Yamaha 2002 FJR1300 Supplementary Service Manual Download | Manualshive

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FJR1300

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P

)

5JW1-AE2

SUPPLEMENTARY

SERVICE MANUAL

2002

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Summary of Contents for 2002 FJR1300

Page 1: ...FJR1300 P 5JW1 AE2 SUPPLEMENTARY SERVICEMANUAL 2002 ...

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Page 3: ...t is necessary to use this Supple mentary Service Manual together with the following manual FJR1300 N 2001 SERVICE MANUAL 5JW1 AE1 FJR1300 P 2002 SUPPLEMENTARY SERVICE MANUAL 2001 by Yamaha Motor Co Ltd First edition November 2001 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...els Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and will appear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice EAS00004 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following The Safety Alert...

Page 5: ...of each page except in chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number indicates...

Page 6: ...g fluid B Lubricant C Special tool D Tightening torque E Wear limit clearance F Engine speed G Electrical data Symbols H to M in the exploded diagrams indicate the types of lubricants and lubrication points H Engine oil I Gear oil J Molybdenum disulfide oil K Wheel bearing grease L Lithium soap base grease M Molybdenum disulfide grease Symbols N to O in the exploded diagrams indicate the following...

Page 7: ...RICATION POINTS AND LUBRICANT TYPES 6 CABLE ROUTING 7 PERIODIC CHECKS AND ADJUSTMENTS 10 INTRODUCTION 10 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS 10 COWLINGS AND COVERS 12 COWLINGS 12 COVERS 15 CHASSIS 16 FRONT AND REAR BRAKES 16 REAR BRAKE PADS 16 REAR BRAKE CALIPER 17 FRONT FORK 19 INSTALLING THE FRONT FORK LEGS 20 SHAFT DRIVE 22 ENGINE 24 CAMSHAFTS 24 CAMSHAFTS 24 FUEL INJECTION SYSTEM 26...

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Page 9: ... 117 6 kPa 0 78 1 18 kg cm2 0 78 1 18 bar Cooling system Radiator capacity 3 2 L Radiator cap opening pressure 93 3 122 7 kPa 0 93 1 23 kg cm2 0 93 1 23 bar Valve relief pressure 4 9 kPa 0 05 kg cm2 0 05 bar Radiator core Width 360 mm Height 295 8 mm Depth 27 mm Coolant reservoir Capacity 0 25 L From low to full level 0 15 L Water pump Water pump type Single suction centrifugal pump Reduction rati...

Page 10: ... wheel runout 0 5 mm Front tire Tire type Tubeless Size 120 70ZR 17M C 58W 120 70ZR 17 58W Model manufacturer MEZ4J FRONT METZELER BT020F N BRIDGESTONE Tire pressure cold 0 90 kg 250 kPa 2 5 kgf cm2 2 5 bar 90 208 kg 250 kPa 2 5 kgf cm2 2 5 bar High speed riding 250 kPa 2 5 kgf cm2 2 5 bar Min tire tread depth 1 6 mm Rear tire Tire type Tubeless Size 180 55ZR 17M C 73W 180 55ZR 17 73W Model manufa...

Page 11: ...ngth 74 mm 72 52 mm Installed length 65 4 mm Spring rate K1 71 6 N mm 7 16 kgf mm Spring stroke K1 0 31 3 mm Spring rate K2 102 N mm 10 2 kgf mm Spring stroke K2 31 3 60 0 mm Optional spring available No Standard spring preload gas air pres sure 1 200 kPa 12 0 kg cm2 12 0 bar Spring preload adjusting positions Rider only SOFT With passenger or cargo HARD Rebound damping adjusting posi tions Minimu...

Page 12: ...oil ignition unit model manufacturer F8T911 MITSUBISHI for Europe F8T912 MITSUBISHI for F F8T913 MITSUBISHI for Oceania Fuses amperage quantity Main fuse 50 A 1 Fuel injection system fuse 15 A Headlight fuse 25 A 1 Signaling system fuse 15 A 1 Ignition fuse 10 A 1 Radiator fan motor fuse 15 A 1 Hazard lighting fuse 7 5 A Parking lighting fuse 10 A Backup fuse odometer and clock 10 A Windshield mot...

Page 13: ...UES CHASSIS TIGHTENING TORQUES Part to be tightened Part name Thread size Q ty Tightening torque Remarks Nm m kgf Timing chain tensioner cap Bolt M6 1 7 0 7 Part to be tightened Thread size Tightening torque Remarks Nm m kgf Rear brake caliper retaining bolt M10 27 2 7 ...

