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Yamaha FJR13AEV(C) Service Manual

Other manuals for FJR13AEV(C): Owner's Manual

Summary of FJR13AEV(C)

  • Page 1

    Service manual fjr13av(c) fjr13aev(c) lit-11616-19-83 3p6-28197-10

  • Page 2

    Eas20050 fjr13av(c)/fjr13aev(c) service manual ©2006 by yamaha motor corporation, u.S.A. First edition, april 2006 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor corporation, u.S.A. Is expressly prohibited. Printed in u.S.A. P/n lit-11616-19-...

  • Page 3

    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

    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

    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 lt new t r . . 1 2 3 4 5 6 7 8 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Special tool ...

  • 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, 46.1 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 warning ewa13870 the abs controls only the tendency of the wheel to lock caused by applying the brakes. The abs cannot prevent wheel lock on slippery surfaces, such as ice, when it is caused by engine braking, even if the abs is operating. Electronic abs features the yamaha abs (anti-lo...

  • 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 speed and transmit the rotation signal to the abs ecu. Each wheel sensor is composed of a permanent magnet and a coil. The wheel sensors are installed in the sen...

  • 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 when the abs is activated, the flow control valve regulates the flow of brake fluid to the brake and the solenoid valve decreases and increases the brake fluid pressure. 1. When the brakes are operated normally, the solenoid valve “2” is closed, the spool “3” of the flow control valve ...

  • Page 22: Features

    Features 1-13 abs ecu (electronic control unit) the abs ecu “1” controls the abs and is installed under the storage compartment. To protect the abs ecu from water damage, it is protected by a cover “2”. As shown in the block following diagram, the abs ecu receives wheel sensor signals from the front...

  • Page 23: Features

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

  • Page 24: Features

    Features 1-15 abs motor relay the abs motor relay “1” controls the power supply of the hydraulic unit and is located beside the hy- draulic unit. Composition and operation the abs motor relay is activated by signals transmitted from the abs ecu and the abs motor oper- ates when the abs starts to red...

  • Page 25: Features

    Features 1-16 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. 12 14 1 11 10 2 3 4 5 6 7 8 9 13 1. Abs ecu 2. Pump motor monitor 3. Power supp...

  • Page 26: Features

    Features 1-17 normal braking (abs not activated) when the abs is not activated, port d “11” of the solenoid valve is closed because a control signal has not been transmitted from the abs ecu and port a “7” and port b “9” of the flow control valve are open. Therefore, when the brake lever is squeezed...

  • Page 27: Features

    Features 1-18 emergency braking (abs activated) 1. Depressurized state when the front wheel is about to lock, port d “11” of the solenoid valve is opened by the “depressur- ization” signal transmitted from the abs ecu. When this occurs, the spool of the flow control valve compresses the return sprin...

  • Page 28: Features

    Features 1-19 2. Pressurized state port d “11” is closed by the “pressurization” signal transmitted from the abs ecu. Before this oc- curs, the spool of the flow control valve has compressed the return spring and closed port b “9”. Brake fluid that has entered through port a “7” is further restricte...

  • Page 29: Features

    Features 1-20 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. Instances when the abs warning light comes on 1. The abs warning light comes on when the main switch...

  • Page 30: Features

    Features 1-21 3. The abs warning light comes on while riding. If the abs warning light comes on while riding, a malfunction has been detected in the abs. The abs hydraulic control will not be performed. The abs will have recourse to manual braking if this occurs. 4. The abs warning light flashes whi...

  • Page 31: Features

    Features 1-22 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 32: Features

    Features 1-23 • 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 33: Features

    Features 1-24 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 34: Features

    Features 1-25 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 35: Features

    Features 1-26 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 36: Features

    Features 1-27 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 37: Features

    Features 1-28 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 after the other and then disappear in orde...

  • Page 38: Features

    Features 1-29 instantaneous fuel consumption mode the display shows the distance that can be trav- eled on 1.0 us.Gal of fuel under the current riding conditions. Note: 1. If traveling at speeds under 10 km/h (6.0 mi/h), “_ _._ ” will be displayed. Average fuel consumption mode this display shows th...

  • 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 slide metal installer 90890-01508 ym-01508 4-79 fork seal driver 90890-01502 ym-a0948 4-79, 4-80 final gear backlash band 90890-01511 ym-01230 4-101 coupling gear/middle shaft tool 90890-01229 gear holder ym-01229 4-103, 4-106 bearing retainer wrench 90890-04050 pinion bearing ret...

  • Page 45: Special Tools

    Special tools 1-36 pivot shaft wrench adapter 90890-01476 5-8, 5-9 digital circuit tester 90890-03174 model 88 multimeter with tachometer yu-a1927 5-11, 5-70, 7-9 rotor holding tool 90890-01235 universal magneto & rotor holder yu-01235 5-14, 5-17 yamaha bond no. 1215 90890-85505 (three bond no.1215 ...

  • Page 46: Special Tools

    Special tools 1-37 valve guide reamer (ø5) 90890-04099 valve guide reamer (5.0 mm) ym-04099 5-26 sheave holder 90890-01701 primary clutch holder ys-01880-a 5-34, 5-35, 5-38 flywheel puller 90890-01362 heavy duty puller yu-33270-b 5-34 universal clutch holder 90890-04086 ym-91042 5-56, 5-59 thickness...

  • Page 47: Special Tools

    Special tools 1-38 gear lash measurement tool 90890-01467 ym-01467 5-91 piston pin puller set 90890-01304 piston pin puller yu-01304 5-105 piston ring compressor 90890-05158 ym-08037 5-110 slide hammer bolt 90890-01083 slide hammer bolt 6 mm yu-01083-1 5-123 weight 90890-01084 yu-01083-3 5-123 radia...

  • Page 48: Special Tools

    Special tools 1-39 radiator cap tester adapter 90890-01352 radiator pressure tester adapter yu-33984 6-3 mechanical seal installer 90890-04078 water pump seal installer ym-33221-a 6-13 middle driven shaft bearing driver 90890-04058 bearing driver 40 mm ym-04058 6-13 pressure gauge 90890-03153 yu-031...

  • Page 49: Specifications

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

  • Page 50: General Specifications

    General specifications 2-1 eas20280 general specifications model model fjr13a 3p64 (usa) fjr13a 3p65 (california) fjr13ae 2d24 (usa) fjr13ae 2d25 (california) dimensions overall length 2230 mm (87.8 in) overall width 750 mm (29.5 in) overall height 1450 mm (57.1 in) seat height 800 mm (31.5 in) whee...

  • Page 51: Engine Specifications

    Engine specifications 2-2 eas20290 engine specifications engine engine type liquid cooled 4-stroke, dohc displacement 1298.0 cm³ (79.20 cu.In) 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 press...

