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Yamaha FJR1300A(X) Service Manual

Summary of FJR1300A(X)

  • Page 1

    2008 service manual fjr1300a(x) fjr1300as(x) 3p6-28197-e2.

  • Page 2

    Eas20040 fjr1300a(x)/fjr1300as(x) 2008 service manual ©2007 by yamaha motor co., ltd. First edition, october 2007 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited..

  • Page 3: Notice

    Eas20070 notice this manual was produced by the yamaha motor company, ltd. Primarily for use by yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on yama...

  • Page 4: How to Use This Manual

    Eas20090 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. • the manual is di...

  • Page 5: Symbols

    Eas20100 symbols the following symbols are used in this manual for easier understanding. Note: the following symbols are not relevant to every vehicle. G m e b ls m 9 10 11 12 13 14 15 16 17 18 lt new bf s t r . . 1 2 3 4 5 6 7 8 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Sp...

  • Page 7: Table of Contents

    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 9: General Information

    1 general information identification ............................................................................................ 1-1 vehicle identification number ..................................................... 1-1 model label......................................................................

  • Page 10: Identification

    Identification 1-1 eas20130 identification eas20140 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: Features

    Features 1-2 eas20170 features et2c01025 outline of the fi system the main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor sy...

  • Page 12: Features

    Features 1-3 et3p61042 fi system the fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kpa (3.24 kg/cm², 47.0 psi). Accordingly, when the energizing signal from the ecu energizes the f...

  • Page 13: Features

    Features 1-4 et3p61050 outline of the unified brake system the yamaha unified brake system is a system that operates one set of pistons in the front brakes to- gether with the rear brake when the brake pedal is depressed. Compared to conventional brake sys- tems, the ability to slow the vehicle usin...

  • Page 14: Features

    Features 1-5 brake pedal input force and braking force at each wheel metering valve this valve prevents the brake fluid pressure that is transmitted to the right front brake caliper from in- creasing until the pressure exceeds a set level. Only the rear brake caliper is operated when there is an ext...

  • Page 15: Features

    Features 1-6 abs layout abs the operation of the yamaha abs brakes is the same as conventional brakes on other vehicles, with a brake lever for operating the front brake and a brake pedal for operating the rear brake. However, part of the front brake is operated together with rear brake. When wheel ...

  • Page 16: Features

    Features 1-7 • slip ratio: when the brakes are applied, slipping occurs between the tires and the road surface. This causes a difference between the wheel speed and the chassis speed. Slip ratio is the value that shows the rate of wheel slippage and is defined by the following formula. 0%: there is ...

  • Page 17: Features

    Features 1-8 the difference between the chassis speed and the wheel speed calculated in the slip ratio formula is equal to the wheel slip. When the wheel speed is suddenly reduced, the wheel has a tendency to lock. When the wheel slip and the wheel speed reduction rate exceed the preset values, the ...

  • Page 18: Features

    Features 1-9 the abs functions to prevent the tendency of the wheel to lock by controlling the brake fluid pressure. However, if there is a tendency of the wheel to lock on a slippery road surface, due to engine braking, the abs may not be able to prevent the wheel from locking. Warning ewa13870 the...

  • Page 19: Features

    Features 1-10 abs block diagram et3p61051 abs component functions wheel sensors and wheel sensor rotors wheel sensors “1” detect the wheel rotation speed and transmit the wheel rotation signal to the abs ecu. Each wheel sensor contains a hall ic. The wheel sensors are installed in the sensor housing...

  • Page 20: Features

    Features 1-11 abs warning light the abs warning light “1” comes on to warn the rider if a malfunction in the abs occurs. When the main switch is turned to “on”, the abs warning light comes on for 2 seconds, then goes off, so that the rider can check if the abs warning light is disconnected and check...

  • Page 21: Features

    Features 1-12 • hydraulic control valve the hydraulic control valve is composed of a inlet solenoid valve and outlet solenoid valve. The electromagnetic force generated in the inlet solenoid valve varies proportionally with the duty cy- cle control voltage that is supplied to it. Since this voltage ...

  • Page 22: Features

    Features 1-13 • buffer chamber the buffer chamber accumulates the brake fluid that is depressurized while the abs is operating. • abs ecu the abs ecu is integrated with the hydraulic unit to achieve a compact and lightweight design. As shown in the block following diagram, the abs ecu receives wheel...

  • Page 23: Features

    Features 1-14 the necessary actions are confirmed using the monitor circuit and control signals are transmitted to the hydraulic unit assembly. Abs control operation the abs control operation performed in the abs ecu is divided into the following two parts. • hydraulic control • self-diagnosis when ...

  • Page 24: Features

    Features 1-15 et3p61052 abs operation the abs hydraulic circuit consists of two systems: the front wheel, and rear wheel. The following de- scribes the system for the front wheel only, excluding the unified brake system. Normal braking (abs not activated) when the abs is not activated, the inlet sol...

  • Page 25: Features

    Features 1-16 emergency braking (abs activated) 1. Depressurizing phase when the front wheel is about to lock, the outlet solenoid valve is opened by the “depressurization” signal transmitted from the abs ecu. When this occurs, the inlet solenoid valve compresses the spring and closes the brake line...

  • Page 26: Features

    Features 1-17 et3p61053 abs self-diagnosis function abs warning light the abs warning light “1” comes on when a malfunction is detected 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 p...

  • Page 27: Features

    Features 1-18 instances when the abs warning light comes on 1. The abs warning light comes on when the main switch is turned to “on”. The abs warning light comes on for 2 seconds while the abs is performing a self-diagnosis, then goes off if there are no problems. 2. The abs warning light comes on w...

  • Page 28: Features

    Features 1-19 4. The abs warning light flashes while riding. If the abs warning light flashes while riding, there is no problem with the function of the abs. How- ever, the abs ecu input has unstable factors. (for details, refer to “abs troubleshooting outline” on page 8-143.) note: the abs warning ...

  • Page 29: Features

    Features 1-20 et3p61054 abs warning light and operation abs warning light • when the main switch is turned to “on”, the abs warning light comes on for 2 seconds, then goes off. • the abs warning light comes on while the start switch is being pushed. • if the abs warning light comes on while riding, ...

  • Page 30: Features

    Features 1-21 • depending on the road conditions, the braking distance may be longer compared to that of vehicles not equipped with abs. Therefore, ride at a safe speed and keep a safe distance between yourself and other vehicles. • the braking of the vehicle, even in the worst case, is principally ...

  • Page 31: Features

    Features 1-22 shift pattern this vehicle is equipped with a constant-mesh 5-speed transmission. The gears can be shifted using either the shift pedal “1” or the hand shift switch “2”. The hand shift switch has to be enabled by pressing the hand shift select button “3” prior to being used. The gear p...

  • Page 32: Features

    Features 1-23 attention • do not turn the main switch to “off” while the vehicle is moving, otherwise the electrical systems will be switched off, including the ycc-s system, which may result in loss of control or an accident. Make sure that the vehicle is stopped before turning the main switch to “...

  • Page 33: Features

    Features 1-24 et3p61043 instrument functions speedometer the speedometer shows the riding speed. When the key is turned to “on”, the speedome- ter needle will sweep once across the speed range and then return to zero in order to test the electrical circuit. Tachometer the electric tachometer allows ...

  • Page 34: Features

    Features 1-25 odometer and tripmeter modes pushing the “select” button switches the dis- play between the odometer mode “odo” and the tripmeter modes “trip 1” and “trip 2” in the following order: odo → trip 1 → trip 2 → odo note: when selecting “trip 1” or “trip 2”, the display flashes for five seco...

  • Page 35: Features

    Features 1-26 refer to “signaling system” on page 8-39. Coolant temperature meter with the key in the “on” position, the coolant temperature meter indicates the temperature of the coolant. When the key is turned to “on”, all of the display segments of the coolant tempera- ture meter will appear one ...

  • Page 36: Features

    Features 1-27 • the accuracy of the temperature reading may be affected when riding slowly (approximately under 20 km/h) or when stopped at traffic sig- nals, railroad crossings, etc. Instantaneous fuel consumption mode the instantaneous fuel consumption display can be set to either “km/l” or “l/100...

  • Page 37: Features

    Features 1-28 ambient temperature mode this display shows the ambient temperature from -9 °c to 50 °c in 1 °c increments. The tem- perature displayed may vary from the ambient temperature. Note: 1. • if the ambient temperature falls below -9 °c, a lower temperature than -9 °c will not be dis- played...

  • Page 38: Features

    Features 1-29 if the multi-function display indicates such an fault code, note the code number, and check the vehicle. Refer to “fuel injection system” on page 8-57. Caution: ec3p61042 if the multi-function display indicates an fault code, the vehicle should be checked as soon as possible in order t...

  • Page 39: Important Information

    Important information 1-30 eas20180 important information eas20190 preparation for removal and disassembly 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equip- ment. Refer to “special tools” on page 1-33. 3. When disasse...

  • Page 40: Important Information

    Important information 1-31 eas20230 bearings and oil seals install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if...

  • Page 41: Checking The Connections

    Checking the connections 1-32 eas20250 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector moisture → dry with an air blower. Rust/stains → connect and disconnect sev- e...

  • Page 42: Special Tools

    Special tools 1-33 eas20260 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers o...

  • Page 43: Special Tools

    Special tools 1-34 compression gauge 90890-03081 engine compression tester yu-33223 3-13 oil filter wrench 90890-01426 yu-38411 3-15 oil pressure gauge set 90890-03120 3-16 oil pressure adapter b 90890-03124 3-16 vacuum/pressure pump gauge set 90890-06756 mityvac brake bleeding tool ys-42423 3-19 ma...

  • Page 44: Special Tools

    Special tools 1-35 damper rod holder 90890-01447 ym-01447 4-82, 4-83 slide metal installer 90890-01508 ym-01508 4-84 fork seal driver 90890-01502 ym-a0948 4-84, 4-85 ring gear fix bolt (m14) 90890-01524 ym-01524 4-106 final gear backlash band 90890-01511 middle drive gear lash tool ym-01230 4-106 co...

  • Page 45: Special Tools

    Special tools 1-36 oil seal installing tool 90890-01512 ym-01512 4-113, 4-115 pivot shaft wrench 90890-01471 frame spanner socket ym-01471 5-8, 5-9 pivot shaft wrench adapter 90890-01476 5-8, 5-9 digital circuit tester 90890-03174 model 88 multimeter with tachometer yu-a1927 5-11, 5-72, 7-8 rotor ho...

  • Page 46: Special Tools

    Special tools 1-37 valve guide remover (ø5) 90890-04097 valve guide remover (5.0 mm) ym-04097 5-28 valve guide installer (ø5) 90890-04098 valve guide installer (5.0 mm) ym-04098 5-28 valve guide reamer (ø5) 90890-04099 valve guide reamer (5.0 mm) ym-04099 5-28 sheave holder 90890-01701 primary clutc...

  • Page 47: Special Tools

    Special tools 1-38 damper spring compressor 90890-04090 5-89, 5-90 bearing retainer wrench 90890-04140 middle drive shaft bearing retainer wrench ym-04140 5-90 gear lash measurement tool 90890-01467 ym-01467 5-93 piston pin puller set 90890-01304 piston pin puller yu-01304 5-108 piston ring compress...

  • Page 48: Special Tools

    Special tools 1-39 weight 90890-01084 yu-01083-3 5-127 radiator cap tester 90890-01325 radiator pressure tester yu-24460-01 6-3 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...

  • Page 49: Special Tools

    Special tools 1-40 pressure gauge 90890-03153 yu-03153 7-7 fuel pressure adapter 90890-03176 ym-03176 7-7 ignition checker 90890-06754 opama pet-4000 spark checker ym-34487 8-248 tool name/tool no. Illustration reference pages.

  • Page 50: Special Tools

    Special tools 1-41.

  • Page 51: Specifications

    2 specifications general specifications ........................................................................ 2-1 engine specifications ............................................................................ 2-2 chassis specifications ............................................................

  • Page 52: General Specifications

    General specifications 2-1 eas20280 general specifications model model fjr1300a 3p6d (europe except (b) and (f)) (za) fjr1300a 3p6e (b) (f) fjr1300a 3p6f (aus) fjr1300as 2d2d (europe except (b) and (f)) (za) fjr1300as 2d2e (b) (f) fjr1300as 2d2f (aus) dimensions overall length 2230 mm (87.8 in) over...

  • Page 53: Engine Specifications

    Engine specifications 2-2 eas20290 engine specifications engine engine type liquid cooled 4-stroke, dohc displacement 1298.0 cm³ cylinder arrangement forward-inclined parallel 4-cylinder bore × stroke 79.0 × 66.2 mm (3.11 × 2.61 in) compression ratio 10.80 :1 standard compression pressure (at sea le...

  • Page 54: Engine Specifications

    Engine specifications 2-3 relief valve operating pressure 480.0–560.0 kpa (69.6–81.2 psi) (4.80–5.60 kgf/cm²) cooling system radiator capacity (including all routes) 2.60 l (2.75 us qt) (2.29 imp.Qt) radiator capacity 0.65 l (0.69 us qt) (0.57 imp.Qt) coolant reservoir capacity (up to the maximum le...

  • Page 55: Engine Specifications

    Engine specifications 2-4 limit 24.897 mm (0.9802 in) camshaft runout limit 0.030 mm (0.0012 in) timing chain model/number of links 92rh2015/136 tensioning system automatic valve, valve seat, valve guide valve clearance (cold) intake 0.15–0.22 mm (0.0059–0.0087 in) exhaust 0.18–0.25 mm (0.0071–0.009...

  • Page 56: Engine Specifications

    Engine specifications 2-5 valve-stem-to-valve-guide clearance (exhaust) 0.020–0.047 mm (0.0008–0.0019 in) limit 0.105 mm (0.0041 in) valve stem runout 0.010 mm (0.0004 in) cylinder head valve seat width (intake) 0.90–1.10 mm (0.0354–0.0433 in) cylinder head valve seat width (exhaust) 0.90–1.10 mm (0...

  • Page 57: Engine Specifications

    Engine specifications 2-6 height h 5.0 mm (0.20 in) offset 0.50 mm (0.0197 in) offset direction intake side piston pin bore inside diameter 19.004–19.015 mm (0.7482–0.7486 in) limit 19.045 mm (0.7498 in) piston pin outside diameter 18.991–19.000 mm (0.7477–0.7480 in) limit 18.971 mm (0.7469 in) pist...

  • Page 58: Engine Specifications

    Engine specifications 2-7 small end inside diameter 19.005–19.018 mm (0.7482–0.7487 in) crankshaft width a 61.60–63.20 mm (2.425–2.488 in) width b 325.10–326.30 mm (12.80–12.85 in) runout limit c 0.030 mm (0.0012 in) big end side clearance d 0.160–0.262 mm (0.0063–0.0103 in) journal oil clearance (u...

  • Page 59: Engine Specifications

    Engine specifications 2-8 drive axle runout limit 0.08 mm (0.0032 in) shifting mechanism shift mechanism type shift drum and guide bar shift fork guide bar bending limit 0.100 mm (0.0039 in) air filter air filter element dry element fuel pump pump type electrical model/manufacturer 5jw 21/denso maxi...

  • Page 60: Chassis Specifications

    Chassis specifications 2-9 eas20300 chassis specifications chassis frame type diamond caster angle 26.00° trail 109.0 mm (4.29 in) front wheel wheel type cast wheel rim size 17m/c × mt3.50 rim material aluminum wheel travel 135.0 mm (5.31 in) radial wheel runout limit 1.0 mm (0.04 in) lateral wheel ...

  • Page 61: Chassis Specifications

    Chassis specifications 2-10 front disc brake disc outside diameter × thickness 320.0 × 4.5 mm (12.60 × 0.18 in) brake disc thickness limit 4.0 mm (0.16 in) brake disc deflection limit 0.10 mm (0.0039 in) brake pad lining thickness (inner) 5.5 mm (0.22 in) limit 0.5 mm (0.02 in) brake pad lining thic...

  • Page 62: Chassis Specifications

    Chassis specifications 2-11 optional spring available no recommended oil suspension oil m1 or ohlins r & t43 quantity 696.0 cm³ (23.53 us oz) (24.55 imp.Oz) level 92.0 mm (3.62 in) rear suspension type swingarm (link suspension) spring/shock absorber type coil spring/gas-oil damper rear shock absorb...

  • Page 63: Electrical Specifications

    Electrical specifications 2-12 eas20310 electrical specifications voltage system voltage 12 v ignition system ignition system transistorized coil ignition (digital) ignition timing (b.T.D.C.) 5.0°/1050 r/min engine control unit model/manufacturer fua0023/mitsubishi (europe except (b) and (f)) (za) (...

  • Page 64: Electrical Specifications

    Electrical specifications 2-13 license plate light 12 v, 5.0 w × 1 meter lighting led indicator light neutral indicator light led turn signal indicator light led oil level warning light led high beam indicator light led engine trouble warning light led abs warning light led immobilizer system indica...

  • Page 65: Electrical Specifications

    Electrical specifications 2-14 starting circuit cut-off relay model/manufacturer g8r-30y-v3/omron coil resistance 180.0 Ω headlight relay model/manufacturer acm33211 m05/matsushita coil resistance 96.0 Ω radiator fan model/manufacturer 3p6/denso running rpm 4250 r/min fan motor relay model/manufactu...

  • Page 66: Tightening Torques

    Tightening torques 2-15 eas20320 tightening torques eas20330 general tightening torque specifications this chart specifies tightening torques for stan- dard fasteners with a standard iso thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapt...

  • Page 67: Tightening Torques

    Tightening torques 2-16 eas20340 engine tightening torques item thread size q’ty tightening torque remarks spark plug m10 4 13 nm (1.3 m·kg, 9.4 ft·lb) cylinder head bolt m10 10 see note. Cylinder head bolt m6 2 12 nm (1.2 m·kg, 8.7 ft·lb) camshaft cap bolt m6 20 10 nm (1.0 m·kg, 7.2 ft·lb) cylinder...

  • Page 68: Tightening Torques

    Tightening torques 2-17 oil pump housing cover bolt m6 3 12 nm (1.2 m·kg, 8.7 ft·lb) oil level switch bolt m6 2 10 nm (1.0 m·kg, 7.2 ft·lb) throttle body joint clamp screw m4 8 3 nm (0.3 m·kg, 2.2 ft·lb) air filter case joint clamp screw m4 4 4 nm (0.4 m·kg, 2.9 ft·lb) air filter case and rear lower...

  • Page 69: Tightening Torques

    Tightening torques 2-18 main gallery bolt m20 1 12 nm (1.2 m·kg, 8.7 ft·lb) starter clutch bolt m8 3 32 nm (3.2 m·kg, 23 ft·lb) clutch boss nut m20 1 90 nm (9.0 m·kg, 65 ft·lb) use a lock washer. Clutch spring bolt m6 6 8 nm (0.8 m·kg, 5.8 ft·lb) clutch release cylinder bolt m6 3 10 nm (1.0 m·kg, 7....

  • Page 70: Tightening Torques

    Tightening torques 2-19 note: cylinder head bolt tighten the cylinder head bolts to 25 nm (2.5 m·kg 18 ft·lb) in the proper tightening sequence, loosen and retighten the bolts to 25 nm (2.5 m·kg 18 ft·lb) in the proper tightening sequence, and then tighten them further to reach the specified angle 1...

  • Page 71: Tightening Torques

    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 72: Tightening Torques

    Tightening torques 2-21 eas20350 chassis tightening torques item thread size q’ty tightening torque remarks engine mounting bolts (right front lower side) m12 1 49 nm (4.9 m·kg, 35 ft·lb) engine mounting bolts (right front upper side) m12 1 49 nm (4.9 m·kg, 35 ft·lb) engine mounting bolts (left fron...

  • Page 73: Tightening Torques

    Tightening torques 2-22 lower ring nut (initial tightening torque) m30 1 52 nm (5.2 m·kg, 37 ft·lb) see note. Lower ring nut (final tightening torque) m30 1 18 nm (1.8 m·kg, 13 ft·lb) see note. Handlebar bolt m8 2 23 nm (2.3 m·kg, 17 ft·lb) handlebar nut m12 2 65 nm (6.5 m·kg, 47 ft·lb) clutch maste...

  • Page 74: Tightening Torques

    Tightening torques 2-23 rear fender nut m6 2 7 nm (0.7 m·kg, 5.1 ft·lb) front wheel axle bolt m14 1 91 nm (9.1 m·kg, 66 ft·lb) see note. Front wheel axle pinch bolt m8 4 21 nm (2.1 m·kg, 15 ft·lb) front brake disc bolt m6 12 18 nm (1.8 m·kg, 13 ft·lb) front wheel sensor bolt m6 1 7 nm (0.7 m·kg, 5.1...

  • Page 75: Tightening Torques

    Tightening torques 2-24 note: lower ring nut 1. First, tighten the lower ring nut to approximately 52 nm (5.2 m·kg, 37 ft·lb) with a torque wrench, then loosen the lower ring nut completely. 2. Retighten the lower ring nut to 18 nm (1.8 m·kg, 13 ft·lb) with a torque wrench. Note: front wheel axle pi...

  • Page 76: Tightening Torques

    Tightening torques 2-25 2. In the order pinch bolt “2” → pinch bolt “1” → pinch bolt “2”, tighten each bolt to 21 nm (2.1 m·kg, 15 ft·lb) without performing temporary tightening. 3. Check that the right end of the front axle is flush with the front fork. If necessary, manually push the front axle or...

  • Page 77: 2-26

    Lubrication points and lubricant types 2-26 eas20360 lubrication points and lubricant types eas20370 engine lubrication point lubricant oil seal lips o-rings bearings crankshaft pins piston surfaces piston pins connecting rod bolts and nuts crankshaft journals camshaft lobes camshaft journals balanc...

  • Page 78: 2-27

    Lubrication points and lubricant types 2-27 cylinder head cover mating surface three bond 1541 ® cylinder 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 (th...

  • Page 79: 2-28

    Lubrication points and lubricant types 2-28 eas20380 chassis lubrication point lubricant steering bearings and upper bearing cover lip lower bearing dust seal lip front wheel oil seal lips (right and left) rear wheel oil seal lips rear wheel drive hub oil seal rear wheel drive hub mating surface rea...

  • Page 80: 2-29

    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 81: 2-30

    Lubrication system chart and diagrams 2-30 1. Oil 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...

  • Page 82: 2-31

    Lubrication system chart and diagrams 2-31 eas20410 lubrication diagrams 5 6 7 1 2 3 4.

  • Page 83: 2-32

    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 84: 2-33

    Lubrication system chart and diagrams 2-33 1 3 2.

  • Page 85: 2-34

    Lubrication system chart and diagrams 2-34 1. Main axle 2. Drive axle 3. Oil delivery pipe 1.

  • Page 86: 2-35

    Lubrication system chart and diagrams 2-35 6 5 4 3 2 1.

  • Page 87: 2-36

    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 88: 2-37

    Lubrication system chart and diagrams 2-37 1 2 3 4 5 6 7 8 9.

  • Page 89: 2-38

    Lubrication 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 90: 2-39

    Lubrication system chart and diagrams 2-39 4 5 3 2 1 9 8 6 7.

  • Page 91: 2-40

    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 92: Cooling System Diagrams

    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 93: Cooling System Diagrams

    Cooling system diagrams 2-42 1. Thermostat inlet pipe 1 2. Thermostat inlet hose 1 3. Plunger control unit hose 1 4. Plunger control unit hose 2 5. Oil cooler outlet hose 6. Radiator 7. Coolant reservoir breather hose 8. Thermostat inlet pipe 2 9. Coolant reservoir hose 10. Radiator inlet hose 11. T...

  • Page 94: Cooling System Diagrams

    Cooling system diagrams 2-43 a a 7 1 2 3 4 5 5 7 8 6 8 9 10 11 12.

  • Page 95: Cooling System Diagrams

    Cooling system diagrams 2-44 1. Thermostat inlet pipe 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...

  • Page 96: Cable Routing (Fjr1300A)

    Cable routing (fjr1300a) 2-45 eas20430 cable routing (fjr1300a) c-c b-b a a c c a b c d e g h h i i j k l 1 2 2 2 3 4 5 6 7 8 9 10 11 12 13 13 14 14 15 16 17 18 19 20 21 1 2 3 22 3 13 14 1 3 7 8 b b f m 21 21 22 22 n.