Page 14: ...g point LS Centerstand pivoting point and sliding surface LS Sidestand pivoting point and metal to metal moving parts LS Throttle grip inner surface LS Brake lever pivot bolt and contact surface LS Clutch lever pivot bolt and contact surface LS Rear shock absorber assembly oil seal LS Rear shock absorber assembly bearing LS Rear shock absorber assembly spacer LS Pivot shaft LS Connecting arm beari...

Page 15: ... lead 4 Headlight lead 5 Main switch lead 6 Throttle cable 7 Right handlebar switch lead 8 T bar 9 Spark plug lead 3 0 Spark plug lead 2 A Spark plug lead 1 B Spark plug lead 4 C Throttle position sensor D Sidestand switch lead E Spark plug lead 1 F Spark plug lead 4 CABLE ROUTING ...

Page 16: ...t handlebar switch lead and throttle cables through the hole on the right side of the frame Ë To the lower left slit of the plate Ì To the cylinder identification sensor Í To the fuel tank Î Pass the cylinder identification sensor lead through the lead guide of throttle body Ï To the sidestand switch lead Ð Pass the cylinder identification sensor lead under the fuel hose and then to the wire har n...

Page 17: ... leads 1 2 3 and 4 and the wire harness head light lead main switch lead right handlebar switch lead and left handlebar switch lead Install the thermostat heat protector throttle cables spark plug leads wire harnesses and air cut valve under the cable guide in the respec tive order Ó To the left slit of the plate CABLE ROUTING ...

Page 18: ...CHECK OR MAINTENANCE JOB ODOMETER READING 1 000 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40 000 km 4 Air filter element Clean Replace 5 Clutch Check operation fluid level and vehicle for fluid leakage See NOTE on page 11 6 Front brake Check operation fluid level ...

Page 19: ...eration and shock absorber for oil leak age 19 Rear suspension relay arm and con necting arm pivot ing points Check operation Lubricate with lithium soap based grease 20 Electronic fuel injection system Adjust engine idling speed and synchronization 21 Engine oil Change Check oil level and vehicle for oil leakage 22 Engine oil filter cartridge Replace 23 Cooling system Check coolant level and vehi...

Page 20: ... Manual No 5JW1 AE1 1 Left side cowling 1 2 Right side cowling 1 3 Front bottom cowling 1 4 Front turn signal connector left 2 5 Front turn signal connector right 2 6 Left inner panel front cowling 1 7 Fuse box 1 8 Hazard switch 1 9 Right inner panel front cowling 1 10 Front right inner panel front cowling 1 11 Front left inner panel front cowling 1 12 Sub wire harness coupler 3 13 Front cowling a...

Page 21: ...front cowling assembly Remove the parts in the order listed 1 Windshield outer bracket 1 2 Windshield 1 3 Grommet 7 4 Windshield inner bracket 1 5 Rear view mirror left and right 2 6 Panel 1 7 Front cowling 1 8 Auxiliary light coupler 2 9 Headlight coupler 2 For assembly reverse the disassembly procedure ...

Page 22: ...the parts in the order listed 1 Windshield drive unit 1 2 Windshield drive unit coupler 2 3 Meter assembly 1 4 Meter assembly coupler 1 5 Headlight relay 1 1 6 Headlight relay 2 1 7 Fuel injection system relay 1 8 Turn signal relay 1 9 Radiator fan motor relay 1 For installation reverse the removal procedure COWLINGS AND COVERS ...

Page 23: ... Part Q ty Remarks Removing the covers Remove the parts in the order listed Seats Refer to SEATS AND FUEL TANK Manual No 5JW1 AE1 1 Left side cover 1 2 Right side cover 1 3 Rear carrier 1 4 Rear cover 1 For installation reverse the removal procedure ...

Page 24: ...ND REAR BRAKES EAS00578 REAR BRAKE PADS Order Job Part Q ty Remarks Removing the rear brake pads Remove the parts in the order listed 1 Retaining bolt 2 2 Brake pad 2 3 Brake pad shim 2 4 Bleed screw 1 For installation reverse the removal procedure ...

Page 25: ...ed Brake fluid Drain 1 Union bolt 1 Refer to DISASSEMBLING ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER Manual No 5JW1 AE1 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Retaining bolt 2 Loosen 5 Brake torque rod 1 6 Wheel axle nut 1 7 Wheel axle pinch bolt 1 Loosen 8 Rear wheel axle 1 9 Brake caliper 1 For installation reverse the removal procedure ...