  • Page 52: Engine Specifications

    Engine specifications 2-3 coolant reservoir capacity (up to the maximum level mark) 0.25 l (0.26 us qt) (0.22 imp.Qt) radiator cap opening pressure 93.3–122.7 kpa (13.5–17.8 psi) (0.93–1.23 kgf/cm²) valve relief pressure 4.9 kpa (0.7 psi) (0.05 kgf/cm²) thermostat model/manufacturer 4fm/nippon therm...

  • Page 53: 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 54: Engine Specifications

    Engine specifications 2-5 valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) limit 0.080 mm (0.0032 in) 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 se...

  • Page 55: 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 56: Engine Specifications

    Engine specifications 2-7 connecting rod oil clearance (using plastigauge ® ) 0.031–0.048 mm (0.0012–0.0019 in) bearing color code 1.Blue 2.Black 3.Brown 4.Green 5.Yellow 6.Pink 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 3...

  • Page 57: Engine Specifications

    Engine specifications 2-8 2nd 39/22 (1.773) 3rd 31/23 (1.348) 4th 28/26 (1.077) 5th 26/28 (0.929) main axle runout limit 0.08 mm (0.0032 in) 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 (0.003...

  • Page 58: Engine Specifications

    Engine specifications 2-9 ring-gear-to-stopper-bolt clearance 0.30–0.60 mm (0.0118–0.0236 in) ring-gear-to-thrust-washer clearance 0.10–0.20 mm (0.0039–0.0079 in) final gear backlash 0.22–0.45 mm (0.0087–0.0177 in).

  • Page 59: Chassis Specifications

    Chassis specifications 2-10 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 60: Chassis Specifications

    Chassis specifications 2-11 front brake type dual disc brake operation right hand operation 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 (inne...

  • Page 61: Chassis Specifications

    Chassis specifications 2-12 spring rate k1 8.30 n/mm (47.39 lb/in) (0.85 kgf/mm) spring stroke k1 0.0–135.0 mm (0.00–5.31 in) inner tube outer diameter 48.0 mm (1.89 in) inner tube bending limit 0.2 mm (0.01 in) optional spring available no recommended oil ohlins r & t43 (acc-rt43f-00-00) quantity 6...

  • Page 62: Electrical Specifications

    Electrical specifications 2-13 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 fua0010/mitsubishi ignition coil model/manufacturer j...

  • Page 63: Electrical Specifications

    Electrical specifications 2-14 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 electric starting system system type constant mesh starter motor model/manufactu...

  • Page 64: Electrical Specifications

    Electrical specifications 2-15 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/manufacturer acm33211 m05/matsushita coil resistance 96.0 Ω thermo unit model/manufacturer 25978/mit...

  • Page 65: Tightening Torques

    Tightening torques 2-16 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 66: Tightening Torques

    Tightening torques 2-17 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 67: Tightening Torques

    Tightening torques 2-18 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 68: Tightening Torques

    Tightening torques 2-19 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, 7.2 ft·lb) clutch hose union bolt m10 1 30 nm (3.0 m·k...

  • Page 69: Tightening Torques

    Tightening torques 2-20 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 70: Tightening Torques

    Tightening torques 2-21 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 71: Tightening Torques

    Tightening torques 2-22 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 72: Tightening Torques

    Tightening torques 2-23 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 73: Tightening Torques

    Tightening torques 2-24 rear lower fuel tank bracket and frame bolt m6 4 8 nm (0.8 m·kg, 5.8 ft·lb) fuel tank cap bolt m5 3 6 nm (0.6 m·kg, 4.3 ft·lb) canister bolt (for california only) m6 2 7 nm (0.7 m·kg, 5.1 ft·lb) canister bracket bolt (for califor- nia only) m6 2 10 nm (1.0 m·kg, 7.2 ft·lb) st...

  • Page 74: Tightening Torques

    Tightening torques 2-25 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 75: Tightening Torques

    Tightening torques 2-26 3. Check that the right end of the front axle is flush with the front fork. If necessary, manually push the front axle or lightly tap it with a soft hammer until its end is flush with the front fork. However, if the surface of the front axle end is not parallel to the surface...

  • Page 76

    Lubrication points and lubricant types 2-27 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 77

    Lubrication points and lubricant types 2-28 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 78

    Lubrication points and lubricant types 2-29 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 79

    Lubrication points and lubricant types 2-30

  • Page 80

    Lubrication system chart and diagrams 2-31 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

    Lubrication system chart and diagrams 2-32 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

    Lubrication system chart and diagrams 2-33 eas20410 lubrication diagrams 5 6 7 1 2 3 4.

  • Page 83

    Lubrication system chart and diagrams 2-34 1. Intake camshaft 2. Cylinder head 3. Exhaust camshaft 4. Oil check bolt 5. Main gallery bolt 6. Crankshaft 7. Oil nozzle.

  • Page 84

    Lubrication system chart and diagrams 2-35 1 3 2.

  • Page 85

    Lubrication system chart and diagrams 2-36 1. Main axle 2. Drive axle 3. Oil delivery pipe 1.

  • Page 86

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

  • Page 87

    Lubrication system chart and diagrams 2-38 1. Oil check bolt 2. Crankshaft 3. Oil cooler 4. Oil strainer 5. Oil delivery pipe 3 6. Oil pump.

  • Page 88

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

  • Page 89

    Lubrication system chart and diagrams 2-40 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

    Lubrication system chart and diagrams 2-41 4 5 3 2 1 9 8 6 7.

  • Page 91

    Lubrication system chart and diagrams 2-42 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 2-43 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 2-44 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 2-45 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 2-46 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 (Fjr13A)

    Cable routing (fjr13a) 2-47 eas20430 cable routing (fjr13a) b-b a a b b a b c d e f g g g h i j k l 1 1 1 2 2 2 2 3 3 3 4 4 4 5 5 5 6 7 8 9 10 10 11 11 10 11 12 13 14 15 16 17 18 19 19 19 20 20 20 1 2 3 l.

  • Page 97: Cable Routing (Fjr13A)

    Cable routing (fjr13a) 2-48 1. Brake hose (front brake master cylinder to hydraulic unit) 2. Right handlebar switch lead 3. Clutch hose 4. Left handlebar switch lead 5. Main switch lead 6. Left horn (low) 7. Brake hose (hydraulic unit to left front brake caliper) 8. Front wheel sensor lead 9. Brake ...

  • Page 98: Cable Routing (Fjr13A)

    Cable routing (fjr13a) 2-49 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 27 27 28 29 29 30 31 32 33 34 35 36 37 38 d f g m n s 27 29 29 18 h c-c b-b 5 18 18 q r 39 41 o p 11 c 40 c b b.

