Yamaha 2004 FJR1300(S) Supplementary Service Manual Download | Manualshive

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2004

FJR1300(S)

FJR1300A(S)

5JW1-AE5

SUPPLEMENTARY

SERVICE MANUAL

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Summary of Contents for 2004 FJR1300(S)

Page 1: ...2004 FJR1300 S FJR1300A S 5JW1 AE5 SUPPLEMENTARY SERVICE MANUAL ...

Page 2: ......

Page 3: ...ether with the following manuals FJR1300 N 2001 SERVICE MANUAL 5JW1 AE1 FJR1300 P 2002 SUPPLEMENTARY SERVICE MANUAL 5JW1 AE2 FJR1300 R FJR1300A R 2003 SUPPLEMENTARY SERVICE MANUAL 5JW1 AE4 FJR1300 S FJR1300A S 2004 SUPPLEMENTARY SERVICE MANUAL 2003 by Yamaha Motor Co Ltd First edition September 2003 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha M...

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: ...ANK 7 REMOVING THE FUEL TANK 9 AIR FILTER CASE 10 FUEL INJECTION SYSTEM 12 FUEL INJECTION SYSTEM 12 WIRING DIAGRAM FJR1300 13 WIRING DIAGRAM FJR1300A 14 SUBSTITUTE CHARACTERISTICS OPERATION CONTROL FAIL SAFE ACTION 16 THROTTLE BODIES 21 AIR INDUCTION SYSTEM 25 INSTALLING THE REED VALVES 25 ELECTRICAL 26 ELECTRICAL COMPONENTS 26 FUEL INJECTION SYSTEM 28 CIRCUIT DIAGRAM FJR1300 28 CIRCUIT DIAGRAM FJ...

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Page 9: ...rol the air fuel ratio in a more precise and finely tuned man ner To accommodate 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 the engine operatin...

Page 10: ...ation and the injection timing are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor intake air tem perature sensor coolant temperature sensor and O2 sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft posi tion sensor and the cylinder ...

Page 11: ...pe Electric Model manufacturer 5JW 21 DENSO Maximum consumption amperage 6 0 A Output pressure 324 kPa 3 24 kg cm2 46 08 psi Throttle bodies Model manufacturer quantity 42EHS MIKUNI 4 Intake vacuum pressure 33 3 kPa 250 mmHg 9 8 inHg Throttle cable free play at the flange of the throttle grip 3 5 mm 0 12 0 20 in ID mark 5JW1 50 Fuel injectors Model INP 151 Manufacturer NIPPON INJECTOR Quantity 4 G...

Page 12: ... Ignition timing 5 BTDC at 1 050 r min Advancer type Electric Pickup coil resistance color 420 8 569 3 Ω Gy B Transistorized coil ignition unit model manufacturer F8T818 MITSUBISHI F8T819 MITSUBISHI for F Starting circuit cut off relay Model manufacturer G8R 30Y R OMRON Coil resistance 180 Ω Fuel injection system relay Model manufacturer G8R 30Y R OMRON ...

Page 13: ...NTENANCE 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 6 Front brake Check operation fluid level and vehicle for fluid leakage Re...

Page 14: ... 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 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 vehicle for coolant leak age Change Every 3 years ...

Page 15: ...nk Remove the parts in the order listed Rider seat Refer to SEATS AND FUEL TANK in chapter 3 Manual No 5JW1 AE1 Fuel Drain 1 Fuel tank side panel left and right 1 1 2 Bolt 2 3 Nut 1 4 Fuel sender coupler 1 5 Fuel pump coupler 1 6 Fuel tank overflow hose 1 7 Fuel tank breather hose 1 8 Hose holder 1 9 Fuel hose holder 1 ...

Page 16: ...Job Part Q ty Remarks 10 Fuel hose 1 Refer to REMOVING THE FUEL TANK Refer to INSTALLING THE FUEL HOSE in chapter 3 Manual No 5JW1 AE1 11 Bolt 1 12 Fuel tank 1 Refer to REMOVING THE FUEL TANK For installation reverse the removal procedure ...

