 6 5 4 3 2 1 6 E M M M M ...

Page 434: ...nd wheel gear 1 4 Collar 1 5 Washer 1 6 5th wheel gear 1 7 Circlip 2 8 Toothed washer 2 9 3rd wheel gear 1 10 Toothed spacer 1 11 Toothed lock washer 1 12 Toothed lock washer retainer 1 13 4th wheel gear 1 14 Washer 1 15 1st wheel gear 1 16 Bearing 1 17 Washer 1 1 18 17 16 15 14 8 7 12 11 10 2 3 4 6 7 8 9 13 E M M M M M M 5 New New ...

Page 435: ... 130 18 Drive axle 1 For assembly reverse the disassembly pro cedure Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks 1 18 17 16 15 14 8 7 12 11 10 2 3 4 6 7 8 9 13 E M M M M M M 5 New New ...

Page 436: ...to straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar as a set EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum groove Damage scratches wear Replace the shift drum assembly Shift drum segment 1 Damage wear Replace the shift drum as sembly Shift drum bearing 2 Damage pitting Re...

Page 437: ...efective part s 6 Check Circlips Bends damage looseness Replace ET3P61030 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1 Install Toothed washer 1 Circlip 2 TIP Be sure the circlip sharp edged corner a is positioned opposite side to the toothed washer and gear For main axle Install the circlip so that both ends b rest on the sides of a spline c with both axles aligned 2 Install Toothed lock washer retai...

Page 438: ...g hole with the corresponding hole in the upper crankcase Stake the main axle bearing housing bolts at a cutout a in the main axle bearing housing 2 Install Shift fork C Shift drum assembly Springs Short shift fork guide bar Shift fork R Shift fork L Long shift fork guide bar TIP The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence...

Page 439: ...earing housing hole with the corresponding hole in the upper crankcase Stake the main axle bearing housing bolts at a cutout a in the main axle bearing housing 2 Install Shift fork C Shift drum assembly Springs Short shift fork guide bar Shift fork R Shift fork L Long shift fork guide bar TIP The embossed marks on the shift forks should face towards the right side of the engine and be in the follo...

Page 440: ...rankcase Make sure the bearing circlip 2 is inserted into the groove in the upper crankcase 5 Check Transmission Rough movement Repair TIP Oil each gear shaft and bearing thoroughly 6 Install Oil seal 1 to gear position sensor bracket Installed depth a 4 2 4 7 mm 0 17 0 19 in 1 2 1 a ...

Page 441: ...er Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 101 1 Front balancer lever 1 2 Front balancer shaft 1 3 Washer 2 4 Bearing 2 5 Front balancer gear 1 6 Damper 4 7 Front balancer weight 1 For installation reverse the removal proce dure ...

Page 442: ...7 5 Pickup rotor cover Refer to PICKUP ROTOR on page 5 39 Clutch cover Refer to CLUTCH on page 5 46 1 Rear balancer cover 1 2 Rear balancer cover gasket 1 3 Rear balancer lever 1 4 Rear balancer shaft 1 5 Washer 2 6 Bearing 2 7 Rear balancer gear 1 8 Damper 4 9 Rear balancer weight 1 For installation reverse the removal proce dure ...

Page 443: ...ach damper is positioned to the outside of the gear projec tions as shown in the illustration Align the punch mark b in the balancer weight with the mark c in the balancer gear 2 Align T mark on the pickup rotor with the crankcase mating surface a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres sion stroke align the T mark a on the pick up rotor with the crankcase mating sur...

Page 444: ...om 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 ET3P61033 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 g...

Page 445: ...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 446: ... Rear 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 kg 0 29 ft lb f e c 2 1 ...

Page 447: ...OOLER 6 4 CHECKING THE OIL COOLER 6 5 INSTALLING THE OIL COOLER 6 5 THERMOSTAT 6 6 CHECKING THE THERMOSTAT 6 8 INSTALLING THE THERMOSTAT ASSEMBLY 6 8 WATER PUMP 6 10 DISASSEMBLING THE WATER PUMP 6 12 CHECKING THE WATER PUMP 6 12 ASSEMBLING THE WATER PUMP 6 12 INSTALLING THE WATER PUMP 6 13 ...

Page 448: ...nt reservoir 1 6 Radiator inlet hose 1 7 Plunger control unit hose 2 1 8 Oil cooler outlet hose 1 9 Left horn low 1 10 Coolant reservoir bracket 1 11 Water pump breather hose 1 12 Radiator outlet hose 1 13 Right horn high 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R ...

Page 449: ... 1 21 Air deflector 1 For installation reverse the removal proce dure Removing the radiator Order Job Parts to remove Q ty Remarks T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib LT LT LT LT T R 7 Nm 0 7 m kg 5 1 ft Ib 1 2 4 5 6 7 8 3 9 10 11 13 14...

Page 450: ...nd make sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 53 EAS26400 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 25 2 Check Cooling system Leaks Repair or replace any faulty part 3 Measure Radiator cap opening pressure B...

Page 451: ...rain Refer to CHANGING THE COOLANT on page 3 25 Radiator Refer to RADIATOR on page 6 1 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 1 1 Water pump outlet hose 1 2 Water pump outlet pipe 1 3 Water jacket joint inlet hose 1 4 Water jacket joint 1 5 Oil cooler inlet hose 1 6 Oil cooler outlet hose 1 7 Oil cooler 1 For installation reverse the removal proce dure ...

Page 452: ...r 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 25 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 15 4 Check Cooling system Leaks Repair or replace any faulty part 5 Measure Radiator ...

Page 453: ...nect 3 Radiator inlet hose 1 Disconnect 4 Thermostat inlet hose 2 1 5 Thermostat cover radiator filler pipe 1 6 Thermostat housing 1 7 Thermostat 1 8 Thermostat inlet pipe 2 1 9 Thermostat inlet hose 1 1 10 Plunger control unit hose 1 1 11 Coolant temperature sensor coupler 1 Disconnect 12 Coolant temperature sensor 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 18 Nm 1 8 m kg 13 ...

Page 454: ...tion reverse the removal proce dure Removing the thermostat assembly Order Job Parts to remove Q ty Remarks T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib New T R 7 Nm 0 7 m kg 5 1 ft Ib 1 10 13 12 11 2 7 5 3 4 6 8 9 3 ...

Page 455: ...at pipes Radiator inlet hose Thermostat cover radiator filler pipe Plunger control unit hose 1 Cracks damage wear Replace EAS26490 INSTALLING THE THERMOSTAT ASSEMBLY 1 Install Copper washer Coolant temperature sensor NOTICE EC3P61019 Use extreme care when handling the coolant temperature sensor Replace any part that was dropped or subjected to a strong im pact 2 Install Thermostat 1 Thermostat hou...

Page 456: ...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 457: ...ant level is extremely low or the coolant contains engine oil Right side cowling Refer to GENERAL CHASSIS on page 4 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 25 1 Water pump breather hose 1 Disconnect 2 Radiator outlet hose 1 Disconnect 3 Water pump outlet hose 1 Disconnect 4 Water pump assembly 1 For installation reverse the removal proce dure ...

Page 458: ...arts to remove Q ty Remarks 1 Water pump housing cover 1 2 O ring 1 3 Circlip 1 4 Impeller shaft 1 5 Rubber damper holder 1 6 Rubber damper 1 7 Water pump seal 1 8 Oil seal 1 9 Bearing 2 10 Water pump housing 1 For assembly reverse the disassembly pro cedure ...

Page 459: ...r pump housing Impeller shaft Cracks damage wear Replace 2 Check Bearing Rough movement Replace EAS26560 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 into the water pump housing 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 Water pump seal 1 NOTICE ECA14080 Never lubricate the wa...

Page 460: ...s smoothly EAS26580 INSTALLING THE WATER PUMP 1 Install O ring 1 Water pump assembly 2 TIP Align the slit a on the impeller shaft with the projection b on the oil pump driven sprocket Lubricate the O ring with a thin coat of lithium soap base grease Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A Middle driven shaft bearing driv er 90890 04058 Bearing driver 40 mm YM 040...

Page 461: ... the recom mended coolant Refer to CHANGING THE COOLANT on page 3 25 3 Check Cooling system Leaks Repair or replace any faulty part 4 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 ...

Page 462: ...WATER PUMP 6 15 ...

Page 463: ...ly 7 3 INSTALLING THE FUEL PUMP 7 3 INSTALLING THE FUEL TANK 7 4 THROTTLE BODIES 7 5 CHECKING THE INJECTORS 7 8 CHECKING THE THROTTLE BODIES 7 8 CHECKING THE FUEL PRESSURE 7 8 ADJUSTING THE THROTTLE POSITION SENSOR 7 8 AIR INDUCTION SYSTEM 7 11 CHECKING THE PRESSURE REGULATOR 7 15 CHECKING THE AIR INDUCTION SYSTEM 7 15 INSTALLING THE AIR INDUCTION SYSTEM 7 15 ...

Page 464: ...eather hose 1 Except for California 5 Fuel tank breather hose fuel tank to joint 1 For California only 6 Fuel tank overflow hose 1 Except for California 7 Fuel tank overflow hose fuel tank to joint 1 For California only 8 Fuel hose holder 1 9 Fuel hose 1 10 Fuel tank 1 11 Fuel pump 1 For installation reverse the removal proce dure T R 16 Nm 1 6 m kg 11 ft Ib New T R 4 Nm 0 4 m kg 2 9 ft Ib T R 10 ...

Page 465: ... Canister purge hose throttle body 1 to 3 way joint 1 2 3 way joint 1 3 Canister purge hose throttle body 4 to 3 way joint 1 4 Canister purge hose 3 way joint to canister 1 5 Fuel tank breather hose joint to rollover valve 1 6 Rollover valve 1 7 Fuel tank breather hose rollover valve to canis ter 1 8 Canister breather hose 1 9 Canister 1 10 Canister bracket 1 For installation reverse the removal p...

Page 466: ...a wall or the like EAS26640 REMOVING THE FUEL PUMP 1 Remove Fuel pump NOTICE ECA14720 Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender EAS26670 CHECKING THE FUEL PUMP BODY 1 Check Fuel pump body Obstruction Clean Cracks damage Replace fuel pump as sembly ET3P6G004 CHECKING THE ROLLOVER VALVES for California only 1 Check Rollover valve Damage faul...

Page 467: ...il slide the fuel hose connector cover 1 on the end of the hose in the direction of the arrow shown 2 Install Fuel hose fuel pump side Fuel hose holder NOTICE EC3P61008 When installing the fuel hose make sure that it is securely connected and that the fuel hose holder is in the correct position other wise the fuel hose will not be properly in stalled TIP Install the fuel hose connector securely on...

Page 468: ... THE COOLANT on page 3 25 1 O2 sensor coupler 1 Disconnect 2 Cylinder identification sensor coupler 1 Disconnect 3 Sub wire harness coupler 1 Disconnect 4 Engine idle speed adjusting screw 1 Disconnect 5 Throttle body joint clamp screw 8 Loosen 6 Throttle bodies 1 7 Throttle cable accelerator cable 1 Disconnect 8 Throttle cable decelerator cable 1 Disconnect 9 Plunger control unit hose 1 1 Disconn...

Page 469: ...Disconnect 11 Throttle body joint 4 For installation reverse the removal proce dure Removing the throttle bodies Order Job Parts to remove Q ty Remarks T R 3 Nm 0 3 m kg 2 2 ft Ib T R 3 Nm 0 3 m kg 2 2 ft Ib 5 5 5 5 11 11 11 5 5 5 5 11 9 10 1 2 4 8 7 6 3 ...

Page 470: ... 3 injector coupler 1 Disconnect 6 Cylinder 4 injector coupler 1 Disconnect 7 Sub wire harness 1 8 Negative pressure hose 7 9 Bypass air unit inlet hose 1 10 Bypass air unit 1 11 Bypass air unit outlet hose 4 12 Intake air pressure sensor 1 13 Fuel rail 1 14 Injector 4 15 Throttle position sensor 1 For installation reverse the removal proce dure 12 3 4 5 6 1 7 2 8 8 8 8 9 8 8 8 14 15 11 11 11 13 1...

Page 471: ...ause fuel to spurt out when removing the hoses c Connect the fuel pressure adapter 3 be tween the fuel hose 1 and fuel rail 2 d Connect the pressure gauge 4 to fuel pres sure adapter 3 e Start the engine f Measure the fuel pressure Faulty Replace the fuel pump EAS27030 ADJUSTING THE THROTTLE POSITION SENSOR TIP Before adjusting the throttle position sensor the engine idling speed should be properl...

Page 472: ...at the voltage is within the specified range f After adjusting the throttle position sensor an gle tighten the throttle position sensor screws 3 to specification Digital circuit tester 90890 03174 Model 88 Multimeter with ta chometer YU A1927 Output voltage at idle 0 63 0 73 V T R Throttle position sensor screw 3 5 Nm 0 35 m kg 2 53 ft lb 3 2 1 ...