  • Page 97: Cable Routing (Fjr1300A)

    Cable routing (fjr1300a) 2-46 1. Right grip warmer lead 2. Brake hose (front brake master cylinder to brake pipe/lower joint assembly) 3. Right handlebar switch lead 4. Clutch hose 5. Left handlebar switch lead 6. Left grip warmer lead 7. Main switch lead 8. Immobilizer unit lead 9. Left horn (low) ...

  • Page 98: Cable Routing (Fjr1300A)

    Cable routing (fjr1300a) 2-47 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 99: Cable Routing (Fjr1300A)

    Cable routing (fjr1300a) 2-48 1. O 2 sensor lead 2. Engine idling speed adjusting cable 3. Starter motor lead 4. Air deflector 5. Wire harness 6. Spark plug lead #4 7. Spark plug lead #1 8. Cylinders-#1/#4 ignition coil 9. Cylinders-#2/#3 ignition coil 10. Starter relay 11. Starter relay lead 12. Fu...

  • Page 100: Cable Routing (Fjr1300A)

    Cable routing (fjr1300a) 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 101: Cable Routing (Fjr1300A)

    Cable routing (fjr1300a) 2-50 1. Rear wheel sensor lead 2. Brake hose (rear brake master cylinder to brake pipe/middle joint assembly) 3. Rear brake fluid reservoir hose 4. Rear brake fluid reservoir 5. Brake pipe (hydraulic unit to metering valve) 6. Hydraulic unit assembly 7. Brake pipe (hydraulic...

  • Page 102: Cable Routing (Fjr1300A)

    Cable routing (fjr1300a) 2-51 1 2 3 4 5 6 7 8 a b c d e 9 10 11 12 13.

  • Page 103: Cable Routing (Fjr1300A)

    Cable routing (fjr1300a) 2-52 1. Auxiliary dc jack 2. Left radiator fan motor lead 3. Accessory box solenoid 4. Wire harness 5. Front cowling wire harness 6. Radiator inlet hose 7. Grip warmer control unit leads 8. Left radiator fan 9. Coolant reservoir breather hose 10. Left horn (low) 11. Left hor...

  • Page 104: Cable Routing (Fjr1300A)

    Cable routing (fjr1300a) 2-53 a-a b c c b d a a a d f h i j k l m n o p q u v 1 2 7 7 16 16 10 11 14 12 13 15 17 18 19 22 23 24 25 26 27 28 g 8 9 7 3 5 4 30 27 29 d r 10 s t b 6 c 20 21 e.

  • Page 105: Cable Routing (Fjr1300A)

    Cable routing (fjr1300a) 2-54 1. Grip warmer couplers 2. Handlebar switch couplers 3. Right grip warmer lead 4. Right handlebar switch lead 5. Immobilizer unit lead 6. Main switch lead 7. Clutch hose 8. Left grip warmer lead 9. Left handlebar switch lead 10. Stator coil lead 11. Air filter case brea...

  • Page 106: Cable Routing (Fjr1300A)

    Cable routing (fjr1300a) 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 107: Cable Routing (Fjr1300A)

    Cable routing (fjr1300a) 2-56 1. Wire harness 2. Ecu (engine control unit) 3. Tail/brake light 4. Rear turn signal light 5. Tail/brake light assembly lead 6. License plate light lead 7. Seat lock cable 8. Stator coil lead 9. Rear shock absorber spring preload adjusting cable 10. Rectifier/regulator ...

  • Page 108: Cable Routing (Fjr1300A)

    Cable routing (fjr1300a) 2-57 h a d e f g i i j k l m n o p 1 2 4 5 6 7 8 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 31 30 c b 3 9 10

  • Page 109: Cable Routing (Fjr1300A)

    Cable routing (fjr1300a) 2-58 1. Spark plug lead #1 2. Spark plug lead #2 3. Clutch hose 4. Front wheel sensor lead 5. Immobilizer unit lead 6. Main switch lead 7. Throttle cable (accelerator cable) 8. Throttle cable (decelerator cable) 9. Brake hose (brake pipe/upper joint assembly to front brake c...

  • Page 110: Cable Routing (Fjr1300A)

    Cable routing (fjr1300a) 2-59 1 2 3 4 a b b c d e.

  • Page 111: Cable Routing (Fjr1300A)

    Cable routing (fjr1300a) 2-60 1. License plate light lead 2. Tail/brake light assembly lead 3. Seat lock cable 4. Intake air temperature sensor a. 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 lea...

  • Page 112: Cable Routing (Fjr1300A)

    Cable routing (fjr1300a) 2-61 a 1 13 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 11 12 a.

  • Page 113: Cable Routing (Fjr1300A)

    Cable routing (fjr1300a) 2-62 1. Windshield drive unit 2. Thermistor 3. Windshield drive unit lead 4. Meter assembly lead 5. Left auxiliary light lead 6. Left headlight beam adjusting cable 7. Left headlight lead 8. Right headlight lead 9. Right headlight beam adjusting cable 10. Turn signal/hazard ...

  • Page 114: Cable Routing (Fjr1300A)

    Cable routing (fjr1300a) 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 115: Cable Routing (Fjr1300A)

    Cable routing (fjr1300a) 2-64 1. Hydraulic unit assembly 2. Brake pipe/middle joint assembly 3. Brake pipe (hydraulic unit to metering valve) 4. Brake pipe (hydraulic unit to proportioning valve) 5. Brake pipe/upper joint assembly 6. Brake pipe/lower joint assembly 7. Brake pipe (proportioning valve...

  • Page 116: Cable Routing (Fjr1300As)

    Cable routing (fjr1300as) 2-65 et3p66048 cable routing (fjr1300as) 17 c-c a a c c a b c d e f f g g h i j k l 1 3 2 2 2 3 7 5 4 8 6 9 13 13 14 14 10 13 12 11 14 15 16 18 19 20 22 21 21 21 22 22 1 2 3 b b b-b 1 3 7 8.

  • Page 117: Cable Routing (Fjr1300As)

    Cable routing (fjr1300as) 2-66 1. Right grip warmer lead 2. Brake hose (front brake master cylinder to brake pipe/lower joint assembly) 3. Right handlebar switch lead 4. Left handlebar switch lead 5. Left grip warmer lead 6. Hand shift switch lead 7. Main switch lead 8. Immobilizer unit lead 9. Left...

  • Page 118: Cable Routing (Fjr1300As)

    Cable routing (fjr1300as) 2-67 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 119: Cable Routing (Fjr1300As)

    Cable routing (fjr1300as) 2-68 1. O 2 sensor lead 2. Engine idling speed adjusting cable 3. Starter motor lead 4. Air deflector 5. Wire harness 6. Spark plug lead #4 7. Spark plug lead #1 8. Cylinders-#1/#4 ignition coil 9. Cylinders-#2/#3 ignition coil 10. Starter relay 11. Starter relay lead 12. F...

  • Page 120: Cable Routing (Fjr1300As)

    Cable routing (fjr1300as) 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 121: Cable Routing (Fjr1300As)

    Cable routing (fjr1300as) 2-70 1. Rear wheel sensor lead 2. Brake hose (rear brake master cylinder to brake pipe/middle joint assembly) 3. Rear brake fluid reservoir hose 4. Rear brake fluid reservoir 5. Brake pipe (hydraulic unit to metering valve) 6. Hydraulic unit assembly 7. Brake pipe (hydrauli...

  • Page 122: Cable Routing (Fjr1300As)

    Cable routing (fjr1300as) 2-71 1 2 3 4 5 6 7 8 a b c d e 9 10 11 12 13.

  • Page 123: Cable Routing (Fjr1300As)

    Cable routing (fjr1300as) 2-72 1. Auxiliary dc jack 2. Left radiator fan motor lead 3. Accessory box solenoid 4. Wire harness 5. Front cowling wire harness 6. Radiator inlet hose 7. Grip warmer control unit leads 8. Left radiator fan 9. Coolant reservoir breather hose 10. Left horn (low) 11. Left ho...

  • Page 124: Cable Routing (Fjr1300As)

    Cable routing (fjr1300as) 2-73 up a-a b d c c b d a a a b d c f g h i j k l m n o t r s 1 3 2 19 19 11 12 13 11 15 14 17 18 20 21 22 23 10 24 25 26 16 27 28 29 30 31 32 33 e 7 9 8 4 6 5 30 34 35 16 p q.

  • Page 125: Cable Routing (Fjr1300As)

    Cable routing (fjr1300as) 2-74 1. Grip warmer couplers 2. Hand shift switch couplers 3. Handlebar switch couplers 4. Right grip warmer lead 5. Right handlebar switch lead 6. Immobilizer unit lead 7. Main switch lead 8. Hand shift switch lead 9. Left grip warmer lead 10. Left handlebar switch lead 11...

  • Page 126: Cable Routing (Fjr1300As)

    Cable routing (fjr1300as) 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 127: Cable Routing (Fjr1300As)

    Cable routing (fjr1300as) 2-76 1. Wire harness 2. Ecu (engine control unit) 3. Mcu (motor control unit) 4. Tail/brake light 5. Rear turn signal light 6. Tail/brake light assembly lead 7. License plate light lead 8. Seat lock cable 9. Foot shift switch lead 10. Shift actuator motor lead 11. Shift act...

  • Page 128: Cable Routing (Fjr1300As)

    Cable routing (fjr1300as) 2-77 h a d e f g i i j k l m n o p 1 2 4 5 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 c b 3 10 6 7 8 9.

  • Page 129: Cable Routing (Fjr1300As)

    Cable routing (fjr1300as) 2-78 1. Spark plug lead #1 2. Spark plug lead #2 3. Front wheel sensor lead 4. Immobilizer unit lead 5. Main switch lead 6. Throttle cable (accelerator cable) 7. Throttle cable (decelerator cable) 8. Brake hose (brake pipe/upper joint assembly to front brake calipers) 9. Br...

  • Page 130: Cable Routing (Fjr1300As)

    Cable routing (fjr1300as) 2-79 1 4 2 5 6 a b c d d e 3 f g.

  • Page 131: Cable Routing (Fjr1300As)

    Cable routing (fjr1300as) 2-80 1. Clutch actuator motor lead 2. Clutch actuator sensor lead 3. License plate light lead 4. Tail/brake light assembly lead 5. Seat lock cable 6. Intake air temperature sensor a. Fasten the clutch actuator motor lead and clutch actuator sensor lead with the band that is...

  • Page 132: Cable Routing (Fjr1300As)

    Cable routing (fjr1300as) 2-81 a 1 13 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 11 12 a.

  • Page 133: Cable Routing (Fjr1300As)

    Cable routing (fjr1300as) 2-82 1. Windshield drive unit 2. Thermistor 3. Windshield drive unit lead 4. Meter assembly lead 5. Left auxiliary light lead 6. Left headlight beam adjusting cable 7. Left headlight lead 8. Right headlight lead 9. Right headlight beam adjusting cable 10. Turn signal/hazard...

  • Page 134: Cable Routing (Fjr1300As)

    Cable routing (fjr1300as) 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 135: Cable Routing (Fjr1300As)

    Cable routing (fjr1300as) 2-84 1. Hydraulic unit assembly 2. Brake pipe/middle joint assembly 3. Brake pipe (hydraulic unit to metering valve) 4. Brake pipe (hydraulic unit to proportioning valve) 5. Brake pipe/upper joint assembly 6. Brake pipe/lower joint assembly 7. Brake pipe (proportioning valv...

  • Page 136: Cable Routing (Fjr1300As)

    Cable routing (fjr1300as) 2-85.

  • Page 137

    3 periodic checks and adjustments periodic maintenance ............................................................................ 3-1 introduction ....................................................................................... 3-1 periodic maintenance and lubrication chart (fjr1300a) ........

  • Page 138

    Chassis ....................................................................................................... 3-28 adjusting the front disc brake ................................................ 3-28 adjusting the rear disc brake .................................................. 3-28 checking the...

  • Page 140: Periodic Maintenance

    Periodic maintenance 3-1 eas20450 periodic maintenance eas20460 introduction this chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a long- er service life and re...

  • Page 141: Periodic Maintenance

    Periodic maintenance 3-2 eau17670 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 replace the internal componen...

  • Page 142: Periodic Maintenance

    Periodic maintenance 3-3 et3p6d018 periodic maintenance and lubrication chart (fjr1300as) note: • the annual checks must be performed every year, except if a kilometer-based maintenance, or for the uk, a mileage-based maintenance, is performed instead. • from 50000 km (30000 mi), repeat the maintena...

  • Page 143: Periodic Maintenance

    Periodic maintenance 3-4 et3p6d019 note: • the air filter needs more frequent service if you are riding in unusually wet or dusty areas. • hydraulic brake and ycc-s clutch service • regularly check and, if necessary, correct the brake and ycc-s clutch fluid levels. • every two years replace the inte...

  • Page 144: Engine

    Engine 3-5 eas20470 engine eas20490 adjusting the valve clearance the following procedure applies to all of the valves. Note: • valve clearance adjustment should be made on a cold engine, at room temperature. • when the valve clearance is to be measured or adjusted, the piston must be at top dead ce...

  • Page 145: Engine

    Engine 3-6 • measure the valve clearance in the following sequence. D. To measure the valve clearances of the other cylinders, starting with cylinder #1 at tdc, turn the crankshaft clockwise as specified in the following table. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 6. Remove: • camshafts...

  • Page 146: Engine

    Engine 3-7 example: if the valve pad is marked “155”, the pad thickness is 1.55 mm (0.061 in). D. Calculate the sum of the values obtained in steps (b) and (c) to determine the required valve pad thickness and the valve pad num- ber. Example: 1.55 mm (0.061 in) + 0.03 mm (0.001 in) = 1.58 mm (0.062 ...

  • Page 147: Engine

    Engine 3-8 2. 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. 3. Remove: • caps “1” 4. Install: • vacuum gauge “1” • digital tachometer 5. Install: • fuel tank 6. Start the engine and let it wa...

  • Page 148: Engine

    Engine 3-9 9. Measure: • engine idling speed out of specification → adjust. Make sure that the vacuum pressure is within specification. 10.Stop the engine and remove the measuring equipment. 11.Adjust: • throttle cable free play refer to “adjusting the throttle ca- ble free play” on page 3-10. 12.In...

  • Page 149: Engine

    Engine 3-10 note: the co adjustment volume appears on the odometer/tripmeter/fuel reserve tripmeter lcd. • to decrease the co adjustment volume, press the “reset” button. • to increase the co adjustment volume, press the “select” button. 8. Simultaneously press the “select” and “reset” buttons to re...

  • Page 150: Engine

    Engine 3-11 2. 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. 3. Adjust: • throttle cable free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ throttle body side a. Loosen the locknut “...

  • Page 151: Engine

    Engine 3-12 5. Check: • electrode “1” damage/wear → replace the spark plug. • insulator “2” abnormal color → replace the spark plug. Normal color is medium-to-light tan. 6. Clean: • spark plug (with a spark plug cleaner or wire brush) 7. Measure: • spark plug gap “a” (with a wire thickness gauge) ou...

  • Page 152: Engine

    Engine 3-13 5. Install: • fuel tank refer to “fuel tank” on page 7-1. 6. Check: • ignition timing ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Start the engine, warm it up for several min- utes, and then let it run at the specified en- gine idling speed. B. Check that pointer “a” on the pick...

  • Page 153: Engine

    Engine 3-14 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Set the main switch to “on”. B. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. Note: the difference in compression pressure be- tween cylinders should not exceed 100 kpa (1 kg/cm², ...

  • Page 154: Engine

    Engine 3-15 note: before checking the engine oil level, wait a few minutes until the oil has settled. 4. Start the engine, warm it up for several min- utes, and then turn it off. 5. Check the engine oil level again. Note: before checking the engine oil level, wait a few minutes until the oil has set...

  • Page 155: Engine

    Engine 3-16 8. Install: • engine oil filler cap 9. Start the engine, warm it up for several min- utes, and then turn it off. 10.Check: • engine (for engine oil leaks) 11.Check: • engine oil level refer to “checking the engine oil level” on page 3-14. 12.Check: • engine oil pressure ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼...

  • Page 156: Engine

    Engine 3-17 7. Install: • main gallery bolt 8. Install: • right side cowling refer to “general chassis” on page 4-1. Eas20860 adjusting the clutch lever (fjr1300a only) 1. Adjust: • clutch lever position (distance “a” from the handlebar grip to the clutch lever) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 157: Engine

    Engine 3-18 et3p66026 checking the clutch fluid level (fjr1300as) 1. Stand the vehicle on a level surface. Note: place the vehicle on the centerstand. 2. Remove: • left side cover refer to “general chassis” on page 4-1. 3. Check: • clutch fluid level below the minimum level mark “a” → add the recomm...

  • Page 158: Engine

    Engine 3-19 g. Loosen the bleed screw. This will release the tension and cause the clutch lever to contact the handlebar grip. H. Tighten the bleed screw and then release the clutch lever. I. Repeat steps (e) to (h) until all of the air bub- bles have disappeared from the clutch fluid in the plastic...

  • Page 159: Engine

    Engine 3-20 k. Engage the clutch by turning the manual clutch operation bolt in direction “b” until it stops. Note: the following illustration shows the manual clutch operation bolt when viewed from the rear of the vehicle with the swingarm removed. L. Repeat steps (i) to (k) until all of the air bu...

  • Page 160: Engine

    Engine 3-21 e. Disengage the clutch by turning the manual clutch operation bolt. F. Measure the clutch pressure plate stroke. G. If the pressure plate stroke is out of specifica- tion, repeat steps (j) to (l) in the procedure for step “2. Bleed” until clutch pressure plate stroke is within specifica...

  • Page 161: Engine

    Engine 3-22 e. Shift the transmission into neutral, and then raise the centerstand. F. Shift the transmission into 1st gear, and then slowly turn the throttle grip and check the starting-off performance of the vehicle. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas20920 cleaning the air filte...

  • Page 162: Engine

    Engine 3-23 note: 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. Eas21010 checking the throttle body joints the following procedure applies to all of the throttle body joints and intake manifolds. 1. Rem...

  • Page 163: Engine

    Engine 3-24 3. Install: • air filter case • 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. Eas21080 checking the exhaust system the following procedure applies to all of the ex- haust pipes and gaskets....

  • Page 164: Engine

    Engine 3-25 caution: eca13470 • adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if nec- essary, correct the antifreeze concentra- tion of the coolant. • use only distilled water. However, if dis- tilled water is not availab...

  • Page 165: Engine

    Engine 3-26 warning ewa13030 a hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot. Scalding hot fluid and steam may be blown out, which could cause serious in- jury. When the engine has cooled, open the radiator cap as follows: place a thick rag or a t...

  • Page 166: Engine

    Engine 3-27 • if coolant is swallowed, induce vomiting and get immediate medical attention. Caution: eca13480 • adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if nec- essary, correct the antifreeze concentra- tion of the c...

  • Page 167: Chassis

    Chassis 3-28 eas21140 chassis eas21160 adjusting the front disc brake 1. Adjust: • brake lever position (distance “a” from the throttle grip to the brake lever) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. While pushing the brake lever forward, turn the adjusting dial “1” until the brake lev...

  • Page 168: Chassis

    Chassis 3-29 air must be removed by bleeding the brake system. Air in the brake system will consid- erably reduce braking performance. Caution: eca13510 after adjusting the brake pedal position, make sure there is no brake drag. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Adjust: • rear bra...

  • Page 169: Chassis

    Chassis 3-30 eas21250 checking the front brake pads the following procedure applies to all of the brake pads. Caution: ec3p61037 the amount of wear may differ for the brake pads of the right front brake caliper between the brake pads operated by the brake lever and the brake pads operated by the bra...

  • Page 170: Chassis

    Chassis 3-31 eas22780 bleeding the hydraulic brake system (abs) warning ewa14000 always bleed the brake system when the brake related parts are removed. Caution: ec3p61012 • bleed the brake system in the following or- der. • 1st step: front brake calipers • 2nd step: right front brake caliper (unifi...

  • Page 171: Chassis

    Chassis 3-32 caution: ec3p61029 make sure that the main switch is turned to “off” before checking the operation of the hydraulic unit. K. After operating the abs, repeat steps (e) to (i), and then fill the brake master cylinder res- ervoir or brake fluid reservoir to the proper level with the recomm...

  • Page 172: Chassis

    Chassis 3-33 b. Move the shift pedal to the desired position. C. Install the shift pedal bolt, and then tighten it to specification. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas21460 checking the final gear oil level 1. Stand the vehicle on a level surface. Note: • place the vehicle on the ...

  • Page 173: Chassis

    Chassis 3-34 note: place the vehicle on a suitable stand so that the front wheel is elevated. 2. Check: • steering head grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness → adjust the steering head. 3. Remove: • upper bracket refer to “steering head” on page 4-...

  • Page 174: Chassis

    Chassis 3-35 2. Adjust: • handlebar position ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the plates “1”. B. Remove the handlebar nuts “2” and bolts “3”. C. Remove the handlebars. D. Install the handlebars in the desired position. Note: fit the projections on each handlebar into the h...

  • Page 175: Chassis

    Chassis 3-36 eas21580 adjusting the front fork legs the following procedure applies to both of the front fork legs. Warning ewa13150 • always adjust both front fork legs evenly. Uneven adjustment can result in poor han- dling and loss of stability. • securely support the motorcycle so that there is ...

  • Page 176: Chassis

    Chassis 3-37 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ compression damping caution: eca13590 never go beyond the maximum or minimum adjustment positions. 1. Adjust: • compression damping ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”...

  • Page 177: Chassis

    Chassis 3-38 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ et3p61035 adjusting the side panels 1. Adjust: • side panel position note: the side panels “1” can be tilted back 30 mm (1.18 in) for added ventilation to suit the riding conditions. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ to o...

  • Page 178: Chassis

    Chassis 3-39 note: make sure that the side panel is properly in- stalled. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ et3p61036 adjusting the rider seat height 1. Check: • rider seat height note: • the rider seat height can be adjusted to one of two positions to suit the rider’s preference. • ...

  • Page 179: Chassis

    Chassis 3-40 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ to change to the low position a. Move the rider seat holder cover “1” to the up- per position as shown. B. Install the rider seat height position adjuster “2” so that the “l” mark “a” is ...

  • Page 180: Chassis

    Chassis 3-41 warning ewa13190 it is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, re- place the tire immediately. 2. Check: • tire surfaces damage/wear → replace the tire. Warning ewa14080 • do not use a tubeless tire on a wheel de- signed only for tube tires to...

  • Page 181: Chassis

    Chassis 3-42 warning ewa13210 new tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. Note: for tires with a direction of rotation mark “1”: install the tire ...

  • Page 182: Chassis

    Chassis 3-43 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.

  • Page 183: Electrical System

    Electrical system 3-44 eas21750 electrical system eas21760 checking and charging the battery refer to “electrical components” on page 8-225. Eas21770 checking the fuses refer to “electrical components” on page 8-225. Eas21790 replacing the headlight bulbs the following procedure applies to both of t...

  • Page 184: Electrical System

    Electrical system 3-45 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Adjust: • headlight beam (horizontally) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting screws “1” in direction “a” or “b”. Left headlight right headlight ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 185: Chassis

    4 chassis general chassis....................................................................................... 4-1 removing the side panels .............................................................. 4-9 installing the front cowling left inner panel 2 ................ 4-9 installing the front c...

  • Page 186

    Rear brake ............................................................................................... 4-44 introduction ..................................................................................... 4-50 checking the rear brake disc.................................................... 4-5...

  • Page 187

    Rear shock absorber assembly .................................................... 4-92 handling the rear shock absorber ........................................ 4-94 disposing of a rear shock absorber ..................................... 4-94 removing the rear shock absorber assembly..................

  • Page 188: General Chassis

    General chassis 4-1 eas21830 general chassis removing the seats and covers order job/parts to remove q’ty remarks 1 passenger seat 1 2 rider seat 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 ...