  • Page 99: Cable Routing (Fjr13A)

    Cable routing (fjr13a) 2-50 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. Fuse...

  • Page 100: Cable Routing (Fjr13A)

    Cable routing (fjr13a) 2-51 a b c d e 1 1 2 3 4 5 6 7 8 9 11 10 12.

  • Page 101: Cable Routing (Fjr13A)

    Cable routing (fjr13a) 2-52 1. Rear wheel sensor lead 2. Rear brake fluid reservoir 3. Rear brake light switch lead 4. Hydraulic unit 5. Brake hose (front brake master cylinder to hydraulic unit) 6. Brake hose (hydraulic unit to proportioning valve) 7. Brake hose (hydraulic unit to metering valve) 8...

  • Page 102: Cable Routing (Fjr13A)

    Cable routing (fjr13a) 2-53 a b c d 1 2 3 4 6 5 7 8 9 10 11 12.

  • Page 103: Cable Routing (Fjr13A)

    Cable routing (fjr13a) 2-54 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. Left radiator fan 8. Coolant reservoir breather hose 9. Left horn (low) 10. Left horn (low) leads 11. Thermostat assembly...

  • Page 104: Cable Routing (Fjr13A)

    Cable routing (fjr13a) 2-55 a-a b c c a a a b c d f e h i j k 1 2 9 10 12 13 g 7 3 5 4 26 27 28 29 5 5 x 6 p q r s t u v w 22 23 24 25 15 21 14 8 l m n o 16 17 18 19 20 8 11 34 30 33 d b y z 15 7 32 30 31 d aa ab.

  • Page 105: Cable Routing (Fjr13A)

    Cable routing (fjr13a) 2-56 1. Grip warmer couplers (for optional grip warmers) 2. Handlebar switch couplers 3. Right handlebar switch lead 4. Main switch lead 5. Clutch hose 6. Left handlebar switch lead 7. Stator coil lead 8. Fuel tank breather hose (joint to rollover valve) (for california only) ...

  • Page 106: Cable Routing (Fjr13A)

    Cable routing (fjr13a) 2-57 a-a b-b c c b b a a a b c e d f g h i j k 2 2 1 1 4 4 4 5 5 5 6 7 8 9 10 11 12 13 3 3 3 14 15 16 17 16 17 18 19 20 21 22.

  • Page 107: Cable Routing (Fjr13A)

    Cable routing (fjr13a) 2-58 1. Wire harness 2. Ecu (engine control unit) 3. Abs ecu (electronic 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. Hydraulic unit breather hose 10. Stator coil lead 11. Rear s...

  • Page 108: Cable Routing (Fjr13A)

    Cable routing (fjr13a) 2-59 b e a c d f g h i j k l m n 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 32 31 30 f.

  • Page 109: Cable Routing (Fjr13A)

    Cable routing (fjr13a) 2-60 1. Spark plug lead #1 2. Spark plug lead #2 3. Clutch hose 4. Front wheel sensor lead 5. Main switch lead 6. Throttle cable (accelerator cable) 7. Throttle cable (decelerator cable) 8. Brake hose (hydraulic unit to front brake calipers) 9. Brake hose (metering valve to ri...

  • Page 110: Cable Routing (Fjr13A)

    Cable routing (fjr13a) 2-61 d a b b c e 1 2 3 4.

  • Page 111: Cable Routing (Fjr13A)

    Cable routing (fjr13a) 2-62 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 leads...

  • Page 112: Cable Routing (Fjr13A)

    Cable routing (fjr13a) 2-63 a a a b c d e p f h i j k l m n q r 1 2 3 4 5 6 9 10 11 13 14 15 16 g 7 8 o 12.

  • Page 113: Cable Routing (Fjr13A)

    Cable routing (fjr13a) 2-64 1. Windshield drive unit 2. Relay unit 3. Thermistor 4. Windshield drive unit lead 5. Meter assembly lead 6. Headlight relay (dimmer) 7. Left headlight beam adjusting cable 8. Left auxiliary light lead 9. Left headlight lead 10. Lean angle sensor 11. Right headlight lead ...

  • Page 114: Cable Routing (Fjr13A)

    Cable routing (fjr13a) 2-65 c-c a b a b c c a b j c d f g g i 1 1 1 1 2 2 2 3 3 3 3 4 4 4 4 4 5 5 5 6 6 6 7 7 7 8 8 8 9 9 8 9 10 10 10 10 12 11 12 17 17 13 13 17 13 14 16 15 16 e h 11.

  • Page 115: Cable Routing (Fjr13A)

    Cable routing (fjr13a) 2-66 1. Hydraulic unit 2. Proportioning valve 3. Brake hose (proportioning valve to rear brake caliper) 4. Brake hose (rear brake master cylinder to hydraulic unit) 5. Brake hose (hydraulic unit to metering valve) 6. Brake hose (hydraulic unit to front brake calipers) 7. Brake...

  • Page 116: Cable Routing (Fjr13Ae)

    Cable routing (fjr13ae) 2-67 et3p66048 cable routing (fjr13ae) b-b a a b b a b c d e f f g g h i j k l 1 1 1 2 2 2 2 3 3 3 7 7 6 7 4 5 8 6 12 12 13 13 9 12 11 10 13 14 16 15 17 18 19 21 20 22 22 22 23 23 23 1 2 3 m.

  • Page 117: Cable Routing (Fjr13Ae)

    Cable routing (fjr13ae) 2-68 1. Brake hose (front brake master cylinder to hydraulic unit) 2. Right handlebar switch lead 3. Left handlebar switch lead 4. Left grip warmer lead 5. Hand shift switch lead 6. Right grip warmer lead 7. Main switch lead 8. Left horn (low) 9. Brake hose (hydraulic unit to...

  • Page 118: Cable Routing (Fjr13Ae)

    Cable routing (fjr13ae) 2-69 b c c-c d-d e-e a-a b-b f f a a cb d 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 18 19 20 21 23 24 25 26 27 27 29 28 30 30 31 32 33 34 35 36 37 38 39 d f g m n s 27 30 30 18 q r h 22 40 41 42 41 o p 11.

  • Page 119: Cable Routing (Fjr13Ae)

    Cable routing (fjr13ae) 2-70 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. Fus...

  • Page 120: Cable Routing (Fjr13Ae)

    Cable routing (fjr13ae) 2-71 b c 1 a d e g 1 2 3 4 5 6 7 8 9 14 13 10 11 12 15 f.

  • Page 121: Cable Routing (Fjr13Ae)

    Cable routing (fjr13ae) 2-72 1. Rear wheel sensor lead 2. Rear brake fluid reservoir 3. Rear brake light switch lead 4. Clutch actuator motor lead 5. Clutch actuator sensor lead 6. Hydraulic unit 7. Brake hose (front brake master cylinder to hydraulic unit) 8. Brake hose (hydraulic unit to proportio...