Page 473: ...THROTTLE BODIES 7 10 ...

Page 474: ...AIR INDUCTION SYSTEM 7 11 EAS27040 AIR INDUCTION SYSTEM 1 2 3 4 5 1 1 1 1 2 2 5 2 3 3 4 7 8 6 ...

Page 475: ...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 476: ... Disconnect 2 Air induction system hose air filter case joint assembly to 3 way joint 1 3 Air induction system hose 3 way joint to hose plug 1 4 Air induction system hose 3 way joint to air cut off valve 1 5 Air induction system hose 3 way joint to reed valve cover 4 6 Air induction system hose air cut off valve to 3 way joint 2 7 Air cut off valve 1 For installation reverse the removal proce dure...

Page 477: ...t inlet pipe 1 Refer to THERMOSTAT on page 6 6 1 Reed valve cover cylinder 1 1 2 Reed valve cover cylinders 2 3 1 3 Reed valve cover cylinder 4 1 4 Reed valve assembly 4 5 Reed valve plate 4 For installation reverse the removal proce dure LT LT LT LT 1 4 5 2 3 4 4 4 5 5 5 T R 14 Nm 1 4 m kg 10 ft Ib ...

Page 478: ...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 Pip...

Page 479: ...AM 2 2 FJR13AE 8 19 STARTING CIRCUIT CUT OFF SYSTEM OPERATION FJR13A 8 21 STARTING CIRCUIT CUT OFF SYSTEM OPERATION FJR13AE 8 22 TROUBLESHOOTING FJR13A 8 23 TROUBLESHOOTING FJR13AE 8 25 CHARGING SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 TROUBLESHOOTING 8 31 LIGHTING SYSTEM 8 33 CIRCUIT DIAGRAM 1 2 8 33 CIRCUIT DIAGRAM 2 2 8 35 TROUBLESHOOTING 8 37 SIGNALING SYSTEM 8 39 CIRCUIT DIAGRAM 1 2 FJR13A 8 39 CIRCU...

Page 480: ...OSTIC FUNCTION TABLE 8 66 TROUBLESHOOTING METHOD 8 68 DIAGNOSTIC MODE 8 69 TROUBLESHOOTING DETAILS 8 76 FUEL PUMP SYSTEM 8 99 CIRCUIT DIAGRAM 1 2 8 99 CIRCUIT DIAGRAM 2 2 8 101 TROUBLESHOOTING 8 103 WINDSHIELD DRIVE SYSTEM 8 105 CIRCUIT DIAGRAM 1 2 8 105 CIRCUIT DIAGRAM 2 2 8 107 TROUBLESHOOTING 8 109 ACCESSORY BOX SYSTEM 8 111 CIRCUIT DIAGRAM 1 2 8 111 CIRCUIT DIAGRAM 2 2 8 113 TROUBLESHOOTING 8 ...

Page 481: ... 8 134 B 5 MALFUNCTION ARE CURRENTLY DETECTED 8 135 C 1 ONLY THE ABS WARNING LIGHT FAILS TO COME ON 8 135 C 2 ALL INDICATOR LIGHTS FAIL TO COME ON 8 136 C 3 THE ABS WARNING LIGHT REMAINS ON 8 136 C 4 THE ABS WARNING LIGHT FLASHES 8 137 C 5 DIAGNOSIS USING THE FAULT CODES 8 137 D 1 DELETING THE FAULT CODES 8 167 D 2 DELETE FUNCTION TEST 8 167 D 3 FINAL CHECK 8 168 GRIP WARMER SYSTEM FJR13AE only 8 ...

Page 482: ...LATOR 8 238 CHECKING THE HORNS 8 238 CHECKING THE OIL LEVEL SWITCH 8 239 CHECKING THE FUEL SENDER 8 239 CHECKING THE RADIATOR FAN MOTORS 8 240 CHECKING THE COOLANT TEMPERATURE SENSOR 8 240 CHECKING THE THROTTLE POSITION SENSOR 8 241 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 8 241 CHECKING THE CYLINDER IDENTIFICATION SENSOR 8 241 CHECKING THE INTAKE AIR PRESSURE SENSOR 8 242 CHECKING THE INTAKE AI...

Page 483: ......

Page 484: ... Y L Sb W B Y Y W Y L Sb W L W W W L G W G R B R GRAY P L G B R RED L B L Y RED GRAY W B Br B L W W Y L B B W Gy W G R L R Y G W L G Y Sb Br W B W B G R R L ON OFF R R Br W Br L Br R Br R R R G R R R R B O R L Gy R R L R L B R R R B B R R W L W L R W B R G B R B Y R B G Y G W W Y L W Dg Ch B W B R W R W R W G O Br R L B L B W L B R L W B W L Y B L B L B L B L Br W G W Y L L B L P W L W Gy W W B Gy...

Page 485: ...ire harness front cowling wire harness 20 Relay unit 23 Sidestand switch 35 Cylinders 1 4 ignition coil 36 Spark plug 37 Cylinders 2 3 ignition coil 43 ECU engine control unit 44 Crankshaft position sensor 45 Lean angle sensor 52 Coupler 4 wire harness front cowling wire harness 57 Ignition fuse ...

Page 486: ...G Y G Y Dg Br W L R W Ch Br G R B B B Ch B W B R R B Dg W B B Y G Y G Y R B B R Ch B W W B B Y Dg B R Y Dg B Lg L Y Br W L B P Sb B Y Ch R Y Dg B Lg B R Br G L B P Sb W B Y Ch Ch L R B Dg L R B Ch L R B Dg L R B UP DOWN W B G L B Y R G P Br P Br B R G R G B L W Y W P B Y Y L G W B L B W B W B L G B Sb W G R B R L W Y W P B Y B W B B R W W P Sb Dg Ch Y B G L B Ch Br G Dg Sb W Br W Sb Lg L B Br Sb B...

Page 487: ...IGNITION SYSTEM 8 4 19 Coupler 3 wire harness front cowling wire harness 52 Coupler 4 wire harness front cowling wire harness 68 Engine stop switch ...

Page 488: ...Y RED L G B R RED B Y Y W Y L Sb W L W W W L G W G R B R GRAY P B W R W GRAY B L R GRAY GRAY B W B G R R L W B Br B L W W Y L B B W Gy W G R L R Br B Y W L G Y Sb Br W ON OFF R R Br W Br L Br R Br R R R G R R R R B O R L Gy R R L R L B R R R B B B R R W L W L R R W R W W Y L B R G W Sb W G R W L Br R L W B L Gy W Gy W Gy W B R L W Y L Y B L B L L W W L O G B W B L Y W B W B B L L L2 G Y B L R O B ...

Page 489: ...Coupler 3 wire harness front cowling wire harness 35 Sidestand switch 36 Cylinders 1 4 ignition coil 37 Spark plug 38 Cylinders 2 3 ignition coil 44 ECU engine control unit 45 Crankshaft position sensor 48 Lean angle sensor 64 Coupler 5 wire harness front cowling wire harness 70 Ignition fuse ...

Page 490: ...G Y G Y Dg Br W L R W Ch Br G R B B Lg W R B BLACK B Y Y W Y L Sb W L W W W L G W G R B R GRAY P L B B Dg Br W P Lg Sb Ch R Y BLACK Ch R Y Br G Dg B Lg Sb W BLACK P L B Ch L R B Dg L R B Ch L R B Dg L R B UP DOWN PUSH Shift up Shift down W B R G R B G Y B B W Ch Dg G L B Y O W B L B O B G R G B Br L R G W Lg W P Br P Br Lg W R B B R G R G B L W Y W P B Y Y L G W B L B W B L B B G B Sb W G R B R L ...

Page 491: ...IGNITION SYSTEM 8 8 26 Coupler 3 wire harness front cowling wire harness 64 Coupler 5 wire harness front cowling wire harness 87 Engine stop switch ...

Page 492: ...he engine continues to run under the following con ditions The transmission is in gear the neutral circuit of the gear position switch is open and the sidestand is up the sidestand switch circuit is closed The transmission is in neutral the neutral circuit of the gear position switch is closed and the side stand is down the sidestand switch circuit is open 10 11 12 9 1 4 5 7 2 6 3 8 1 Battery 2 Ma...

Page 493: ...TTERY on page 8 228 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 11 Re gap or replace the spark plug s 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 236 Ignition system is OK 5 Check the spark plug caps Refer to CHECKING THE SPARK PLUG CAPS on page 8 235 Replace the spark plug ca...

Page 494: ...CHES on page 8 221 Replace the neutral switch 12 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 221 Replace the sidestand switch 13 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 234 Replace the relay unit 14 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 236 Replace the lean angle sensor 15 Check the entire ignition ...

Page 495: ...IGNITION SYSTEM 8 12 ...

Page 496: ...LACK L B L Y L Sb W B Y Y W Y L Sb W L W W W L G W G R B R GRAY P L G B R RED L B L Y RED GRAY W B Br B L W W Y L B B W Gy W G R L R Y G W L G Y Sb Br W B W B G R R L ON OFF R R Br W Br L Br R Br R R R G R R R R B O R L Gy R R L R L B R R R B B R R W L W L R W B R G B R B Y R B G Y G W W Y L W Dg Ch B W B R W R W R W G O Br R L B L B W L B R L W B W L Y B L B L B L B L Br W G W Y L L B L P W L W G...

Page 497: ... 13 Starter motor 17 Gear position switch 18 Coupler 2 wire harness front cowling wire harness 19 Coupler 3 wire harness front cowling wire harness 20 Relay unit 21 Starting circuit cut off relay 23 Sidestand switch 52 Coupler 4 wire harness front cowling wire harness 57 Ignition fuse ...

Page 498: ...W Ch G Y G Y Dg Br W L R W Ch Br G R B B B Ch B W B R R B Dg W B B Y G Y G Y R B B R Ch B W W B B Y Dg B R Y Dg B Lg L Y Br W L B P Sb B Y Ch R Y Dg B Lg B R Br G L B P Sb W B Y Ch Ch L R B Dg L R B Ch L R B Dg L R B UP DOWN W B G L B Y R G P Br P Br B R G R G B L W Y W P B Y Y L G W B L B W B W B L G B Sb W G R B R L W Y W P B Y B W B B R W W P Sb Dg Ch Y B G L B Ch Br G Dg Sb W Br W Sb Lg L B Br...

Page 499: ...TEM 8 16 18 Coupler 2 wire harness front cowling wire harness 19 Coupler 3 wire harness front cowling wire harness 52 Coupler 4 wire harness front cowling wire harness 68 Engine stop switch 69 Start switch 72 Clutch switch ...

Page 500: ... B L Y RED L G B R RED B Y Y W Y L Sb W L W W W L G W G R B R GRAY P B W R W GRAY B L R GRAY GRAY B W B G R R L W B Br B L W W Y L B B W Gy W G R L R Br B Y W L G Y Sb Br W ON OFF R R Br W Br L Br R Br R R R G R R R R B O R L Gy R R L R L B R R R B B B R R W L W L R R W R W W Y L B R G W Sb W G R W L Br R L W B L Gy W Gy W Gy W B R L W Y L Y B L B L L W W L O G B W B L Y W B W B B L L L2 G Y B L R...

Page 501: ...ire harness 18 Relay unit 19 Starting circuit cut off relay 21 Neutral switch 26 Coupler 3 wire harness front cowling wire harness 28 Brake light relay 29 Rear brake light switch 35 Sidestand switch 57 MCU motor control unit 63 YCC S control relay 64 Coupler 5 wire harness front cowling wire harness 68 Signaling system fuse 70 Ignition fuse ...

Page 502: ...W Ch G Y G Y Dg Br W L R W Ch Br G R B B Lg W R B BLACK B Y Y W Y L Sb W L W W W L G W G R B R GRAY P L B B Dg Br W P Lg Sb Ch R Y BLACK Ch R Y Br G Dg B Lg Sb W BLACK P L B Ch L R B Dg L R B Ch L R B Dg L R B UP DOWN PUSH Shift up Shift down W B R G R B G Y B B W Ch Dg G L B Y O W B L B O B G R G B Br L R G W Lg W P Br P Br Lg W R B B R G R G B L W Y W P B Y Y L G W B L B W B L B B G B Sb W G R B...

Page 503: ... 20 14 Coupler 2 wire harness front cowling wire harness 26 Coupler 3 wire harness front cowling wire harness 64 Coupler 5 wire harness front cowling wire harness 86 Front brake light switch 87 Engine stop switch 88 Start switch ...

Page 504: ...lay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay stays open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engine can be started by pushing the start switch 13 1 12 4 5 7 7 a b 9 7 10 8 6 2 3 11 a WHEN...