  • Page 189: General Chassis

    General chassis 4-2 removing the front cowling assembly (fjr1300a) order job/parts to remove q’ty remarks open the accessory box lid. 1 left side panel 1 2 left side cowling 1 3 front left turn signal light coupler 1 disconnect. 4 right side panel 1 5 right side cowling 1 6 front right turn signal l...

  • Page 190: General Chassis

    General chassis 4-3 17 plastic band 2 disconnect. 18 plastic holder 1 disconnect. 19 handlebar switch coupler 2 disconnect. 20 front cowling wire harness coupler 4 disconnect. 21 horn connector 4 disconnect. 22 grip warmer coupler 2 disconnect. 23 front cowling assembly 1 for installation, reverse t...

  • Page 191: General Chassis

    General chassis 4-4 removing the front cowling assembly (fjr1300as) order job/parts to remove q’ty remarks open the accessory box lid. 1 left side panel 1 2 left side cowling 1 3 front left turn signal light coupler 1 disconnect. 4 right side panel 1 5 right side cowling 1 6 front right turn signal ...

  • Page 192: General Chassis

    General chassis 4-5 17 plastic band 2 disconnect. 18 plastic holder 1 disconnect. 19 handlebar switch coupler 2 disconnect. 20 hand shift switch coupler 2 disconnect. 21 front cowling wire harness coupler 6 disconnect. 22 horn connector 4 disconnect. 23 grip warmer coupler 2 disconnect. 24 front cow...

  • Page 193: General Chassis

    General chassis 4-6 disassembling the front cowling assembly order job/parts to remove q’ty remarks front cowling assembly refer to “removing the front cowling assem- bly”. 1 windshield outer bracket 1 2 windshield 1 3 windshield inner bracket 1 4 rearview mirror 2 5 accessory box solenoid coupler 1...

  • Page 194: General Chassis

    General chassis 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 195: General Chassis

    General chassis 4-8 removing the windshield drive unit, meter assembly, and relays order job/parts to remove q’ty remarks front cowling stay refer to “disassembling the front cowling assembly”. 1 windshield drive unit coupler 2 disconnect. 2 windshield drive unit 1 3 windshield drive unit side rail ...

  • Page 196: General Chassis

    General chassis 4-9 et3p61037 removing the side panels 1. Remove: • side panel “1” note: to release a pin on the side panel “1” from its corresponding hinge on the side cowling “2”, push the end “a” of the hinge with a flathead screwdriver. Et3p61038 installing the front cowling left inner panel 2 1...

  • Page 197: General Chassis

    General chassis 4-10 i. Insert the adjusting knob shaft into the hole in inner panel 2, making sure to align the projec- tion “a” on the shaft’s sleeve with the slot “b” in the panel, and then install the nut. J. Install the headlight beam adjusting knob “4”. K. Install the hexagon socket bolts and ...

  • Page 198: General Chassis

    General chassis 4-11 b a 1 2.

  • Page 199: General Chassis

    General chassis 4-12 removing the t-bar order job/parts 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...

  • Page 200: General Chassis

    General chassis 4-13 removing the air filter case (fjr1300a) order job/parts to remove q’ty remarks left side cover/t-bar refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. 1 air shroud 1 2 air duct 1 3 air filter case cover 1 4 air filter element 1 5 tool kit 1 6 ec...

  • Page 201: General Chassis

    General chassis 4-14 15 air filter case joint assembly 1 16 air filter case 1 17 air filter case breather hose 2 18 filter assembly 1 for installation, reverse the removal proce- dure. Removing the air filter case (fjr1300a) order job/parts to remove q’ty remarks t r . . 8 nm (0.8 m • kg, 5.8 ft • i...

  • Page 202: General Chassis

    General chassis 4-15 removing the air filter case (fjr1300as) order job/parts to remove q’ty remarks left side cover/t-bar refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Shift actuator refer to “shift actuator and shift rod (fjr1300as only)” on page 5-69. 1 air s...

  • Page 203: General Chassis

    General chassis 4-16 14 crankcase breather hose 1 disconnect. 15 air induction system hose (air filter case joint assembly to 3-way joint) 1 disconnect. 16 air filter case joint clamp screw 4 loosen. 17 air filter case joint assembly 1 18 air filter case 1 19 air filter case breather hose 2 20 filte...

  • Page 204: Front Wheel

    Front wheel 4-17 eas21880 front wheel removing the front wheel, brake discs, wheel sensor, and sensor housing order job/parts to remove q’ty remarks rider seat/t-bar refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. 1 front fender 1 2 front wheel sensor coupler 1 di...

  • Page 205: Front Wheel

    Front 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 206: Front Wheel

    Front wheel 4-19 eas21900 removing the front wheel caution: eca3p6d002 keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away from the front wheel hub “1”, otherwise the wheel sensor rotor equipped in the wheel hub may be damaged, resulting in improper performance of the a...

  • Page 207: Front Wheel

    Front wheel 4-20 2. Check: • tire • front wheel damage/wear → replace. Refer to “checking the tires” on page 3-40 and “checking the wheels” on page 3-42. 3. Measure: • radial wheel runout “1” • lateral wheel runout “2” over the specified limits → replace. 4. Check: • wheel bearings front wheel turns...

  • Page 208: Front Wheel

    Front wheel 4-21 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Hold the dial gauge at a right angle against the wheel sensor rotor surface. B. Measure the wheel sensor rotor deflection. Note: do not touch the surface of the rotor magnet with a sharp object. C. If the deflection is above speci...

  • Page 209: Front Wheel

    Front wheel 4-22 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Install: • front wheel sensor rotor caution: eca3p6d006 replace the wheel sensor bolts with new ones. 3. Measure: • wheel sensor rotor deflection out of specification → correct the wheel sen- sor rotor deflection or replace the wh...

  • Page 210: Front Wheel

    Front wheel 4-23 c. If the heavy spot does not stay in that posi- tion, install a heavier weight. D. Repeat steps (b) and (c) until the front wheel is balanced. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Check: • front wheel static balance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ ...

  • Page 211: Front Wheel

    Front wheel 4-24 caution: ec3p61022 before tightening the wheel axle bolt, push down hard on the handlebars several times and check if the front fork rebounds smooth- ly. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Insert the front wheel axle from the right side and tighten it with the fron...

  • Page 212: Rear Wheel

    Rear wheel 4-25 eas22030 rear wheel removing the rear wheel, brake disc, wheel sensor, and sensor housing order job/parts to remove q’ty remarks right side cover refer to “general chassis” on page 4-1. 1 rear wheel sensor coupler 1 disconnect. 2 rear wheel sensor 1 3 rear wheel axle pinch bolt 1 loo...

  • Page 213: Rear Wheel

    Rear wheel 4-26 disassembling the rear wheel order job/parts to remove q’ty remarks 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 s...

  • Page 214: Rear Wheel

    Rear wheel 4-27 eas22050 removing the rear wheel caution: eca3p6d013 keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away from the rear wheel hub “1”, otherwise the wheel sensor rotor equipped in the wheel hub may be damaged, resulting in improper performance of the abs ...

  • Page 215: Rear Wheel

    Rear wheel 4-28 d. Remove the wheel sensor rotor. E. Remove the wheel bearings “1” with a gener- al bearing puller. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas22090 checking the rear wheel 1. Check: • rear wheel axle • rear wheel • wheel bearings • oil seals refer to “checking the front wh...

  • Page 216: Rear Wheel

    Rear wheel 4-29 2. Install: • wheel bearings ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the new wheel bearings in the reverse order of disassembly. Caution: ec3p61021 do not contact the wheel bearing inner race “1” or balls “2”. Contact should be made only with the outer race “3”. ...

  • Page 217: Rear Wheel

    Rear wheel 4-30 eas22170 installing the rear wheel (rear brake disc) 1. Install: • rear brake disc note: tighten the brake disc bolts in stages and in a crisscross pattern. 2. Check: • rear brake disc refer to “checking the rear brake disc” on page 4-50. 3. Lubricate: • oil seal lips 4. Install: • r...

  • Page 218: Rear Wheel

    Rear wheel 4-31 7. Install: • rear wheel sensor caution: ec3p66004 to route the rear wheel sensor lead, refer to “cable routing (fjr1300a)” on page 2-45 and “cable routing (fjr1300as)” on page 2-65. Note: when installing the rear wheel sensor, check the rear wheel sensor lead for twists and the sens...

  • Page 219: Front Brake

    Front brake 4-32 eas22210 front brake removing the front brake pads order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 1 brake hose holder 1 2 front brake caliper 1 3 brake pad bolt 2 4 brake pad spring 2 5 front brake pad 4 for installation, ...

  • Page 220: Front Brake

    Front brake 4-33 removing the front brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-31. 1 brake master cylinder reservoir cap 1 2 brake master cylinder reservoir diaphragm hold- er 1 3 brake master cylinde...

  • Page 221: Front Brake

    Front brake 4-34 disassembling the front brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder push rod 1 2 dust boot 1 3 circlip 1 4 brake master cylinder kit 1 5 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure. S.

  • Page 222: Front Brake

    Front brake 4-35 removing the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. Brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-31. 1 brake hose holder 1 2 brake hose union bolt 1 3 coppe...

  • Page 223: Front Brake

    Front brake 4-36 disassembling the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 1 brake pad bolt 2 2 brake pad spring 2 3 front brake pad 4 4 brake caliper piston 4 5 brake caliper piston dust seal 4 6 brake caliper ...

  • Page 224: Front Brake

    Front brake 4-37 eas22220 introduction warning ewa14100 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the...

  • Page 225: Front Brake

    Front brake 4-38 d. Measure the brake disc deflection. E. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. F. If the brake disc deflection cannot be brought within specification, replace the brake disc. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ...

  • Page 226: Front Brake

    Front brake 4-39 3. Install: • brake pad bolts • brake caliper 4. 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. 5. Check: • brake lever and brake pedal operation soft or spong...

  • Page 227: Front Brake

    Front brake 4-40 warning ewa13560 • cover the brake caliper pistons with a rag. Be careful not to get injured when the pis- tons are expelled from the brake caliper. • never try to pry out the brake caliper pis- tons. B. Remove the brake caliper piston dust seals and brake caliper piston seals. ▲▲▲ ...

  • Page 228: Front Brake

    Front brake 4-41 2. Remove: • brake caliper 3. Install: • brake pads • brake pad springs • brake pad bolts • brake caliper • brake hose holder refer to “replacing the front brake pads” on page 4-38. 4. Fill: • brake master cylinder reservoir • brake fluid reservoir (with the specified amount of the ...

  • Page 229: Front Brake

    Front brake 4-42 • copper washers “2” • brake hose (front brake master cylinder to brake pipe/lower joint assembly) “3” note: to collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose. Eas22500 checking the front brake master cylinder 1. Check: •...

  • Page 230: Front Brake

    Front brake 4-43 note: turn the handlebar to the left and right to make sure the brake hose does not touch other parts (e.G., wire harness, cables, leads). Correct if necessary. 3. Fill: • brake master cylinder reservoir • brake fluid reservoir (with the specified amount of the recom- mended brake f...

  • Page 231: Rear Brake

    Rear brake 4-44 eas22550 rear brake 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 232: Rear Brake

    Rear brake 4-45 removing the rear brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-31. Right side cover/storage compartment refer to “general chassis” on page 4-1. 1 brake fluid reservoir cap 1 2 brake flui...

  • Page 233: Rear Brake

    Rear brake 4-46 12 rear brake master cylinder 1 for installation, 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 . . 3...

  • Page 234: Rear Brake

    Rear brake 4-47 disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 dust boot 1 2 circlip 1 3 brake master cylinder push rod 1 4 brake master cylinder kit 1 5 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure. S t r . . 16 nm (1.6 m • kg...

  • Page 235: Rear Brake

    Rear brake 4-48 removing the rear brake caliper order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake 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 bol...

  • Page 236: Rear Brake

    Rear brake 4-49 disassembling the rear brake caliper order job/parts to remove q’ty remarks 1 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 ...

  • Page 237: Rear Brake

    Rear brake 4-50 eas22560 introduction warning ewa14100 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the ...

  • Page 238: Rear Brake

    Rear brake 4-51 note: always install new brake pads, brake pad shims, and brake pad springs as a set. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container. B. Loosen the bleed screw ...

  • Page 239: Rear Brake

    Rear brake 4-52 eas22600 disassembling the rear brake caliper 1. Remove: • brake caliper piston “1” • brake caliper piston dust seal “2” • brake caliper piston seal “3” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Blow compressed air into the brake hose joint opening “a” to force out the pis...

  • Page 240: Rear Brake

    Rear brake 4-53 • never use solvents on internal brake com- ponents as they will cause the brake caliper piston dust seal and brake caliper piston seal to swell and distort. • whenever a brake caliper is disassembled, replace the brake caliper piston dust seal and brake caliper piston seal. Eas22670...

  • Page 241: Rear Brake

    Rear brake 4-54 4. Remove: • rear brake caliper bolts • rear brake caliper 5. Install: • brake pad springs • rear brake pads • brake pad shims • rear brake caliper bolts • rear brake caliper refer to “replacing the rear brake pads” on page 4-50. 6. Fill: • brake fluid reservoir (with the specified a...

  • Page 242: Rear Brake

    Rear brake 4-55 eas22720 checking the rear brake master cylinder 1. Check: • brake master cylinder damage/scratches/wear → replace. • brake fluid delivery passages (brake master cylinder body) obstruction → blow out with compressed air. 2. Check: • brake master cylinder kit damage/scratches/wear → r...

  • Page 243: Rear Brake

    Rear brake 4-56 warning ewa13090 • use only the designated 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 chem...

  • Page 244: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-57 eas22760 abs (anti-lock brake system) et3p61060 abs components chart 4 4 6 5 6 7 8 9 10 11 12,13 14 15 1 1 2 2 3 3 5 21 20 a a 16 17 19 18 11 1. Brake hose (metering valve to right front brake caliper) 2. Brake hose (brake pipe/upper joint assembly to front brake ca...

  • Page 245: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-58 removing the rear fender assembly order job/parts to remove q’ty remarks air filter case refer to “general chassis” on page 4-1. Brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-31. 1 brake fluid reservoir 1 refer to “rear brake” on ...

  • Page 246: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-59 removing the metering valve, proportioning valve, and brake pipes order job/parts to remove q’ty remarks 1 brake pipe union bolt/gasket 2/4 2 brake pipe (metering valve to right front brake caliper) 1 disconnect. 3 brake pipe (hydraulic unit to metering valve) 1 4 m...

  • Page 247: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-60 15 brake pipe/joint assembly stay 1 16 brake pipe/middle joint assembly 1 17 brake pipe/lower joint assembly 1 for installation, reverse the removal proce- dure. Removing the metering valve, proportioning valve, and brake pipes order job/parts to remove q’ty remarks...

  • Page 248: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-61 removing the hydraulic unit assembly order job/parts to remove q’ty remarks 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 ...

  • Page 249: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-62 et3p6d003 removing the hydraulic unit assembly caution: eca3p6d018 unless necessary, avoid removing and in- stalling the brake pipes of the hydraulic unit assembly. Warning ewa13930 refill with the same type of brake fluid that is already in the system. Mixing fluid...

  • Page 250: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-63 et3p61057 checking the proportioning valve and metering valve 1. Check: • proportioning valve cracks/damage → replace the proportioning valve. • metering valve cracks/damage → replace the metering valve et3p6d020 checking the brake pipes the following procedure appl...

  • Page 251: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-64 • brake pipe (brake pipe/upper joint assembly to front brake calipers) “3” • gaskets • brake pipe union bolts • brake hose union bolt note: when installing the brake hose and brake pipes onto the brake pipe joint assembly or brake hose joint assembly, make sure that...

  • Page 252: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-65 11.Install: • metering valve “1” • brake pipe (metering valve to right front brake caliper) “2” • brake pipe (hydraulic unit to metering valve) “3” • gaskets • brake pipe union bolts note: temporarily install the metering valve and brake pipes. 12.Tighten: • brake p...

  • Page 253: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-66 16.Delete the fault codes. (refer to “[d-1] de- leting the fault codes” on page 8-179.) 17.Perform a trial run. (refer to “trial run” on page 4-69.) eas22800 hydraulic unit operation tests the reaction-force pulsating action generated in the brake lever and brake pe...

  • Page 254: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-67 when the main switch is turned to “on”, a single pulse will be generated in the brake le- ver “1”. After the pulse is generated in the brake lever, it is generated in the brake pedal “2” twice. Note: a single pulse will be felt in the brake lever once, then in the b...

  • Page 255: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-68 6. Set the engine stop switch “1” to “ ”. 7. Turn the main switch to “on”. 8. Push the start switch “1” for at least 4 sec- onds. Caution: eca14790 do not operate the brake lever or the brake pedal. 9. After releasing the start switch, operate the brake lever and th...

  • Page 256: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-69 caution: eca3p6d020 • check that the pulsating action is felt in the brake lever, brake pedal, and again in the brake lever, in this order. • if the pulsating action is felt in the brake pedal before it is felt in the brake lever, check that the brake hoses and brak...

  • Page 257: Handlebars

    Handlebars 4-70 eas22850 handlebars removing the left handlebar (fjr1300a) order job/parts to remove 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 1 7 lead hol...

  • Page 258: Handlebars

    Handlebars 4-71 removing the left handlebar (fjr1300as) order job/parts to remove 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 ha...

  • Page 259: Handlebars

    Handlebars 4-72 removing the right handlebar order job/parts to remove q’ty remarks 1 front brake light switch connector 2 disconnect. 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 gri...

  • Page 260: Handlebars

    Handlebars 4-73 eas22870 removing the handlebars 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • handlebar grip “1” note: blow compressed air between the handlebar and the handlebar grip, and gradually...

  • Page 261: Handlebars

    Handlebars 4-74 5. Install: • right handlebar • left handlebar note: fit the projections on each handlebar into the holes in the upper bracket, making sure that the handlebars are installed in the same position. 6. Install: • handlebar bolts “1” (temporarily) • handlebar nuts “2” (temporarily) 7. Ti...

  • Page 262: Handlebars

    Handlebars 4-75 9. Install: • front brake master cylinder assembly • front brake master cylinder holder “1” note: • 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, ti...

  • Page 263: Handlebars

    Handlebars 4-76 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • right handlebar switch “1” note: align the projection “a” on the right handlebar switch with the hole “b” on the right handlebar. 4. Install: • left handlebar switch “1” note: align the projection “a” on the left handleb...

  • Page 264: Handlebars

    Handlebars 4-77 8. Tighten: • handlebar bolts • handlebar nuts note: first tighten the bolts, then tighten the nuts. 9. Install: • throttle grip • throttle cables • throttle cable housing “1” • grip end “2” note: • route the right grip warmer lead “3” through the throttle cable housing so that it fo...

  • Page 265: Front Fork

    Front fork 4-78 eas22950 front fork removing the front fork legs order job/parts to remove q’ty remarks the following procedure applies to both of the front fork legs. 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...

  • Page 266: Front Fork

    Front fork 4-79 disassembling the front fork legs order job/parts to remove q’ty remarks the following procedure 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 was...

  • Page 267: Front Fork

    Front fork 4-80 17 inner tube 1 18 outer tube bushing 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...

  • Page 268: Front Fork

    Front fork 4-81 eas22960 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Note: place the vehicle on a suitable stand so t...

  • Page 269: Front Fork

    Front fork 4-82 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Pull up the inner tube completely, fill it with oil up to the top, and then install the cap bolt. Note: do not install the fork spring. B. Place the front fork leg in a press and gradu- ally apply pressure to remove the oil seal. C...

  • Page 270: Front Fork

    Front fork 4-83 3. Check: • damper rod assembly damage/wear → replace. Obstruction → blow out all of the oil passag- es with compressed air. • oil flow stopper damage → replace. Caution: eca14200 • the front fork leg has a built-in damper ad- justing rod and a very sophisticated inter- nal construct...

  • Page 271: Front Fork

    Front fork 4-84 4. Install: • outer tube bushing 2 (d = 51 mm (2.01 in), l = 15 mm (0.59 in)) “1” (with the slide metal installer “2” and fork seal driver “3”) 5. Install: • outer tube bushing 1 (d = 52 mm (2.05 in), l = 12 mm (0.47 in)) “1” • washer “2” (with the slide metal installer “3” and fork ...

  • Page 272: Front Fork

    Front fork 4-85 7. Remove: • suitable washer 8. Install: • oil seal clip “1” note: adjust the oil seal clip so that it fits into the outer tube’s groove. 9. Install: • dust seal “1” (with the fork seal driver “2”) 10.Fill: • front fork leg (with the specified amount of the recom- mended fork oil) ca...

  • Page 273: Front Fork

    Front fork 4-86 14.Measure: • front fork leg oil level “a” (from the top of the inner tube, with the outer tube fully compressed and without the fork spring) out of specification → correct. Note: • while filling the front fork leg, keep it upright. • after filling, slowly pump the front fork leg up ...

  • Page 274: Front Fork

    Front fork 4-87 • upper bracket pinch 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 275: Steering Head

    Steering head 4-88 eas23090 steering head removing the lower bracket order job/parts to remove q’ty remarks rider seat/t-bar refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Handlebars refer to “handlebars” on page 4-70. Front fork legs refer to “front fork” on pag...

  • Page 276: Steering Head

    Steering head 4-89 12 rubber washer 1 13 lower ring nut 1 14 lower bracket 1 15 upper bearing cover 1 16 upper bearing inner race 1 17 upper bearing 1 18 lower bearing 1 19 dust seal 1 20 lower bearing inner race 1 21 upper bearing outer race 1 22 lower bearing outer race 1 for installation, reverse...

  • Page 277: Steering Head

    Steering head 4-90 eas23110 removing the lower bracket 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • upper ring nut • rubber washer • lower ring nut “1” • lower bracket warning ewa13730 securely supp...

  • Page 278: Steering Head

    Steering head 4-91 • lock washer “4” refer to “checking and adjusting the steering head” on page 3-33. 3. Install: • upper bracket • steering stem nut note: temporarily tighten the steering stem nut. 4. Install: • front fork legs refer to “front fork” on page 4-78. Note: temporarily tighten the uppe...

  • Page 279: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-92 eas23160 rear shock absorber assembly removing the rear shock absorber assembly order job/parts to remove q’ty remarks air filter case refer to “general chassis” on page 4-1. Rear wheel refer to “rear wheel” on page 4-25. Mufflers/exhaust pipe assembly refer to “eng...

  • Page 280: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-93 11 relay arm 1 12 spacer 1 13 spacer 1 14 spacer 1 15 oil seal 6 16 bearing 2 17 bearing 2 for installation, reverse the removal 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...

  • Page 281: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-94 eas23180 handling the rear shock absorber warning ewa13740 this rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held respons...

  • Page 282: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-95 • rear shock absorber gas leaks/oil leaks → replace the rear shock absorber assembly. • spring damage/wear → replace the rear shock ab- sorber assembly. • bushing damage/wear → replace the rear shock ab- sorber assembly. • spacer damage/scratches → replace. • bolts ...

  • Page 283: Swingarm

    Swingarm 4-96 eas23330 swingarm removing the swingarm order job/parts to remove q’ty remarks rear wheel refer to “rear wheel” on page 4-25. Rear shock absorber assembly/connecting arms refer to “rear shock absorber as- sembly” on page 4-92. Final drive assembly/universal joint refer to “shaft drive”...

  • Page 284: Swingarm

    Swingarm 4-97 13 spacer 1 14 oil seal 1 15 circlip 1 16 bearing 1 17 spacer 1 18 bearing 1 for installation, reverse the removal 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...

  • Page 285: Swingarm

    Swingarm 4-98 eas23350 removing the swingarm 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Note: place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Measure: • swingarm side play • swinga...

  • Page 286: Swingarm

    Swingarm 4-99 3. Tighten: • pivot shaft • pivot 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 ...

  • Page 287: Shaft Drive

    Shaft drive 4-100 eas23550 shaft drive removing 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- ...

  • Page 288: Shaft Drive

    Shaft drive 4-101 removing the universal joint order job/parts to remove q’ty remarks left footrest assembly/sidestand fjr1300as refer to “shift actuator and shift rod (fjr1300as only)” on page 5-69. 1 shift arm 1 fjr1300a 2 left footrest assembly 1 fjr1300a 3 sidestand switch coupler 1 fjr1300a dis...