  • Page 122: Cable Routing (Fjr13Ae)

    Cable routing (fjr13ae) 2-73 a b c d e 1 2 3 4 6 5 8 7 9 11 10 12 13.

  • Page 123: Cable Routing (Fjr13Ae)

    Cable routing (fjr13ae) 2-74 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 horn...

  • Page 124: Cable Routing (Fjr13Ae)

    Cable routing (fjr13ae) 2-75 up a-a b d c c b d a a a b d c f g h i n o p q r s t u x v w 1 3 2 20 20 10 12 11 13 10 15 14 16 18 19 26 27 28 29 9 30 31 32 17 33 34 11 35 36 37 38 39 e 6 8 7 4 5 36 40 41 y 17 j k l 21 22 23 24 25 m.

  • Page 125: Cable Routing (Fjr13Ae)

    Cable routing (fjr13ae) 2-76 1. Grip warmer couplers 2. Hand shift switch coupler 3. Handlebar switch couplers 4. Right grip warmer lead 5. Right handlebar switch lead 6. Main switch lead 7. Hand shift switch lead 8. Left grip warmer lead 9. Left handlebar switch lead 10. Stator coil lead 11. Fuel t...

  • Page 126: Cable Routing (Fjr13Ae)

    Cable routing (fjr13ae) 2-77 a-a b-b c c b b a a a b e d c g f h i j l k m 2 2 1 1 5 5 5 6 6 6 7 8 9 16 11 12 13 15 10 17 18 19 12 3 3 4 3 20 21 11 22 11 22 23 24 25 26 27 14.

  • Page 127: Cable Routing (Fjr13Ae)

    Cable routing (fjr13ae) 2-78 1. Wire harness 2. Ecu (engine control unit) 3. Abs ecu (electronic control unit) 4. Mcu (motor control unit) 5. Tail/brake light 6. Rear turn signal light 7. Tail/brake light assembly lead 8. License plate light lead 9. Seat lock cable 10. Shift actuator motor lead 11. ...

  • Page 128: Cable Routing (Fjr13Ae)

    Cable routing (fjr13ae) 2-79 e a c b d f f g h i j k l m n 1 2 3 4 5 6 7 8 9 10 11 13 12 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 31 30 29.

  • Page 129: Cable Routing (Fjr13Ae)

    Cable routing (fjr13ae) 2-80 1. Spark plug lead #1 2. Spark plug lead #2 3. Front wheel sensor lead 4. Main switch lead 5. Throttle cable (accelerator cable) 6. Throttle cable (decelerator cable) 7. Brake hose (hydraulic unit to front brake calipers) 8. Brake hose (metering valve to right front brak...

  • Page 130: Cable Routing (Fjr13Ae)

    Cable routing (fjr13ae) 2-81 d b c a e e f i 3 4 5 2 1 6 h g.

  • Page 131: Cable Routing (Fjr13Ae)

    Cable routing (fjr13ae) 2-82 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. Connect the clutch actuator motor lead and clutch actuator sensor lead, install the rubber co...

  • Page 132: Cable Routing (Fjr13Ae)

    Cable routing (fjr13ae) 2-83 a a a b c d e p f h i j k l m n q r 1 2 3 4 5 6 9 10 11 13 14 15 16 g 7 8 o 12.

  • Page 133: Cable Routing (Fjr13Ae)

    Cable routing (fjr13ae) 2-84 1. Windshield drive unit 2. Relay unit 3. Thermistor 4. Windshield drive unit lead 5. Meter assembly lead 6. Headlight relay (dimmer) 7. Left headlight beam adjusting cable 8. Left auxiliary light lead 9. Left headlight lead 10. Lean angle sensor 11. Right headlight lead...

  • Page 134: Cable Routing (Fjr13Ae)

    Cable routing (fjr13ae) 2-85 c-c a b a b c c a b j c d f g g i 1 1 1 1 2 2 2 3 3 3 3 4 4 4 4 4 5 5 5 6 6 6 7 7 7 8 8 8 9 9 8 9 10 10 10 10 12 11 12 17 17 13 13 17 13 14 16 15 16 e h 11.

  • Page 135: Cable Routing (Fjr13Ae)

    Cable routing (fjr13ae) 2-86 1. Hydraulic unit 2. Proportioning valve 3. Brake hose (proportioning valve to rear brake caliper) 4. Brake hose (rear brake master cylinder to hydraulic unit) 5. Brake hose (hydraulic unit to metering valve) 6. Brake hose (hydraulic unit to front brake calipers) 7. Brak...

  • Page 136: Cable Routing (Fjr13Ae)

    Cable routing (fjr13ae) 2-87.

  • Page 137

    3 periodic checks and adjustments periodic maintenance ............................................................................ 3-1 introduction....................................................................................... 3-1 periodic maintenance chart for the emission control system (...

  • 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 5 * brake hoses • check for cracks or damage. √ √ √ √ √ • replace. Every 4 years 6 * wheels • check runout and for dam- age. • replace if necessary. √ √ √ √ √ 7 * tires • check tread depth and for damage. • replace if necessary. • check air pressure. • correct if necessary. ...

  • Page 142: Periodic Maintenance

    Periodic maintenance 3-3 * since these items require special tools, data and technical skills, have a yamaha dealer perform the service. Note: from 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. Eau17660 note: • the air filter needs ...

  • Page 143: Periodic Maintenance

    Periodic maintenance 3-4 * since these items require special tools, data and technical skills, have a yamaha dealer perform the service. Et3p66052 general maintenance and lubrication chart (fjr13ae) 8 * air induction sys- tem • check the air cut-off valve, reed valve, and hose for dam- age. • replac...

  • Page 144: Periodic Maintenance

    Periodic maintenance 3-5 * since these items require special tools, data and technical skills, have a yamaha dealer perform the service. Note: from 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. Et3p66053 note: • the air filter needs...

  • Page 145: Engine

    Engine 3-6 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 146: Engine

    Engine 3-7 • 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 147: Engine

    Engine 3-8 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 148: Engine

    Engine 3-9 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 149: Engine

    Engine 3-10 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.I...

  • 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 caution: eca13320 before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders. 4. Check: • spark plug type incorrect → change. 5. Check: • electrode “1” damage/wear → replace the spark plug. • i...

  • 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 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 settled. Eas20780 changing the engine oil 1. Start the engine, warm it up for several min- ut...

  • Page 155: Engine

    Engine 3-16 12.Check: • engine oil pressure ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the right side cowling. Refer to “general chassis” on page 4-1. B. Slightly loosen the engine oil check bolt “1”. C. Start the engine and keep it idling until engine oil starts to seep from the oi...