Page 505: ...e starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay stays open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engine can be started by pushing the start switch 18 1 17 4 6 7 12 a b 9 14 10 8 15 2 3 11 8 8 13 16 5 a WHEN...

Page 506: ...y terminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 237 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 44 Repair or replace the starter motor 5 Check the relay unit starting circuit cut off relay...

Page 507: ...ce the gear position switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 221 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 221 Replace the clutch switch 13 Check the start switch Refer to CHECKING THE SWITCHES on page 8 221 Replace the right handlebar switch 14 Check the entire starting system wiring Refer to CIRCUIT DIAG...

Page 508: ...the battery terminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 237 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 44 Repair or replace the starter motor 5 Check the relay unit starting circuit cut...

Page 509: ...fer to CHECKING THE SWITCHES on page 8 221 Replace the right handlebar switch 12 Check the neutral switch Refer to CHECKING THE SWITCHES on page 8 221 Replace the neutral switch 13 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 221 Replace the sidestand switch 14 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 221 Replace the front brake light switc...

Page 510: ...TEM 8 27 NG OK 17 Check the entire starting system wiring Refer to CIRCUIT DIAGRAM 1 2 FJR13AE on page 8 17 and CIRCUIT DIAGRAM 2 2 FJR13AE on page 8 19 Properly connect or repair the starting sys tem wiring Replace the MCU ...

Page 511: ...ELECTRIC STARTING SYSTEM 8 28 ...

Page 512: ... G L Br R Y Br B R W L R G L Br L R Y G L R Y Y W R Br B R W G Y P W B L BLAC Y L L G B R RED L B L Y RED ON OFF R R Br W Br L Br R Br R R R G R R R R LR L B R R R B B R R W L W L R R G R Y R Y R W Br L R Br L Br L Br L Br L Br B Br B R Y Y W G L G L W B Br W W W W W W R R B G B W B B R R W Br B G Y B R Br L B R L G B Lg W B G W Y Br R Y G L R W L Y L B Br 1 2 3 4 5 6 7 8 9 11 12 13 14 10 52 53 54...

Page 513: ...CHARGING SYSTEM 8 30 2 Rectifier regulator 3 AC magneto 8 Main fuse 10 Battery ...

Page 514: ... Refer to CHECKING AND CHARGING THE BATTERY on page 8 228 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 237 Replace the stator coil 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 238 Replace the rectifier regulator 5 Check the entire charging system wiring Refer to CIRCUIT DIAGRA...

Page 515: ...CHARGING SYSTEM 8 32 ...

Page 516: ...L Sb W B Y Y W Y L Sb W L W W W L G W G R B R GRAY P L G B R RED L B L Y RED GRAY W B Br B L W W Y L B B W Gy W G R L R Y G W L G Y Sb Br W B W B G R R L ON OFF R R Br W Br L Br R Br R R R G R R R R B O R L Gy R R L R L B R R R B B R R W L W L R W B R G B R B Y R B G Y G W W Y L W Dg Ch B W B R W R W R W G O Br R L B L B W L B R L W B W L Y B L B L B L B L Br W G W Y L L B L P W L W Gy W W B Gy Y ...

Page 517: ...pler 3 wire harness front cowling wire harness 30 License plate light 32 Tail brake light 43 ECU engine control unit 52 Coupler 4 wire harness front cowling wire harness 53 Headlight on off grip warmer relay 54 Hazard lighting fuse 56 Headlight fuse 57 Ignition fuse ...

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

Page 519: ...owling wire harness 52 Coupler 4 wire harness front cowling wire harness 73 Dimmer switch 86 Meter light 87 High beam indicator light 92 Front left turn signal position light 93 Front right turn signal position light 94 Headlight relay dimmer 96 Headlight ...

Page 520: ...es Main headlight ignition and haz ard lighting Refer to CHECKING THE FUS ES on page 8 227 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 228 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 221 Replace the main switch 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on ...

Page 521: ...efer to CHECKING THE RE LAYS on page 8 231 Replace the headlight relay dimmer 9 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 33 and CIRCUIT DIA GRAM 2 2 on page 8 35 Properly connect or repair the lighting sys tem wiring Replace the ECU ...

Page 522: ... L Y L Sb W B Y Y W Y L Sb W L W W W L G W G R B R GRAY P L G B R RED L B L Y RED GRAY W B Br B L W W Y L B B W Gy W G R L R Y G W L G Y Sb Br W B W B G R R L ON OFF R R Br W Br L Br R Br R R R G R R R R B O R L Gy R R L R L B R R R B B R R W L W L R W B R G B R B Y R B G Y G W W Y L W Dg Ch B W B R W R W R W G O Br R L B L B W L B R L W B W L Y B L B L B L B L Br W G W Y L L B L P W L W Gy W W B ...

Page 523: ...oupler 2 wire harness front cowling wire harness 19 Coupler 3 wire harness front cowling wire harness 20 Relay unit 25 ABS ECU electronic control unit 27 Rear wheel sensor 28 Rear brake light switch 29 Brake light relay 32 Tail brake light 33 Rear left turn signal light 34 Rear right turn signal light 43 ECU engine control unit 52 Coupler 4 wire harness front cowling wire harness 54 Hazard lightin...

Page 524: ... G Y G Y Dg Br W L R W Ch Br G R B B B Ch B W B R R B Dg W B B Y G Y G Y R B B R Ch B W W B B Y Dg B R Y Dg B Lg L Y Br W L B P Sb B Y Ch R Y Dg B Lg B R Br G L B P Sb W B Y Ch Ch L R B Dg L R B Ch L R B Dg L R B UP DOWN W B G L B Y R G P Br P Br B R G R G B L W Y W P B Y Y L G W B L B W B W B L G B Sb W G R B R L W Y W P B Y B W B B R W W P Sb Dg Ch Y B G L B Ch Br G Dg Sb W Br W Sb Lg L B Br Sb ...

Page 525: ...s front cowling wire harness 65 Turn signal hazard relay 67 Front brake light switch 70 Hazard switch 75 Turn signal switch 76 Horn switch 81 Neutral indicator light 83 Multi function meter 84 Oil level warning light 88 Right turn signal indicator light 89 Left turn signal indicator light 91 Horn 92 Front left turn signal position light 93 Front right turn signal position light 98 Windshield drive...

Page 526: ... Y RED L G B R RED B Y Y W Y L Sb W L W W W L G W G R B R GRAY P B W R W GRAY B L R GRAY GRAY B W B G R R L W B Br B L W W Y L B B W Gy W G R L R Br B Y W L G Y Sb Br W ON OFF R R Br W Br L Br R Br R R R G R R R R B O R L Gy R R L R L B R R R B B B R R W L W L R R W R W W Y L B R G W Sb W G R W L Br R L W B L Gy W Gy W Gy W B R L W Y L Y B L B L L W W L O G B W B L Y W B W B B L L L2 G Y B L R O B...

Page 527: ... Neutral switch 23 ABS ECU electronic control unit 25 Rear wheel sensor 26 Coupler 3 wire harness front cowling wire harness 27 Diode 28 Brake light relay 29 Rear brake light switch 32 Tail brake light 33 Rear left turn signal light 34 Rear right turn signal light 44 ECU engine control unit 57 MCU motor control unit 62 Gear position sensor 64 Coupler 5 wire harness front cowling wire harness 67 Ha...

Page 528: ... G Y G Y Dg Br W L R W Ch Br G R B B Lg W R B BLACK B Y Y W Y L Sb W L W W W L G W G R B R GRAY P L B B Dg Br W P Lg Sb Ch R Y BLACK Ch R Y Br G Dg B Lg Sb W BLACK P L B Ch L R B Dg L R B Ch L R B Dg L R B UP DOWN PUSH Shift up Shift down W B R G R B G Y B B W Ch Dg G L B Y O W B L B O B G R G B Br L R G W Lg W P Br P Br Lg W R B B R G R G B L W Y W P B Y Y L G W B L B W B L B B G B Sb W G R B R L...

Page 529: ...front cowling wire harness 79 Turn signal hazard relay 83 Turn signal switch 84 Horn switch 86 Front brake light switch 89 Hazard switch 92 Neutral indicator light 94 Multi function meter 95 Oil level warning light 99 Right turn signal indicator light 100 Left turn signal indicator light 107 Horn 108 Front left turn signal position light 109 Front right turn signal position light 113 Windshield dr...

Page 530: ...13AE Refer to CHECKING THE FUS ES on page 8 227 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 228 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 221 Replace the main switch 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM 1 2 FJR13A on page 8 39 CIRCUIT DIA...

Page 531: ...age 8 41 CIRCUIT DIAGRAM 1 2 FJR13AE on page 8 43 and CIRCUIT DIAGRAM 2 2 FJR13AE on page 8 45 Properly connect or repair the signaling system wiring This circuit is OK 1 Check the tail brake light bulbs and sockets Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 226 Replace the tail brake light bulb socket or both 2 Check the front brake light switch Refer to CHECKING THE SWITCHES on page ...

Page 532: ...UIT DIAGRAM 2 2 FJR13AE on page 8 45 Properly connect or repair the signaling system wiring This circuit is OK 1 Check the turn signal light bulbs and sockets Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 226 Replace the turn signal light bulb socket or both 2 Check the turn signal switch Refer to CHECKING THE SWITCHES on page 8 221 Replace the left handlebar switch 3 Check the hazard swi...

Page 533: ...KING THE SWITCHES on page 8 221 Replace the gear position switch 2 Check the neutral switch FJR13AE Refer to CHECKING THE SWITCHES on page 8 221 Replace the neutral switch 3 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 234 Replace the relay unit 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM 1 2 FJR13A on page 8 39 CIRCUIT DIAGRAM 2 2 FJR13A on p...

Page 534: ...re signaling system wiring Refer to CIRCUIT DIAGRAM 1 2 FJR13A on page 8 39 CIRCUIT DIAGRAM 2 2 FJR13A on page 8 41 CIRCUIT DIAGRAM 1 2 FJR13AE on page 8 43 and CIRCUIT DIAGRAM 2 2 FJR13AE on page 8 45 Properly connect or repair the signaling system wiring Replace the meter assembly 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 8 239 Replace the fuel pump 2 Check the entire sig...

Page 535: ...coupler and ECU coupler white yellow white yellow Between ECU coupler and meter assembly coupler yellow blue yellow blue 1 Check the rear wheel sensor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 28 Replace the rear wheel sensor 2 Check the entire speed sensor wir ing Refer to NOTE Properly connect or repair the speed sen sor wiring Replace the hydraulic unit assembly E...

Page 536: ...b W B Y Y W Y L Sb W L W W W L G W G R B R GRAY P L G B R RED L B L Y RED GRAY W B Br B L W W Y L B B W Gy W G R L R Y G W L G Y Sb Br W B W B G R R L ON OFF R R Br W Br L Br R Br R R R G R R R R B O R L Gy R R L R L B R R R B B R R W L W L R W B R G B R B Y R B G Y G W W Y L W Dg Ch B W B R W R W R W G O Br R L B L B W L B R L W B W L Y B L B L B L B L Br W G W Y L L B L P W L W Gy W W B Gy Y P W...

Page 537: ...in fuse 10 Battery 43 ECU engine control unit 47 Coolant temperature sensor 57 Ignition fuse 60 Radiator fan motor relay 61 Left radiator fan motor fuse 62 Left radiator fan motor 63 Right radiator fan motor fuse 64 Right radiator fan motor ...

Page 538: ... terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 221 Replace the main switch 4 Check the radiator fan motors Refer to CHECKING THE RADIA TOR FAN MOTORS on page 8 240 Replace the radiator fan motor s 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 231 Replace the radiator fan motor relay 6 Check the coolant temp...

Page 539: ...COOLING SYSTEM 8 56 ...

Page 540: ...K L B L Y L Sb W B Y Y W Y L Sb W L W W W L G W G R B R GRAY P L G B R RED L B L Y RED GRAY W B Br B L W W Y L B B W Gy W G R L R Y G W L G Y Sb Br W B W B G R R L ON OFF R R Br W Br L Br R Br R R R G R R R R B O R L Gy R R L R L B R R R B B R R W L W L R W B R G B R B Y R B G Y G W W Y L W Dg Ch B W B R W R W R W G O Br R L B L B W L B R L W B W L Y B L B L B L B L Br W G W Y L L B L P W L W Gy W...

Page 541: ...nition coil 36 Spark plug 37 Cylinders 2 3 ignition coil 38 Injector 4 39 Injector 3 40 Injector 2 41 Injector 1 42 Air induction system solenoid 43 ECU engine control unit 44 Crankshaft position sensor 45 Lean angle sensor 46 Intake air temperature sensor 47 Coolant temperature sensor 48 O2 sensor 49 Cylinder identification sensor 50 Throttle position sensor 51 Intake air pressure sensor 52 Coupl...