Page 26: ...the parts in the order listed 1 Retaining bolt 2 2 Brake pad brake pad shim 2 2 3 Brake pad spring 2 4 Rear brake caliper bracket 1 5 Brake caliper piston 1 Refer to DISASSEMBLING THE REAR BRAKE CALIPER Manual No 5JW1 AE1 6 Brake caliper piston seal 2 7 Bleed screw 1 For assembly reverse the disassembly procedure ...

Page 27: ...ling assembly Refer to COWLINGS AND COVERS in chapter 3 Manual No 5JW1 AE1 Front wheel Refer to FRONT WHEEL AND BRAKE DISCS Manual No 5JW1 AE1 1 Front fender 1 2 Collar 2 3 Collar 2 4 Upper bracket pinch bolt 1 Loosen Refer to REMOVING INSTALLING THE FRONT FORK LEGS Manual No 5JW1 AE1 5 Cap bolt 1 Loosen 6 Lower bracket pinch bolt 2 Loosen 7 Front fork leg 1 For installation reverse the removal pr...

Page 28: ...OTE Make sure that the inner tube end is flush with the top of the upper bracket Temporarily tighten the upper and lower bracket pinch bolts WARNING Make sure the brake hoses are routed prop erly 2 Tighten lower bracket pinch bolts 1 cap bolt 2 upper bracket pinch bolt 3 T R 23 Nm 2 3 m kg T R 25 Nm 2 5 m kg T R 34 Nm 3 4 m kg FRONT FORK ...

Page 29: ...fender Install the collar 2 from the inside of the front fender When installing the front fender make sure that there is no dirt between the front fender and front fork T R 6 Nm 0 6 m kg 4 Adjust spring preload rebound damping compression damping Refer to ADJUSTING THE FRONT FORK LEGS in chapter 3 Manual No 5JW1 AE1 FRONT FORK ...

Page 30: ...the order listed 1 Circlip 2 2 Oil seal 1 3 Drive shaft 1 4 Spring 1 5 Ring gear bearing housing oil seal 1 1 Refer to ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR Manual No 5JW1 AE1 6 Dust cover 1 7 Ring gear bearing 1 1 8 Ring gear shim s 9 Thrust washer 1 0 Stopper bolt 1 Left hand threads A Stopper bolt shim s ...

Page 31: ... ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR Manual No 5JW1 AE1 C Gear coupling 1 D Bearing retainer oil seal 1 1 Left hand threads E Final drive pinion gear bearing 1 1 F Final drive pinion gear shim s G Bearing 1 H Bearing 1 I Oil seal 1 J Collar 1 K Final drive housing 1 For assembly reverse the disassembly procedure ...

Page 32: ...1 AE1 Pickup coil rotor cover Refer to PICKUP COIL ROTOR Manual No 5JW1 AE1 1 Timing chain tensioner 1 Refer to REMOVING INSTALLING THE CAMSHAFTS Manual No 5JW1 AE1 2 Timing chain tensioner gasket 1 3 Intake camshaft cap 4 4 Exhaust camshaft cap 4 5 Dowel pin 16 6 Intake camshaft 1 7 Exhaust camshaft 1 8 Intake camshaft sprocket 1 Refer to INSTALLING THE CAM SHAFTS Manual No 5JW1 AE1 9 Exhaust cam...

Page 33: ... 25 ENG Order Job Part Q ty Remarks 10 Timing chain guide exhaust side 1 11 Pin 1 12 Timing chain guide intake side 1 For installation reverse the removal procedure CAMSHAFTS ...

Page 34: ...upply system or ECU 1 The warning light illuminates 1 4 seconds each time the main switch is turned ON The ECU performs a self diagnosis during this time and turns OFF the light thereafter 2 Warning control when unable to start engine This control is effected when any one of the conditions listed below is present and the starter switch is turned ON a Battery voltage below the specified value defec...

Page 35: ...itch ON Defective coolant temperature sensor Replace if defective Refer to FUEL INJECTION SYSTEM in chapter 8 Manual No 5JW1 AE1 Open or short circuit in wiring harness or sub lead Repair or replace if there is an open or short circuit Main wiring harness Black Blue Black Blue Green White Green White Connected state of connector Inspect the coupler for any pins that may have pulled out Check the l...

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