  • Page 156: Engine

    Engine 3-17 eas20860 adjusting the clutch lever (fjr13a only) 1. Adjust: • clutch lever position (distance “a” from the handlebar grip to the clutch lever) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. While pushing the clutch lever forward, turn the adjusting dial “1” until the clutch lever ...

  • Page 157: Engine

    Engine 3-18 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 158: Engine

    Engine 3-19 warning ewa13010 after bleeding the hydraulic clutch system, check the clutch operation. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ et3p66027 bleeding the hydraulic clutch system (fjr13ae) warning ewa13000 bleed the hydraulic clutch system whenever: • the system was disassembled, ...

  • Page 159: Engine

    Engine 3-20 l. Repeat steps (i) to (k) until all of the air bub- bles have disappeared from the clutch fluid in the plastic hose of the vacuum/pressure pump gauge set. M. Tighten the bleed screw to specification. N. Manually engage and disengage the clutch 30 times using the manual clutch operation ...

  • Page 160: Engine

    Engine 3-21 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 specification. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Install: • swingarm refer to “swingarm” on page 4-91. •...

  • Page 161: Engine

    Engine 3-22 eas20920 cleaning the air filter element (fjr13a) 1. Remove: • rider seat • left side cover • air filter case cover • air filter element refer to “general chassis” on page 4-1. 2. Clean: • air filter element apply compressed air to the outer surface of the air filter element. 3. Check: •...

  • Page 162: Engine

    Engine 3-23 1. Remove: • rider seat refer to “general chassis” on page 4-1. • fuel tank refer to “fuel tank” on page 7-1. • air filter case refer to “general chassis” on page 4-1. • throttle body refer to “throttle bodies” on page 7-5. 2. Check: • throttle body joints “1” cracks/damage → replace. 3....

  • Page 163: Engine

    Engine 3-24 • 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. 1. Remove: • side cowlings refer to “general chassis” on page 4-1. 2. Check: • exhaust pipe assembly “1” • mufflers “2” cra...

  • Page 164: Engine

    Engine 3-25 • use only distilled water. However, if dis- tilled water is not available, soft water may be used. 4. Start the engine, warm it up for several min- utes, and then turn it off. 5. Check: • coolant level note: before checking the coolant level, wait a few minutes until it settles. 6. Inst...

  • 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 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 brake pedal. Each set of brake pads should be checked individually and replaced if neces- sary. 1. O...

  • 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 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 4-83. 4. Adjust: • steering head ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ ...

  • 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 2. Remove: • passenger seat • rider seat refer to “general chassis” on page 4-1. 3. Remove: • rider seat height position adjuster “1” note: remove the rider seat height position adjuster by pulling it upward. 4. Adjust: • rider seat height ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...

  • Page 179: Chassis

    Chassis 3-40 b. Install the rider seat height position adjuster “2” so that the “l” mark “a” is aligned with the match mark “b”. C. Insert the projection “c” on the front of the rid- er seat into seat holder (for low position) “3” as shown. D. Align the low position projection “d” on the bottom of t...

  • 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 8-203. Eas21770 checking the fuses refer to “electrical components” on page 8-203. 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 co...

  • Page 186

    Rear brake ............................................................................................... 4-41 introduction..................................................................................... 4-47 checking the rear brake disc ................................................... 4-47...

  • Page 187

    Swingarm .................................................................................................. 4-91 removing the swingarm ............................................................... 4-93 checking the swingarm ................................................................ 4-93 inst...

  • 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 (fjr13a) 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 lig...

  • Page 190: General Chassis

    General chassis 4-3 * for california only 17 handlebar switch coupler 2 disconnect. 18 front cowling wire harness coupler 5 disconnect. 19 horn connector 4 disconnect. 20 front cowling assembly 1 for installation, reverse the removal proce- dure. Removing the front cowling assembly (fjr13a) order jo...

  • Page 191: General Chassis

    General chassis 4-4 removing the front cowling assembly (fjr13ae) 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 li...

  • Page 192: General Chassis

    General chassis 4-5 * for california only 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 di...

  • 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 upper inner bracket 1 4 windshield lower inner bracket 1 5 rearview mi...

  • 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 side rail 2 3 windshield drive unit ...

  • 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 (fjr13a) 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 ecu ...

  • 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 (fjr13a) order job/parts to remove q’ty remarks t r . . 7 nm (0.7 m • kg, 5.1 ft • ib)...

  • Page 202: General Chassis

    General chassis 4-15 removing the air filter case (fjr13ae) 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 (fjr13ae only)” on page 5-67. 1 air shrou...

  • 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 wheel bearing 2 3 spacer 1 for assembly, reverse the disassembly pro- cedure..

  • Page 206: Front Wheel

    Front wheel 4-19 eas21900 removing the front wheel 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: • front wheel sensor • front brake calipers caution: ec3p61020 • be sure not to contact the sensor elect...

  • Page 207: Front Wheel

    Front wheel 4-20 4. Check: • wheel bearings front wheel turns roughly or is loose → re- place the wheel bearings. • oil seals damage/wear → replace. Eas22010 maintenance of the front wheel sensor and sensor rotor caution: ec3p61031 • handle the abs components with care since they have been accuratel...

  • Page 208: Front Wheel

    Front wheel 4-21 eas21960 assembling the front wheel 1. Install: • wheel bearings • oil seals ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the new wheel bearings and oil seals in the reverse order of disassembly. Caution: ec3p61021 do not contact the wheel bearing inner race “1” or b...

  • Page 209: Front Wheel

    Front wheel 4-22 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 210: Front Wheel

    Front wheel 4-23 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Insert the front wheel axle from the right side and tighten it with the front wheel axle bolt from the left side to 91 nm (9.1 m·kg, 66 ft·lb). B. In the order pinch bolt “2” → pinch bolt “1” → pinch bolt “2”, tighten each bolt to...

  • Page 211: Rear Wheel

    Rear wheel 4-24 eas22030 rear wheel removing the rear wheel, brake disc, wheel sensor, and sensor housing order job/parts to remove q’ty remarks storage compartment 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 ...

  • Page 212: Rear Wheel

    Rear wheel 4-25 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 circlip 1 8 wheel bearing 1 9 spacer 1 10 spacer 1 11 oil seal 1 12 bearing 1 for assembly, rever...

  • Page 213: Rear Wheel

    Rear wheel 4-26 eas22050 removing the rear wheel 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 the centerstand so that the rear wheel is elevated. 2. Remove: • rear wheel sensor • rear ...

  • Page 214: Rear Wheel

    Rear wheel 4-27 2. Install: • wheel bearings • oil seals refer to “assembling the front wheel” on page 4-21. Eas22150 adjusting the rear wheel static balance note: • after replacing the tire, wheel, or both, the rear wheel static balance should be adjusted. • adjust the rear wheel static balance wit...