Page 542: ...Ch G Y G Y Dg Br W L R W Ch Br G R B B B Ch B W B R R B Dg W B B Y G Y G Y R B B R Ch B W W B B Y Dg B R Y Dg B Lg L Y Br W L B P Sb B Y Ch R Y Dg B Lg B R Br G L B P Sb W B Y Ch Ch L R B Dg L R B Ch L R B Dg L R B UP DOWN W B G L B Y R G P Br P Br B R G R G B L W Y W P B Y Y L G W B L B W B W B L G B Sb W G R B R L W Y W P B Y B W B B R W W P Sb Dg Ch Y B G L B Ch Br G Dg Sb W Br W Sb Lg L B Br S...

Page 543: ...oupler 2 wire harness front cowling wire harness 19 Coupler 3 wire harness front cowling wire harness 52 Coupler 4 wire harness front cowling wire harness 68 Engine stop switch 83 Multi function meter 85 Engine trouble warning light ...

Page 544: ... L Y RED L G B R RED B Y Y W Y L Sb W L W W W L G W G R B R GRAY P B W R W GRAY B L R GRAY GRAY B W B G R R L W B Br B L W W Y L B B W Gy W G R L R Br B Y W L G Y Sb Br W ON OFF R R Br W Br L Br R Br R R R G R R R R B O R L Gy R R L R L B R R R B B B R R W L W L R R W R W W Y L B R G W Sb W G R W L Br R L W B L Gy W Gy W Gy W B R L W Y L Y B L B L L W W L O G B W B L Y W B W B B L L L2 G Y B L R O...

Page 545: ...nition coil 37 Spark plug 38 Cylinders 2 3 ignition coil 39 Injector 4 40 Injector 3 41 Injector 2 42 Injector 1 43 Air induction system solenoid 44 ECU engine control unit 45 Crankshaft position sensor 46 Intake air temperature sensor 47 Coolant temperature sensor 48 Lean angle sensor 49 O2 sensor 50 Cylinder identification sensor 51 Throttle position sensor 52 Intake air pressure sensor 64 Coupl...

Page 546: ... Ch G Y G Y Dg Br W L R W Ch Br G R B B Lg W R B BLACK B Y Y W Y L Sb W L W W W L G W G R B R GRAY P L B B Dg Br W P Lg Sb Ch R Y BLACK Ch R Y Br G Dg B Lg Sb W BLACK P L B Ch L R B Dg L R B Ch L R B Dg L R B UP DOWN PUSH Shift up Shift down W B R G R B G Y B B W Ch Dg G L B Y O W B L B O B G R G B Br L R G W Lg W P Br P Br Lg W R B B R G R G B L W Y W P B Y Y L G W B L B W B L B B G B Sb W G R B ...

Page 547: ...oupler 2 wire harness front cowling wire harness 26 Coupler 3 wire harness front cowling wire harness 64 Coupler 5 wire harness front cowling wire harness 87 Engine stop switch 94 Multi function meter 96 Engine trouble warning light ...

Page 548: ...ode has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel injection system operation The warning light flashes when any one of the conditions listed below is present and the start switch is pushed Checking the engine trouble warning light The engine trouble warning light comes on for 1 4 seconds after the main switch has ...

Page 549: ...ode No Item Symptom Able un able to start Able un able to drive 11 Cylinder identification sensor No normal signals are received from the cylinder identification sensor Unable Unable 12 Crankshaft position sensor No normal signals are received from the crankshaft position sen sor Unable Unable 13 Intake air pressure sensor open or short circuit Intake air pressure sensor open or short circuit dete...

Page 550: ...of faulty cylin ders 34 Cylinders 2 3 igni tion coil faulty ignition Malfunction detected in the prima ry wire of the cylinders 2 3 igni tion coil Able depending on the number of faulty cylin ders Able depending on the number of faulty cylin ders 41 Lean angle sensor open or short circuit Lean angle sensor open or short circuit detected Unable Unable 42 Rear wheel sensor No normal signals are rece...

Page 551: ...Engine has been left idling The ECU automatically stops the en gine after 20 minutes if it is left idling Able Able Fault code No Item Symptom Able un able to start Able un able to drive Fault code No Item Symptom Able un able to start Able un able to drive Er 1 ECU internal malfunc tion output signal error No signals are received from the ECU Unable Unable Er 2 ECU internal malfunc tion output si...

Page 552: ...LECT and RESET buttons turn the main switch to ON and continue to press the buttons for 8 seconds or more TIP All displays on the meter disappear except the odometer tripmeter fuel reserve tripmeter displays dIAG appears on the odometer tripmeter fuel reserve tripmeter LCD 4 Press the SELECT button to select the diagnostic mode dIAG 5 After selecting dIAG simultaneously press the SELECT and RESET ...

Page 553: ...2 No normal signals are re ceived from the crankshaft position sensor Open or short circuit in wire harness Defective crankshaft position sensor Malfunction in pickup rotor Malfunction in ECU Improperly installed crankshaft position sensor 13 Intake air pressure sensor open or short circuit detect ed Open or short circuit in sub wire harness Open or short circuit in wire harness Defective intake a...

Page 554: ...function in ECU Improperly installed lean angle sensor d 08 31 The amount of air fuel ratio feedback compensation is maintained continuously in the vicinity of the upper lim it lean air fuel ratio Open or short circuit in sub wire harness Open or short circuit in wire harness Fuel pressure too low Clogged injectors Defective O2 sensor unable to output a rich signal Malfunction in ECU Malfunction i...

Page 555: ... the battery voltage an open or short circuit in the line to the ECU Open or short circuit in front cowling wire harness Open or short circuit in wire harness Malfunction in ECU d 09 44 An error is detected while reading or writing on EE PROM CO adjustment val ue Malfunction in ECU The CO adjustment value is not properly written on or read from the internal memory d 60 46 Power supply to the fuel ...

Page 556: ...pened position 97 100 Check with throttle fully open d 03 Pressure difference atmospheric pressure and intake air pressure Displays the intake air pres sure Set the engine stop switch to and then push the start switch If the dis play value changes the performance is OK d 05 Intake air temperature Displays the intake air tem perature Compare the actually mea sured intake air tempera ture with the m...

Page 557: ...utral ON In gear OFF d 60 EEPROM fault code dis play No history 00 History exists 01 04 Cylinder fault code If more than one cylinder is defective the display alter nates every two seconds to show all the detected cylin der numbers When all cyl inder numbers are shown the display repeats the same process d 61 Malfunction history code display No history 00 History exists Fault codes 11 70 If more t...

Page 558: ...1 4 ignition coil five times at one second intervals Illuminates the engine trou ble warning light Check the spark five times Connect an ignition checker d 31 Cylinders 2 3 ignition coil Actuates the cylinders 2 3 ignition coil five times at one second intervals Illuminates the engine trou ble warning light Check the spark five times Connect an ignition checker d 36 Injector 1 Actuates the injecto...

Page 559: ...hen the relay is ON and the engine trouble warning light is ON when the relay is OFF Check the operating sound of the fuel pump relay five times d 51 Radiator fan motor relay Actuates the radiator fan mo tor relay for five cycles of five seconds ON 2 seconds OFF 3 seconds Illuminates the engine trou ble warning light and rotates the radiator fan motors Check the operating sound of the radiator fan...

Page 560: ...ob Reinstatement method 1 Installed condition of cylinder identifi cation sensor Check for looseness or pinching Starting the en gine and oper ating it at idle 2 Connections Cylinder identification sensor cou pler Wire harness ECU coupler Sub wire harness coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and...

Page 561: ...ns Crankshaft position sensor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between the crankshaft position sensor coupler and ECU cou pler gray gray b...

Page 562: ...fective intake air pressure sensor Execute the diagnostic mode Code No d 03 Replace if defective Refer to CHECKING THE IN TAKE AIR PRESSURE SEN SOR on page 8 242 Fault code No 14 Symptom Intake air pressure sensor hose system malfunction clogged or detached hose Diagnostic code No d 03 Intake air pressure sensor Order Item components and probable cause Check or maintenance job Reinstatement method...

Page 563: ...coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness and or sub wire harness Repair or replace if there is an open or short circuit Between throttle position sen sor coupler and ECU coupler black blue black blue yellow yellow blue blue 4 Throttle position sensor lead wire open circuit output voltage check Check for open circuit and r...

Page 564: ...CU coupler Sub wire harness coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Throttle position sensor lead wire open circuit output voltage check Check for open circuit and re place the throttle position sen sor black blue yellow Open circuit item Output voltage Ground wi...

Page 565: ...on of the coupler If there is a malfunction repair it and connect the coupler se curely If the transmis sion is in gear retracting the sidestand If the transmis sion is in neu tral reconnecting the wiring 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between relay unit coupler and ECU coupler black red black red Between relay unit coupler and sidest...

Page 566: ...t temperature sensor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between coolant temperature sensor coupler and ECU cou pler black blue black blue gr...

Page 567: ...r temperature sensor cou pler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between intake air temperature sensor coupler and ECU cou pler black blue black blu...

Page 568: ...lay unit coupler Wire harness ECU coupler Sub wire harness coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness and or sub wire harness Repair or replace if there is an open or short circuit Between O2 sensor coupler and ECU coupler black...

Page 569: ...e engine can not be restarted unless the main switch is first turned OFF 2 Installed condition of lean angle sen sor Check the installed direction and condition of the sensor 3 Connections Lean angle sensor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se ...

Page 570: ...alfunction repair it and connect the coupler se curely Starting the en gine warming it up until the coolant temper ature is 60 C 140 F or more and then running it be tween 2000 3000 r min un til the engine trouble warn ing light turns off 2 Open or short circuit in wire harness and or sub wire harness Repair or replace if there is an open or short circuit Between O2 sensor coupler and ECU coupler ...

Page 571: ...er to CHECKING THE FUEL PRESSURE on page 7 8 Check the throttle position sen sor Execute the diagnostic mode Code No d 01 Replace if defective Check the fuel system discon nection etc Repair or replace if there is a malfunction Check the intake system im proper sealing etc Repair or replace if there is a malfunction Fault code No 31 Symptom The amount of air fuel ratio feedback compensation is mai...

Page 572: ...Open or short circuit in wire harness and or sub wire harness Repair or replace if there is an open or short circuit Between O2 sensor coupler and ECU coupler black blue black blue gray white gray white Between O2 sensor coupler and relay unit coupler red blue red blue Between O2 sensor coupler and sub wire harness coupler black black 3 Defective O2 sensor Replace if defective Unable to output a r...

Page 573: ...locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and oper ating it at idle 2 Open or short circuit in wire harness and or front cowling wire harness Repair or replace if there is an open or short circuit Between cylinders 1 4 igni tion coil connector and ECU coupler orange orange Between cylinders 1 4 igni tion coil connect...

Page 574: ...ocking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and oper ating it at idle 2 Open or short circuit in wire harness and or front cowling wire harness Repair or replace if there is an open or short circuit Between cylinders 2 3 igni tion coil connector and ECU coupler gray red gray red Between cylinders 2 3 igni tion coil conn...

Page 575: ...y pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between lean angle sensor coupler and ECU coupler black blue black blue yellow green yellow green blue blue 3 Defective lean angle s...

Page 576: ... for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and input ting the vehicle speed signals by operating the vehicle at a 20 to 30 km h A 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between rear wheel sensor coupler and ABS ECU c...

Page 577: ...AE Between relay unit coupler and ECU coupler black red black red Between neutral switch coupler and ECU coupler sky blue sky blue FJR13AE B 3 Faulty shift drum neutral detection ar ea Replace if defective Refer to TRANSMISSION on page 5 124 B 4 Defective gear position switch neutral circuit FJR13A Defective neutral switch FJR13AE Execute the diagnostic mode Code No d 21 Replace if defective Refer...

Page 578: ...CU coupler blue yellow blue yellow red blue red blue Between relay unit coupler and engine stop switch coupler red black red black 3 Malfunction or open circuit in fuel pump relay Execute the diagnostic mode Code No d 09 Replace if defective If there is no malfunction with the fuel pump relay replace the ECU Fault code No 44 Symptom An error is detected while reading or writing on EEPROM CO adjust...

Page 579: ...n page 8 228 3 Malfunction in rectifier regulator Replace if defective Refer to CHARGING SYS TEM on page 8 29 4 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between battery and main switch coupler red red Between main switch coupler and ignition fuse brown blue brown blue Between ignition fuse and ECU coupler red white red white Fault code No 50 Symp...

Page 580: ...lue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 2 Symptom No signals are received from the ECU within the specified duration Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Meter assembly coupler Wire harness ECU coupler Front cowling wire harness coupler Che...

Page 581: ...lue yellow blue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 4 Symptom Non registered data has been received from the meter Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Meter assembly coupler Wire harness ECU coupler Front cowling wire harness coupler Check...