  • Page 289: Shaft Drive

    Shaft drive 4-102 disassembling the final drive assembly order job/parts to remove q’ty remarks 1 circlip 2 2 oil 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 ...

  • Page 290: Shaft Drive

    Shaft drive 4-103 * apply shaft drive gear oil (part no.: 9079e-sh001-00) 18 final drive pinion 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-...

  • Page 291: Shaft Drive

    Shaft drive 4-104 eas23560 troubleshooting note: causes a, b and c may be extremely difficult to diagnose. The symptoms are quite subtle and difficult to distinguish from normal operating noises. If there is reason to believe that these components are damaged, remove them and check them individual. ...

  • Page 292: Shaft Drive

    Shaft drive 4-105 no → yes ↓ yes → no ↓ eas23570 checking the final drive oil for contamination and checking the shaft drive for leaks 1. Drain: • final gear oil (from the final gear case) refer to “changing the final gear oil” on page 3-33. 2. Check: • final gear oil large amount of metal particles...

  • Page 293: Shaft Drive

    Shaft drive 4-106 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the ring gear fix bolt (m14) “1”, into the final gear oil drain hole. B. Finger tighten the ring gear fix bolt (m14) until it stops the ring gear from moving. Note: do not overtighten the ring gear fix bolt (m14). C. Inst...

  • Page 294: Shaft Drive

    Shaft drive 4-107 b. If it is necessary to increase the final gear backlash by more than 0.2 mm, reduce the thrust washer thickness by 0.2 mm for every 0.2 mm increase of ring gear shim thickness. C. If it is necessary to reduce the final gear back- lash by more than 0.2 mm, increase the thrust wash...

  • Page 295: Shaft Drive

    Shaft drive 4-108 caution: eca14320 • the stopper bolt has left-hand threads. To tighten the stopper bolt, turn it counter- clockwise. • apply loctite ® onto the stopper bolt. 4. Measure: • ring-gear-to-stopper-bolt clearance note: if the ring-gear-to-stopper-bolt clearance is out of specification, ...

  • Page 296: Shaft Drive

    Shaft drive 4-109 eas23630 removing and installing the bearings 1. Check: • bearings damage → replace. 2. Remove: • collar “1” • oil seal “2” • bearing “3” (with an appropriate press tool “4” and an ap- propriate support for the final gear case) 3. Remove: • bearing “1” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 297: Shaft Drive

    Shaft drive 4-110 b. To find final drive pinion gear shim thickness “a”, use the following formula: where: a = 84 b = a numeral on the final gear case, to be di- vided by 100 and added to “83”. Example: if the final drive pinion gear is marked “+01” and the final gear case is marked “50”: therefore,...

  • Page 298: Shaft Drive

    Shaft drive 4-111 f = the ring gear bearing thickness constant. Example: if the final gear case is marked “51”, the ring gear bearing housing is marked “35”, the ring gear is marked “- 05”, and “f” is 13.00: therefore, the calculated ring gear shim thickness is 0.41 mm. Shim sizes are supplied in th...

  • Page 299: Shaft Drive

    Shaft drive 4-112 4. Stake the coupling gear nut “1” at a cutout “a” in the final drive pinion gear. 5. Install: • ring gear bearing housing (along with the ring gear, but without the thrust washer) 6. Adjust: • final gear backlash refer to “measuring the final gear backlash” on page 4-105 and “adju...

  • Page 300: Shaft Drive

    Shaft drive 4-113 eas23660 installing the drive shaft and final drive assembly (fjr1300a) 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...

  • Page 301: Shaft Drive

    Shaft drive 4-114 note: install the left footrest assembly/sidestand bolts “1”, left footrest assembly bolts (m8) “2” and left footrest assembly bolt (m10) “3” temporarily and then tighten them to the specified torques in the proper tightening sequence as shown. 9. Install: • shift arm “1” note: ali...

  • Page 302: Shaft Drive

    Shaft drive 4-115 6. Install: • universal joint • final drive assembly note: 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 refer to “shift actuator and shift rod (fjr1300as only)” on...

  • Page 303: Engine

    5 engine engine removal ........................................................................................ 5-1 removing the gear position sensor (fjr1300as only) ........... 5-8 removing the engine (fjr1300a).................................................... 5-8 removing the engine (fjr1300a...

  • Page 304

    Clutch ........................................................................................................ 5-46 removing the clutch ..................................................................... 5-58 checking the friction plates..................................................... 5-58 c...

  • Page 305

    Middle gear .............................................................................................. 5-83 removing the middle drive shaft assembly ......................... 5-89 disassembling the middle drive shaft assembly ............... 5-89 disassembling the middle driven shaft assembly......

  • Page 306: Engine Removal

    Engine removal 5-1 eas23710 engine removal removing the exhaust pipe assembly order job/parts to remove q’ty remarks left side cowling/right side cowling/t-bar refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Coolant drain. Refer to “changing the coolant” on page 3...

  • Page 307: Engine Removal

    Engine removal 5-2 disconnecting the leads and hoses (fjr1300a) order job/parts to remove q’ty remarks front fender refer to “front wheel” on page 4-17. Air filter case refer to “general chassis” on page 4-1. Throttle bodies refer to “throttle bodies” on page 7-4. Air cut-off valve/reed valves refer...

  • Page 308: Engine Removal

    Engine removal 5-3 5 oil level switch coupler 1 disconnect. 6 crankshaft position sensor 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 (fjr1300a) o...

  • Page 309: Engine Removal

    Engine removal 5-4 disconnecting the leads and hoses (fjr1300as) order job/parts to remove q’ty remarks front fender refer to “front wheel” on page 4-17. Air filter case refer to “general chassis” on page 4-1. Throttle bodies refer to “throttle bodies” on page 7-4. Air cut-off valve/reed valves refe...

  • Page 310: Engine Removal

    Engine removal 5-5 3 clutch release cylinder 1 4 dowel pin 2 5 crankcase breather hose 1 6 stator coil coupler 1 disconnect. 7 oil level switch coupler 1 disconnect. 8 crankshaft position sensor coupler 1 disconnect. 9 neutral switch coupler 1 disconnect. 10 ycc-s speed sensor coupler 1 disconnect. ...

  • Page 311: Engine Removal

    Engine removal 5-6 removing the engine order job/parts to remove q’ty remarks note: place a suitable stand under the engine. 1 brake pedal 1 2 engine mounting bolt (left rear side) 2 3 engine bracket bolt (left rear side) 1 4 engine bracket (left rear side) 1 5 engine bracket bolt (top) 4 6 engine m...

  • Page 312: Engine Removal

    Engine removal 5-7 16 spacer bolt 1 loosen. 17 engine mounting bolt (rear lower side) 1 18 spacer 1 19 engine mounting bolt (rear upper side) 1 20 engine 1 for installation, reverse the removal proce- dure. Removing the engine order job/parts to remove q’ty remarks t r . . 32 nm (3.2 m • kg, 23 ft •...

  • Page 313: Engine Removal

    Engine removal 5-8 et3p66033 removing the gear position sensor (fjr1300as only) 1. Disconnect: • gear position sensor coupler 2. Remove: • gear position sensor note: remove only the screws “1” when removing the gear position sensor. Do not remove the screws “2”. Et3p61023 removing the engine (fjr130...

  • Page 314: Engine Removal

    Engine removal 5-9 • engine mounting bolt (left front lower side) “6” • spacers “7” • engine mounting bolt (right front upper side) “8” • engine mounting bolt (right front lower side) “9” • pinch bolts (front side) “10” • pinch bolts (rear side) “11” • engine brackets (top) “12” • engine bracket bol...

  • Page 315: Engine Removal

    Engine removal 5-10 note: tighten the pinch bolts (rear side) one at a time, making sure to tighten the first bolt again after tightening the second bolt. 11.Tighten: • engine mounting bolts (top) “15” (temporarily tighten) • engine bracket bolts (top) “13” (temporarily tighten) note: when temporari...

  • Page 316: Engine Removal

    Engine removal 5-11 et3p66035 installing the gear position sensor (fjr1300as only) 1. Connect: • mcu coupler • ecu coupler refer to “general chassis” on page 4-1. 2. Install: • gear position sensor “1” caution: ec3p66001 shift the transmission into neutral before in- stalling the gear position senso...

  • Page 317: Engine Removal

    Engine removal 5-12 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Check: • gear position setting refer to “diagnostic code table (diagnostic code no. Sh_ _65)”. 1 2 3.

  • Page 318: Camshafts

    Camshafts 5-13 eas23760 camshafts removing the cylinder head cover order job/parts to remove q’ty remarks right side cowling refer to “general chassis” on page 4-1. Air cut-off valve/reed valves refer to “air induction system” on page 7-9. 1 spark plug 4 2 cylinder identification sensor 1 3 cylinder...

  • Page 319: Camshafts

    Camshafts 5-14 removing the camshafts order job/parts to remove q’ty remarks throttle bodies refer to “throttle bodies” on page 7-4. Pickup rotor cover refer to “pickup 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 ...

  • Page 320: Camshafts

    Camshafts 5-15 eas23810 removing the camshafts 1. 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-...

  • Page 321: Camshafts

    Camshafts 5-16 eas23850 checking the camshafts 1. Check: • camshaft lobes blue discoloration/pitting/scratches → re- place the camshaft. 2. Measure: • camshaft lobe dimensions “a” and “b” out of specification → replace the camshaft. 3. Measure: • camshaft runout out of specification → replace. 4. Me...

  • Page 322: Camshafts

    Camshafts 5-17 note: • tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. • do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance with the plastigauge ® . D. Remove the camshaft caps and then mea- sure the width of ...

  • Page 323: Camshafts

    Camshafts 5-18 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas24010 installing the camshafts 1. Install: • exhaust camshaft sprocket • intake camshaft sprocket note: • while holding the camshaft sprockets with the rotor holding tool “1”, tighten the camshaft sprocket bolts. • make sure that th...

  • Page 324: Camshafts

    Camshafts 5-19 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • exhaust camshaft caps • intake camshaft caps note: • make sure each camshaft cap is installed in its original place. Refer to the identification marks as follows: “e”, “e1”, “e2”, “e3”: exhaust “i”, “i1”, “i2”, “i3”: inta...

  • Page 325: Camshafts

    Camshafts 5-20 d. Remove the screwdriver, make sure the tim- ing chain tensioner rod releases, and then tighten the cap bolt to the specified torque. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 7. Turn: • crankshaft (several turns clockwise) 8. Check: • “t” mark make sure the “t” mark “a” on t...

  • Page 326: Camshafts

    Camshafts 5-21.

  • Page 327: Cylinder Head

    Cylinder head 5-22 eas24100 cylinder head removing the cylinder head order job/parts to remove q’ty remarks engine refer to “engine removal” 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-...

  • Page 328: Cylinder Head

    Cylinder head 5-23 eas24120 removing the cylinder head 1. Remove: • cylinder head bolts note: • loosen the bolts in the proper sequence as shown. • loosen each bolt 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them. Eas24160 checking the cylinder head 1. Eliminate: • co...

  • Page 329: Cylinder Head

    Cylinder head 5-24 e. Tighten the cylinder head bolts further to reach the specified angle 175–185° in the proper tightening sequence as shown. Warning ew3p61014 if the bolt is tightened more than the speci- fied angle, do not loosen the bolt and then re- tighten it. Instead, replace the bolt with a...

  • Page 330: Valves and Valve Springs

    Valves and valve springs 5-25 eas24270 valves and valve springs removing the valves and valve springs order job/parts to remove q’ty remarks cylinder 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 exhaus...

  • Page 331: Valves and Valve Springs

    Valves and valve springs 5-26 eas24280 removing the valves the following procedure applies to all of the valves and related components. Note: before removing the internal parts of the cylinder head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Remove: • valve lif...

  • Page 332: Valves and Valve Springs

    Valves and valve springs 5-27 1. Measure: • valve-stem-to-valve-guide clearance out of specification → replace the valve guide. 2. Replace: • valve guide note: to ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °c (212 °f) in an oven. ▼▼▼ ▼ ▼...

  • Page 333: Valves and Valve Springs

    Valves and valve springs 5-28 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Eliminate: • carbon deposits (from the valve face and valve seat) 4. Check: • valve face pitting/wear → grind the valve face. • valve stem end mushroom shape or diameter larger than the body of the valve stem → replac...

  • Page 334: Valves and Valve Springs

    Valves and valve springs 5-29 b. Install the valve into the cylinder head. C. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion. D. Measure the valve seat width. Note: where the valve seat and valve face contacted one another, the blueing will have been re-...

  • Page 335: Valves and Valve Springs

    Valves and valve springs 5-30 eas24310 checking the valve springs the following procedure applies to all of the valve springs. 1. Measure: • valve spring free length “a” out of specification → replace the valve spring. 2. Measure: • compressed valve spring force “a” out of specification → replace th...

  • Page 336: Valves and Valve Springs

    Valves and valve springs 5-31 2. Lubricate: • valve stem “1” • valve stem seal “2” (with the recommended lubricant) 3. Lubricate: • valve stem end (with the recommended lubricant) 4. Install: • lower spring seat “1” • valve stem seal “2” • valve “3” • valve spring “4” • upper spring seat “5” (into t...

  • Page 337: Valves and Valve Springs

    Valves and valve springs 5-32 6. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. Caution: eca13800 hitting the valve tip with excessive force could damage the valve. 7. Lubricate: • valve lifter (with the recommended lubricant) 8. Install: • valve ...

  • Page 338: Generator and Starter Clutch

    Generator and starter clutch 5-33 eas24480 generator and starter clutch removing the generator rotor and starter clutch order job/parts to remove q’ty remarks fuel tank 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 ...

  • Page 339: Generator and Starter Clutch

    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: Generator and Starter Clutch

    Generator 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: Generator and Starter Clutch

    Generator and starter clutch 5-36 eas24490 removing the generator 1. Remove: • generator rotor bolt “1” • washer note: while holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt. 2. Remove: • generator rotor “1” (with the flywheel puller “2”) • woodruff key cau...

  • Page 342: Generator and Starter Clutch

    Generator and starter clutch 5-37 b. When turning the starter clutch gear clock- wise “a”, the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be replaced. C. When turning the starter clutch gear counter- clockwise “b”, it should turn freely,...

  • Page 343: Generator and Starter Clutch

    Generator and starter clutch 5-38 4. Install: • generator cover gasket • generator cover note: 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: Pickup Rotor

    Pickup rotor 5-39 eas24520 pickup rotor removing the pickup rotor order job/parts to remove q’ty remarks side cowlings/air filter case refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Generator cover refer to “generator and starter clutch” on page 5-33. 1 pickup ro...

  • Page 345: Pickup Rotor

    Pickup rotor 5-40 eas24530 removing the pickup rotor 1. Remove: • pickup rotor bolt “1” • washer “2” • pickup rotor “3” note: while holding the generator rotor “4” with the sheave holder “5”, loosen the pickup rotor bolt. Eas24540 installing the pickup rotor 1. Install: • pickup rotor “1” • washer •...

  • Page 346: Pickup Rotor

    Pickup rotor 5-41 4. Install: • pickup rotor cover gasket • pickup rotor cover note: 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: Electric Starter

    Electric starter 5-42 eas24780 electric starter removing the starter motor order job/parts to remove q’ty remarks throttle bodies refer to “throttle bodies” on page 7-4. 1 starter motor lead 1 disconnect. 2 starter motor assembly 1 for installation, reverse the removal proce- dure..

  • Page 348: Electric Starter

    Electric starter 5-43 disassembling the starter motor order job/parts to remove q’ty remarks 1 o-ring 1 2 starter motor front cover 1 3 brush 2 4 brush seat (along with brushes) 1 5 washer 1 6 lock washer 1 7 oil seal 1 8 bearing 1 9 starter motor rear cover 1 10 collar 1 11 o-ring 2 12 starter moto...

  • Page 349: Electric Starter

    Electric starter 5-44 eas24790 checking the starter motor 1. Check: • commutator dirt → clean with 600 grit sandpaper. 2. Measure: • commutator diameter “1” out of specification → replace the starter motor. 3. Measure: • mica undercut “a” out of specification → scrape the mica to the proper measurem...

  • Page 350: Electric Starter

    Electric starter 5-45 7. Check: • gear teeth damage/wear → replace the gear. 8. Check: • bearing • oil seal damage/wear → replace the defective part(s). Eas24800 assembling the starter motor 1. Install: • brush seat “1” note: align the slot “a” on the brush seat with the tab “b” in the starter motor...

  • Page 351: Clutch

    Clutch 5-46 eas25060 clutch removing the clutch cover order job/parts to remove q’ty remarks right side cowling refer to “general 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 ...

  • Page 352: Clutch

    Clutch 5-47 removing the clutch order job/parts to remove q’ty remarks rear balancer refer to “balancers” on page 5-132. 1 oil guide plate 1 2 clutch spring plate retainer 1 3 clutch spring plate 1 4 clutch spring plate seat 1 5 pressure plate 1 6 short clutch push rod 1 7 ball 1 8 long clutch push ...

  • Page 353: Clutch

    Clutch 5-48 17 thrust washer 1 18 spacer 1 19 clutch housing 1 for installation, reverse the removal proce- dure. Removing the clutch order job/parts to remove q’ty remarks 19 18 17 16 14 15 12 11 10 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...

  • Page 354: Clutch

    Clutch 5-49 removing the clutch master cylinder (fjr1300a) order job/parts to remove q’ty remarks clutch fluid drain. Refer to “bleeding the hydraulic clutch system (fjr1300a)” on page 3-18. 1 clutch master cylinder reservoir cap 1 2 clutch master cylinder reservoir diaphragm holder 1 3 clutch maste...

  • Page 355: Clutch

    Clutch 5-50 12 clutch master cylinder 1 for installation, reverse the removal proce- dure. Removing the clutch master cylinder (fjr1300a) order job/parts to remove q’ty remarks.

  • Page 356: Clutch

    Clutch 5-51 removing the clutch actuator and clutch master cylinder (fjr1300as) order job/parts to remove q’ty remarks clutch fluid drain. Refer to “bleeding the hydraulic clutch system (fjr1300as)” on page 3-19. Swingarm refer to “swingarm” on page 4-96. 1 rear brake hose/rear wheel sensor lead hol...

  • Page 357: Clutch

    Clutch 5-52 15 o-ring (clutch master cylinder kit) 1 16 clutch actuator 1 for installation, reverse the removal proce- dure. Removing the clutch actuator and clutch master cylinder (fjr1300as) 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....

  • Page 358: Clutch

    Clutch 5-53 disassembling the clutch master cylinder (fjr1300a) 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 359: Clutch

    Clutch 5-54 disassembling the clutch master cylinder (fjr1300as) 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 new.

  • Page 360: Clutch

    Clutch 5-55 removing the clutch release cylinder (fjr1300a) order job/parts to remove q’ty remarks clutch fluid drain. Refer to “bleeding the hydraulic clutch system (fjr1300a)” 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...

  • Page 361: Clutch

    Clutch 5-56 removing the clutch release cylinder (fjr1300as) order job/parts to remove q’ty remarks clutch fluid drain. Refer to “bleeding the hydraulic clutch system (fjr1300as)” 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 dow...

  • Page 362: Clutch

    Clutch 5-57 disassembling the clutch release cylinder order job/parts to 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- cedur...

  • Page 363: Clutch

    Clutch 5-58 eas25080 removing the clutch 1. Remove: • clutch cover “1” note: loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • rear balancer weight refer to “balancers” on page 5-132. 3. Remove: • c...

  • Page 364: Clutch

    Clutch 5-59 eas25110 checking the clutch plates the following procedure applies to all of the clutch plates. 1. Check: • clutch plate damage → replace the clutch plates as a set. 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge “1”) out of specification → replace the clut...

  • Page 365: Clutch

    Clutch 5-60 eas25170 checking the pressure plate 1. Check: • pressure plate cracks/damage → replace. • bearing damage/wear → replace. Eas25190 checking the clutch push rods 1. Check: • o-ring • short clutch push rod • long clutch push rod • ball cracks/damage/wear → replace the defec- tive part(s). ...

  • Page 366: Clutch

    Clutch 5-61 3. Install: • clutch boss “1” • lock washer “2” • clutch boss nut “3” note: • 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...

  • Page 367: Clutch

    Clutch 5-62 et3p66068 breaking in the friction plates after replacement (fjr1300as only) 1. If the friction plates are replaced, perform the following procedure to break them in. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Start the engine and warm it up until at least three segments appear...

  • Page 368: Clutch

    Clutch 5-63 eas25290 checking the clutch master cylinder 1. Check: • clutch master cylinder body cracks/damage → replace the clutch mas- ter cylinder. • clutch fluid delivery passage (clutch master cylinder body) obstruction → blow out with compressed air. 2. Check: • clutch master cylinder • clutch...

  • Page 369: Clutch

    Clutch 5-64 3. Fill: • clutch master cylinder reservoir (with the specified amount of the recom- mended clutch fluid) warning ewa13370 • use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance. • refill with the...

  • Page 370: Clutch

    Clutch 5-65 warning ewa13370 • use only the designated 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 c...

  • Page 371: Clutch

    Clutch 5-66 b. If the thickness of the shim installed on the vehicle is 1.5 mm (0.06 in), refer to the follow- ing table. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 7. Check: • rear wheel drag torque refer to “checking the vehicle after bleeding the hydraulic clutch system (fjr1300as only)” o...

  • Page 372: Clutch

    Clutch 5-67 et3p61024 removing the clutch release cylinder 1. Remove: • clutch hose union bolt “1” • copper washers “2” • clutch hose “3” note: put the end of the clutch hose into a container and pump out the clutch fluid carefully. Eas25330 checking the clutch release cylinder 1. Check: • clutch re...

  • Page 373: Clutch

    Clutch 5-68 2. Fill: • clutch master cylinder reservoir (with the specified amount of the recom- mended clutch fluid) warning ewa13370 • use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance. • refill with the...

  • Page 374: 5-69

    Shift actuator and shift rod (fjr1300as only) 5-69 et3p66037 shift actuator and shift rod (fjr1300as only) removing the shift actuator, shift rod and foot shift switch order job/parts to remove q’ty remarks rider seat/left side cover/air shroud refer to “general chassis” on page 4-1. 1 gear position...

  • Page 375: 5-70

    Shift actuator and shift rod (fjr1300as only) 5-70 15 washer 1 16 shift pedal 1 17 ball 1 18 spring 1 19 washer 1 for installation, reverse the removal proce- dure. Removing the shift actuator, 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...

  • Page 376: 5-71

    Shift actuator and shift rod (fjr1300as only) 5-71 et3p66038 removing the shift actuator 1. Remove: • shift actuator ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Pass a suitable 5 mm diameter rod “1” through the holes in the rear shift arm and shift actuator to secure the shift rod. B. Remov...

  • Page 377: 5-72

    Shift actuator and shift rod (fjr1300as only) 5-72 • shift pedal pivot bolt note: • position the projection “a” on the shift pedal be- tween the ends “b” of the spring on the left foot- rest assembly. • be sure to fit the projections “c” on the shift pedal pivot into the holes “d” in the left footre...

  • Page 378: 5-73

    Shift actuator and shift rod (fjr1300as only) 5-73 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ et3p66041 installing the left footrest assembly 1. Install: • sidestand • left footrest assembly note: install the left footrest assembly/sidestand bolts “1”, left footrest assembly bolts (m8) “2” an...

  • Page 379: 5-74

    Shift actuator and shift rod (fjr1300as only) 5-74 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 380: Shift Shaft

    Shift shaft 5-75 eas25410 shift shaft removing the shift shaft and stopper lever order job/parts to remove q’ty remarks clutch housing refer to “clutch” on page 5-46. Shift rod fjr1300as refer to “shift actuator and shift rod (fjr1300as only)” on page 5-69. 1 oil baffle plate 1 1 2 shift arm 1 3 cir...

  • Page 381: Shift Shaft

    Shift shaft 5-76 eas25420 checking the shift shaft 1. Check: • shift shaft bends/damage/wear → replace. • shift shaft spring damage/wear → replace. Eas25430 checking the stopper lever 1. Check: • stopper lever bends/damage → replace. Roller turns roughly → replace the stopper lever. • shift lever sp...