  • Page 215: Rear Wheel

    Rear wheel 4-28 5. Tighten: • brake torque rod nuts • rear wheel axle nut • rear wheel axle pinch bolt 6. Install: • rear wheel sensor caution: ec3p66004 to route the rear wheel sensor lead, refer to “cable routing (fjr13a)” on page 2-47 and “cable routing (fjr13ae)” on page 2-67. Note: when install...

  • Page 216: Front Brake

    Front brake 4-29 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 217: Front Brake

    Front brake 4-30 * apply silicon grease 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...

  • Page 218: Front Brake

    Front brake 4-31 * apply silicon grease 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..

  • Page 219: Front Brake

    Front brake 4-32 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 220: Front Brake

    Front brake 4-33 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 seal 8 6 bleed screw 1 7 ble...

  • Page 221: Front Brake

    Front brake 4-34 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 222: Front Brake

    Front brake 4-35 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 223: Front Brake

    Front brake 4-36 3. Lubricate: • brake pad bolts caution: eca14150 • do not allow grease to contact the brake pads. • remove any excess grease. 4. Install: • brake pad bolts • brake caliper 5. Check: • brake fluid level below the minimum level mark “a” → add the recommended brake fluid to the proper...

  • Page 224: Front Brake

    Front brake 4-37 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 seals. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ...

  • Page 225: Front Brake

    Front brake 4-38 caution: eca14170 when installing the brake hose onto the brake caliper “1”, make sure the brake pipe “a” touches the projection “b” on the brake caliper. 2. Remove: • brake caliper 3. Install: • brake pads • brake pad springs • brake pad bolts • brake caliper • brake hose holder re...

  • Page 226: Front Brake

    Front brake 4-39 eas22490 removing the front brake master cylinder note: before removing the front brake master cylinder, drain the brake fluid from the entire brake sys- tem. 1. Remove: • brake hose union bolt “1” • copper washers “2” • brake hose (front brake master cylinder to hydraulic unit) “3”...

  • Page 227: Front Brake

    Front brake 4-40 warning ew3p66002 proper brake hose routing is essential to in- sure safe vehicle operation. Refer to “cable routing (fjr13a)” on page 2-47 and “ca- ble routing (fjr13ae)” on page 2-67. Caution: ec3p61025 when installing the brake hose onto the brake master cylinder, make sure the b...

  • Page 228: Rear Brake

    Rear brake 4-41 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..

  • Page 229: Rear Brake

    Rear brake 4-42 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 230: Rear Brake

    Rear brake 4-43 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 231: Rear Brake

    Rear brake 4-44 * apply silicon grease 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..

  • Page 232: Rear Brake

    Rear brake 4-45 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 233: Rear Brake

    Rear brake 4-46 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 seal 2 8 bleed screw 1 for assembly, rever...

  • Page 234: Rear Brake

    Rear brake 4-47 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 235: Rear Brake

    Rear brake 4-48 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 236: Rear Brake

    Rear brake 4-49 eas22600 disassembling the rear brake caliper 1. Remove: • brake caliper piston “1” • brake caliper piston seals “2” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Blow compressed air into the brake hose joint opening “a” to force out the piston from the brake caliper. Warning ...

  • Page 237: Rear Brake

    Rear brake 4-50 • rear wheel axle nut note: • do not install the brake pads, brake pad shims, and brake pad springs. • align the slot “a” of the rear wheel sensor hous- ing “1” with the projection “b” of the rear brake caliper bracket “2”, and then assemble them. • after assembling the rear wheel se...

  • Page 238: Rear Brake

    Rear brake 4-51 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 239: Rear Brake

    Rear brake 4-52 eas22740 installing the rear brake master cylinder 1. Install: • copper washers • brake hose (rear brake master cylinder to hy- draulic unit) “1” • rear brake hose union bolt “2” warning ew3p66002 proper brake hose routing is essential to in- sure safe vehicle operation. Refer to “ca...

  • Page 240: Rear Brake

    Rear brake 4-53 7. Adjust: • brake pedal position refer to “adjusting the rear disc brake” on page 3-28. 8. Adjust: • rear brake light operation timing refer to “adjusting the rear brake light switch” on page 3-30..

  • Page 241: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-54 eas22760 abs (anti-lock brake system) et3p61060 abs components chart 1 4 5 6 7 9,10 11 12 2 3 a a 16 18 13 4 8 14 15 17 15 2 3 1 1. Brake hose (metering valve to right front brake caliper) 2. Brake hose (hydraulic unit to front brake calipers) 3. Brake hose (front b...

  • Page 242: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-55 removing the rear fender assembly order job/parts to remove q’ty remarks air filter case refer to “general chassis” on page 4-1. Abs ecu/abs motor relay refer to “abs (anti-lock brake sys- tem)” on page 8-119. Brake fluid drain. Refer to “bleeding the hydraulic brak...

  • Page 243: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-56 removing the hydraulic unit order job/parts to remove q’ty remarks 1 brake hose union bolt/copper washer 1/2 2 brake hose (front brake master cylinder to hy- draulic unit) 1 disconnect. 3 brake hose union bolt/copper washer 1/2 4 brake hose (rear brake master cylind...

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

    Abs (anti-lock brake system) 4-57 15 brake hose (metering valve to right front brake caliper) 1 disconnect. 16 metering valve 1 17 brake hose (proportioning valve to rear brake caliper) 1 18 proportioning valve 1 for installation, reverse the removal proce- dure. Removing the hydraulic unit order jo...

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

    Abs (anti-lock brake system) 4-58 et3p61055 removing the hydraulic unit caution: eca14510 do not remove the hydraulic unit to check the resistance of the solenoid valves and the abs motor for continuity. Warning ewa13930 refill with the same type of brake fluid that is already in the system. Mixing ...

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

    Abs (anti-lock brake system) 4-59 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 et3p61058 installing the hydraulic unit proceed in the reverse ...

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

    Abs (anti-lock brake system) 4-60 5. Fill: • brake master cylinder reservoir • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) warning ewa13090 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and ...

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

    Abs (anti-lock brake system) 4-61 5. Connect the test coupler adapter “1” to the abs test coupler “2”. 6. Turn the main switch to “on” while operating the brake lever and the brake pedal simulta- neously. Note: this check cannot be performed unless both the brake lever and the brake pedal are operat...

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

    Abs (anti-lock brake system) 4-62 the first pulse in the brake pedal, check that the brake hoses are connected correctly to the hydraulic unit. • if the pulse is hardly felt in either the brake lever or brake pedal, check that the brake hoses are connected correctly to the hy- draulic unit. • if the...