Page 17: ... be fuel remaining in it NOTE To remove the fuel hose from the fuel injec tion pipe slide the cover a on the end of the hose in the direction of the arrow shown and then remove the hose Before removing the hose place a few rags in the area under the hose 3 Remove fuel tank NOTE Do not set the fuel tank down on the installa tion surface of the fuel pump Be sure to lean the fuel tank up against a wa...

Page 18: ...l No 5JW1 AE1 Fuel tank Refer to SEATS AND FUEL TANK Side covers left and right Refer to COWLINGS AND COVERS Manual No 5JW1 AE2 1 Air shroud 1 2 Air filter case cover 1 3 Air filter element 1 4 Tray 1 5 Fuel tank bracket 1 6 Plastic locking tie 1 7 Intake air temperature sensor coupler 1 8 Bypass air unit inlet hose 1 Disconnect 9 Crankcase breather hose 1 Disconnect AIR FILTER CASE ...

Page 19: ...Order Job Part Q ty Remarks 10 Air induction system hose 5 1 Disconnect 11 Clamp screw 4 Loosen 12 Air filter case 1 13 Air filter case breather hose 1 For installation reverse the removal procedure AIR FILTER CASE ...

Page 20: ...ump 7 Intake air pressure sensor 8 Throttle position sensor 9 Fuel injector 0 O2 sensor A Catalytic converter B Crankshaft position sensor C Coolant temperature sensor D Spark plug E Cylinder identifica tion sensor F Battery G ECU H Fuel injection system relay I Engine trouble warn ing light J Lean angle cut off switch K Air cut off valve 6 8 4 5 2 3 G H J 7 A 9 0 B D C K 1 I F E ...

Page 21: ... L L B L B L B R L L B D GRAY R L G B G B G B R LG B D GRAY R L R B R B R B R L R B D GRAY R B R G B2 Br R R W G W Y L G L Lg Y L Ch W Dg BLACK BLUE BLUE BLUE L G B B B BB1 BB2 BB4 BB3 B B B B R W R B L W G Y Br B R W R B W L G Y Br B C B L P W Gy G Y W B B L P W W B Y Gy G E BLACK BLACK WIRE HARNESS SUB WIRE HARNESS 2 L B O B L R L R B G B O B L L B G B R B R L D WIRE HARNESS SUB WIRE HARNESS 2 C...

Page 22: ... W G Y Br B R W R B W L G Y Br B B W R L B R L Y Br W L W B1 Lg Sb B2 W1 G R Lg Sb B1 B2 W1 G R R G R W R B W W R R Y Br W L W L B Br G C B L P W Gy G Y W B B L P W W B Y Gy G E BLACK BLACK BLACK BLACK WIRE HARNESS SUB WIRE HARNESS 2 L B O B L R L R B G B O B L L B G B R B R L D WIRE HARNESS SUB WIRE HARNESS 2 G SUB WIRE HARNESS 3 SUB WIRE HARNESS 1 C WIRE HARNESS SUB WIRE HARNESS 1 R G G L G R G ...

Page 23: ...ted Able Able 32 The amount of air fuel ratio feed back compensation is maintained continuously in the vicinity of the lower limit rich air fuel ratio Able Able 14 Faulty intake air pressure sensor pipe system a hose is detached or clogged Able Able 33 Open circuit detected in the pri mary wire of the ignition coil 1 4 Able Able 15 Throttle position sensor open or short circuit detected Able Able ...

Page 24: ...r identification that existed up to that point Able Able 12 Crankshaft position sen sor Stops the engine by stopping the injection and ignition Unable Unable 13 14 Intake air pressure sensor open or short circuit pipe system Fixes the intake air pressure to 760 mmHg Able Able 15 16 Throttle position sensor open or short circuit stuck Fixes the throttle position sensor to fully open Able Able 19 Br...

