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  5. Supplementary Service Manual

Yamaha FJR1300(S) Supplementary Service Manual

Summary of FJR1300(S)

  • Page 1

    2004 fjr1300(s) fjr1300a(s) 5jw1-ae5 supplementary service manual.

  • Page 3: Foreword

    Foreword this supplementary service manual has been prepared to introduce new service and data for the fjr1300(s)/fjr1300a(s) 2004. For complete service information procedures it is necessary to use this supplementary service manual together with the following manuals. Fjr1300(n) 2001 service manual...

  • Page 4: Notice

    Eas00002 notice this manual was produced by the yamaha motor company, ltd. Primarily for use by yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on yama...

  • Page 5: How to Use This Manual

    Eas00007 how to use this manual this manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 the manual is di...

  • Page 6: Symbols

    Eas00008 symbols the following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 general information 2 specifications 3 periodic checks and adjustments 4 chassis 5 engine 6 cooling system 7 fuel injection system 8 electrical system 9 troubleshooting sy...

  • Page 7: Contents

    Contents general information ..............................................................................1 features ...............................................................................................1 outline ................................................................................

  • Page 9: – 1 –

    – 1 – gen info features general information features outline the main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture. In the conventional carburetor sys...

  • Page 10: – 2 –

    – 2 – gen info features fi system the fuel pump delivers fuel to the injector via the fuel filter. The fuel pump maintains the fuel pres- sure that is applied to the injector at only 324 kpa (3.24 kg/cm 2 , 46.08 psi). Accordingly, when the energizing signal from the ecu energizes the injector, the ...

  • Page 11: – 3 –

    – 3 – spec specifications general specifications engine specifications item standard limit model code fjr1300: 5jwg (for europe) 5jwh (for f) 5jwj (for oceania) fjr1300a: 5vs7 (for europe) 5vs8 (for f) 5vs9 (for oceania) ---- ---- ---- ---- ---- ---- item standard limit fuel pump pump type electric ...

  • Page 12: – 4 –

    – 4 – spec electrical specifications electrical specifications item standard limit ignition system ignition system type transistorized coil ignition (digital) ---- ignition timing 5° btdc at 1,050 r/min ---- advancer type electric ---- pickup coil resistance/color 420.8 ~ 569.3 Ω/gy–b ---- transisto...

  • Page 13: – 5 –

    – 5 – chk adj introduction/ periodic maintenance and lubrication chart eas00036 periodic checks and adjustments introduction this chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable v...

  • Page 14: – 6 –

    – 6 – chk adj periodic maintenance and lubrication chart note: • the air filter needs more frequent service if you are riding in unusually wet or dusty areas. • hydraulic brake and clutch service • regularly check and, if necessary, correct the brake and clutch fluid levels. • every two years replac...

  • Page 15: – 7 –

    – 7 – chk adj seats and fuel tank seats and fuel tank eas00040 fuel tank order job/part q’ty remarks removing the fuel tank 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 b...

  • Page 16: – 8 –

    – 8 – chk adj seats and fuel tank order 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: – 9 –

    – 9 – chk adj removing the fuel tank 1. Remove the fuel in the fuel tank through the fuel tank filler hole with a pump. 2. Remove: • fuel hose caution: although the fuel has been removed from the fuel tank, be careful when removing the fuel hose since there may be fuel remaining in it. Note: • to re...

  • Page 18: – 10 –

    – 10 – chk adj eas00043 air filter case order job/part q’ty remarks removing the air filter case remove the parts in the order listed. Seats refer to “seats and fuel tank” in chapter 3. (manual no.: 5jw1-ae1) fuel tank refer to “seats and fuel tank”. Side covers (left and right) refer to “cowlings a...

  • Page 19: – 11 –

    – 11 – chk adj 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: – 12 –

    – 12 – fi fuel injection system fuel injection system fuel injection system 1 ignition coil 2 air filter case 3 intake air tempera- ture sensor 4 fuel delivery hose 5 fuel tank 6 fuel pump 7 intake air pressure sensor 8 throttle position sensor 9 fuel injector 0 o 2 sensor a catalytic converter b cr...

  • Page 21: – 13 –

    – 13 – fi fuel injection system wiring diagram (fjr1300) on off p r r r br /l br /r bb1 bb2 bb4 bb3 g /y br bl y ch dg y dg b l /r ch dg ch br/w br/w ch dg br /w br /g b /r r /b b /r r /b r /b b /r b b l /y b /y b /y l /y (black) (black) r r r r br /l br /l br /r br /r (black) (gray) w w w b g /w b ...

  • Page 22: – 14 –

    – 14 – fi fuel injection system wiring diagram (fjr1300a) on off p r r r br /l br /r bb1 bb2 bb4 bb3 g /y br bl y ch dg y dg b l /r ch dg ch br/w br/w ch dg br /w br /g b /r r /b b /r r /b r /b b /r b b l /y b /y b /y l /y (black) (black) r r r r br /l br /l b b /w r r /l b b /w r r /l br /r br /r (...

  • Page 23: – 15 –

    – 15 – fi fuel injection system * table of self-diagnostic fault code numbers displayed on meter • how to erase the self-diagnostic fault code from memory: if the ecu detects a normal signal upon the completion of the repair of the malfunction, the self- diagnostic fault code disappears from the met...

  • Page 24: – 16 –

    – 16 – fi fuel injection system substitute characteristics operation control (fail-safe action) if the ecu detects an abnormal signal from a sensor while the motorcycle is being driven, the ecu illuminates the engine trouble warning light and provides the engine with substitute characteristic operat...