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

    Abs (anti-lock brake system) 4-63 9. After releasing the start switch, operate the brake lever and the brake pedal simulta- neously. 10.A reaction-force pulsating action is generated in the brake lever “1” 0.5 second after the brake lever and the brake pedal are operated simultaneously and continues...

  • Page 251: Handlebars

    Handlebars 4-64 eas22850 handlebars removing the left handlebar (fjr13a) 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 7 left handleb...

  • Page 252: Handlebars

    Handlebars 4-65 removing the left handlebar (fjr13ae) 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 hand...

  • Page 253: Handlebars

    Handlebars 4-66 removing the right handlebar (fjr13a) 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 thr...

  • Page 254: Handlebars

    Handlebars 4-67 removing the right handlebar (fjr13ae) 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 th...

  • Page 255: Handlebars

    Handlebars 4-68 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 256: Handlebars

    Handlebars 4-69 • 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. Tighten: • handlebar bolts • han...

  • Page 257: Handlebars

    Handlebars 4-70 note: • install the clutch master cylinder holder with the “up” mark facing up • align the mating surfaces of the clutch master cylinder holder with the punch mark “a” on the left handlebar. • first, tighten the upper bolt, then the lower bolt. 11.Adjust: • throttle cable free play r...

  • Page 258: Handlebars

    Handlebars 4-71 • lead holder 2 “2” note: • align the projection “a” on the hand shift switch with hole “b” on the left handlebar. • when installing the hand shift switch, route the left grip warmer lead “3” and left handlebar switch lead “4” through the switch as shown in the illustration, making s...

  • Page 259: Handlebars

    Handlebars 4-72 10.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 260: Front Fork

    Front fork 4-73 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 261: Front Fork

    Front fork 4-74 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 262: Front Fork

    Front fork 4-75 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 263: Front Fork

    Front fork 4-76 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 264: Front Fork

    Front fork 4-77 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 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 265: Front Fork

    Front fork 4-78 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 266: Front Fork

    Front fork 4-79 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 fork seal driver “3”) 6. Install: •...

  • Page 267: Front Fork

    Front fork 4-80 8. Install: • dust seal “1” (with the fork seal driver “2”) 9. Fill: • front fork leg (with the specified amount of the recom- mended fork oil) caution: eca14230 • be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance. • when disasse...

  • Page 268: Front Fork

    Front fork 4-81 note: install the fork spring so that the end “a” shown in the illustration is facing up. 15.Install: • nut “1” • damper adjusting rod “2” • cap bolt “3” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the nut “1” and finger tighten it. B. Install the damper adjusting ro...

  • Page 269: Front Fork

    Front fork 4-82 3. Adjust: • spring preload • rebound damping • compression damping refer to “adjusting the front fork legs” on page 3-36..

  • Page 270: Steering Head

    Steering head 4-83 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 4-64. Front fork legs refer to “front fork” on pag...

  • Page 271: Steering Head

    Steering head 4-84 12 upper bearing cover 1 13 upper bearing inner race 1 14 upper bearing 1 15 lower bearing 1 16 dust seal 1 17 lower bearing inner race 1 18 upper bearing outer race 1 19 lower bearing outer race 1 for installation, reverse the removal proce- dure. Removing the lower bracket order...

  • Page 272: Steering Head

    Steering head 4-85 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 273: Steering Head

    Steering head 4-86 • 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 4-73. Note: temporarily tighten the uppe...

  • Page 274: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-87 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 4-24. Mufflers/exhaust pipe assembly refer to “eng...

  • Page 275: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-88 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 276: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-89 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 277: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-90 • 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 278: Swingarm

    Swingarm 4-91 eas23330 swingarm removing the swingarm order job/parts to remove q’ty remarks rear wheel refer to “rear wheel” on page 4-24. Rear shock absorber assembly/connecting arms refer to “rear shock absorber as- sembly” on page 4-87. Final drive assembly/universal joint refer to “shaft drive”...

  • Page 279: Swingarm

    Swingarm 4-92 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 280: Swingarm

    Swingarm 4-93 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 281: Swingarm

    Swingarm 4-94 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 282: Shaft Drive

    Shaft drive 4-95 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 4-24. 1 final drive assembly 1 for installation, reverse the removal proce- d...

  • Page 283: Shaft Drive

    Shaft drive 4-96 removing the universal joint order job/parts to remove q’ty remarks left footrest assembly/sidestand fjr13ae refer to “shift actuator and shift rod (fjr13ae only)” on page 5-67. 1 shift arm 1 fjr13a 2 left footrest assembly 1 fjr13a 3 sidestand switch coupler 1 fjr13a disconnect. 4 ...

  • Page 284: Shaft Drive

    Shaft drive 4-97 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 1...

  • Page 285: Shaft Drive

    Shaft drive 4-98 * 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 286: Shaft Drive

    Shaft drive 4-99 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. I...

  • Page 287: Shaft Drive

    Shaft drive 4-100 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 288: Shaft Drive

    Shaft drive 4-101 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install a bolt “1” of the specified size, into the final gear oil drain hole. B. Finger tighten the bolt until it stops the ring gear from moving. Note: do not overtighten the bolt. C. Install the final gear backlash band “2” and...

  • Page 289: Shaft Drive

    Shaft drive 4-102 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 290: Shaft Drive

    Shaft drive 4-103 • 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, repeat the above procedure. Eas23620 disassembling the final drive assembly 1. Remove: • ring gear bearing housing bo...

  • Page 291: Shaft Drive

    Shaft drive 4-104 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 292: Shaft Drive

    Shaft drive 4-105 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 293: Shaft Drive

    Shaft drive 4-106 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 294: Shaft Drive

    Shaft drive 4-107 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 4-100 and “adju...

  • Page 295: Shaft Drive

    Shaft drive 4-108 eas23660 installing the drive shaft and final drive assembly (fjr13a) 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 s...

  • Page 296: Shaft Drive

    Shaft drive 4-109 11.Check: • shift pedal position refer to “adjusting the shift pedal (fjr13a)” on page 3-32. Et3p66032 installing the drive shaft and final drive assembly (fjr13ae) 1. Lubricate: • drive shaft spline (final drive pinion gear side) 2. Lubricate: • drive shaft spline (universal joint...

  • Page 297: Shaft Drive

    Shaft drive 4-110 10.Fill: • final gear case refer to “checking the final gear oil level” on page 3-33..

  • Page 298: Shaft Drive

    Shaft drive 4-111.

  • Page 299: Engine

    5 engine engine removal ........................................................................................ 5-1 removing the gear position sensor (fjr13ae only)............... 5-8 removing the engine (fjr13a) ....................................................... 5-8 removing the engine (fjr13...

  • Page 300

    Clutch ........................................................................................................ 5-44 removing the clutch ..................................................................... 5-56 checking the friction plates .................................................... 5-56 c...