Page 25: ...air pressure sensor Malfunction in ECU 03 Or a stuck throttle position sensor is detected Open or short circuit in wiring sub lead Open or short circuit in wiring harness Defective sensor stuck throttle position sensor 01 15 Throttle position sensor open or short circuit detected Open or short circuit in wiring sub lead Open or short circuit in wiring harness Defective throttle position sensor Mal...

Page 26: ...t of ignition cutoff circuit system 30 34 Open circuit is detected in the primary wire of the ignition coil 2 3 Open or short circuit in wiring harness Malfunction in ignition coil Malfunction in ECU Malfunction in a component of ignition cutoff circuit system 31 41 Lean angle cut off switch open or short circuit detected Open or short circuit in wiring harness Defective lean angle cut off switch ...

Page 27: ... if the numbers appear on the meter 08 Lean angle cut off switch Displays the lean angle cut off switch values Upright 0 4 1 4 V Overturned 3 8 4 2 V 09 Fuel system voltage battery voltage Displays the fuel system voltage battery voltage Engine stop switch is on 0 18 7 V Normally approximately 12 0 V 20 Sidestand switch Displays that the switch is ON or OFF When the gear is in a position other tha...

Page 28: ...ective Refer to CHECKING THE SWITCHES in chapter 8 Manual No 5JW1 AE1 If the transmission is in gear it is rein stated by retracting the sidestand If the transmission is in neutral it is reinstated by reconnecting the wiring Open circuit in wiring harness or sub lead Repair or replace if there is an open circuit Between ECU and black red lead Connected state of connector Inspect the coupler for an...

Page 29: ...ATS AND FUEL TANK in chapter 3 Manual No 5JW1 AE1 Fuel tank Refer to SEATS AND FUEL TANK Air filter case Refer to AIR FILTER CASE Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Manual No 5JW1 AE1 1 O2 sensor coupler 1 Disconnect 2 Cylinder identification sensor coupler 1 Disconnect 3 Sub wire harness 2 coupler 2 Disconnect 4 Throttle stop screw 1 5 Throttle body joint clamp screw 8 6 Thr...

Page 30: ... 5 5 5 10 10 3 7 7 6 10 10 Order Job Part Q ty Remarks 7 Throttle cable 2 Disconnect 8 Plunger control unit hose 1 1 Disconnect 9 Plunger control unit hose 2 1 Disconnect 10 Throttle body joint 4 For installation reverse the removal procedure ...

Page 31: ...sition sensor coupler 1 Disconnect 2 Intake air pressure sensor coupler 1 Disconnect 3 Cylinder 1 injector coupler 1 Disconnect 4 Cylinder 2 injector coupler 1 Disconnect 5 Cylinder 3 injector coupler 1 Disconnect 6 Cylinder 4 injector coupler 1 Disconnect 7 Sub wire harness 2 1 8 Negative pressure hose 1 Disconnect 9 Bypass air unit 1 10 Bypass air unit outlet hose 4 ...

Page 32: ... SYSTEM 11 3 4 5 6 1 7 2 8 12 13 14 10 10 10 9 Order Job Part Q ty Remarks 11 Intake air pressure sensor 1 12 Fuel injection pipe 1 13 Injector 4 14 Throttle position sensor 1 For installation reverse the removal procedure ...

Page 33: ...I AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM INSTALLING THE REED VALVES 1 Install plate 1 NOTE Align the notch a in each plate with the pro jection b of each reed valve seat on the cylin der head cover b a 1 ...

Page 34: ... unit 2 Battery 3 Starter relay 4 Fuel injection system fuse 5 Front brake light switch 6 Clutch switch 7 Fuse box 8 Radiator fan motor 9 Wire harness 0 Neutral switch A Sidestand switch B Oil level switch C Rear brake light switch D Horn E Ignition coil F Main fuse G ABS motor fuse FJR1300A ...

Page 35: ...5 Lean angle cut off switch 6 Hydraulic unit FJR1300A 7 Fail safe relay FJR1300A 8 ECU engine 9 ECU ABS FJR1300A 0 Speed sensor A Cylinder identification sensor B O2 sensor C Crankshaft position sensor D Accessory box solenoid E Accessory box relay F Headlight relay 1 G Radiator fan motor relay H Turn signal relay I Headlight relay 2 ...