  • Page 382: Shift Shaft

    Shift shaft 5-77 3. Install: • front shift arm “1” note: 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 383: Oil Pump

    Oil pump 5-78 eas24920 oil pump removing the oil pan and oil pump order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-15. Throttle bodies refer to “throttle bodies” on page 7-4. Exhaust pipe assembly refer to “engine removal” on page 5-1. Sidestand r...

  • Page 384: Oil Pump

    Oil pump 5-79 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 385: Oil Pump

    Oil pump 5-80 disassembling the oil pump 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 386: Oil Pump

    Oil pump 5-81 eas24960 checking the oil pump 1. Check: • oil pump driven sprocket • oil pump housing • oil pump housing cover cracks/damage/wear → replace the defec- tive part(s). 2. Measure: • inner-rotor-to-outer-rotor-tip clearance “a” • outer-rotor-to-oil-pump-housing clearance “b” • oil-pump-ho...

  • Page 387: Oil Pump

    Oil pump 5-82 1. Check: • oil delivery pipes damage → replace. Obstruction → wash and blow out with com- pressed air. Eas24990 checking the oil strainer 1. Check: • oil strainer damage → replace. Contaminants → clean with solvent. Eas25010 assembling the oil pump 1. Lubricate: • inner rotor • outer ...

  • Page 388: Middle Gear

    Middle gear 5-83 eas25710 middle gear removing the middle gear (fjr1300a) order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-1. Oil pan/oil pump refer to “oil pump” on page 5-78. 1 middle gear case cover 1 2 middle gear case cover gasket 1 3 dowel pin 2 4 damper cover ...

  • Page 389: Middle Gear

    Middle gear 5-84 15 spacer 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 (fjr1300a) order job/parts to remove q’ty remarks.

  • Page 390: Middle Gear

    Middle gear 5-85 removing the middle gear (fjr1300as) order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-1. Oil pan/oil pump refer to “oil pump” on page 5-78. 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 middl...

  • Page 391: Middle Gear

    Middle gear 5-86 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 (fjr1300as) order job/parts to remove q’ty remarks.

  • Page 392: Middle Gear

    Middle gear 5-87 disassembling the middle drive shaft assembly order job/parts to remove q’ty remarks 1 spring retainer 2 2 spring seat 1 3 damper spring 1 4 damper driven cam 1 5 damper drive cam 1 6 middle drive shaft 1 for assembly, reverse the disassembly pro- cedure..

  • Page 393: Middle Gear

    Middle gear 5-88 disassembling the middle driven shaft assembly 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 t...

  • Page 394: Middle Gear

    Middle gear 5-89 eas25730 removing the middle drive shaft assembly 1. Remove: • middle drive pinion gear nut “1” • lock washer “2” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Straighten the lock washer tab. B. Loosen the middle drive pinion gear nut. Note: while holding the middle drive sha...

  • Page 395: Middle Gear

    Middle gear 5-90 c. Remove the middle driven pinion gear nut. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Remove: • bearing retainer ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Temporarily install the middle driven shaft bearing housing onto the lower crankcase. B. Straighten the t...

  • Page 396: Middle Gear

    Middle gear 5-91 d. Lock the threads with a drift punch. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Tighten: • middle driven pinion gear nut ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Tighten the middle driven pinion gear nut to specification. Note: secure the middle driven shaft...

  • Page 397: Middle Gear

    Middle gear 5-92 • middle drive pinion gear nut “2” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Tighten the middle drive pinion gear nut to specification. Note: • lubricate the nut threads with engine oil. • install the middle drive pinion gear nut with its large inner diameter side facing ...

  • Page 398: Middle Gear

    Middle gear 5-93 eas25880 measuring the middle gear backlash 1. Measure: • middle gear backlash out of specification → refer to “adjusting the middle gear backlash” on page 5-93. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Hold the middle drive shaft “1”. B. Install the gear lash measuremen...

  • Page 399: Middle Gear

    Middle gear 5-94 • after tightening the middle driven shaft bearing housing bolts, loosen them until the clearance between the crankcase and the housing is ap- proximately 2 mm (0.08 in), when measured with a thickness gauge “1”. 4. Hold the middle drive shaft. 5. Turn: • middle driven shaft note: w...

  • Page 400: Middle Gear

    Middle gear 5-95 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Position the middle gears with the appropri- ate shim(s) that has had its respective thick- ness calculated from information marked on the crankcase and middle driven pinion gear. B. To find middle drive pinion gear shim thick- ne...

  • Page 401: Middle Gear

    Middle gear 5-96 “d” is 33.97 (i.E., 34.00 + (- 0.03) = 33.97) “e” is 54.49 if the lower crankcase is marked “95” “f” is 87.95 (i.E., 87.00 + 0.95 = 87.95) “b” = 33.97 + 54.49 - 87.95 = 0.51 round off to the hundredths digit and select the appropriate shim(s). Note: in the above example, the calcula...

  • Page 402: Crankcase

    Crankcase 5-97 eas25540 crankcase separating the crankcase (fjr1300a) order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-1. Cylinder head refer to “cylinder head” on page 5-22. Starter clutch refer to “generator and starter clutch” on page 5-33. Pickup rotor refer to “...

  • Page 403: Crankcase

    Crankcase 5-98 9 lower crankcase 1 10 dowel pin 3 for installation, reverse the removal proce- dure. Separating the crankcase (fjr1300a) order job/parts to remove 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 ....

  • Page 404: Crankcase

    Crankcase 5-99 separating the crankcase (fjr1300as) order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-1. Cylinder head refer to “cylinder head” on page 5-22. Starter clutch refer to “generator and starter clutch” on page 5-33. Pickup rotor refer to “pickup rotor” on p...

  • Page 405: Crankcase

    Crankcase 5-100 11 dowel pin 3 for installation, reverse the removal proce- dure. Separating the crankcase (fjr1300as) order job/parts to remove 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 ...

  • Page 406: Crankcase

    Crankcase 5-101 removing the oil baffle plate and bearings order job/parts to remove q’ty remarks connecting rod refer to “connecting rods and pis- tons” on page 5-107. Crankshaft/crankshaft journal bearings refer to “crankshaft” on page 5-116. Transmission refer to “transmission” on page 5-120. 1 o...

  • Page 407: Crankcase

    Crankcase 5-102 13 lower crankcase 1 for installation, reverse the removal proce- dure. Removing the oil baffle plate and bearings order job/parts 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 • ...

  • Page 408: Crankcase

    Crankcase 5-103 eas25550 disassembling the crankcase 1. Place the engine upside down. 2. Remove: • crankcase bolts note: • loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. • loosen the bolts in decreasing numer...

  • Page 409: Crankcase

    Crankcase 5-104 eas25680 assembling the crankcase 1. Lubricate: • crankshaft journal bearings (with the recommended lubricant) 2. Apply: • sealant (onto the crankcase mating surfaces and oil baffle plate 2) note: do not allow any sealant to come into contact with the oil gallery or crankshaft journa...

  • Page 410: Crankcase

    Crankcase 5-105 caution: eca13980 before tightening the crankcase bolts, make sure the transmission gears shift correctly when the shift drum assembly is turned by hand. 6. Install: • crankcase bolts note: • lubricate the bolts “1”–“10” thread and wash- ers with engine oil. • lubricate the bolts “11...

  • Page 411: Crankcase

    Crankcase 5-106 warning ew3p61014 if the bolt is tightened more than the speci- fied angle, do not loosen the bolt and then re- tighten it. Instead, replace the bolt with a new one and perform the procedure again. Caution: ec3p61033 • do not use a torque wrench to tighten the bolt to the specified a...

  • Page 412: Connecting Rods and Pistons

    Connecting rods and pistons 5-107 et3p61027 connecting rods and pistons removing the connecting rods and pistons order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-97. 1 connecting rod cap 4 2 big end lower bearing 4 3 piston pin clip 8 4 piston pin 4 5 piston ...

  • Page 413: Connecting Rods and Pistons

    Connecting rods and pistons 5-108 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” note: identify the position of each connecting rod so that it can be reinstalled in its original place....

  • Page 414: Connecting Rods and Pistons

    Connecting rods and pistons 5-109 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Measure cylinder bore “c” with the cylinder bore gauge. Note: measure cylinder bore “c” by taking side-to-side and front-to-back measurements of the cylinder. Then, find the average of the measurements. B. If out ...

  • Page 415: Connecting Rods and Pistons

    Connecting rods and pistons 5-110 2. Install: • piston ring (into the cylinder) note: level the piston ring into the cylinder with the piston crown. 3. Measure: • piston ring end gap out of specification → replace the piston ring. Note: the oil ring expander spacer’s end gap cannot be measured. If t...

  • Page 416: Connecting Rods and Pistons

    Connecting rods and pistons 5-111 4. Calculate: • piston-pin-to-piston-pin-bore clearance out of specification → replace the piston pin and piston as a set. Et3p61028 checking the connecting rods 1. Measure: • crankshaft-pin-to-big-end-bearing clearance out of specification → replace the big end bea...

  • Page 417: Connecting Rods and Pistons

    Connecting rods and pistons 5-112 e. Tighten the connecting rod nuts. Refer to “installing the connecting rods and pistons” on page 5-112. F. Remove the connecting rod and big end bearings. Refer to “removing the connecting rods and pistons” on page 5-108. G. Measure the compressed plastigauge ® wid...

  • Page 418: Connecting Rods and Pistons

    Connecting rods and pistons 5-113 2. Install: • piston “1” (onto the respective connecting rod “2”) • piston pin “3” • piston pin clips “4” note: • apply engine oil onto the piston pin. • make sure that the “y” mark “a” on the connect- ing rod is facing to the left when the punch mark “b” on the pis...

  • Page 419: Connecting Rods and Pistons

    Connecting rods and pistons 5-114 • while compressing the piston rings with piston ring compressor “2”, install the connecting rod assembly “1” into the cylinder with the other hand. • make sure the “y” marks “a” on the connecting rods face towards the left side of the crank- shaft. • make sure the ...

  • Page 420: Connecting Rods and Pistons

    Connecting rods and pistons 5-115 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲.

  • Page 421: Crankshaft

    Crankshaft 5-116 eas25950 crankshaft removing the crankshaft order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-97. Front balancer weight refer to “balancers” on page 5-132. Connecting rod caps refer to “connecting rods and pis- tons” on page 5-107. 1 crankshaf...

  • Page 422: Crankshaft

    Crankshaft 5-117 eas26040 removing the crankshaft journal bearings 1. Remove: • crankshaft journal upper bearings (from the upper crankcase) • crankshaft journal lower bearings (from the lower crankcase) note: identify the position of each crankshaft journal bearing so that it can be reinstalled in ...

  • Page 423: Crankshaft

    Crankshaft 5-118 e. Install the crankshaft journal lower bearings “3” into the lower crankcase and assemble the crankcase halves. Note: • align the projections “c” of the crankshaft jour- nal lower bearings with the notches “d” in the lower crankcase. • do not move the crankshaft until the clearance...

  • Page 424: Crankshaft

    Crankshaft 5-119 note: • 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 425: Transmission

    Transmission 5-120 eas26240 transmission removing the transmission, shift drum assembly, and shift forks (fjr1300a) order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-97. Stopper lever refer to “shift shaft” on page 5-75. 1 drive axle assembly 1 2 bearing 1 3 w...

  • Page 426: Transmission

    Transmission 5-121 13 main axle assembly 1 for installation, reverse the removal proce- dure. Removing the transmission, shift drum assembly, and shift forks (fjr1300a) order job/parts to remove q’ty remarks.

  • Page 427: Transmission

    Transmission 5-122 removing the transmission, shift drum assembly, and shift forks (fjr1300as) order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-97. Stopper lever refer to “shift shaft” on page 5-75. 1 gear position sensor bracket 1 2 oil seal 1 3 drive axle a...

  • Page 428: Transmission

    Transmission 5-123 15 main axle assembly 1 for installation, reverse the removal proce- dure. Removing the transmission, shift drum assembly, and shift forks (fjr1300as) order job/parts to remove q’ty remarks.

  • Page 429: Transmission

    Transmission 5-124 disassembling the main axle assembly order job/parts to remove q’ty remarks 1 2nd pinion gear 1 2 toothed lock washer 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 mai...

  • Page 430: Transmission

    Transmission 5-125 disassembling the drive axle assembly order job/parts to remove q’ty remarks 1 middle drive gear 1 2 washer 1 3 2nd 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 ...

  • Page 431: Transmission

    Transmission 5-126 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 432: Transmission

    Transmission 5-127 eas26250 removing the transmission 1. Remove: • main axle assembly note: remove the main axle assembly with the slide hammer bolts “1” and weight. Eas26260 checking the shift forks the following procedure applies to all of the shift forks. 1. Check: • shift fork cam follower “1” •...

  • Page 433: Transmission

    Transmission 5-128 2. Measure: • drive axle runout (with a centering device and dial gauge “1”) out of specification → replace the drive axle. 3. Check: • transmission gears blue discoloration/pitting/wear → replace the defective gear(s). • transmission gear dogs cracks/damage/rounded edges → replac...

  • Page 434: Transmission

    Transmission 5-129 • be sure to align the projection on the toothed lock washer that is between the alignment marks “b” with the alignment mark “c” on the re- tainer. 3. Install: • 2nd pinion gear “1” note: install the 2nd pinion gear with its chamfered side facing inward as shown in the illustratio...

  • Page 435: Transmission

    Transmission 5-130 4. Install: • drive axle assembly note: • the bearing pin “1” must face towards the rear of the upper crankcase. • make sure the bearing circlip “2” is inserted into the groove in the upper crankcase. 5. Check: • transmission rough movement → repair. Note: oil each gear, shaft, an...

  • Page 436: Transmission

    Transmission 5-131 note: • the bearing pin “1” must face towards the rear of the upper crankcase. • make sure the bearing circlip “2” is inserted into the groove in the upper crankcase. 5. Check: • transmission rough movement → repair. Note: oil each gear, shaft, and bearing thoroughly. 6. Install: ...

  • Page 437: Balancers

    Balancers 5-132 et3p61031 balancers removing the front balancer order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-97. 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 inst...

  • Page 438: Balancers

    Balancers 5-133 removing the rear balancer order job/parts to remove q’ty remarks throttle bodies refer to “throttle bodies” on page 7-4. 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 rea...

  • Page 439: Balancers

    Balancers 5-134 eas26120 checking the balancers 1. Check: • front balancer gear damage/wear → replace the front balancer gear and crankshaft. • rear balancer gear damage/wear → replace the rear balancer gear and clutch housing. 2. Check: • balancer shafts cracks/damage/wear → replace the balanc- er ...

  • Page 440: Balancers

    Balancers 5-135 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Install: • front balancer lever “1” • front balancer lever bolt “2” note: • apply locking agent (loctite ® ) to the threads of the balancer lever bolt. • temporarily tighten the balancer lever bolt. 5. Tighten: • front balancer sha...

  • Page 441: Balancers

    Balancers 5-136 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 ma...

  • Page 442: Balancers

    Balancers 5-137 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Install: • rear balancer lever “1” • rear balancer lever bolt “2” note: • apply locking agent (loctite ® ) to the threads of the balancer lever bolt. • temporarily tighten the balancer lever bolt. 5. Tighten: • rear balancer shaft ...

  • Page 443: Cooling System

    6 cooling system radiator ...................................................................................................... 6-1 checking the radiator.................................................................... 6-3 installing the radiator.....................................................

  • Page 444: Radiator

    Radiator 6-1 eas26380 radiator removing the radiator order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-25. Throttle bodies refer to “throttle bodies” on page 7-4. 1 radiator cap 1 2 coolant reservoir hose 1 3 coolant reservoir breather hose 1 4 coolant r...

  • Page 445: Radiator

    Radiator 6-2 14 left radiator fan motor coupler 1 disconnect. 15 right radiator fan motor coupler 1 disconnect. 16 radiator 1 17 radiator cover 1 18 left radiator fan motor 1 19 right radiator fan motor 1 20 radiator bracket 1 21 air deflector 1 for installation, reverse the removal proce- dure. Rem...

  • Page 446: Radiator

    Radiator 6-3 eas26390 checking the radiator 1. Check: • radiator fins obstruction → clean. Apply compressed air to the rear of the radia- tor. Damage → repair or replace. Note: straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: • radiator hoses • radiator pipes cracks/damage...

  • Page 447: Oil Cooler

    Oil cooler 6-4 eas26410 oil cooler removing the oil cooler order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-15. Coolant drain. Refer to “changing the coolant” on page 3-25. Radiator refer to “radiator” on page 6-1. Exhaust pipe assembly refer to “...

  • Page 448: Oil Cooler

    Oil cooler 6-5 eas26420 checking the oil cooler 1. Check: • oil cooler cracks/damage → replace. 2. Check: • oil cooler inlet hose • oil cooler outlet hose • water pump outlet hose • water pump outlet pipe • water jacket joint inlet hose cracks/damage/wear → replace. Eas26430 installing the oil coole...

  • Page 449: Thermostat

    Thermostat 6-6 eas26440 thermostat removing the thermostat assembly order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-25. Throttle bodies refer to “throttle bodies” on page 7-4. 1 radiator cap 1 2 coolant reservoir hose 1 disconnect. 3 radiator inlet hos...

  • Page 450: Thermostat

    Thermostat 6-7 13 thermostat inlet pipe 1 1 for installation, 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 ...

  • Page 451: Thermostat

    Thermostat 6-8 eas26450 checking the thermostat 1. Check: • thermostat does not open at 71–85 °c (159.8–185.0 °f) → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Suspend the thermostat “1” in a container “2” filled with water. B. Slowly heat the water “3”. C. Place a thermometer “4” ...

  • Page 452: Thermostat

    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 453: Water Pump

    Water pump 6-10 eas26500 water pump removing the water pump order job/parts to remove q’ty remarks it is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil. Right side cowling refer to “general chassis” on page 4-1. Coolant drain. Refe...

  • Page 454: Water Pump

    Water pump 6-11 disassembling the water pump order job/parts 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 disasse...

  • Page 455: Water Pump

    Water pump 6-12 eas26510 disassembling the water pump 1. Remove: • rubber damper holder “1” • rubber damper “2” (from the impeller, with a thin, flat-head screwdriver) note: do not scratch the impeller shaft. 2. Remove: • water pump seal “1” note: remove the water pump seal from the inside of the wa...

  • Page 456: Water Pump

    Water pump 6-13 3. Install: • rubber damper “1” • rubber damper holder “2” note: before installing the rubber damper, apply tap water or coolant onto its outer surface. 4. Measure: • impeller shaft tilt out of specification → repeat steps (3) and (4). Caution: eca14090 make sure the rubber damper an...

  • Page 457: Water Pump

    Water pump 6-14 2. Fill: • cooling system (with the specified amount of 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 th...

  • Page 458: Water Pump

    Water pump 6-15.

  • Page 459: Fuel System

    7 fuel system fuel tank..................................................................................................... 7-1 removing the fuel tank .................................................................. 7-2 removing the fuel pump .........................................................

  • Page 460: Fuel Tank

    Fuel tank 7-1 eas26620 fuel tank removing the fuel tank order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. 1 fuel tank panel 1 2 fuel sender coupler 1 disconnect. 3 fuel pump coupler 1 disconnect. 4 fuel tank breather hose 1 5 fuel tank overflow hose 1 6 fuel h...

  • Page 461: Fuel Tank

    Fuel tank 7-2 eas26630 removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • fuel hose warning ew3p61012 cover fuel hose connections with a cloth when disconnecting them. Residual pres- sure in the fuel lines could cause fuel to spurt out whe...

  • Page 462: Fuel Tank

    Fuel tank 7-3 2. Install: • fuel hose (fuel pump side) • fuel hose holder caution: 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. Note: • install t...

  • Page 463: Throttle Bodies

    Throttle bodies 7-4 eas26970 throttle bodies removing the throttle bodies order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. T-bar/air filter case refer to “general chassis” on page 4-1. Air cut-off valve refer to “air induction system” on page 7-9. Coolant drain. Ref...

  • Page 464: Throttle Bodies

    Throttle bodies 7-5 10 plunger control unit hose 2 1 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...

  • Page 465: Throttle Bodies

    Throttle bodies 7-6 removing the injectors order job/parts to remove q’ty remarks 1 throttle position 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 coupl...

  • Page 466: Throttle Bodies

    Throttle bodies 7-7 eas26980 checking the injectors 1. Check: • injectors damage → replace. Eas26990 checking the throttle bodies 1. Check: • throttle bodies cracks/damage → replace the throttle bod- ies as a set. 2. Check: • fuel passages obstructions → clean. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ...

  • Page 467: Throttle Bodies

    Throttle bodies 7-8 c. Turn the main switch to “on”. D. Measure the throttle position sensor voltage. E. Adjust the throttle position sensor angle so that the voltage is within the specified range. F. After adjusting the throttle position sensor an- gle, tighten the throttle position sensor screws “...

  • Page 468: Air Induction System

    Air induction system 7-9 eas27040 air induction system 1 2 3 4 5 1 1 1 1 2 2 5 2 3 3 4 7 8 6.

  • Page 469: Air Induction System

    Air induction system 7-10 1. Reed valve assembly 2. Air induction system hose (3-way joint to reed valve cover) 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 joi...

  • Page 470: Air Induction System

    Air induction system 7-11 removing the air cut-off valve order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. T-bar refer to “general chassis” on page 4-1. 1 air induction system solenoid coupler 1 disconnect. 2 air induction system hose (air filter case joint assembly ...

  • Page 471: Air Induction System

    Air induction system 7-12 removing the reed valves order job/parts to remove q’ty remarks thermostat inlet pipe 1 refer to “thermostat” on page 6-6. 1 reed valve cover (cylinder-#1) 1 2 reed valve cover (cylinders-#2/#3) 1 3 reed valve cover (cylinder-#4) 1 4 reed valve assembly 4 5 reed valve plate...

  • Page 472: Air Induction System

    Air induction system 7-13 eas27050 checking the pressure regulator 1. Check: • pressure regulator damage → replace. Eas27060 checking the air induction system air injection the air induction system burns unburned ex- haust gases by injecting fresh air (secondary air) into the exhaust port, reducing ...

  • Page 473: Electrical System

    8 electrical system ignition system ......................................................................................... 8-1 circuit diagram (1/2) (fjr1300a) ..................................................... 8-1 circuit diagram (2/2) (fjr1300a) .................................................

  • Page 474

    Fuel injection system.......................................................................... 8-57 circuit diagram (1/2) (fjr1300a) ................................................... 8-57 circuit diagram (2/2) (fjr1300a) ................................................... 8-59 circuit diagram (1/...

  • Page 475

    Abs (anti-lock brake system)......................................................... 8-129 circuit diagram (1/2) (fjr1300a) ................................................. 8-129 circuit diagram (2/2) (fjr1300a) ................................................. 8-131 circuit diagram (1/2) (fjr1300...

  • Page 476

    Electrical components.................................................................... 8-225 checking the switches ............................................................... 8-233 checking the bulbs and bulb sockets ................................. 8-238 checking the fuses ....................

  • Page 478: Ignition System

    Ignition system 8-1 eas27090 ignition system eas27110 circuit diagram (1/2) (fjr1300a) r br /b r /wg /y b lg /w w /yb /g w /b br ( blue ) g /l w /b ( blue ) br /r br /r r br /l r br /l b b /w r r b b /g w (gray) ww r (black) b r /lr /l l/ wr /w (black) (dark green) r /g r /w g /b y /l b /w bb b y /l...

  • Page 479: Ignition System

    Ignition system 8-2 1. Main switch 8. Main fuse 9. Battery 15.Gear position switch 20.Coupler 3 (wire harness–front cowling wire harness) 21.Relay unit 24.Sidestand switch 36.Cylinders-#1/#4 ignition coil 37.Spark plug 38.Cylinders-#2/#3 ignition coil 44.Ecu (engine control unit) 45.Crankshaft posit...

  • Page 480: Ignition System

    Ignition system 8-3 et3p61001 circuit diagram (2/2) (fjr1300a) front cowling wire harness sb b lg br /r rb r r /g sb lg b sb /w br r /g r /g b /r r /b b (gray) b b /l (gray) b /w b b br /b b ( black ) b br /y ( black ) r /b b /r l /r b b b l /r b dg b ch b b b b b b b ch dg r /g b /wg /r sb b /l b /...