Page 582: ... L Sb W B Y Y W Y L Sb W L W W W L G W G R B R GRAY P L G B R RED L B L Y RED GRAY W B Br B L W W Y L B B W Gy W G R L R Y G W L G Y Sb Br W B W B G R R L ON OFF R R Br W Br L Br R Br R R R G R R R R B O R L Gy R R L R L B R R R B B R R W L W L R W B R G B R B Y R B G Y G W W Y L W Dg Ch B W B R W R W R W G O Br R L B L B W L B R L W B W L Y B L B L B L B L Br W G W Y L L B L P W L W Gy W W B Gy Y...

Page 583: ...el injection system fuse 8 Main fuse 10 Battery 15 Fuel pump 19 Coupler 3 wire harness front cowling wire harness 20 Relay unit 22 Fuel pump relay 43 ECU engine control unit 52 Coupler 4 wire harness front cowling wire harness 57 Ignition fuse ...

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

Page 585: ...FUEL PUMP SYSTEM 8 102 19 Coupler 3 wire harness front cowling wire harness 52 Coupler 4 wire harness front cowling wire harness 68 Engine stop switch ...

Page 586: ...attery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 221 Replace the main switch 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 221 Replace the right handlebar switch 5 Check the relay unit fuel pump re lay Refer to CHECKING THE RE LAYS on page 8 231 Replace the relay unit 6 Check the fuel pump Refer to CHECKING ...

Page 587: ...FUEL PUMP SYSTEM 8 104 ...

Page 588: ...R Y R W L R G L Br R Y Br B R W L R G L Br L R Y G L R Y Y W R Br B R W G Y P W B L BLAC Y L L G B R RED L B L Y RED ON OFF R R Br W Br L Br R Br R R R G R R R R LR L B R R R B B R R W L W L R R G R Y R Y R W Br L R Br L Br L Br L Br L Br B Br B R Y Y W G L G L W B Br W W W W W W R R B G B W B B R R W Br B G Y B R Br L B R L G B Lg W B G W Y Br R Y G L R W L Y L B Br 1 2 3 4 5 6 7 8 9 11 12 13 14 ...

Page 589: ...106 1 Main switch 7 Backup fuse odometer clock and windshield drive system 8 Main fuse 9 Coupler 1 wire harness front cowling wire harness 10 Battery 52 Coupler 4 wire harness front cowling wire harness 55 Signaling system fuse ...

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

Page 591: ...WINDSHIELD DRIVE SYSTEM 8 108 9 Coupler 1 wire harness front cowling wire harness 52 Coupler 4 wire harness front cowling wire harness 74 Windshield position switch 98 Windshield drive unit ...

Page 592: ...hat there is no foreign mate rial between the cable and the pul ley Remove the foreign material 3 Check the fuses Main signaling system and back up Refer to CHECKING THE FUS ES on page 8 227 Replace the fuse s 4 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 228 Clean the battery terminals Recharge or replace the battery 5 Check the main switch Refer to CHECKING THE SWITCHE...

Page 593: ...G OK 7 Check the entire windshield drive system wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 105 and CIRCUIT DIA GRAM 2 2 on page 8 107 Properly connect or repair the windshield drive system wiring Replace the windshield drive unit ...

Page 594: ...Y R W L R G L Br R Y Br B R W L R G L Br L R Y G L R Y Y W R Br B R W G Y P W B L BLAC Y L L G B R RED L B L Y RED ON OFF R R Br W Br L Br R Br R R R G R R R R LR L B R R R B B R R W L W L R R G R Y R Y R W Br L R Br L Br L Br L Br L Br B Br B R Y Y W G L G L W B Br W W W W W W R R B G B W B B R R W Br B G Y B R Br L B R L G B Lg W B G W Y Br R Y G L R W L Y L B Br 1 2 3 4 5 6 7 8 9 11 12 13 14 10...

Page 595: ...ACCESSORY BOX SYSTEM 8 112 1 Main switch 8 Main fuse 10 Battery 52 Coupler 4 wire harness front cowling wire harness 55 Signaling system fuse ...

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

Page 597: ...ACCESSORY BOX SYSTEM 8 114 52 Coupler 4 wire harness front cowling wire harness 77 Accessory box solenoid ...

Page 598: ... CHARGING THE BATTERY on page 8 228 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 221 Replace the main switch 4 Check the accessory box solenoid Refer to CHECKING THE ACCES SORY BOX SOLENOID on page 8 243 Replace the accessory box solenoid 5 Check the entire accessory box system wiring Refer to CIRCUIT DIAGRAM 1 2 on pa...

Page 599: ...ACCESSORY BOX SYSTEM 8 116 ...

Page 600: ... BLACK L B L Y L Sb W B Y Y W Y L Sb W L W W W L G W G R B R GRAY P L G B R RED L B L Y RED GRAY W B Br B L W W Y L B B W Gy W G R L R Y G W L G Y Sb Br W B W B G R R L ON OFF R R Br W Br L Br R Br R R R G R R R R B O R L Gy R R L R L B R R R B B R R W L W L R W B R G B R B Y R B G Y G W W Y L W Dg Ch B W B R W R W R W G O Br R L B L B W L B R L W B W L Y B L B L B L B L Br W G W Y L L B L P W L W...

Page 601: ...e harness 19 Coupler 3 wire harness front cowling wire harness 21 Starting circuit cut off relay 24 ABS test coupler 25 ABS ECU electronic control unit 26 Front wheel sensor 27 Rear wheel sensor 28 Rear brake light switch 29 Brake light relay 32 Tail brake light 43 ECU engine control unit 52 Coupler 4 wire harness front cowling wire harness 55 Signaling system fuse 57 Ignition fuse ...

Page 602: ... W Ch G Y G Y Dg Br W L R W Ch Br G R B B B Ch B W B R R B Dg W B B Y G Y G Y R B B R Ch B W W B B Y Dg B R Y Dg B Lg L Y Br W L B P Sb B Y Ch R Y Dg B Lg B R Br G L B P Sb W B Y Ch Ch L R B Dg L R B Ch L R B Dg L R B UP DOWN W B G L B Y R G P Br P Br B R G R G B L W Y W P B Y Y L G W B L B W B W B L G B Sb W G R B R L W Y W P B Y B W B B R W W P Sb Dg Ch Y B G L B Ch Br G Dg Sb W Br W Sb Lg L B B...

Page 603: ... harness front cowling wire harness 19 Coupler 3 wire harness front cowling wire harness 52 Coupler 4 wire harness front cowling wire harness 67 Front brake light switch 68 Engine stop switch 69 Start switch 82 ABS warning light 83 Multi function meter ...

Page 604: ...L B L Y RED L G B R RED B Y Y W Y L Sb W L W W W L G W G R B R GRAY P B W R W GRAY B L R GRAY GRAY B W B G R R L W B Br B L W W Y L B B W Gy W G R L R Br B Y W L G Y Sb Br W ON OFF R R Br W Br L Br R Br R R R G R R R R B O R L Gy R R L R L B R R R B B B R R W L W L R R W R W W Y L B R G W Sb W G R W L Br R L W B L Gy W Gy W Gy W B R L W Y L Y B L B L L W W L O G B W B L Y W B W B B L L L2 G Y B L ...

Page 605: ...ing circuit cut off relay 22 ABS test coupler 23 ABS ECU electronic control unit 24 Front wheel sensor 25 Rear wheel sensor 26 Coupler 3 wire harness front cowling wire harness 27 Diode 28 Brake light relay 29 Rear brake light switch 32 Tail brake light 44 ECU engine control unit 57 MCU motor control unit 64 Coupler 5 wire harness front cowling wire harness 68 Signaling system fuse 70 Ignition fus...

Page 606: ...r W Ch G Y G Y Dg Br W L R W Ch Br G R B B Lg W R B BLACK B Y Y W Y L Sb W L W W W L G W G R B R GRAY P L B B Dg Br W P Lg Sb Ch R Y BLACK Ch R Y Br G Dg B Lg Sb W BLACK P L B Ch L R B Dg L R B Ch L R B Dg L R B UP DOWN PUSH Shift up Shift down W B R G R B G Y B B W Ch Dg G L B Y O W B L B O B G R G B Br L R G W Lg W P Br P Br Lg W R B B R G R G B L W Y W P B Y Y L G W B L B W B L B B G B Sb W G R...

Page 607: ... harness front cowling wire harness 26 Coupler 3 wire harness front cowling wire harness 64 Coupler 5 wire harness front cowling wire harness 86 Front brake light switch 87 Engine stop switch 88 Start switch 93 ABS warning light 94 Multi function meter ...

Page 608: ...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 Left front brake caliper 13 Right front brake caliper partially operated together with the rear brake 14 Front wheel sensor 15 Front wheel sensor rotor ...

Page 609: ...ABS ANTI LOCK BRAKE SYSTEM 8 126 ...

Page 610: ... B Y G W W L W L W P B R G B G R B Y Y W Y L Sb W L W W W LG W P G R B R Ch Dg R G B W G R Sb B L B W W G B B R L W Y W P B Y R W G W Y L Sb W Y W B W Gy Gy W W Gy B Ch B W B R R B Dg W B B Y G Y R B B R Ch B W G Y W B B Y Dg B W B Br B L W W Y L B B W Gy W G R L R Y G W L G Y Sb Br W B W B G R R L 2 4 5 1 6 3 BLACK BLACK BLACK BLACK GRAY GRAY GRAY ...

Page 611: ...ABS ANTI LOCK BRAKE SYSTEM 8 128 1 Meter assembly coupler 2 ABS test coupler 3 Rear wheel sensor coupler 4 ABS ECU coupler 5 Front wheel sensor coupler 6 Wire harness front cowling wire harness coupler ...

Page 612: ...B Sb 5 W B W Gy 1 6 Ch Dg R G B W G R Sb B L Lg W W G B B R L W Y W P B Y R W G W Y L Sb W Y 3 Gy W W Gy Sb W Y L Y W B Y G W W L W L W P B R G B G R B Y Y W Y L Sb W L W W W L G W P G R B R G Y Dg B W W B Ch R B B B W Dg G Y B Ch W B R B Br B L R R Y R W G L Br R Y Br B L R R W G L Br 4 GRAY GRAY BLACK BLACK BLACK BLACK GRAY ...

Page 613: ...ABS ANTI LOCK BRAKE SYSTEM 8 130 1 Meter assembly coupler 2 ABS test coupler 3 Rear wheel sensor coupler 4 ABS ECU coupler 5 Front wheel sensor coupler 6 Wire harness front cowling wire harness coupler ...

Page 614: ...perform a final check before delivering the vehicle to the customer Refer to D 3 FINAL CHECK on page 8 168 ABS operation when the ABS warning light comes on 1 The ABS warning light remains on ABS operates as a normal brake system A malfunction was detected using the ABS self diagnosis function 2 The ABS warning light comes on and then goes off when starting the engine ABS operation is normal The A...

Page 615: ... malfunction occurs EAS27800 BASIC INSTRUCTIONS FOR TROUBLESHOOTING WARNING EW3P61004 Perform the troubleshooting A B C D in order Be sure to follow the order since a wrong diagnosis could result if the steps are followed in a different order or omitted Use sufficiently charged regular batteries only A Malfunction check using the ABS warning light B Detailed check of the malfunction The results of...

Page 616: ...fault codes D 1 Delete the fault codes D 2 Delete function test Finished B 5 Malfunctions are currently detected C 3 Does the ABS warning light remain on Connect the test coupler adapter to the ABS test coupler and then check for fault codes in the multi function display Are fault codes displayed in the multi function display NOTE The ABS ECU fuse is blown The ABS ECU coupler is disconnected or a ...

Page 617: ...itch is turned to ON C 1 2 The ABS warning light and all other indicator lights fail to come on C 2 ET3P6D008 B 2 THE ABS WARNING LIGHT FLASHES 1 Test coupler adapter Check if the test coupler adapter 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 If the test coupler adapter is not connected ...

Page 618: ...nected to the ABS test coupler to display the fault codes If the adapter is not connected the ABS warning light will come on or flash but no fault codes will be dis played ET3P6D011 B 5 MALFUNCTION ARE CURRENTLY DETECTED Remove front cowling right inner panel 1 to access the ABS test coupler Connect the test coupler adapter to the ABS test coupler When the test coupler adapter is connected to the ...

Page 619: ... The battery voltage is low Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 228 If the battery voltage is low clean the battery terminals and recharge it or replace the battery 2 ABS ECU fuse Check the ABS ECU fuse for continuity Refer to CHECKING THE FUSES on page 8 227 If the ABS ECU fuse is blown replace the fuse 3 ABS ECU coupler and front cowling wire h...

Page 620: ...d to the ground the internal circuit of the meter assembly is defective Replace the meter assembly ET3P6D016 C 5 DIAGNOSIS USING THE FAULT CODES Connect the test coupler adapter to the ABS test coupler and then turn the main switch to ON Information for the fault codes from the ABS ECU is contained in the following table Refer to this table for troubleshooting TIP Record all of the fault codes dis...