Page 36: ...r Br R GRAY R L L B L B L B R L L B D GRAY R L G B G B G B R LG B D GRAY R L R B R B R B R L R B D GRAY R B R G B2 Br R R W G W Y L G L Lg Y L Ch W Dg BLACK BLUE BLUE BLUE L G B B B BB1 BB2 BB4 BB3 B B B B R W R B L W G Y Br B R W R B W L G Y Br B C B L P W Gy G Y W B B L P W W B Y Gy G E BLACK BLACK WIRE HARNESS SUB WIRE HARNESS 2 L B O B L R L R B G B O B L L B G B R B R L D WIRE HARNESS SUB WIR...

Page 37: ...L W G Y Br B R W R B W L G Y Br B B W R L B R L Y Br W L W B1 Lg Sb B2 W1 G R Lg Sb B1 B2 W1 G R R G R W R B W W R R Y Br W L W L B Br G C B L P W Gy G Y W B B L P W W B Y Gy G E BLACK BLACK BLACK BLACK WIRE HARNESS SUB WIRE HARNESS 2 L B O B L R L R B G B O B L L B G B R B R L D WIRE HARNESS SUB WIRE HARNESS 2 G SUB WIRE HARNESS 3 SUB WIRE HARNESS 1 C WIRE HARNESS SUB WIRE HARNESS 1 R G G L G R G...

Page 38: ...cidentally spill gasoline wipe it up immediately with dry rags If gasoline touches the engine when it is hot a fire may occur Therefore make sure the engine is completely cool before performing the following test 1 Check fuel pump operation a Fill the fuel tank b Put the end of the fuel hose into an open container c Connect the battery 12 V to the fuel pump terminals as shown d If fuel flows out o...

Page 39: ...tch k Dimmer switch l Windshield position switch m Turn signal switch n Horn switch o Horn p Front turn signal light left q Front turn signal light right r Hazard switch s Headlight relay 1 t Headlight relay 2 u Headlight assembly v Auxiliary light w Headlight x Taillight assembly y Tail brake light z Rear turn signal light left Rear turn signal light right Rear brake light switch Turn signal rela...

Page 40: ...cator light p Meter light q Oil level switch r Left handlebar switch s Clutch switch t Pass switch u Dimmer switch v Windshield position switch w Turn signal switch x Horn switch y Horn z Front turn signal light left Front turn signal light right Hazard switch Headlight relay 1 Headlight relay 2 å Headlight assembly ç Auxiliary light Headlight Taillight assembly Tail brake light Rear turn signal l...

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Page 42: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 43: ... R L R L D B L B L E W L B1 BB B2 B2 B L W B W B W B E P W P W B L Gy B L Y L B L Gy G Gy G Gy G W L Y B L L W B B L W L Y B L L W Y B L L Y B L BLACK DARK GREEN L B L P W P W B L L BLACK L O W B BLACK Y G B L Br R R W Br Br R GRAY R L L B L B L B R L L B D GRAY R L G B G B G B R LG B D GRAY R L R B R B R B R LR B D GRAY R B R G B2 Br R R W G W Y L G L Lg Y L Ch W Dg BLACK BLUE BLUE BLUE L G B B B...

Page 44: ... R R W Br Br R GRAY R L L B L B L B R L L B D GRAY R L G B G B G B R LG B D GRAY R L R B R B R B R LR B D GRAY R B R G B2 Br R R W G W Y L G L G R Lg Y L Ch W Dg BLACK BLUE BLUE BLUE L G B B B Br Y B B Gy W BB1 BB2 BB4 BB3 B B B B R W R B L W G Y Br B R W R B W L G Y Br B B W R L B R L Y Br W L W B1 Lg Sb B2 W1 G R Lg Sb B1 B2 W1 G R R G R W R B W W R R Y Br W L W L B Br G C B L P W Gy G Y W B B L...

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