  • Page 481: Ignition System

    Ignition system 8-4 20.Coupler 3 (wire harness–front cowling wire harness) 54.Coupler 4 (wire harness–front cowling wire harness) 70.Engine stop switch.

  • Page 482: Ignition System

    Ignition system 8-5 et3p66001 circuit diagram (1/2) (fjr1300as) r r br /r br /r r br /l r br /l b b /w r r b b /g w (gray) ww r (black) b r /lr /l l/ wr /w (black) r /g r /w g /b y /l b /w bb b y /l lg r /w r /g b2 br /l o /b o /w g /rg /bb /l g /r o /w o /b br /l b g /b w w r /lb (dark green) g /w ...

  • Page 483: Ignition System

    Ignition system 8-6 1. Main switch 8. Main fuse 9. Battery 18.Relay unit 21.Neutral switch 27.Coupler 3 (wire harness–front cowling wire harness) 36.Sidestand switch 37.Cylinders-#1/#4 ignition coil 38.Spark plug 39.Cylinders-#2/#3 ignition coil 45.Ecu (engine control unit) 46.Crankshaft position se...

  • Page 484: Ignition System

    Ignition system 8-7 et3p66002 circuit diagram (2/2) (fjr1300as) front cowling wire harness sb b lg br /r rb r r /g sb lg b sb /w br o /b g /b b /l g /r o /wb r/l o /w g /r b /l g /b o /bb r/l b /l br /l o /b o /w g /rg /b g /r o /w o /b br /l b g /b r /bl g/ w (black) r /g r /g l /b y b dg br /w p l...

  • Page 485: Ignition System

    Ignition system 8-8 27.Coupler 3 (wire harness–front cowling wire harness) 66.Coupler 5 (wire harness–front cowling wire harness) 90.Engine stop switch.

  • Page 486: Ignition System

    Ignition system 8-9 et3p61002 engine stopping due to sidestand operation when the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ecu when both the gear position ...

  • Page 487: Ignition System

    Ignition system 8-10 eas27140 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Note: • before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar 4. Throttle bodies 5. Storage compartment ng → ok ↓ ng → ok ↓ ng → ok ↓ o...

  • Page 488: Ignition System

    Ignition system 8-11 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the main switch. Refer to “checking the switches” on page 8-233. Replace the main switch/immobilizer unit. 9. Check the engine stop switch. Refer to “checking the switches” on page 8-233. Re...

  • Page 489: Ignition System

    Ignition system 8-12.

  • Page 490: Electric Starting System

    Electric starting system 8-13 eas27160 electric starting system eas27170 circuit diagram (1/2) (fjr1300a) r br /b r /wg /y b lg /w w /yb /g w /b br ( blue ) g /l w /b ( blue ) br /r br /r r br /l r br /l b b /w r r b b /g w (gray) ww r (black) b r /lr /l l/ wr /w (black) (dark green) r /g r /w g /b ...

  • Page 491: Electric Starting System

    Electric starting system 8-14 1. Main switch 8. Main fuse 9. Battery 11.Starter relay 12.Starter motor 15.Gear position switch 16.Coupler 1 (wire harness–front cowling wire harness) 20.Coupler 3 (wire harness–front cowling wire harness) 21.Relay unit 22.Starting circuit cut-off relay 24.Sidestand sw...

  • Page 492: Electric Starting System

    Electric starting system 8-15 et3p61003 circuit diagram (2/2) (fjr1300a) front cowling wire harness sb b lg br /r rb r r /g sb lg b sb /w br r /g r /g b /r r /b b (gray) b b /l (gray) b /w b b br /b b ( black ) b br /y ( black ) r /b b /r l /r b b b l /r b dg b ch b b b b b b b ch dg r /g b /wg /r s...

  • Page 493: Electric Starting System

    Electric starting system 8-16 16.Coupler 1 (wire harness–front cowling wire harness) 20.Coupler 3 (wire harness–front cowling wire harness) 54.Coupler 4 (wire harness–front cowling wire harness) 70.Engine stop switch 71.Start switch 74.Clutch switch.

  • Page 494: Electric Starting System

    Electric starting system 8-17 et3p66005 circuit diagram (1/2) (fjr1300as) r r br /r br /r r br /l r br /l b b /w r r b b /g w (gray) ww r (black) b r /lr /l l/ wr /w (black) r /g r /w g /b y /l b /w bb b y /l lg r /w r /g b2 br /l o /b o /w g /rg /bb /l g /r o /w o /b br /l b g /b w w r /lb (dark gr...

  • Page 495: Electric Starting System

    Electric starting system 8-18 1. Main switch 8. Main fuse 9. Battery 11.Starter relay 12.Starter motor 14.Coupler 1 (wire harness–front cowling wire harness) 18.Relay unit 19.Starting circuit cut-off relay 21.Neutral switch 27.Coupler 3 (wire harness–front cowling wire harness) 29.Brake light relay ...

  • Page 496: Electric Starting System

    Electric starting system 8-19 et3p66006 circuit diagram (2/2) (fjr1300as) front cowling wire harness sb b lg br /r rb r r /g sb lg b sb /w br o /b g /b b /l g /r o /wb r/l o /w g /r b /l g /b o /bb r/l b /l br /l o /b o /w g /rg /b g /r o /w o /b br /l b g /b r /bl g/ w (black) r /g r /g l /b y b dg...

  • Page 497: Electric Starting System

    Electric starting system 8-20 14.Coupler 1 (wire harness–front cowling wire harness) 27.Coupler 3 (wire harness–front cowling wire harness) 66.Coupler 5 (wire harness–front cowling wire harness) 89.Front brake light switch 90.Engine stop switch 91.Start switch.

  • Page 498: Electric Starting System

    Electric starting system 8-21 eas27180 starting circuit cut-off system operation (fjr1300a) if the engine stop switch is set to “ ” and the main switch is turned “on” (both switch circuits are closed), the starter motor can only operate if at least one of the following conditions is met: • the trans...

  • Page 499: Electric Starting System

    Electric starting system 8-22 et3p66007 starting circuit cut-off system operation (fjr1300as) if the engine stop switch is set to “ ” (the switch circuit is closed), the main switch is turned “on” (the switch circuit is closed), and the brake lever is squeezed (the front brake light switch circuit i...

  • Page 500: Electric Starting System

    Electric starting system 8-23 eas27190 troubleshooting (fjr1300a) the starter motor fails to turn. Note: • before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar 4. Throttle bodies 5. Storage compartment ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng → ok ↓...

  • Page 501: Electric Starting System

    Electric starting system 8-24 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the main switch. Refer to “checking the switches” on page 8-233. Replace the main switch/immobilizer unit. 9. Check the engine stop switch. Refer to “checking the switches” on page 8-233. Rep...

  • Page 502: Electric Starting System

    Electric starting system 8-25 et3p66008 troubleshooting (fjr1300as) the starter motor fails to turn. Note: • before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar 4. Throttle bodies 5. Storage compartment ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng → ok...

  • Page 503: Electric Starting System

    Electric starting system 8-26 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the brake light relay. Refer to “checking the re- lays” on page 8-243. Replace the brake light relay. 9. Check the ycc-s control relay. Refer to “checking the re- lays” on...

  • Page 504: Electric Starting System

    Electric starting system 8-27 ng → ok ↓ 17.Check the entire starting system wiring. Refer to “circuit diagram (1/2) (fjr1300as)” on page 8-17 and “circuit diagram (2/2) (fjr1300as)” on page 8-19. Properly connect or repair the starting sys- tem wiring. Replace the mcu..

  • Page 505: Electric Starting System

    Electric starting system 8-28.

  • Page 506: Charging System

    Charging system 8-29 eas27200 charging system eas27210 circuit diagram r br/b r/w g/y b lg/w w/y b/g w/b br (blue) g/l w/b (blue) br/r br/r r br/l r br/l b b/w r r b b/g w (gray) w w r (black) b r/l r/l l/w r/w (black) r/g r/w g/b y/l b/w bb b y/l lg r/w r/g b2 br/b r/y r/w l/r g/l br r/y br/b r/w l...

  • Page 507: Charging System

    Charging system 8-30 2. Rectifier/regulator 3. Ac magneto 8. Main fuse 9. Battery.

  • Page 508: Charging System

    Charging system 8-31 eas27230 troubleshooting the battery is not being charged. Note: • before troubleshooting, remove the following part(s): 1. Front cowling right inner panel 1 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuse. (main) refer to “checking the fus- es” on page 8-239...

  • Page 509: Charging System

    Charging system 8-32.

  • Page 510: Lighting System

    Lighting system 8-33 eas27240 lighting system eas27250 circuit diagram (1/2) r br /b r /wg /y b lg /w w /yb /g w /b br ( blue ) g /l w /b ( blue ) br /r br /r r br /l r br /l b b /w r r b b /g w (gray) ww r (black) b r /lr /l l/ wr /w (black) (dark green) r /g r /w g /b y /l b /w bb b y /l lg r /w r...

  • Page 511: Lighting System

    Lighting system 8-34 1. Main switch 8. Main fuse 9. Battery 20.Coupler 3 (wire harness–front cowling wire harness) 31.License plate light 33.Tail/brake light 44.Ecu (engine control unit) 54.Coupler 4 (wire harness–front cowling wire harness) 55.Headlight (on/off)/grip warmer relay 56.Hazard lighting...

  • Page 512: Lighting System

    Lighting system 8-35 et3p61004 circuit diagram (2/2) front cowling wire harness sb b lg br /r rb r r /g sb lg b sb /w br r /g r /g b /r r /b b (gray) b b /l (gray) b /w b b br /b b ( black ) b br /y ( black ) r /b b /r l /r b b b l /r b dg b ch b b b b b b b ch dg r /g b /wg /r sb b /l b /w w g /b b...

  • Page 513: Lighting System

    Lighting system 8-36 20.Coupler 3 (wire harness–front cowling wire harness) 54.Coupler 4 (wire harness–front cowling wire harness) 75.Pass switch 76.Dimmer switch 90.Meter light 91.High beam indicator light 98.Headlight relay (dimmer) 100.Auxiliary light 101.Headlight.

  • Page 514: Lighting System

    Lighting system 8-37 eas27260 troubleshooting any of the following fail to light: headlights, high beam indicator light, taillight, license plate light, auxiliary lights or meter light. Note: • before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar ng →...

  • Page 515: Lighting System

    Lighting system 8-38 ng → ok ↓ ng → ok ↓ 8. Check the headlight relay (dimmer). Refer to “checking the re- lays” on page 8-243. 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. ...

  • Page 516: Signaling System

    Signaling system 8-39 eas27270 signaling system eas27280 circuit diagram (1/2) (fjr1300a) r br /b r /wg /y b lg /w w /yb /g w /b br ( blue ) g /l w /b ( blue ) br /r br /r r br /l r br /l b b /w r r b b /g w (gray) ww r (black) b r /lr /l l/ wr /w (black) (dark green) r /g r /w g /b y /l b /w bb b y...

  • Page 517: Signaling System

    Signaling system 8-40 1. Main switch 5. Abs ecu fuse 7. Backup fuse (odometer, clock, immobilizer system, and windshield drive system) 8. Main fuse 9. Battery 14.Oil level switch 15.Gear position switch 16.Coupler 1 (wire harness–front cowling wire harness) 18.Fuel sender 19.Coupler 2 (wire harness–...

  • Page 518: Signaling System

    Signaling system 8-41 et3p61005 circuit diagram (2/2) (fjr1300a) front cowling wire harness sb b lg br /r rb r r /g sb lg b sb /w br r /g r /g b /r r /b b (gray) b b /l (gray) b /w b b br /b b ( black ) b br /y ( black ) r /b b /r l /r b b b l /r b dg b ch b b b b b b b ch dg r /g b /wg /r sb b /l b...

  • Page 519: Signaling System

    Signaling system 8-42 16.Coupler 1 (wire harness–front cowling wire harness) 19.Coupler 2 (wire harness–front cowling wire harness) 20.Coupler 3 (wire harness–front cowling wire harness) 54.Coupler 4 (wire harness–front cowling wire harness) 67.Turn signal/hazard relay 69.Front brake light switch 72...

  • Page 520: Signaling System

    Signaling system 8-43 et3p66009 circuit diagram (1/2) (fjr1300as) r r br /r br /r r br /l r br /l b b /w r r b b /g w (gray) ww r (black) b r /lr /l l/ wr /w (black) r /g r /w g /b y /l b /w bb b y /l lg r /w r /g b2 br /l o /b o /w g /rg /bb /l g /r o /w o /b br /l b g /b w w r /lb (dark green) g /...

  • Page 521: Signaling System

    Signaling system 8-44 1. Main switch 5. Abs ecu fuse 7. Backup fuse (odometer, clock, immobilizer system, and windshield drive system) 8. Main fuse 9. Battery 14.Coupler 1 (wire harness–front cowling wire harness) 16.Fuel sender 17.Oil level switch 18.Relay unit 21.Neutral switch 23.Abs ecu (electro...

  • Page 522: Signaling System

    Signaling system 8-45 et3p66010 circuit diagram (2/2) (fjr1300as) front cowling wire harness sb b lg br /r rb r r /g sb lg b sb /w br o /b g /b b /l g /r o /wb r/l o /w g /r b /l g /b o /bb r/l b /l br /l o /b o /w g /rg /b g /r o /w o /b br /l b g /b r /bl g/ w (black) r /g r /g l /b y b dg br /w p...

  • Page 523: Signaling System

    Signaling system 8-46 14.Coupler 1 (wire harness–front cowling wire harness) 26.Coupler 2 (wire harness–front cowling wire harness) 27.Coupler 3 (wire harness–front cowling wire harness) 66.Coupler 5 (wire harness–front cowling wire harness) 81.Turn signal/hazard relay 86.Turn signal switch 87.Horn ...

  • Page 524: Signaling System

    Signaling system 8-47 eas27290 troubleshooting • any of the following fail to light: turn signal light, brake light or indicator light. • the horn fails to sound. • the fuel meter fails to come on. • the speedometer fails to operate. Note: • before troubleshooting, remove the following part(s): 1. F...

  • Page 525: Signaling System

    Signaling system 8-48 checking the signaling system the horn fails to sound. Ng → ok ↓ ng → ok ↓ ng → ok ↓ the tail/brake light fails to come on. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the horn switch. Refer to “checking the switches” on page 8-233. Replace the left handlebar switch. 2. Ch...

  • Page 526: Signaling System

    Signaling system 8-49 ng → ok ↓ ng → ok ↓ the turn signal light, turn signal indicator light or both fail to blink. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 5. Check the diode 2. (fjr1300as only) refer to “checking the diode (fjr1300as only)” on page 8-257. Replace the diode. 6. Check the entire sign...

  • Page 527: Signaling System

    Signaling system 8-50 ng → ok ↓ the neutral indicator light fails to come on. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ the shift indicator fails to come on. (fjr1300a) ng → ok ↓ 5. Check the entire signaling system wiring. Refer to “circuit diagram (1/2) (fjr1300a)” on page 8-39, “cir- cuit diagram (...

  • Page 528: Signaling System

    Signaling system 8-51 ng → ok ↓ the oil level warning light fails to come on. Ng → ok ↓ ng → ok ↓ the fuel meter fails to come on. Ng → ok ↓ ng → ok ↓ 2. Check the entire signaling system wiring. Refer to “circuit diagram (1/2) (fjr1300a)” on page 8-39 and “circuit diagram (2/2) (fjr1300a)” on page ...

  • Page 529: Signaling System

    Signaling system 8-52 the speedometer fails to operate. Ng → ok ↓ ng → ok ↓ note: repair or replace if there is an open or short circuit. • between rear wheel sensor coupler and abs ecu coupler. (white–white) (gray–gray) • between abs ecu coupler and ecu coupler. (white/yellow–white/yellow) • betwee...

  • Page 530: Cooling System

    Cooling system 8-53 eas27300 cooling system eas27310 circuit diagram r br /b r /wg /y b lg /w w /yb /g w /b br ( blue ) g /l w /b ( blue ) br /r br /r r br /l r br /l b b /w r r b b /g w (gray) ww r (black) b r /lr /l l/ wr /w (black) (dark green) r /g r /w g /b y /l b /w bb b y /l lg r /w r /g b2 s...

  • Page 531: Cooling System

    Cooling system 8-54 1. Main switch 8. Main fuse 9. Battery 44.Ecu (engine control unit) 48.Coolant temperature sensor 59.Ignition fuse 62.Radiator fan motor relay 63.Left radiator fan motor fuse 64.Left radiator fan motor 65.Right radiator fan motor fuse 66.Right radiator fan motor.

  • Page 532: Cooling System

    Cooling system 8-55 eas27320 troubleshooting the radiator fan motor fails to turn. Note: • before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition, ...

  • Page 533: Cooling System

    Cooling system 8-56.

  • Page 534: Fuel Injection System

    Fuel injection system 8-57 eas27330 fuel injection system eas27340 circuit diagram (1/2) (fjr1300a) r br /b r /wg /y b lg /w w /yb /g w /b br ( blue ) g /l w /b ( blue ) br /r br /r r br /l r br /l b b /w r r b b /g w (gray) ww r (black) b r /lr /l l/ wr /w (black) (dark green) r /g r /w g /b y /l b...

  • Page 535: Fuel Injection System

    Fuel injection system 8-58 1. Main switch 5. Abs ecu fuse 6. Fuel injection system fuse 8. Main fuse 9. Battery 15.Gear position switch 16.Coupler 1 (wire harness–front cowling wire harness) 17.Fuel pump 20.Coupler 3 (wire harness–front cowling wire harness) 21.Relay unit 23.Fuel pump relay 24.Sides...

  • Page 536: Fuel Injection System

    Fuel injection system 8-59 et3p61006 circuit diagram (2/2) (fjr1300a) front cowling wire harness sb b lg br /r rb r r /g sb lg b sb /w br r /g r /g b /r r /b b (gray) b b /l (gray) b /w b b br /b b ( black ) b br /y ( black ) r /b b /r l /r b b b l /r b dg b ch b b b b b b b ch dg r /g b /wg /r sb b...

  • Page 537: Fuel Injection System

    Fuel injection system 8-60 16.Coupler 1 (wire harness–front cowling wire harness) 20.Coupler 3 (wire harness–front cowling wire harness) 54.Coupler 4 (wire harness–front cowling wire harness) 70.Engine stop switch 87.Multi-function meter 89.Engine trouble warning light.

  • Page 538: Fuel Injection System

    Fuel injection system 8-61 et3p66012 circuit diagram (1/2) (fjr1300as) r r br /r br /r r br /l r br /l b b /w r r b b /g w (gray) ww r (black) b r /lr /l l/ wr /w (black) r /g r /w g /b y /l b /w bb b y /l lg r /w r /g b2 br /l o /b o /w g /rg /bb /l g /r o /w o /b br /l b g /b w w r /lb (dark green...

  • Page 539: Fuel Injection System

    Fuel injection system 8-62 1. Main switch 5. Abs ecu fuse 6. Fuel injection system fuse 8. Main fuse 9. Battery 14.Coupler 1 (wire harness–front cowling wire harness) 15.Fuel pump 18.Relay unit 20.Fuel pump relay 21.Neutral switch 23.Abs ecu (electronic control unit) 25.Rear wheel sensor 27.Coupler ...

  • Page 540: Fuel Injection System

    Fuel injection system 8-63 et3p66013 circuit diagram (2/2) (fjr1300as) front cowling wire harness sb b lg br /r rb r r /g sb lg b sb /w br o /b g /b b /l g /r o /wb r/l o /w g /r b /l g /b o /bb r/l b /l br /l o /b o /w g /rg /b g /r o /w o /b br /l b g /b r /bl g/ w (black) r /g r /g ch r /y br /g ...

  • Page 541: Fuel Injection System

    Fuel injection system 8-64 14.Coupler 1 (wire harness–front cowling wire harness) 27.Coupler 3 (wire harness–front cowling wire harness) 66.Coupler 5 (wire harness–front cowling wire harness) 90.Engine stop switch 98.Multi-function meter 100.Engine trouble warning light.

  • Page 542: Fuel Injection System

    Fuel injection system 8-65 eas27350 ecu self-diagnostic function the ecu is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute ch...

  • Page 543: Fuel Injection System

    Fuel injection system 8-66 eas27380 self-diagnostic function table if the ecu detects an abnormal signal from a sensor while the vehicle is being driven, the ecu illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the ...

  • Page 544: Fuel Injection System

    Fuel injection system 8-67 22 intake air tempera- ture sensor (open or short circuit) intake air temperature sensor: open or short circuit detected. Able able 24 o 2 sensor (inactive) no normal signal is received from the o 2 sensor. Able able 30 lean angle sensor latch up detected. No normal signal...

  • Page 545: Fuel Injection System

    Fuel injection system 8-68 communication error with the meter eas27400 troubleshooting method the engine operation is not normal and the engine trouble warning light comes on. 1. Check: • fault code number ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Check the fault code number displayed on ...

  • Page 546: Fuel Injection System

    Fuel injection system 8-69 5. Erase the malfunction history in the diagnos- tic mode. Refer to “sensor operation table (diagnostic code no.D:62)”. Note: turning the main switch to “off” will not erase the malfunction history. The engine operation is not normal but the engine trouble warning light do...

  • Page 547: Fuel Injection System

    Fuel injection system 8-70 7. Verify the operation of the sensor or actuator. • sensor operation the data representing the operating conditions of the sensor appears on the trip lcd. • actuator operation set the engine stop switch to “ ” to operate the actuator. Note: if the engine stop switch is se...

  • Page 548: Fuel Injection System

    Fuel injection system 8-71 19 a break or disconnection of the black/red lead of the ecu is detected. • open or short circuit in wire harness. • malfunction in ecu. • defective relay unit (diode). D:20 21 coolant temperature sen- sor: open or short circuit detected. • open or short circuit in wire ha...

  • Page 549: Fuel Injection System

    Fuel injection system 8-72 34 malfunction detected in the primary wire of the cylin- ders-#2/#3 ignition coil. • open or short circuit in front cowling wire harness. • open or short circuit in wire harness. • malfunction in cylinders-#2/#3 ignition coil. • malfunction in ecu. D:31 41 lean angle sens...

  • Page 550: Fuel Injection System

    Fuel injection system 8-73 sensor operation table er-3 data from the ecu cannot be received correctly. • open or short circuit in front cowling wire harness. • open or short circuit in wire harness. • malfunction in meter assembly. • malfunction in ecu. — er-4 non-registered data has been received f...

  • Page 551: Fuel Injection System

    Fuel injection system 8-74 d:09 fuel system voltage (battery voltage) approximately 12.0 set the engine stop switch to “ ”, and then compare with the actually measured battery voltage. (if the bat- tery voltage is lower, per- form recharging.) d:20 sidestand switch set on/off the sidestand switch. (...

  • Page 552: Fuel Injection System

    Fuel injection system 8-75 *1 if it is not possible to check the intake temperature, use the ambient temperature as reference (use the compared values for reference). Actuator operation table d:62 malfunction history code erasure • no history 0 — • history exists • displays the total number of malfu...

  • Page 553: Fuel Injection System

    Fuel injection system 8-76 eas27450 troubleshooting details this section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunc...

  • Page 554: Fuel Injection System

    Fuel injection system 8-77 fault code no.: code number displayed on the meter when the engine failed to work normally. Refer to “self-diagnostic function table”. Diagnostic code no.: diagnostic code number to be used when the diagnostic mode is operated. Refer to “diagnostic mode” on page 8-69. Faul...

  • Page 555: Fuel Injection System

    Fuel injection system 8-78 fault code no. 12 symptom no normal signals are received from the crankshaft posi- tion sensor. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of crankshaft posi- tion sensor check for lo...

  • Page 556: Fuel Injection System

    Fuel injection system 8-79 fault code no. 13 symptom intake air pressure sensor: open or short circuit detected. Diagnostic code no. D:03 intake air pressure sensor order item/components and probable cause check or maintenance job reinstatement method 1 connections • intake air pressure sensor coupl...