Page 621: ...ight signal is not received prop erly when main switch is turned to ON brake light circuit or front or rear brake light switch circuit Improper adjustment of the rear brake light switch Brake light switches Brake light relay Wire harness and front cowling wire har ness brake light switch circuit Brake light system couplers and connectors AbS_24 Brake light signal is not received prop erly while ve...

Page 622: ...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 Installation of the rear wheel sensor Rear wheel sensor housing Rear wheel sensor rotor AbS_51 AbS_52 Po...

Page 623: ...ff Perform a tri al run at a constant speed of 30 km h and check that the ABS warning light does not come on 2 Installed condition of wheel bearings axle sensor housing and sensor ro tor Check the components for loose ness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 19 3 Foreign material inside sensor hous ing Check the interior of the sensor housing and the surface of the sen...

Page 624: ...ng light does not come on 2 Installed condition of wheel bearings axle sensor housing and sensor ro tor Check the components for loose ness distortion and bends Refer to CHECKING THE REAR WHEEL on page 4 28 3 Foreign material inside sensor hous ing Check the interior of the sensor housing and the surface of the sensor rotor for foreign material such as metal particles Clean the sensor housing and ...

Page 625: ...t come on 2 Installed condition of wheel bearings axle sensor housing and sensor ro tor Check the components for loose ness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 19 3 Foreign material inside sensor hous ing Check the interior of the sensor housing and the surface of the sensor rotor for foreign material such as metal particles Clean the sensor housing and sensor rotor if...

Page 626: ...of the sensor rotor for foreign material such as metal particles Clean the sensor housing and sensor rotor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 28 4 Defective sensor rotor Check the surface of the sensor rotor for damage If there is visi ble damage replace the sensor rotor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 28 5...

Page 627: ...erminal 4 If there is continuity the wire harness is defective Properly repair or replace the wire har ness Check that there is no continuity between the white terminal 1 and the black terminal 2 and between the white terminal 3 and the black terminal 4 If there is continuity the wire harness is defective Properly repair or replace the wire har ness 5 ABS ECU 6 Front wheel sensor Fault code No AbS...

Page 628: ...eel sensor circuit Order Item components and probable cause Check or maintenance job Reinstatement confirmation method 1 Connections Rear wheel sensor coupler ABS ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely TIP Turn the main switch to OFF be fore disconnecting or c...

Page 629: ...rminal 4 If there is continuity the wire harness is defective Properly repair or replace the wire har ness Check that there is no continuity between the gray terminal 1 and the white terminal 2 and between the gray terminal 3 and the white terminal 4 If there is continuity the wire harness is defective Properly repair or replace the wire har ness 5 ABS ECU 6 Rear wheel sensor Fault code No AbS_16 ...

Page 630: ...t codes If fault code No AbS_16 could not be deleted the rear wheel sensor is defective Re place the rear wheel sensor TIP Before deleting the fault codes record all of the fault codes and perform the related checks and maintenance Fault code No AbS_16 Symptom No continuity in the rear wheel sensor circuit Order Item components and probable cause Check or maintenance job Reinstatement confirmation...

Page 631: ...ive sensor rotor Check the surface of the sensor rotor for damage If there is visible damage re place the sensor rotor Fault code No AbS_18 AbS_46 Symptom Missing pulses detected in the rear wheel sen sor signal Order Item components and probable cause Check or maintenance job Reinstatement confirmation method 1 Installed condition of wheel bearings axle sensor housing and sensor ro tor Check the ...

Page 632: ...e electric starting sys tem Refer to ELECTRIC STARTING SYSTEM on page 8 13 Push the start switch and check that the engine starts Turn the main switch to ON and check that the ABS warning light comes on for 2 seconds then goes off Check that the ABS warning light comes on while the start switch is be ing pushed 2 Connections Starter relay coupler ABS ECU coupler Right handlebar switch coupler Fron...

Page 633: ...Refer to CHECKING THE SWITCHES on page 8 221 Check that the brake light comes on when the front or rear brake is applied Turn the main switch to ON and check that the ABS warning light comes on for 2 seconds then goes off 2 Connections ABS ECU coupler Brake light relay coupler Front brake light switch connectors Rear brake light switch coupler Front cowling wire harness coupler Check the coupler f...

Page 634: ... that the ABS warning light does not flash when the front rear or both brakes are applied for 2 seconds or more 2 Connections ABS ECU coupler Brake light relay coupler Front brake light switch connectors Rear brake light switch coupler Front cowling wire harness coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair...

Page 635: ...d fuse Check the ABS solenoid fuse If the ABS solenoid fuse is blown replace the fuse and check the wire harness Refer to CHECKING THE FUS ES on page 3 44 3 Connections ABS ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely TIP Turn the main switch to OFF be fore disconne...

Page 636: ...tement confirmation method 1 Short circuit in solenoid relay Replace the hydraulic unit as sembly Turn the main switch to ON and check that the ABS warning light comes on for 2 seconds then goes off Perform hy draulic unit operation test 1 and check that the oper ation of the hydraulic unit is normal 2 Hydraulic unit assembly internal mal function Replace the hydraulic unit as sembly ...

Page 637: ... fuse Check the ABS motor fuse If the ABS motor fuse is blown replace the fuse and check the wire har ness Refer to CHECKING THE FUS ES on page 3 44 3 Connections ABS ECU coupler Starter relay coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely TIP Turn the main switch to OFF ...

Page 638: ...is normal Order Item components and probable cause Check or maintenance job Reinstatement confirmation method 1 Rotation of wheel Check that there is no brake disc drag on the front wheel and make sure that it rotates smoothly Check the front wheel axle for loose bearings and bends and the brake discs for distortion Refer to CHECKING THE FRONT BRAKE DISCS on page 4 37 Perform hy draulic unit op er...

Page 639: ...aster cylinder to the hydraulic unit and from the hydraulic unit to the front brake calipers and the metering valve are correct See WARNING and NOTE Fault code No AbS_41 Symptom Front wheel will not recover from the locking tendency even though the signal is continuous ly transmitted from the ABS ECU to release the hydraulic pressure when the battery voltage is normal Order Item components and pro...

Page 640: ... the reverse order when the final check on page D 3 FINAL CHECK on page 8 168 is performed If the brake pipes to the proportioning valve and the metering valve are switched during assembly the brakes will continue to operate as 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 o...

Page 641: ...ke master cylinder and brake cali per Check that the brake fluid pres sure is correctly transmitted to the brake caliper when the brake pedal is operated and that the pressure decreases when the pedal is released 3 Brake fluid Visually check the brake fluid in the brake fluid reservoir for wa ter foreign materials solidifica tion and contamination Check for air in the brake lines 4 Brake lines Che...

Page 642: ...al check on page D 3 FINAL CHECK on page 8 168 is performed If the brake pipes to the proportioning valve and the metering valve are switched during assembly the brakes will continue to operate as 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 D 3 FINAL CHECK on page ...

Page 643: ...of 30 km h and check that the ABS warning light does not come on 2 Installed condition of wheel bearings axle sensor housing and sensor ro tor Check the components for loose ness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 19 3 Foreign material inside sensor hous ing Check the interior of the sensor housing and the surface of the sensor rotor for foreign material such as metal...

Page 644: ...sor housing and the surface of the sensor rotor for foreign material such as metal particles Clean the sensor housing and sensor rotor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 28 4 Defective sensor rotor Check the surface of the sensor rotor for damage If there is visible damage re place the sensor rotor Fault code No AbS_51 AbS_52 Symptom Power voltage...

Page 645: ...f Perform a tri al run and check that the ABS warning light does not come on 2 Connections ABS ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely TIP Turn the main switch to OFF be fore disconnecting or connecting a coupler 3 Open or short circuit in wire harness Repair o...

Page 646: ...e on 2 Connections ABS ECU coupler Starter relay coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely TIP Turn the main switch to OFF be fore disconnecting or connecting a coupler 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Bet...

Page 647: ...ause Check or maintenance job Reinstatement confirmation method 1 Defective internal monitor circuit sen sor power Replace the hydraulic unit as sembly Turn the main switch to ON and check that the ABS warning light comes on for 2 seconds then goes off Perform hy draulic unit operation test 1 and check that the oper ation of the hydraulic unit is normal ...

Page 648: ...ness TIP Disconnect the ABS ECU coupler before checking the wire har ness Turn the main switch to ON and check that the ABS warn ing light comes on for 2 sec onds then goes off 2 Short circuit in front wheel sensor lead Check that there is no short cir cuit between the white terminal 3 and the gray terminal 4 Check that there is no short cir cuit between the frame ground and the white terminal 3 I...

Page 649: ...ness TIP Disconnect the ABS ECU coupler before checking the wire har ness Turn the main switch to ON and check that the ABS warn ing light comes on for 2 sec onds then goes off 2 Short circuit in rear wheel sensor lead Check that there is no short cir cuit between the white terminal 3 and the gray terminal 4 Check that there is no short cir cuit between the frame ground and the white terminal 3 If...

Page 650: ...ctions have not been re paired Diagnose the malfunctions using the fault codes 8 Turn the main switch to OFF 9 Disconnect the test coupler adapter from the ABS test coupler and then install the protec tive cap onto the ABS test coupler Deleting the fault codes is now finished TIP Do not forget to install the protective cap onto the ABS test coupler NOTICE ECA3P6D014 Since the fault codes remain in...

Page 651: ...ID LEVEL on page 3 29 2 Check the wheel sensor housings and wheel sensors for proper installation Refer to INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS on page 4 23 and IN STALLING THE REAR WHEEL REAR BRAKE DISC on page 4 30 3 Perform hydraulic unit operation test 1 or 2 Refer to HYDRAULIC UNIT OPERATION TESTS on page 4 66 4 Delete the fault codes Refer to D 1 DELETING THE FAULT CODES on page 8 16...

Page 652: ... Y Br B R Br R Br L L B L Y RED L G B R RED B Y Y W Y L Sb W L W W W L G W G R B R GRAY P B W R W GRAY B L R GRAY GRAY B W B G R R L W B Br B L W W Y L B B W Gy W G R L R Br B Y W L G Y Sb Br W ON OFF R R Br W Br L Br R Br R R R G R R R R B O R L Gy R R L R L B R R R B B B R R W L W L R R W R W W Y L B R G W Sb W G R W L Br R L W B L Gy W Gy W Gy W B R L W Y L Y B L B L L W W L O G B W B L Y W B W...

Page 653: ...n fuse 9 Battery 26 Coupler 3 wire harness front cowling wire harness 44 ECU engine control unit 64 Coupler 5 wire harness front cowling wire harness 65 Headlight on off grip warmer relay 68 Signaling system fuse 69 Headlight fuse 72 Grip warmer control unit ...

Page 654: ...W Ch G Y G Y Dg Br W L R W Ch Br G R B B Lg W R B BLACK B Y Y W Y L Sb W L W W W L G W G R B R GRAY P L B B Dg Br W P Lg Sb Ch R Y BLACK Ch R Y Br G Dg B Lg Sb W BLACK P L B Ch L R B Dg L R B Ch L R B Dg L R B UP DOWN PUSH Shift up Shift down W B R G R B G Y B B W Ch Dg G L B Y O W B L B O B G R G B Br L R G W Lg W P Br P Br Lg W R B B R G R G B L W Y W P B Y Y L G W B L B W B L B B G B Sb W G R B...

Page 655: ...GRIP WARMER SYSTEM FJR13AE only 8 172 26 Coupler 3 wire harness front cowling wire harness 64 Coupler 5 wire harness front cowling wire harness 114 Left grip warmer 115 Right grip warmer ...

Page 656: ...ng system and head light Refer to CHECKING THE FUS ES on page 8 227 Replace the fuse s 2 Check that the engine is started Start the engine 3 Check that the headlight is on Replace the headlight on off grip warmer relay 4 Check the grip warmers Refer to CHECKING THE GRIP WARMERS FJR13AE only on page 8 243 Replace the grip warmer s 5 Check the entire grip warmer sys tem wiring Refer to CIRCUIT DIAGR...

Page 657: ...ight green white and check for continuity between the light green white terminal of the ECU coupler and the light green white terminal of the grip warmer control unit coupler The wiring system from ECU coupler to the grip warmer control unit coupler black and light green white is faulty and must be repaired 2 Check that the grip warmer adjust ing knob is set to the HI position Adjust the grip warm...

Page 658: ...R Br B R W G Y Y G Br G Y Br B R Br R Br L L B L Y RED L G B R RED B Y Y W Y L Sb W L W W W L G W G R B R GRAY P B W R W GRAY B L R GRAY GRAY B W B G R R L W B Br B L W W Y L B B W Gy W G R L R Br B Y W L G Y Sb Br W ON OFF R R Br W Br L Br R Br R R R G R R R R B O R L Gy R R L R L B R R R B B B R R W L W L R R W R W W Y L B R G W Sb W G R W L Br R L W B L Gy W Gy W Gy W B R L W Y L Y B L B L L W ...