  • Page 25: – 17 –

    – 17 – fi fuel injection system self-diagnostic fault codes, symptoms, and probable causes diagnostic code indication code no. Symptom probable cause of malfunction diagnostic code 11 no normal signals are received from the cylinder identification sensor. • open or short circuit in wiring sub lead. ...

  • Page 26: – 18 –

    – 18 – fi fuel injection system 24 no normal signals are received from the o 2 sensor. • open or short circuit in wiring harness. • defective o 2 sensor. • malfunction in ecu. • improperly installed sensor. — 30 the motorcycle has overturned. • overturned. • malfunction in ecu. 08 31 the amount of a...

  • Page 27: – 19 –

    – 19 – fi fuel injection system sensor operation data display verification table note: • check the intake air temperature and coolant temperature as close as possible to the area in which the respective sensor is mounted. • if it is not possible to check the intake temperature, use the ambient tempe...

  • Page 28: – 20 –

    – 20 – fi fuel injection system troubleshooting details troubleshooting the self-diagnostic fault code code no. 19 symptom a break or disconnection of the black/red lead of the ecu is detected. Used diagnostic code no. 20 (sidestand switch) inspection operation item and probable cause operation item...

  • Page 29: – 21 –

    – 21 – fi fuel injection system throttle bodies 8 9 2 4 1 5 5 5 5 10 10 3 7 7 6 10 10 order job/part q’ty remarks removing the throttle bodies remove the parts in the order listed. Seats/t-bar/rubber sheet refer to “seats and fuel tank” in chapter 3. (manual no.: 5jw1-ae1) fuel tank refer to “seats ...

  • Page 30: – 22 –

    – 22 – fi fuel injection system 8 9 2 4 1 5 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: – 23 –

    – 23 – fi fuel injection system 11 3 4 5 6 1 7 2 8 12 13 14 10 10 10 9 order job/part q’ty remarks removing the injectors remove the parts in the order listed. 1 throttle position sensor coupler 1 disconnect. 2 intake air pressure sensor coupler 1 disconnect. 3 cylinder #1-injector coupler 1 disconn...

  • Page 32: – 24 –

    – 24 – fi fuel injection 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: – 25 –

    – 25 – fi 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: – 26 –

    – 26 – – + elec electrical components eas00729 electrical electrical components 1 windshield drive 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 swi...

  • Page 35: – 27 –

    – 27 – – + elec electrical components 1 coolant temperature sensor 2 intake air pressure sensor 3 intake air temperature sensor 4 relay unit 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 identifica...

  • Page 36: – 28 –

    – 28 – – + elec fuel injection system fuel injection system circuit diagram (fjr1300) on off p r r r br /l br /r bb1 bb2 bb4 bb3 g /y br bl y ch dg y dg b l /r ch dg ch br/w br/w ch dg br /w br /g b /r r /b b /r r /b r /b b /r b b l /y b /y b /y l /y (black) (black) r r r r br /l br /l br /r br /r (...

  • Page 37: – 29 –

    – 29 – – + elec fuel injection system circuit diagram (fjr1300a) on off p r r r br /l br /r bb1 bb2 bb4 bb3 g /y br bl y ch dg y dg b l /r ch dg ch br/w br/w ch dg br /w br /g b /r r /b b /r r /b r /b b /r b b l /y b /y b /y l /y (black) (black) r r r r br /l br /l b b /w r r /l b b /w r r /l br /r ...

  • Page 38: – 30 –

    – 30 – – + elec fuel injection system eas00819 checking the fuel pump warning @ gasoline is extremely flammable and under certain circumstances there can be a dan- ger of an explosion or fire. Be extremely careful and note the following points: • stop the engine before refueling. • do not smoke, and...

  • Page 39: Fjr1300 Wiring Diagram

    Fjr1300 wiring diagram 1 immobilizer unit 2 main switch 3 rectifier/regulator 4 generator 5 backup fuse (odometer, clock and windshield) 6 main fuse 7 battery 8 fuel injection system fuse 9 starter relay 0 starter motor a relay unit b starting circuit cut-off relay c fuel injection system relay d ne...

  • Page 40: Fjr1300A Wiring Diagram

    Fjr1300a wiring diagram 1 immobilizer unit 2 main switch 3 rectifier/regulator 4 generator 5 abs fuse 6 backup fuse (odometer, clock and windshield) 7 main fuse 8 abs motor fuse 9 battery 0 fuel injection system fuse a starter relay b starter motor c relay unit d starting circuit cut-off relay e fue...

  • Page 42

    Yamaha motor co., ltd. 2500 shingai iwata shizuoka japan.

  • Page 43: Fjr1300 Wiring Diagram

    On off p r r r br/l br/r bb1 bb2 bb4 bb3 g/y br b l y ch dg y dg b l/r ch dg ch br/w br/w ch dg br/w br/g b/r r/b b/r r/b r/b b/r b b l/y b/y b/y l/y (black) (black) r r r r br/l br/l br/r br/r (black) (gray) w w w b g/w b r/l r b b b r r r r r br/l br/y b b b r r r b l/w r/g bb r/w r/w r l/w b r b ...

  • Page 44: Fjr1300A Wiring Diagram

    Fjr1300a wiring diagram on off p r r r br/l br/r bb1 bb2 bb4 bb3 g/y br b l y ch dg y dg b l/r ch dg ch br/w br/w ch dg br/w br/g b/r r/b b/r r/b r/b b/r b b l/y b/y b/y l/y (black) (black) r r r r br/l br/l b b/w r r/l b b/w r r/l br/r br/r (black) (gray) w w w b g/w b r/l r b b b r r r r r br/l br...