  • Page 557: Fuel Injection System

    Fuel injection system 8-80 fault code no. 15 symptom throttle position sensor: open or short circuit detected. Diagnostic code no. D:01 throttle position sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of throttle position sensor. C...

  • Page 558: Fuel Injection System

    Fuel injection system 8-81 fault code no. 16 symptom stuck throttle position sensor is detected. Diagnostic code no. D:01 throttle position sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of throttle position sensor. Check for loose...

  • Page 559: Fuel Injection System

    Fuel injection system 8-82 fault code no. 19 symptom a break or disconnection of the black/red lead of the ecu is detected. Diagnostic code no. D:20 sidestand switch order item/components and probable cause check or maintenance job reinstatement method 1 connections • wire harness ecu coupler • rela...

  • Page 560: Fuel Injection System

    Fuel injection system 8-83 fault code no. 21 symptom coolant temperature sensor: open or short circuit detect- ed. Diagnostic code no. D:06 coolant temperature sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of coolant tempera- ture...

  • Page 561: Fuel Injection System

    Fuel injection system 8-84 fault code no. 22 symptom intake air temperature sensor: open or short circuit de- tected. Diagnostic code no. D:05 intake air temperature sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of intake air tem-...

  • Page 562: Fuel Injection System

    Fuel injection system 8-85 fault code no. 24 symptom no normal signal is received from the o 2 sensor. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of o 2 sensor check for looseness or pinching. Starting the en- ...

  • Page 563: Fuel Injection System

    Fuel injection system 8-86 fault code no. 30 symptom latch up detected. No normal signal is received from the lean angle sensor. Diagnostic code no. D:08 lean angle sensor order item/components and probable cause check or maintenance job reinstatement method 1 the vehicle has overturned. Raise the v...

  • Page 564: Fuel Injection System

    Fuel injection system 8-87 fault code no. 31 symptom the amount of air-fuel ratio feedback compensation is maintained continuously in the vicinity of the upper limit (lean air-fuel ratio). Diagnostic code no. D:01 throttle position sensor order item/components and probable cause check or maintenance...

  • Page 565: Fuel Injection System

    Fuel injection system 8-88 5 the fuel pressure is too low. • compare the fuel pressures at idle and with throttle open. • about the same → normal • too low → refer to the following table. • check the fuel pump. • replace if defective. Refer to “checking the fuel pump body” on page 7-2. • check the d...

  • Page 566: Fuel Injection System

    Fuel injection system 8-89 fault code no. 32 symptom the amount of air-fuel ratio feedback compensation is maintained continuously in the vicinity of the lower limit (rich air-fuel ratio). Diagnostic code no. D:01 throttle position sensor order item/components and probable cause check or maintenance...

  • Page 567: Fuel Injection System

    Fuel injection system 8-90 fault code no. 33 symptom malfunction detected in the primary wire of the cylinders- #1/#4 ignition coil. Diagnostic code no. D:30 cylinders-#1/#4 ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinders...

  • Page 568: Fuel Injection System

    Fuel injection system 8-91 fault code no. 34 symptom malfunction detected in the primary wire of the cylinders- #2/#3 ignition coil. Diagnostic code no. D:31 cylinders-#2/#3 ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinders...

  • Page 569: Fuel Injection System

    Fuel injection system 8-92 fault code no. 41 symptom lean angle sensor: open or short circuit detected. Diagnostic code no. D:08 lean angle sensor order item/components and probable cause check or maintenance job reinstatement method 1 connections • lean angle sensor coupler • wire harness ecu coupl...

  • Page 570: Fuel Injection System

    Fuel injection system 8-93 fault code no. 42 symptom a. No normal signals are received from the rear wheel sensor. B. Open or short circuit is detected in the neutral circuit of the gear position switch. (fjr1300a) open or short circuit is detected in the neutral switch. (fjr1300as) diagnostic code ...

  • Page 571: Fuel Injection System

    Fuel injection system 8-94 b-1 connections • gear position switch coupler (fjr1300a) • neutral switch coupler (fjr1300as) • wire harness ecu coupler • relay 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...

  • Page 572: Fuel Injection System

    Fuel injection system 8-95 fault code no. 43 symptom the ecu is unable to monitor the battery voltage (an open or short circuit in the line to the ecu). Diagnostic code no. D:09 fuel system voltage order item/components and probable cause check or maintenance job reinstatement method 1 connections •...

  • Page 573: Fuel Injection System

    Fuel injection system 8-96 fault code no. 46 symptom power supply to the fuel injection system is not normal. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 connections • wire harness ecu coupler • check the coupler for any pins that ...

  • Page 574: Fuel Injection System

    Fuel injection system 8-97 fault code no. Er-1 symptom no signals are received from the ecu. 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 c...

  • Page 575: Fuel Injection System

    Fuel injection system 8-98 fault code no. Er-3 symptom data from the ecu cannot be received correctly. 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...

  • Page 576: Fuel Pump System

    Fuel pump system 8-99 eas27550 fuel pump system eas27560 circuit diagram (1/2) r br /b r /wg /y b lg /w w /yb /g w /b br ( blue ) g /l w /b ( blue ) br /r br /r r br /l r br /l b b /w r r b b /g w (gray) ww r (black) b r /lr /l l/ wr /w (black) (dark green) r /g r /w g /b y /l b /w bb b y /l lg r /w...

  • Page 577: Fuel Pump System

    Fuel pump system 8-100 1. Main switch 6. Fuel injection system fuse 8. Main fuse 9. Battery 17.Fuel pump 20.Coupler 3 (wire harness–front cowling wire harness) 21.Relay unit 23.Fuel pump relay 44.Ecu (engine control unit) 54.Coupler 4 (wire harness–front cowling wire harness) 59.Ignition fuse.

  • Page 578: Fuel Pump System

    Fuel pump system 8-101 et3p61007 circuit diagram (2/2) front cowling wire harness sb b lg br /r rb r r /g sb lg b sb /w br r /g r /g b /r r /b b (gray) b b /l (gray) b /w b b br /b b ( black ) b br /y ( black ) r /b b /r l /r b b b l /r b dg b ch b b b b b b b ch dg r /g b /wg /r sb b /l b /w w g /b...

  • Page 579: Fuel Pump System

    Fuel pump system 8-102 20.Coupler 3 (wire harness–front cowling wire harness) 54.Coupler 4 (wire harness–front cowling wire harness) 70.Engine stop switch.

  • Page 580: Fuel Pump System

    Fuel pump system 8-103 eas27570 troubleshooting if the fuel pump fails to operate. Note: • before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar 4. Storage compartment ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the f...

  • Page 581: Fuel Pump System

    Fuel pump system 8-104.

  • Page 582: Windshield Drive System

    Windshield drive system 8-105 eas27610 windshield drive system eas27620 circuit diagram (1/2) r br /b r /wg /y b lg /w w /yb /g w /b br ( blue ) g /l w /b ( blue ) br /r br /r r br /l r br /l b b /w r r b b /g w (gray) ww r (black) b r /lr /l l/ wr /w (black) (dark green) r /g r /w g /b y /l b /w bb...

  • Page 583: Windshield Drive System

    Windshield drive system 8-106 1. Main switch 7. Backup fuse (odometer, clock, immobilizer system, and windshield drive system) 8. Main fuse 9. Battery 19.Coupler 2 (wire harness–front cowling wire harness) 54.Coupler 4 (wire harness–front cowling wire harness) 57.Signaling system fuse.

  • Page 584: Windshield Drive System

    Windshield drive system 8-107 et3p61008 circuit diagram (2/2) front cowling wire harness sb b lg br /r rb r r /g sb lg b sb /w br r /g r /g b /r r /b b (gray) b b /l (gray) b /w b b br /b b ( black ) b br /y ( black ) r /b b /r l /r b b b l /r b dg b ch b b b b b b b ch dg r /g b /wg /r sb b /l b /w...

  • Page 585: Windshield Drive System

    Windshield drive system 8-108 19.Coupler 2 (wire harness–front cowling wire harness) 54.Coupler 4 (wire harness–front cowling wire harness) 77.Windshield position switch 103.Windshield drive unit.

  • Page 586: Windshield Drive System

    Windshield drive system 8-109 eas27630 troubleshooting the windshield fails to move. Note: • before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check that there are no rocks or other for...

  • Page 587: Windshield Drive System

    Windshield drive system 8-110 ng → 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 588: Accessory Box System

    Accessory box system 8-111 et3p61009 accessory box system et3p61010 circuit diagram (1/2) r br/b r/w g/y b lg/w w/y b/g w/b br (blue) g/l w/b (blue) br/r br/r r br/l r br/l b b/w r r b b/g w (gray) w w r (black) b r/l r/l l/w r/w (black) r/g r/w g/b y/l b/w bb b y/l lg r/w r/g b2 br/b r/y r/w l/r g/...

  • Page 589: Accessory Box System

    Accessory box system 8-112 1. Main switch 8. Main fuse 9. Battery 54.Coupler 4 (wire harness–front cowling wire harness) 57.Signaling system fuse.

  • Page 590: Accessory Box System

    Accessory box system 8-113 et3p61011 circuit diagram (2/2) front cowling wire harness sb b lg br /r rb r r /g sb lg b sb /w br r /g r /g b /r r /b b (gray) b b /l (gray) b /w b b br /b b ( black ) b br /y ( black ) r /b b /r l /r b b b l /r b dg b ch b b b b b b b ch dg r /g b /wg /r sb b /l b /w w ...

  • Page 591: Accessory Box System

    Accessory box system 8-114 54.Coupler 4 (wire harness–front cowling wire harness) 80.Accessory box solenoid.

  • Page 592: Accessory Box System

    Accessory box system 8-115 et3p61012 troubleshooting the accessory box fails to operate. Note: • before troubleshooting, remove the following part(s): 1. Front cowling assembly ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main and signaling system) refer to “checking the fu...

  • Page 593: Accessory Box System

    Accessory box system 8-116.

  • Page 594: Immobilizer System

    Immobilizer system 8-117 eas27640 immobilizer system eas27650 circuit diagram (1/2) r br /b r /wg /y b lg /w w /yb /g w /b br ( blue ) g /l w /b ( blue ) br /r br /r r br /l r br /l b b /w r r b b /g w (gray) ww r (black) b r /lr /l l/ wr /w (black) (dark green) r /g r /w g /b y /l b /w bb b y /l lg...

  • Page 595: Immobilizer System

    Immobilizer system 8-118 1. Main switch 7. Backup fuse (odometer, clock, immobilizer system, and windshield drive system) 8. Main fuse 9. Battery 13.Immobilizer unit 16.Coupler 1 (wire harness–front cowling wire harness) 19.Coupler 2 (wire harness–front cowling wire harness) 20.Coupler 3 (wire harne...

  • Page 596: Immobilizer System

    Immobilizer system 8-119 et3p61013 circuit diagram (2/2) front cowling wire harness sb b lg br /r rb r r /g sb lg b sb /w br r /g r /g b /r r /b b (gray) b b /l (gray) b /w b b br /b b ( black ) b br /y ( black ) r /b b /r l /r b b b l /r b dg b ch b b b b b b b ch dg r /g b /wg /r sb b /l b /w w g ...

  • Page 597: Immobilizer System

    Immobilizer system 8-120 16.Coupler 1 (wire harness–front cowling wire harness) 19.Coupler 2 (wire harness–front cowling wire harness) 20.Coupler 3 (wire harness–front cowling wire harness) 54.Coupler 4 (wire harness–front cowling wire harness) 85.Immobilizer system indicator light 87.Multi-function...

  • Page 598: Immobilizer System

    Immobilizer system 8-121 eas27670 general information this vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) tha...

  • Page 599: Immobilizer System

    Immobilizer system 8-122 * accessory locks mean the seat lock and fuel tank cap. Code re-registering key registration: when the immobilizer unit or ecu is replaced, the code re-registering key must be registered to the unit. To register a code re-registering key: 1. Turn the main switch to “on” with...

  • Page 600: Immobilizer System

    Immobilizer system 8-123 standby mode standard key registration: standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ecu are replaced. Note: do not start the engine with a stand...

  • Page 601: Immobilizer System

    Immobilizer system 8-124 standard key registration voiding the standard key code: if a standard key has been lost, it is possible to disable its use by re-registering the remaining standard key. Standard key registration erases the stored standard key code from the memory, thus disabling the lost st...

  • Page 602: Immobilizer System

    Immobilizer system 8-125 eas27700 troubleshooting when the main switch is turned to “on”, the immobilizer system indicator light does not come on nor flashes. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ eas27720 self-diagnosis fault code indication when a system malfunction occurs, the fault code number...

  • Page 603: Immobilizer System

    Immobilizer system 8-126 immobilizer system indicator light fault code indication units of 10: cycles of on for 1 second and off for 1.5 seconds. Units of 1: cycles of on for 0.5 second and off for 0.5 second. Example: fault code 52 52 immobilizer unit codes between the key and immobilizer unit do n...

  • Page 604: Immobilizer System

    Immobilizer system 8-127 a. Light on b. Light off.

  • Page 605: Immobilizer System

    Immobilizer system 8-128.

  • Page 606: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-129 eas28790 abs (anti-lock brake system) eas27730 circuit diagram (1/2) (fjr1300a) r br /b r /wg /y b lg /w w /yb /g w /b br ( blue ) g /l w /b ( blue ) br /r br /r r br /l r br /l b b /w r r b b /g w (gray) ww r (black) b r /lr /l l/ wr /w (black) (dark green) r /g r...

  • Page 607: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-130 1. Main switch 4. Abs solenoid fuse 5. Abs ecu fuse 8. Main fuse 9. Battery 10.Abs motor fuse 11.Starter relay 16.Coupler 1 (wire harness–front cowling wire harness) 20.Coupler 3 (wire harness–front cowling wire harness) 22.Starting circuit cut-off relay 25.Abs tes...

  • Page 608: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-131 et3p61021 circuit diagram (2/2) (fjr1300a) front cowling wire harness sb b lg br /r rb r r /g sb lg b sb /w br r /g r /g b /r r /b b (gray) b b /l (gray) b /w b b br /b b ( black ) b br /y ( black ) r /b b /r l /r b b b l /r b dg b ch b b b b b b b ch dg r /g b /wg...

  • Page 609: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-132 16.Coupler 1 (wire harness–front cowling wire harness) 20.Coupler 3 (wire harness–front cowling wire harness) 54.Coupler 4 (wire harness–front cowling wire harness) 69.Front brake light switch 70.Engine stop switch 71.Start switch 86.Abs warning light 87.Multi-func...

  • Page 610: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-133 et3p66014 circuit diagram (1/2) (fjr1300as) r r br /r br /r r br /l r br /l b b /w r r b b /g w (gray) ww r (black) b r /lr /l l/ wr /w (black) r /g r /w g /b y /l b /w bb b y /l lg r /w r /g b2 br /l o /b o /w g /rg /bb /l g /r o /w o /b br /l b g /b w w r /lb (da...

  • Page 611: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-134 1. Main switch 4. Abs solenoid fuse 5. Abs ecu fuse 8. Main fuse 9. Battery 10.Abs motor fuse 11.Starter relay 14.Coupler 1 (wire harness–front cowling wire harness) 19.Starting circuit cut-off relay 22.Abs test coupler 23.Abs ecu (electronic control unit) 24.Front...

  • Page 612: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-135 et3p66015 circuit diagram (2/2) (fjr1300as) front cowling wire harness sb b lg br /r rb r r /g sb lg b sb /w br o /b g /b b /l g /r o /wb r/l o /w g /r b /l g /b o /bb r/l b /l br /l o /b o /w g /rg /b g /r o /w o /b br /l b g /b r /bl g/ w (black) r /g r /g ch r /...

  • Page 613: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-136 14.Coupler 1 (wire harness–front cowling wire harness) 27.Coupler 3 (wire harness–front cowling wire harness) 66.Coupler 5 (wire harness–front cowling wire harness) 89.Front brake light switch 90.Engine stop switch 91.Start switch 97.Abs warning light 98.Multi-func...

  • Page 614: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-137 eas27740 abs components chart 6 5 7 11 10 12,13 14 15 1 11 2 3,4 6 a a 7 8 9 1. Abs test coupler 2. Abs warning light 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 ...

  • Page 615: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-138.

  • Page 616: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-139 eas27750 abs coupler location chart fjr1300a b l/r l/b sb br/b r/y r/w g/l br l/r r/y br/b r/w l/r g/l br 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/lg/w p g/r g/b 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 ...

  • Page 617: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-140 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 618: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-141 fjr1300as 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 2 b l/r l/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...

  • Page 619: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-142 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 620: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-143 eas27770 maintenance of the abs ecu checking the abs ecu 1. Check: • terminals “1” of the abs ecu cracks/damages → replace the hydraulic unit assembly and the brake pipes that are connected to the assembly as a set. • terminals “2” of the abs ecu coupler connection...

  • Page 621: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-144 note: the abs performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the main switch was turned on. During this test, a “clicking” noise can be heard from under the seat, and if the brake lever or brake pedal are even slightly...

  • Page 622: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-145 eas27810 basic process for troubleshooting [a] turn the main switch to “on”, and check the abs warning light. [b-1] does the abs warning light fail to come on? [b-2] does the abs warning light flash? [b-3] does the abs warning light remain on? [b-4] does the abs wa...

  • Page 623: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-146 warning ew3p61011 when maintenance or checks have been performed on components related to the abs, be sure to perform a final check before delivering the vehicle to the customer. (refer to “[d-3] final check” on page 8-180.) eas27830 [a] checking the abs warning li...

  • Page 624: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-147 1. The fault code “1” is displayed on the multi-function display (example: fault code abs_11). 2. The abs warning light flashes every 0.5 second for more than 6 seconds. The abs warning light flashes every 0.5 second if a fault code for a past malfunction is not st...

  • Page 625: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-148 2. Disconnect the abs ecu coupler and check that the abs warning light comes on when the main switch is turned to “on”. • if the abs warning light does not come on, the meter assembly circuit (including the abs warning light [led]) is defective. Replace the meter a...

  • Page 626: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-149 • if there is no continuity, the front cowling wire harness or the wire harness is defective. Properly re- pair or replace the defective harness. 6. The meter assembly circuit is defective. • disconnect the abs ecu coupler. • the green/red terminal of the abs ecu c...

  • Page 627: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-150 abs_15 no continuity in the front wheel sensor circuit. • continuity of the front wheel sensor circuit • wire harness (abs circuit) • connection of the front wheel sensor cou- pler and abs ecu coupler • front wheel sensor abs_16 no continuity in the rear wheel sens...

  • Page 628: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-151 * a fault code is indicated if the rear wheel rotates for longer than about 20 seconds (fault code no. Abs_11) or for longer than about 2 seconds (fault code no. Abs_25) with the front wheel stopped (e.G., when the vehicle is on the centerstand). Note: fault codes ...

  • Page 629: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-152 note: with front wheel stopped, rear wheel was rotated for longer than about 20 seconds (fault code no. Abs_11) or for longer than about 2 seconds (fault code no. Abs_25). Fault code no. Abs_11 abs_25 symptom front wheel sensor signal is not received prop- erly. Or...

  • Page 630: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-153 fault code no. Abs_12 symptom rear wheel sensor signal is not received proper- ly. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 installed condition of wheel sensor. Check for looseness. Repair or replace the ...

  • Page 631: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-154 note: vehicle possibly ridden on uneven roads. Fault code no. Abs_13 abs_26 symptom incorrect signal from the front wheel sensor is detected. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 installed condition o...

  • Page 632: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-155 note: vehicle possibly ridden on uneven roads. Fault code no. Abs_14 abs_27 symptom incorrect signal from the rear wheel sensor is detected. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 installed condition of...

  • Page 633: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-156 2 wire harness continuity. • check for continuity between the white terminal “1” and the white terminal “3” and between the black terminal “2” and the black terminal “4”. • if there is no continuity, the wire harness is defective. Properly repair or replace the wir...

  • Page 634: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-157 3 defective wheel sensor. If the above items were per- formed and no malfunctions were found, connect the abs ecu coupler and front wheel sensor coupler, and then delete the fault codes. If fault code no. Abs_15 could not be deleted, the front wheel sensor is defec...

  • Page 635: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-158 2 wire harness continuity. • check for continuity between the gray terminal “1” and the gray terminal “3” and between the white terminal “2” and the white terminal “4”. • if there is no continuity, the wire harness is defective. Properly repair or replace the wire ...

  • Page 636: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-159 3 defective wheel sensor. If the above items were per- formed and no malfunctions were found, connect the abs ecu coupler and rear wheel sensor coupler, and then delete the fault codes. If fault code no. Abs_16 could not be deleted, the rear wheel sensor is defecti...

  • Page 637: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-160 fault code no. Abs_17 abs_45 symptom missing pulses detected in the front 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 s...

  • Page 638: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-161 fault code no. Abs_21 symptom hydraulic unit solenoid circuit is open or short- circuited. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 open or short circuit in solenoid cir- cuit. Replace the hydraulic unit ...

  • Page 639: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-162 fault code no. Abs_23 symptom brake light signal is not received properly when main switch is turned to “on” (brake light cir- cuit, or front or rear brake light switch circuit). Order item/components and probable cause check or maintenance job reinstatement confir...

  • Page 640: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-163 fault code no. Abs_24 symptom brake light signal is not received properly while vehicle is traveling (brake light circuit, or front or rear brake light switch circuit). Order item/components and probable cause check or maintenance job reinstatement confirmation met...

  • Page 641: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-164 fault code no. Abs_31 symptom solenoid relay is defective. Power is not supplied to the solenoid relay. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 battery voltage recharge or replace the battery. Refer to “...

  • Page 642: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-165 fault code no. Abs_32 symptom hydraulic unit solenoid relay is short-circuited. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 short circuit in solenoid relay. Replace the hydraulic unit as- sembly. • turn the ...

  • Page 643: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-166 fault code no. Abs_33 symptom abs motor is defective. Power is not supplied to the abs motor. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 battery voltage recharge or replace the battery. Refer to “checking a...

  • Page 644: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-167 fault code no. Abs_34 symptom hydraulic unit abs motor relay is short-circuit- ed. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 short circuit in abs motor relay. Replace the hydraulic unit as- sembly. • turn ...

  • Page 645: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-168 4 brake lines • check the brake lines for kinks and deterioration. Warning ewa3p6d005 only use genuine yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • check that the connections of the brake lines from the brake master cyli...

  • Page 646: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-169 warning ewa3p6d006 the front brakes will not function properly if the connections are reversed. • brake pipe/lower joint assembly “1” and brake pipe “2” inlet: from the front brake master cyl- inder • brake pipe/upper joint assembly “3” and brake pipe “4” outlet: t...

  • Page 647: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-170 fault code no. Abs_42 symptom rear wheel will not recover from the locking ten- dency even though the signal is continuously transmitted from the abs ecu to release the hy- draulic pressure. Order item/components and probable cause check or maintenance job reinstat...

  • Page 648: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-171 warning ewa3p6d007 the rear brake will not function properly if the connections are reversed. • brake pipe/middle joint assembly “1” and brake hose “2” inlet: from the rear brake master cyl- inder • brake pipe “3” outlet: to the proportioning valve • brake pipe “4”...

  • Page 649: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-172 fault code no. Abs_43 symptom incorrect signal from the front wheel sensor is detected. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 installed condition of wheel sensor. Check for looseness. Repair or replace...

  • Page 650: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-173 fault code no. Abs_44 symptom incorrect signal from the rear wheel sensor is detected. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 installed condition of wheel sensor. Check for looseness. Repair or replace ...

  • Page 651: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-174 fault code no. Abs_53 symptom power voltage is too low. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 battery voltage recharge or replace the battery. Refer to “checking and charging the battery” on page 3-44....

  • Page 652: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-175 fault code no. Abs_54 symptom power voltage is too low. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 battery voltage recharge or replace the battery. Refer to “checking and charging the battery” on page 3-44....

  • Page 653: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-176 fault code no. Abs_56 symptom hydraulic unit sensor power monitor circuit is abnormal. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 defective internal monitor circuit (sen- sor power). Replace the hydraulic u...

  • Page 654: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-177 fault code no. Abs_63 symptom front wheel sensor power is abnormal. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 short circuit in wire harness. • check that there is no short cir- cuit between the white termi...