Page 659: ...tch 35 Sidestand switch 44 ECU engine control unit 53 Shift actuator motor 54 Shift actuator sensor 55 Clutch actuator sensor 56 Clutch actuator motor 57 MCU motor control unit 58 YCC S test coupler 59 Coupler 4 wire harness front cowling wire harness 60 Foot shift switch 61 YCC S speed sensor 62 Gear position sensor 63 YCC S control relay 64 Coupler 5 wire harness front cowling wire harness 66 Co...

Page 660: ...Br R B B Br W Ch G Y G Y Dg Br W L R W Ch Br G R B B Lg W R B BLACK B Y Y W Y L Sb W L W W W L G W G R B R GRAY P L B B Dg Br W P Lg Sb Ch R Y BLACK Ch R Y Br G Dg B Lg Sb W BLACK P L B Ch L R B Dg L R B Ch L R B Dg L R B UP DOWN PUSH Shift up Shift down W B R G R B G Y B B W Ch Dg G L B Y O W B L B O B G R G B Br L R G W Lg W P Br P Br Lg W R B B R G R G B L W Y W P B Y Y L G W B L B W B L B B G ...

Page 661: ...g wire harness 64 Coupler 5 wire harness front cowling wire harness 66 Coupler 6 wire harness front cowling wire harness 86 Front brake light switch 87 Engine stop switch 88 Start switch 94 Multi function meter 96 Engine trouble warning light 102 Hand shift switch 103 Hand shift lever switch shift up 104 Hand shift lever switch shift down 105 Hand shift select button 106 Hand shift select indicato...

Page 662: ...fer to CHECKING THE FUS ES on page 8 227 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 228 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 221 Replace the main switch 4 Check the entire YCC S system wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 175 and CIRCUIT DIA GRAM 2 2 on ...

Page 663: ...or control unit After the engine has been stopped the lowest fault code number appears on the odometer tripmeter fuel reserve trip meter LCD Once a fault code has been displayed it remains stored in the memory of the MCU motor control unit until it is deleted TIP If the engine trouble indicator 1 YCC S indicator 2 and engine trouble warning light 3 all come on malfunctions have been detected in bo...

Page 664: ...n When an abnormal signal is received from a sensor the MCU motor control unit processes the spec ified values that are programmed for each sensor in order to provide the YCC S system with alternate operating instructions that enable the system to continue operating or stop operating depending on the conditions Self Diagnostic Function table SHIFT 3 1 2 a b c c d a Main switch OFF b Main switch ON...

Page 665: ...t signal of shift actuator sensor is ab normal Output signal of shift actuator sen sor is below 0 5 V or above 4 5 V Unable Unable Sh_ _21 Output signal of gear position sensor is ab normal Output signal of gear position sen sor is below 0 3 V or above 4 7 V Unable Unable Sh_ _22 Output signal of foot shift switch is abnor mal Output signal of foot shift switch is below 0 9 V or above 4 1 V Able A...

Page 666: ... up or shift down are closed at the same time Able Able Sh_ _39 Ignition timing retard output signal is abnor mal Detected ignition retard signal from MCU motor control unit to ECU is abnormal Able Able Sh_ _41 Coolant temperature sensor signal is ab normal Coolant temperature sensor signal is too high or too low Able Able Sh_ _42 Communication be tween ECU and multi function meter is ab normal Er...

Page 667: ...eck the fault code number displayed on the meter and diagnostic code Sh_ _61 Refer to Diagnostic code table Diagnostic code No Sh_ _61 b Identify the faulty system with the fault code Refer to Self Diagnostic Function table 2 Check and repair the probable cause of the malfunction Refer to TROUBLESHOOTING DETAILS on page 8 190 3 Perform the reinstatement action for the YCC system Refer to Reinstate...

Page 668: ...emove the front cowling left inner panel 1 to access the YCC S test coupler 1 3 Remove the protective cap from the YCC S test coupler 4 Connect the test coupler adapter 2 to the YCC S test coupler 5 Push and hold the hand shift select button 1 turn the main switch 2 to ON and continue to push the button for 8 seconds or more TIP All displays on the meter disappear except the odometer tripmeter fue...

Page 669: ...ference value Checking method Sh_ _61 Malfunction history code display No history Sh_ _61 History exists Fault code numbers Sh_ _11 Sh_ _52 First displays Sh_ _61 for 6 seconds and then displays each fault code number that is stored in the mal function history If more than one code number is detected the dis play alternates ev ery two seconds to show all the de tected code num bers When all of the...

Page 670: ... op eration TIP The checking meth od for the diagnostic code Sh_ _63 can not be performed when any of the fol lowing fault codes are detected Sh_ _11 Sh_ _12 Sh_ _13 Sh_ _15 Sh_ 16 Sh_ _17 Sh_ _25 Sh_ _26 Sh_ _36 Sh_ _37 and Sh_ _44 Sh_ _63 The clutch actuator can be operated in this mode 1 The hand shift select indicator light comes on when the clutch is engaged 2 Set the engine stop switch to an...

Page 671: ...rol unit detects the signal from the shift actuator sensor If the signal received after upshifting is correct the hand shift select indicator light will come on If the signal received after upshifting in incorrect the hand shift select indicator light will flash 4 Set the engine stop switch to and operate the hand shift lever switch shift down simultaneously The MCU motor control unit operates the...

Page 672: ... is pushed 6 Shift the transmission into 4th gear us ing the hand shift lever switch shift down and then rotate the rear wheel at least 1 2 turn by hand to ensure that the dog completely engages the 4th gear 7 Push the start switch If the gear position sensor output signal is correct for the 4th gear position the hand shift select indicator light will come on for 0 5 second 8 Repeat steps 6 and 7 ...

Page 673: ...engagement point manually The clutch engagement point while the ve hicle is starting off can be adjusted manu ally to 21 engine speed settings in this mode The initial setting of the clutch en gagement point varies according to the ve hicle Hand shift lever switch operation shift up To increase the clutch engagement point by approximately 100 150 r min oper ate the hand shift lever switch shift up...

Page 674: ... Refer to CHECKING AND CHARGING THE BATTERY on page 8 228 3 Malfunction in rectifier regulator Replace if detective Refer to CHARGING SYS TEM on page 8 29 4 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between battery and main switch coupler red red Between main switch coupler and signaling system fuse brown blue brown blue Between signaling system f...

Page 675: ...k or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Clutch actuator motor coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to OFF See NOTE 2 Open or short circuit in wire harness Repair or replace if th...

Page 676: ...use Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Shift actuator motor coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to OFF See NOTE 2 Open or short circuit in wire harness Repair or replac...

Page 677: ...tor coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to OFF See NOTE 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between clutch actuator motor coupler and MCU motor con trol unit coupler black white ...

Page 678: ... Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Clutch actuator motor coupler Shift actuator motor coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to O...

Page 679: ...bable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Clutch actuator motor coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to OFF See NOTE 2 Open or short circuit in wire harness Repair ...

Page 680: ... and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Shift actuator motor coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to OFF See NOTE 2 Open or short circuit in wire harness ...

Page 681: ...ut signal of shift actuator sensor is abnor mal Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Shift actuator sensor coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning th...

Page 682: ... the coupler If there is a malfunction repair it and connect the coupler se curely Repairing the cause of the malfunction 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between gear position sensor coupler and MCU motor con trol unit coupler yellow yellow blue blue black blue black blue 3 Defective gear position sensor Adjust or replace if defective ...

Page 683: ...red orange blue blue black black blue 3 Defective foot shift switch Adjust or replace if defective Refer to ADJUSTING THE FOOT SHIFT SWITCH on page 5 76 and CHECKING THE FOOT SHIFT SWITCH FJR13AE only on page 8 245 Fault code No Sh_ _23 Symptom No input signal from sidestand switch Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU...

Page 684: ... control unit when main switch is turned to ON Order Item components and probable cause Check or maintenance job Reinstatement method 1 Malfunction in MCU motor control unit Replace the MCU motor control unit Replacing the MCU motor control unit Fault code No Sh_ _26 Symptom Abnormal clutch movement is detected during check when main switch is turned to ON Order Item components and probable cause ...

Page 685: ...oupler adapter is not connected Refer to DIAGNOSTIC MODE on page 8 185 Turning the main switch to OFF See NOTE 2 Short circuit in wire harness Repair or replace if there is a short circuit Between YCC S test coupler and MCU motor control unit coupler blue yellow blue yellow Fault code No Sh_ _31 Symptom Engine speed signal is abnormal Order Item components and probable cause Check or maintenance j...

Page 686: ...r it and connect the coupler se curely Turning the main switch to OFF See NOTE 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between YCC S speed sensor coupler and MCU motor con trol unit coupler white yellow white yellow blue blue black blue black blue 3 Defective YCC S speed sensor Replace if detective Refer to CHECKING THE YCC S SPEED SENSOR FJR1...

Page 687: ...hite blue white 3 Defective relay unit Check and replace relay unit Refer to CHECKING THE RE LAYS on page 8 231 4 Defective start switch Check and replace right handle bar switch Refer to CHECKING THE SWITCHES on page 8 221 Fault code No Sh_ _36 Symptom Output signal of clutch actuator sensor is ab normal Order Item components and probable cause Check or maintenance job Reinstatement method 1 Conn...

Page 688: ...and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Clutch actuator motor coupler Shift actuator motor coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to OFF See NOTE 2 Open or s...

Page 689: ...er and MCU motor control unit coupler orange white orange white orange black orange black green red green red green black green black 3 Defective hand shift lever switch shift up or shift down Replace hand shift switch Refer to CHECKING THE SWITCHES on page 8 221 Fault code No Sh_ _39 Symptom Ignition timing retard output signal is abnormal Order Item components and probable cause Check or mainten...

Page 690: ...there is an open or short circuit Between ECU coupler and MCU motor control unit cou pler yellow blue yellow blue Fault code No Sh_ _42 Symptom Communication between ECU and multi func tion meter is abnormal Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler YCC S speed sensor coupler Check the coupler fo...

Page 691: ...thod 1 Connections Wire harness MCU motor control unit coupler ABS ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Repairing the cause of the malfunction 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between ABS ECU coup...

Page 692: ...diagnostic code No Sh_ _61 The fault code numbers can be confirmed in the mal function history Fault code No Sh_ _45 Symptom Shift operation and gear position do not match Order Item components and probable cause Check or maintenance job Reinstatement method 1 Shift rod Check the shift rod pin hole lo cation Check the shift rod groove loca tion Adjust or replace if defective Refer to CHECKING THE ...

Page 693: ...f the coupler If there is a malfunction repair it and connect the coupler se curely Repairing the cause of the malfunction 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between battery and main switch coupler red red Between main switch coupler and signaling system fuse brown blue brown blue Between signaling system fuse and brake light relay couple...

Page 694: ...clutch stroke Refer to BLEEDING THE HY DRAULIC CLUTCH SYSTEM FJR13AE on page 3 19 Turning the main switch to OFF See NOTE 2 Clutch slippage Check the friction plate thick ness and replace the friction plates if necessary Refer to CHECKING THE FRICTION PLATES on page 5 61 Fault code No Sh_ _51 Symptom Shift actuator sensor signal is abnormal Order Item components and probable cause Check or mainten...

Page 695: ...o Sh_ _52 Symptom Main switch signal is abnormal Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to OFF See NOTE...

Page 696: ...ELECTRICAL COMPONENTS 8 213 EAS27970 ELECTRICAL COMPONENTS FJR13A 1 18 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 ...

Page 697: ...tor fuse 5 Front brake light switch 6 Clutch switch 7 Fuse box 2 8 Fuse box 1 9 Right radiator fan motor 10 Left radiator fan motor 11 Gear position switch 12 Sidestand switch 13 Oil level switch 14 Rear brake light switch 15 Left horn low 16 Right horn high 17 Ignition coil 18 Main fuse ...

Page 698: ...ELECTRICAL COMPONENTS 8 215 FJR13A 5 1 3 2 17 8 10 11 12 13 14 15 16 7 6 4 9 ...

Page 699: ...Intake air temperature sensor 6 Lean angle sensor 7 Hydraulic unit assembly 8 ECU engine control unit 9 Relay unit 10 Cylinder identification sensor 11 O2 sensor 12 Crankshaft position sensor 13 Accessory box solenoid 14 Headlight relay dimmer 15 Radiator fan motor relay 16 Headlight on off grip warmer relay 17 Turn signal hazard relay ...

Page 700: ...ELECTRICAL COMPONENTS 8 217 FJR13AE 13 16 18 17 2 3 4 5 6 7 8 1 9 10 11 12 15 14 19 ...