  • Page 655: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-178 fault code no. Abs_64 symptom rear wheel sensor power is abnormal. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 short circuit in wire harness. • check that there is no short cir- cuit between the gray termina...

  • Page 656: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-179 et3p6d017 [d-1] deleting the fault codes 1. Connect the test coupler adapter “1” to the abs test coupler “2”. Refer to “[b-5] mal- function are currently detect- ed” on page 8-147. 2. Turn the main switch to “on”. Fault codes will be displayed in the multi- functio...

  • Page 657: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-180 b. Measure the abs ecu voltage. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 6. Check: • abs-ecu-to-start-switch-lead continuity no continuity → replace or repair the wire harness and front cowling wire harness. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼...

  • Page 658: Grip Warmer System

    Grip warmer system 8-181 et3p66016 grip warmer system et3p66017 circuit diagram (1/2) r br /b r /wg /y b lg /w w /yb /g w /b br ( blue ) g /l w /b ( blue ) br /r br /r r br /l r br /l b b /w r r b b /g w (gray) ww r (black) b r /lr /l l/ wr /w (black) (dark green) r /g r /w g /b y /l b /w bb b y /l ...

  • Page 659: Grip Warmer System

    Grip warmer system 8-182 1. Main switch 8. Main fuse 9. Battery 20.Coupler 3 (wire harness–front cowling wire harness) 44.Ecu (engine control unit) 54.Coupler 4 (wire harness–front cowling wire harness) 55.Headlight (on/off)/grip warmer relay 57.Signaling system fuse 58.Headlight fuse 61.Grip warmer...

  • Page 660: Grip Warmer System

    Grip warmer system 8-183 et3p66018 circuit diagram (2/2) front cowling wire harness sb b lg br /r rb r r /g sb lg b sb /w br r /g r /g b /r r /b b (gray) b b /l (gray) b /w b b br /b b ( black ) b br /y ( black ) r /b b /r l /r b b b l /r b dg b ch b b b b b b b ch dg r /g b /wg /r sb b /l b /w w g ...

  • Page 661: Grip Warmer System

    Grip warmer system 8-184 20.Coupler 3 (wire harness–front cowling wire harness) 54.Coupler 4 (wire harness–front cowling wire harness) 81.Left grip warmer 82.Right grip warmer.

  • Page 662: Grip Warmer System

    Grip warmer system 8-185 et3p66019 troubleshooting • the grip warmers do not become warm at all. • the grip warmers are abnormally hot while the engine is idling. • the grip warmers do not become very warm while the vehicle is traveling. Note: • before troubleshooting, remove the following part(s): ...

  • Page 663: Grip Warmer System

    Grip warmer system 8-186 ng → ok ↓ the grip warmers do not become very warm while the vehicle is traveling. Ng → ok ↓ ng → ok ↓ ng → ok ↓ 2. Disconnect the grip warmer control unit coupler (white/yellow and black/green) and check that the temperature does not drop while the engine is running. Replac...

  • Page 664: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-187 et3p66056 ycc-s (yamaha chip controlled-shift) system (fjr1300as only) et3p66057 circuit diagram (1/2) r r br /r br /r r br /l r br /l b b /w r r b b /g w (gray) ww r (black) b r /lr /l l/ wr /w (black) r /g r /w g /b y /l b /w bb b ...

  • Page 665: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-188 1. Main switch 8. Main fuse 9. Battery 14.Coupler 1 (wire harness–front cowling wire harness) 19.Starting circuit cut-off relay 23.Abs ecu (electronic control unit) 27.Coupler 3 (wire harness–front cowling wire harness) 29.Brake ligh...

  • Page 666: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-189 et3p66058 circuit diagram (2/2) front cowling wire harness sb b lg br /r rb r r /g sb lg b sb /w br o /b g /b b /l g /r o /wb r/l o /w g /r b /l g /b o /bb r/l b /l br /l o /b o /w g /rg /b g /r o /w o /b br /l b g /b r /bl g/ w (bla...

  • Page 667: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-190 14.Coupler 1 (wire harness–front cowling wire harness) 27.Coupler 3 (wire harness–front cowling wire harness) 60.Coupler 4 (wire harness–front cowling wire harness) 66.Coupler 5 (wire harness–front cowling wire harness) 68.Coupler 6 ...

  • Page 668: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-191 et3p66059 troubleshooting • the hand shift select indicator light fails to come on. • the transmission gear display on the multi-function meter fails to indicate the selected gear. Note: • before troubleshooting, remove the following...

  • Page 669: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-192 the transmission gear display on the multi-function meter fails to indicate the selected gear. Ng → ok ↓ ng → et3p66060 maintenance of the mcu checking the mcu 1. Check: • terminals “1” of the mcu cracks/damages → replace the mcu. • ...

  • Page 670: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-193 checking the ycc-s indicator and warning light the ycc-s indicator and warning light come on for 1.4 seconds after the main switch has been turned to “on” and they come on while the start switch is being pushed. If the ycc-s indicato...

  • Page 671: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-194 sh_ _13* overcurrent to clutch actuator motor detected current in clutch actuator motor is too high. Unable unable sh_ _14* overcurrent to shift actuator motor detected current in shift actuator motor is too high. Unable unable sh_ _...

  • Page 672: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-195 sh_ _31 engine speed signal is abnormal. Engine speed signal from ecu does not match multi-function meter engine speed. Unable unable sh_ _32* ycc-s speed sensor signal is abnormal. Ycc-s speed sensor signal does not match multi-func...

  • Page 673: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-196 *if the main switch is turned to “off”, the fault code number will disappear from the display and will not be displayed again when the main switch is turned back to “on”. Therefore, use the engine stop switch to stop the engine, not ...

  • Page 674: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-197 5. Erase the malfunction history in the diagnos- tic mode. Refer to “diagnostic code table (di- agnostic code no. Sh_ _62)”. Note: turning the main switch to “off” will not erase the malfunction history. Et3p66064 diagnostic mode set...

  • Page 675: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-198 6. Select the diagnostic code number corresponding to the fault code number by pushing the hand shift select button and operating the brake lever (or brake pedal) simultaneously. 7. Turn the main switch to “off” to cancel the diagnos...

  • Page 676: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-199 sh_ _62 malfunction history code erasure • no history sh_ _62 — • history exists 01–09 • first displays sh_ _62 for 6 seconds, and then displays the total number of malfunctions, including the cur- rent malfunction, that have oc- cur...

  • Page 677: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-200 sh_ _64 shift actuator opera- tion note: the checking meth- od for the diagnostic code (sh_ _64) can- not be performed when any of the fol- lowing fault codes are detected. Sh_ _11, sh_ _12, sh_ _14, sh_ _15, sh_ 16, sh_ _18, sh_ _19...

  • Page 678: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-201 sh_ _65 gear position setting sh_ _65 the gear position can be set in this mode. 1. Make sure that the transmission is in neutral. 2. Push the start switch. If the gear position sensor output signal is correct for the neutral positio...

  • Page 679: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-202 et3p66065 troubleshooting details this section describes the measures per fault code number displayed on the meter. Select diagnostic code no. Sh_ _61, and then confirm the fault code numbers in the malfunction history. Check and ser...

  • Page 680: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-203 fault code no. Sh_ _11 symptom too low or too high voltage is supplied to the ycc-s system. Order item/components and probable cause check or maintenance job reinstatement method 1 connections • wire harness mcu (motor control unit) ...

  • Page 681: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-204 note: if the main switch is turned to “off”, the fault code number will disappear from the display and will not be displayed again when the main switch is turned back to “on”. Therefore, use the engine stop switch to stop the engine,...

  • Page 682: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-205 note: if the main switch is turned to “off”, the fault code number will disappear from the display and will not be displayed again when the main switch is turned back to “on”. Therefore, use the engine stop switch to stop the engine,...

  • Page 683: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-206 note: if the main switch is turned to “off”, the fault code number will disappear from the display and will not be displayed again when the main switch is turned back to “on”. Therefore, use the engine stop switch to stop the engine,...

  • Page 684: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-207 note: if the main switch is turned to “off”, the fault code number will disappear from the display and will not be displayed again when the main switch is turned back to “on”. Therefore, use the engine stop switch to stop the engine,...

  • Page 685: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-208 note: if the main switch is turned to “off”, the fault code number will disappear from the display and will not be displayed again when the main switch is turned back to “on”. Therefore, use the engine stop switch to stop the engine,...

  • Page 686: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-209 note: if the main switch is turned to “off”, the fault code number will disappear from the display and will not be displayed again when the main switch is turned back to “on”. Therefore, use the engine stop switch to stop the engine,...

  • Page 687: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-210 note: if the main switch is turned to “off”, the fault code number will disappear from the display and will not be displayed again when the main switch is turned back to “on”. Therefore, use the engine stop switch to stop the engine,...

  • Page 688: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-211 fault code no. Sh_ _21 symptom output signal of gear position 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 ...

  • Page 689: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-212 fault code no. Sh_ _22 symptom output signal of foot shift switch is abnormal. Order item/components and probable cause check or maintenance job reinstatement method 1 connections • wire harness mcu (motor control unit) coupler • foo...

  • Page 690: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-213 note: if the main switch is turned to “off”, the fault code number will disappear from the display and will not be displayed again when the main switch is turned back to “on”. Therefore, use the engine stop switch to stop the engine,...

  • Page 691: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-214 note: if the main switch is turned to “off”, the fault code number will disappear from the display and will not be displayed again when the main switch is turned back to “on”. Therefore, use the engine stop switch to stop the engine,...

  • Page 692: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-215 note: if the main switch is turned to “off”, the fault code number will disappear from the display and will not be displayed again when the main switch is turned back to “on”. Therefore, use the engine stop switch to stop the engine,...

  • Page 693: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-216 fault code no. Sh_ _35 symptom start 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 • relay unit coupler...

  • Page 694: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-217 note: if the main switch is turned to “off”, the fault code number will disappear from the display and will not be displayed again when the main switch is turned back to “on”. Therefore, use the engine stop switch to stop the engine,...

  • Page 695: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-218 fault code no. Sh_ _38 symptom malfunction of hand shift lever switch (shift up or shift down). Order item/components and probable cause check or maintenance job reinstatement method 1 connections • wire harness mcu (motor control un...

  • Page 696: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-219 fault code no. Sh_ _41 symptom coolant temperature sensor signal is abnormal. Order item/components and probable cause check or maintenance job reinstatement method 1 connections • wire harness mcu (motor control unit) coupler • wire...

  • Page 697: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-220 note: if the main switch is turned to “off”, the fault code number will disappear from the display and will not be displayed again when the main switch is turned back to “on”. Therefore, use the engine stop switch to stop the engine,...

  • Page 698: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-221 note: if the main switch is turned to “off”, the fault code number will disappear from the display and will not be displayed again when the main switch is turned back to “on”. Therefore, use the engine stop switch to stop the engine,...

  • Page 699: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-222 note: if the main switch is turned to “off”, the fault code number will disappear from the display and will not be displayed again when the main switch is turned back to “on”. Therefore, use the engine stop switch to stop the engine,...

  • Page 700: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-223 note: if the main switch is turned to “off”, the fault code number will disappear from the display and will not be displayed again when the main switch is turned back to “on”. Therefore, use the engine stop switch to stop the engine,...

  • Page 701: Only)

    Ycc-s (yamaha chip controlled-shift) system (fjr1300as only) 8-224 note: if the main switch is turned to “off”, the fault code number will disappear from the display and will not be displayed again when the main switch is turned back to “on”. Therefore, use the engine stop switch to stop the engine,...

  • Page 702: Electrical Components

    Electrical components 8-225 eas27970 electrical components fjr1300a 1 18 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17.

  • Page 703: Electrical Components

    Electrical components 8-226 1. Windshield drive unit 2. Battery 3. Starter relay 4. Abs motor 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. R...

  • Page 704: Electrical Components

    Electrical components 8-227 fjr1300a 5 1 3 2 17 8 10 11 12 13 14 15 16 7 6 4 9.

  • Page 705: Electrical Components

    Electrical components 8-228 1. Coolant temperature sensor 2. Throttle position sensor 3. Intake air pressure sensor 4. Brake light relay 5. 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. ...

  • Page 706: Electrical Components

    Electrical components 8-229 fjr1300as 13 16 18 17 2 3 4 5 6 7 8 1 9 10 11 12 15 14 19.

  • Page 707: Electrical Components

    Electrical components 8-230 1. Windshield drive unit 2. Battery 3. Starter relay 4. Abs motor 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. Re...

  • Page 708: Electrical Components

    Electrical components 8-231 fjr1300as 1 19 3 2 5 7 9 8 12 13 14 15 16 11 10 18 17 6 4.

  • Page 709: Electrical Components

    Electrical components 8-232 1. Coolant temperature sensor 2. Throttle position sensor 3. Intake air pressure sensor 4. Brake light relay 5. Intake air temperature sensor 6. Lean angle sensor 7. Hydraulic unit assembly 8. Mcu (motor control unit) 9. Ecu (engine control unit) 10. Relay unit 11. Ycc-s ...

  • Page 710: Electrical Components

    Electrical components 8-233 eas27980 checking the switches fjr1300a l/y b/y 1 r br/l br/r on off p br/l br/r r 2 (brown) b b 3 p b lg sb br/w l/b ch dg b/y y r/y l/y lg b sb up down 13 dg br/w ch 14 b p 10 12 r/y y 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 (...

  • Page 711: Electrical Components

    Electrical components 8-234 1. Front brake light 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. Pass switch 13. Windshield position switch 14. T...

  • Page 712: Electrical Components

    Electrical components 8-235 fjr1300as 1 r br/l br/r on off p br/l br/r r 2 (brown) (black) b b 3 lg b sb up down 15 dg br/w ch 16 b p 12 14 r/y y r/y l/b 13 b br/w ch dg r/b r/w g/y l/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 ...

  • Page 713: Electrical Components

    Electrical components 8-236 1. Front brake light switch 2. Main switch 3. Rear brake light 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) 1...

  • Page 714: Electrical Components

    Electrical components 8-237 check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Caution: eca14370 never insert the tester probes into the coupler terminal slots “a”. Always insert the prob...

  • Page 715: Electrical Components

    Electrical components 8-238 eas27990 checking the bulbs and bulb sockets note: do not check any of the lights that use leds. Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or...

  • Page 716: Electrical Components

    Electrical components 8-239 checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) no continuity → replace. Note: check each bulb socket for continuity in the same manner as described in...

  • Page 717: Electrical Components

    Electrical components 8-240 cal system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Install: • front cowling right inner panel 1 refer to “general chassis” on page 4-1. Eas28030 checking and charging the...

  • Page 718: Electrical Components

    Electrical components 8-241 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5. Charge: • battery (refer to the appropriate charging method) warning ewa13300 do not quick charge a battery. Caution: eca13670 • never remove the mf battery sealing caps. • do not use a high-rate battery charger since i...

  • Page 719: Electrical Components

    Electrical components 8-242 b. Connect a charger and ammeter to the bat- tery and start charging. Note: set the charging voltage to 16–17 v. If the set- ting is lower, charging will be insufficient. If too high, the battery will be over-charged. C. Make sure that the current is higher than the stand...

  • Page 720: Electrical Components

    Electrical components 8-243 eas28040 checking the relays check each switch for continuity with the pocket tester. If the continuity reading is incorrect, re- place the relay. 1. Disconnect the relay from the wire harness. 2. Connect the pocket tester ( Ω × 1) and battery (12 v) to the relay terminal...

  • Page 721: Electrical Components

    Electrical components 8-244 headlight relay (dimmer) first step: second step: brake light relay first step: second step: 1. Positive tester probe 2. Negative tester probe 3. Negative tester probe result continuity (between “1” and “2”) no continuity (between “1” and “3”) 1. Positive battery terminal...

  • Page 722: Electrical Components

    Electrical components 8-245 ycc-s control relay (fjr1300as) first step: second step: radiator fan motor relay et3p61014 checking the turn signal/hazard relay 1. Check: • turn signal/hazard relay input voltage out of specification → the wiring circuit from the main switch to the turn signal/hazard re...

  • Page 723: Electrical Components

    Electrical components 8-246 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester (dc 20 v) to the turn signal/hazard relay terminal as shown. B. Turn the main switch to “on”. C. Measure the turn signal/hazard relay output voltage. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲...

  • Page 724: Electrical Components

    Electrical components 8-247 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the relay unit coupler from the wire harness. B. Connect the pocket tester ( Ω × 1) to the relay unit terminal as shown. C. Check the relay unit (diode) for continuity. D. Check the relay unit (diode) for no ...

  • Page 725: Electrical Components

    Electrical components 8-248 c. Measure the secondary coil resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ et3p61015 checking the ignition spark gap 1. Check: • ignition spark gap out of specification → perform the ignition system troubleshooting, starting with step 5. Refer to “trouble...

  • Page 726: Electrical Components

    Electrical components 8-249 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the lean angle sensor coupler to the wire harness. B. Connect the pocket tester (dc 20 v) to the lean angle sensor coupler as shown. C. Turn the main switch to “on”. D. Turn the lean angle sensor to 65°. E. Meas...

  • Page 727: Electrical Components

    Electrical components 8-250 b. Measure the stator coil resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28170 checking the rectifier/regulator 1. Check: • charging voltage out of specification → replace the rectifi- er/regulator. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. S...

  • Page 728: Electrical Components

    Electrical components 8-251 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28190 checking the oil level switch 1. Drain: • engine oil 2. Remove: • oil level switch (from the oil pan) 3. Check: • oil level switch continuity out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...

  • Page 729: Electrical Components

    Electrical components 8-252 b. Move the fuel sender float to minimum “3” and maximum “4” level position. C. Measure the fuel sender resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28250 checking the radiator fan motors the following procedure applies to both of the radiator fan moto...

  • Page 730: Electrical Components

    Electrical components 8-253 eas28300 checking the throttle position sensor 1. Remove: • throttle position sensor (from the throttle body) 2. Check: • throttle position sensor maximum resistance out of specification → replace the throttle position sensor. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 731: Electrical Components

    Electrical components 8-254 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester (dc 20 v) to the cylinder identification sensor coupler (wire harness side) as shown. B. Turn the main switch to “on”. C. Rotate the crankshaft. D. Measure the voltage of white/black and black/...

  • Page 732: Electrical Components

    Electrical components 8-255 b. Immerse the intake air temperature sensor “1” in a container filled with water “2”. Note: make sure that the intake air temperature sensor terminals do not get wet. C. Place a thermometer “3” in the water. D. Slowly heat the water, then let it cool down to the specifie...

  • Page 733: Electrical Components

    Electrical components 8-256 et3p66024 checking the grip warmer control unit 1. Check: • grip warmer control unit continuity out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the grip warmer control unit cou- plers from the front cowling wire harness. B. ...

  • Page 734: Electrical Components

    Electrical components 8-257 2. Check: • gear position sensor maximum resistance out of specification → replace the gear posi- tion sensor. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester ( Ω × 1k) to the gear position sensor terminals as shown. B. Measure the gear posi...

  • Page 735: Electrical Components

    Electrical components 8-258 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the 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. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲...

  • Page 736: Electrical Components

    Electrical components 8-259.

  • Page 737: Troubleshooting

    9 troubleshooting troubleshooting..................................................................................... 9-1 general information ....................................................................... 9-1 starting failures...................................................................

  • Page 738: Troubleshooting

    Troubleshooting 9-1 eas28450 troubleshooting eas28460 general information note: the following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic trouble- shooting. Refer to the relative procedure in this manual for checks, ...

  • Page 739: Troubleshooting

    Troubleshooting 9-2 fuel system 1. Throttle body(-ies) • damaged or loose throttle body joint • improperly synchronized throttle bodies • improperly adjusted engine idling speed (throttle stop screw) • improper throttle cable free play • flooded throttle body • faulty air induction system electrical...

  • Page 740: Troubleshooting

    Troubleshooting 9-3 • burnt primary driven gear bushing • damaged clutch release cylinder • match marks not aligned 2. Engine oil • incorrect oil level • incorrect oil viscosity (high) • deteriorated oil eas28600 overheating engine 1. Clogged coolant passages • cylinder head and piston(s) • heavy ca...

  • Page 741: Troubleshooting

    Troubleshooting 9-4 • improperly installed lower bracket (improperly tightened ring nut) • bent steering stem • damaged ball bearing or bearing race 2. Front fork leg(s) • uneven oil levels (both front fork legs) • unevenly tensioned fork spring (both front fork legs) • broken fork spring • bent or ...

  • Page 742: Wiring Diagram

    Eas28740 wiring diagram fjr1300a(x) 2008 1. Main switch 2. Rectifier/regulator 3. Ac magneto 4. Abs solenoid fuse 5. Abs ecu fuse 6. Fuel injection system fuse 7. Backup fuse (odometer, clock, immobilizer system, and wind- shield drive system) 8. Main fuse 9. Battery 10. Abs motor fuse 11. Starter r...

  • Page 743: Wiring Diagram

    Et3p66050 wiring diagram fjr1300as(x) 2008 1. Main switch 2. Rectifier/regulator 3. Ac magneto 4. Abs solenoid fuse 5. Abs ecu fuse 6. Fuel injection system fuse 7. Backup fuse (odometer, clock, immobilizer system, and wind- shield drive system) 8. Main fuse 9. Battery 10. Abs motor fuse 11. Starter...

  • Page 744

    R/g red/green r/l red/blue r/w red/white r/y red/yellow sb/w sky blue/white w/b white/black w/l white/blue w/y white/yellow y/b yellow/black y/g yellow/green y/l yellow/blue y/w yellow/white.

  • Page 746

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

  • Page 747

    Fjr1300a(x) 2008 wiring diagram (1/2) fjr1300a(x) 2008 schÉma de cblage (1/2) fjr1300a(x) 2008 schaltplan (1/2) fjr1300a(x) 2008 schema elettrico (1/2) fjr1300a(x) 2008 diagrama elÉctrico (1/2) r r br/r br/r r br/l r br/l b b/w r r b b/g w (gray) w w r (black) b r/l r/l l/w r/w (black) (dark green) ...

  • Page 748

    Fjr1300a(x) 2008 wiring diagram (2/2) front cowling wire harness fjr1300a(x) 2008 schÉma de cblage (2/2) faisceau de fils au carénage avant fjr1300a(x) 2008 schaltplan (2/2) frontverkleidungs-kabelbaum fjr1300a(x) 2008 schema elettrico (2/2) cablaggio elettrico del cupolino fjr1300a(x) 2008 diagrama...

  • Page 749

    Fjr1300a(x) 2008 wiring diagram (1/2) fjr1300a(x) 2008 schÉma de cblage (1/2) fjr1300a(x) 2008 schaltplan (1/2) fjr1300a(x) 2008 schema elettrico (1/2) fjr1300a(x) 2008 diagrama elÉctrico (1/2) (gray) (black) (black) (dark green) (black) (black) (black) (black) (blue) (brown) (blue) (brown) (blue) (...

  • Page 750

    Fjr1300a(x) 2008 wiring diagram (2/2) front cowling wire harness fjr1300a(x) 2008 schÉma de cblage (2/2) faisceau de fils au carénage avant fjr1300a(x) 2008 schaltplan (2/2) frontverkleidungs-kabelbaum fjr1300a(x) 2008 schema elettrico (2/2) cablaggio elettrico del cupolino fjr1300a(x) 2008 diagrama...

  • Page 751

    Fjr1300as(x) 2008 wiring diagram (1/2) fjr1300as(x) 2008 schÉma de cblage (1/2) fjr1300as(x) 2008 schaltplan (1/2) fjr1300as(x) 2008 schema elettrico (1/2) fjr1300as(x) 2008 diagrama elÉctrico (1/2) r r br/r br/r r br/l r br/l b b/w r r b b/g w (gray) w w r (black) b r/l r/l l/w r/w (black) r/g r/w ...

  • Page 752

    Fjr1300as(x) 2008 wiring diagram (2/2) front cowling wire harness fjr1300as(x) 2008 schÉma de cblage (2/2) faisceau de fils au carénage avant fjr1300as(x) 2008 schaltplan (2/2) frontverkleidungs-kabelbaum fjr1300as(x) 2008 schema elettrico (2/2) cablaggio elettrico del cupolino fjr1300as(x) 2008 dia...

  • Page 753

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