Page 701: ...fuse 5 Front brake light switch 6 Fuse box 2 7 Fuse box 1 8 Right radiator fan motor 9 Left radiator fan motor 10 Neutral switch 11 Sidestand switch 12 YCC S speed sensor 13 Oil level switch 14 Rear brake light switch 15 Left horn low 16 Right horn high 17 Ignition coil 18 Main fuse 19 Diode ...

Page 702: ...ELECTRICAL COMPONENTS 8 219 FJR13AE 1 19 3 2 5 7 9 8 12 13 14 15 16 11 10 18 17 6 4 ...

Page 703: ...nsor 6 Lean angle sensor 7 Hydraulic unit assembly 8 MCU motor control unit 9 ECU engine control unit 10 Relay unit 11 YCC S control relay 12 Cylinder identification sensor 13 O2 sensor 14 Crankshaft position sensor 15 Accessory box solenoid 16 Headlight relay dimmer 17 Radiator fan motor relay 18 Headlight on off grip warmer relay 19 Turn signal hazard relay ...

Page 704: ...JR13A L Y B Y 1 BROWN B B 3 P B Lg Sb Br W L B Ch Dg B Y R Y L Y Lg B Sb UP DOWN 12 DgBr W Ch 13 B P 10 R Y L B 11 B Br W Ch Dg R B R W G Y L W Br 8 L W B R W R B 9 Ch Dg Br W 7 BLACK 6 BLUE B B 5 L B Ch B R Dg B G 4 G Y Br ON OFF R 2 Br L B L Y R Br L B L Y RED ...

Page 705: ...ight switch 2 Main switch 3 Rear brake light switch 4 Gear position switch 5 Sidestand switch 6 Clutch switch 7 Hazard switch 8 Start switch 9 Engine stop switch 10 Horn switch 11 Dimmer switch 12 Windshield position switch 13 Turn signal switch ...

Page 706: ...W Br 7 L W B R W R B 8 Ch Dg Br W 6 BLUE B B 5 4 G Y Br Sb 10 Shift up Shift down G R G B B L 11 O W O B B L Br L B L 9 PUSH B R B G R B L G B O W Br L O B ON OFF R 2 Br L B L Y R Br L B L Y RED Lg B Sb UP DOWN 14 DgBr W Ch 15 B P 12 R Y L B 13 BLACK Dg Sb Ch Lg L B B P Br W R Y ...

Page 707: ...ight switch 4 Neutral switch 5 Sidestand switch 6 Hazard switch 7 Start switch 8 Engine stop switch 9 Hand shift select button 10 Hand shift lever switch shift up 11 Hand shift lever switch shift down 12 Horn switch 13 Dimmer switch 14 Windshield position switch 15 Turn signal switch ...

Page 708: ...r to 0 and to the Ω 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at...

Page 709: ...ulbs 1 Remove Bulb WARNING EW3P61001 Since headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down NOTICE EC3P61002 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of a headlight bulb to keep it free from oil otherwis...

Page 710: ... Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Turn the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit WARNING EWA13310 Never use a fuse with an amperage rating other than...

Page 711: ...balance between cells will not be maintained and battery per formance will deteriorate Charging time charging amperage and charging voltage for an MF battery are dif ferent from those of conventional batteries The MF battery should be charged accord ing to the appropriate charging method If the battery is overcharged the electrolyte level will drop considerably Therefore take special care when cha...

Page 712: ...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 illustration the open circuit voltage of an MF battery stabi lizes about 30 minutes af...

Page 713: ... 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 MF battery A vari able voltage charger is recommended d Charge...

Page 714: ...0 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 FJR13A B Y FJR13AE B R 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe R B L W R W R L R L 1 2 4 3 4 Negative tester probe Result Continuity between 3 and 4 FJR13A B Y FJR13AE B R 1 Positive...

Page 715: ...al 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 5 Negative tester probe Result No continuity between 3 and 4 Continuity between 3 and 5 G L Y L B B 1 3 2 G G L Y L B B 1 2 3 5 4 G 1 Positive tester probe 2 Negative tester probe Result Continuity between 1 and 2 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Res...

Page 716: ... Turn signal hazard relay output voltage Out of specification Replace 1 Positive tester probe 2 Negative tester probe Result No continuity between 1 and 2 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal G L W L Y Y G 1 2 1 2 3 4 G L W L Y Y G R Br B R W ...

Page 717: ...ester YU 03112 C Continuity Positive tester probe sky blue 1 Negative tester probe FJR13A black yellow 2 FJR13AE black red 2 No continuity Positive tester probe FJR13A black yellow 2 FJR13AE black red 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 Conti...

Page 718: ...k Primary coil resistance Out of specification Replace a Disconnect the ignition coil connectors from the ignition coil terminals b Connect the pocket tester Ω 1 to the igni tion coil as shown c Measure the primary coil resistance 2 Check Secondary coil resistance Out of specification Replace a Disconnect the spark plug cap from the igni tion coil b Connect the pocket tester Ω 1k to the ig nition ...

Page 719: ... til a misfire occurs EAS28120 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace the crank shaft position sensor a Connect the pocket tester Ω 100 to the crankshaft position sensor coupler as shown b Measure the crankshaft position sensor re sistance EAS28130 CHECK...

Page 720: ...t least the same capacity of the bat tery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the stator coil a Connect the...

Page 721: ...ification Replace a Disconnect the horn connectors from the horn terminals b Connect the pocket tester Ω 1 to the horn terminals c Measure the horn resistance 2 Check Horn sound Faulty sound Adjust or replace a Connect a battery 12 V to the horn b Turn the adjusting screw in direction a or b until the horn sound is obtained Positive tester probe white 2 Negative tester probe white 3 Charging volta...

Page 722: ...ance Out of specification Replace the fuel pump assembly a Connect the pocket tester Ω 10 to the fuel sender terminals as shown Oil level switch resistance Minimum level position No continuity Maximum level position Continuity Pocket tester 90890 03112 Analog pocket tester YU 03112 C Minimum level position A Positive tester probe white 1 Negative tester probe body ground 2 Maximum level position B...

Page 723: ...coolant temperature sen sor to strong shocks If the coolant temper ature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 100 to the coolant temperature sensor terminals as shown b Immerse the coolant temperature sensor 1 in a container filled with coolant 2 TIP Make sure that the coolant temperature sensor termin...

Page 724: ...sconnect the air induction system solenoid coupler from the wire harness b Connect the pocket tester Ω 1 to the air in duction system solenoid terminals as shown c Measure the air induction system solenoid re sistance EAS28390 CHECKING THE CYLINDER IDENTIFICATION SENSOR 1 Remove Timing plate cover 2 Check Cylinder identification sensor output voltage Out of specification Replace T R Coolant temper...

Page 725: ...ve Intake air temperature sensor from the air filter case WARNING EWA14110 Handle the intake air temperature sensor with special care Never subject the intake air temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it 2 Check Intake air temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 100 to the in take air temperature...

Page 726: ...inals as shown c Measure the accessory box solenoid resis tance ET3P66023 CHECKING THE GRIP WARMERS FJR13AE only The following procedure applies to both of the grip warmers 1 Check Grip warmer resistance Out of specification Replace the grip warmer a Disconnect the grip warmer coupler from the front cowling wire harness b Connect the pocket tester Ω 1 to the grip warmer coupler as shown Accessory ...

Page 727: ...he main switch to ON c Elevate the rear wheel and slowly rotate it d Measure the voltage of white yellow and black blue With each full rotation of the rear wheel the voltage reading should cycle from 0 6 V to 4 8 V to 0 6 V to 4 8 V ET3P66021 CHECKING THE GEAR POSITION SENSOR FJR13AE only 1 Remove Gear position sensor TIP Remove only the screws 1 when removing the gear position sensor Do not remov...

Page 728: ...n Replace the foot shift switch a Connect the pocket tester Ω 1k to the foot shift switch terminals as shown b Measure the foot shift switch maximum resis tance 3 Install Foot shift switch Refer to INSTALLING THE FOOT SHIFT SWITCH on page 5 75 ET3P66025 CHECKING THE DIODE FJR13AE only 1 Check Diode Out of specification Replace Resistance FJR13AE 4 0 6 0 kΩ Pocket tester 90890 03112 Analog pocket t...

Page 729: ...diode from the wire harness b Connect the pocket tester Ω 1 to the diode 2 terminals as shown c Check the diode for continuity d Check the diode for no continuity Continuity Positive tester probe yellow 1 Negative tester probe yel low green 2 No continuity Positive tester probe yel low green 2 Negative tester probe yellow 1 Y Y G 1 2 ...

Page 730: ...ELECTRICAL COMPONENTS 8 247 ...

Page 731: ...DLING SPEED 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 3 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 ...

Page 732: ...uel 2 Fuel pump Faulty fuel pump Faulty fuel pump relay 3 Throttle body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Fault...

Page 733: ...HIFTING Shifting is difficult Refer to Clutch drags EAS28540 SHIFT PEDAL DOES NOT MOVE Shift shaft Improperly adjusted shift rod Bent shift shaft Shift drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shif...

Page 734: ...k plug gap Incorrect spark plug heat range 2 Ignition system Faulty ECU EAS28610 OVERCOOLING Cooling system 1 Thermostat Thermostat stays open EAS28620 POOR BRAKING PERFORMANCE Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper kit Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the br...

Page 735: ...ht bulb burnt out Wrong headlight bulb Faulty battery Faulty rectifier regulator Improperly grounded circuit Faulty main switch Headlight bulb life expired Tail brake light does not come on Wrong tail brake light bulb Too many electrical accessories Incorrect connection Burnt out tail brake light bulb Tail brake light bulb burnt out Wrong tail brake light bulb Faulty battery Incorrectly adjusted r...

Page 736: ...tor fan motor relay 61 Left radiator fan motor fuse 62 Left radiator fan motor 63 Right radiator fan motor fuse 64 Right radiator fan motor 65 Turn signal hazard relay 66 Right handlebar switch 67 Front brake light switch 68 Engine stop switch 69 Start switch 70 Hazard switch 71 Left handlebar switch 72 Clutch switch 73 Dimmer switch 74 Windshield position switch 75 Turn signal switch 76 Horn swit...

Page 737: ...stem fuse 69 Headlight fuse 70 Ignition fuse 71 Auxiliary DC jack fuse 72 Grip warmer control unit 73 Radiator fan motor relay 74 Left radiator fan motor fuse 75 Left radiator fan motor 76 Right radiator fan motor fuse 77 Right radiator fan motor 78 YCC S motor control fuse 79 Turn signal hazard relay 80 Left handlebar switch 81 Dimmer switch 82 Windshield position switch 83 Turn signal switch 84 ...

Page 738: ...W L White Blue W Y White Yellow Y B Yellow Black Y G Yellow Green Y L Yellow Blue Y R Yellow Red Y W Yellow White ...

Page 739: ......

Page 740: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 741: ...K BLACK BLACK BLACK BLACK GRAY A WIRE HARNESS SUB WIRE HARNESS GRAY GRAY GRAY GRAY GRAY GRAY BLACK BLACK A A A A A A A A A A A A RED RED ON OFF GRAY GRAY 1 2 3 4 5 6 7 8 9 11 12 13 14 17 18 15 16 10 19 20 21 22 23 24 25 26 27 28 29 30 31 32 32 33 34 35 36 36 36 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 63 64 62 ...

Page 742: ... Front cowling wire harness GRAY GRAY BLACK BLACK BLACK BLACK GRAY BLACK BLACK BLACK BLACK BLACK BLACK UP DOWN GRAY 18 19 52 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 91 92 93 94 95 98 96 96 97 9 ...

Page 743: ... WIRE HARNESS SUB LEAD1 BLACK BLACK C WIRE HARNESS SUB LEAD2 B WIRE HARNESS SUB WIRE HARNESS GRAY GRAY BLACK BLACK C B B B B B B B B B C C A A A A B B B RED RED ON OFF GRAY GRAY GRAY 1 2 3 4 5 6 7 8 9 10 11 12 15 16 18 19 20 35 22 23 24 25 29 28 30 31 32 32 33 34 36 37 37 37 37 38 42 39 40 41 43 44 45 48 46 47 49 50 61 51 62 60 52 65 67 68 69 70 71 72 78 73 74 76 77 75 14 17 21 13 26 27 53 54 55 5...

Page 744: ...GRAY BLACK BLACK B B BLACK BLACK GRAY BLACK BLACK BLACK BLACK BLACK UP DOWN Shift down PUSH Shift up BLACK BLACK GRAY 64 59 66 79 80 81 82 83 84 85 87 86 88 89 90 91 92 93 94 95 96 13 26 14 100 101 102 103 104 105 106 107 107 108 109 110 111 111 112 113 114 115 116 97 98 99 ...

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