  • Page 301

    Middle gear .............................................................................................. 5-81 removing the middle drive shaft assembly......................... 5-87 disassembling the middle drive shaft assembly ............... 5-87 disassembling the middle driven shaft assembly ......

  • Page 302: 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 303: Engine Removal

    Engine removal 5-2 disconnecting the leads and hoses (fjr13a) 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 7-5. Air cut-off valve/reed valves refer t...

  • Page 304: 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 (fjr13a) ord...

  • Page 305: Engine Removal

    Engine removal 5-4 disconnecting the leads and hoses (fjr13ae) 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 7-5. Air cut-off valve/reed valves refer ...

  • Page 306: 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 307: 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 308: 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 309: Engine Removal

    Engine removal 5-8 et3p66033 removing the gear position sensor (fjr13ae 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 (fjr13a) ...

  • Page 310: Engine Removal

    Engine removal 5-9 • 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 bolts (top) “13” note: • lubricate the engine mounting...

  • Page 311: 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 312: Engine Removal

    Engine removal 5-11 et3p66035 installing the gear position sensor (fjr13ae 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 sensor,...

  • Page 313: Camshafts

    Camshafts 5-12 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 7-11. 1 spark plug 4 2 cylinder identification sensor 1 3 cylinde...

  • Page 314: Camshafts

    Camshafts 5-13 removing the camshafts order job/parts to remove q’ty remarks throttle bodies refer to “throttle bodies” on page 7-5. Pickup rotor cover refer to “pickup rotor” on page 5-37. 1 timing chain tensioner 1 2 timing chain tensioner gasket 1 3 intake camshaft cap 4 4 exhaust camshaft cap 4 ...

  • Page 315: Camshafts

    Camshafts 5-14 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 316: Camshafts

    Camshafts 5-15 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 317: Camshafts

    Camshafts 5-16 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 318: Camshafts

    Camshafts 5-17 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 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 319: Camshafts

    Camshafts 5-18 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 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 320: Camshafts

    Camshafts 5-19 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 321: Camshafts

    Camshafts 5-20

  • Page 322: Cylinder Head

    Cylinder head 5-21 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 5-12. 1 cylinder head 1 2 cylinder head gasket 1 3 dowel pin 2 for installation, reverse the removal proce-...

  • Page 323: Cylinder Head

    Cylinder head 5-22 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 324: Cylinder Head

    Cylinder head 5-23 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 325: Valves and Valve Springs

    Valves and valve springs 5-24 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 5-21. 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 326: Valves and Valve Springs

    Valves and valve springs 5-25 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 327: Valves and Valve Springs

    Valves and valve springs 5-26 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 328: Valves and Valve Springs

    Valves and valve springs 5-27 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 → replace the valve. 5. Measure: • valve margin thickness ...

  • Page 329: Valves and Valve Springs

    Valves and valve springs 5-28 4. Lap: • valve face • valve seat note: after replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply a coarse lapping compound “a” to the valve face. ...

  • Page 330: Valves and Valve Springs

    Valves and valve springs 5-29 2. Measure: • compressed valve spring force “a” out of specification → replace the valve spring. 3. Measure: • valve spring tilt “a” out of specification → replace the valve spring. Eas24320 checking the valve lifters the following procedure applies to all of the valve ...

  • Page 331: Valves and Valve Springs

    Valves and valve springs 5-30 4. Install: • lower spring seat “1” • valve stem seal “2” • valve “3” • valve spring “4” • upper spring seat “5” (into the cylinder head) note: • make sure each valve is installed in its original place. • install the valve springs with the larger pitch “a” facing up. 5....

  • Page 332: Generator and Starter Clutch

    Generator and starter clutch 5-31 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 333: Generator and Starter Clutch

    Generator and starter clutch 5-32 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 334: Generator and Starter Clutch

    Generator and starter clutch 5-33 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 335: Generator and Starter Clutch

    Generator and starter clutch 5-34 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 336: Generator and Starter Clutch

    Generator and starter clutch 5-35 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas24600 installing the starter clutch 1. Install: • starter clutch • starter clutch bolts “1” note: while holding the generator rotor with the sheave holder, tighten the starter clutch bolts. Eas24500 installing the...

  • Page 337: Generator and Starter Clutch

    Generator and starter clutch 5-36 note: tighten the generator cover bolts in stages and in a crisscross pattern..

  • Page 338: Pickup Rotor

    Pickup rotor 5-37 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 5-31. 1 pickup ro...

  • Page 339: Pickup Rotor

    Pickup rotor 5-38 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 340: Pickup Rotor

    Pickup rotor 5-39 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 341: Electric Starter

    Electric starter 5-40 eas24780 electric starter removing the starter motor order job/parts to remove q’ty remarks throttle bodies refer to “throttle bodies” on page 7-5. 1 starter motor lead 1 disconnect. 2 starter motor assembly 1 for installation, reverse the removal proce- dure..

  • Page 342: Electric Starter

    Electric starter 5-41 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 343: Electric Starter

    Electric starter 5-42 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 344: Electric Starter

    Electric starter 5-43 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 345: Clutch

    Clutch 5-44 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 346: Clutch

    Clutch 5-45 removing the clutch order job/parts to remove q’ty remarks rear balancer refer to “balancers” on page 5-127. 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 347: Clutch

    Clutch 5-46 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 348: Clutch

    Clutch 5-47 removing the clutch master cylinder (fjr13a) order job/parts to remove q’ty remarks clutch fluid drain. Refer to “bleeding the hydraulic clutch system (fjr13a)” on page 3-18. 1 clutch master cylinder reservoir cap 1 2 clutch master cylinder reservoir diaphragm holder 1 3 clutch master cy...

  • Page 349: Clutch

    Clutch 5-48 * apply silicon grease 12 clutch master cylinder 1 for installation, reverse the removal proce- dure. Removing the clutch master cylinder (fjr13a) order job/parts to remove q’ty remarks.

  • Page 350: Clutch

    Clutch 5-49 removing the clutch actuator and clutch master cylinder (fjr13ae) order job/parts to remove q’ty remarks clutch fluid drain. Refer to “bleeding the hydraulic clutch system (fjr13ae)” on page 3-19. Swingarm refer to “swingarm” on page 4-91. 1 rear brake hose/rear wheel sensor lead holder ...

  • Page 351: Clutch

    Clutch 5-50 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 (fjr13ae) order job/parts to remove q’ty remarks t r . . 19 nm (1.9 m • kg, 13 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ...

  • Page 352: Clutch

    Clutch 5-51 * apply silicon grease disassembling the clutch master cylinder (fjr13a) order job/parts to remove q’ty remarks 1 clutch master cylinder push rod 1 2 dust boot 1 3 circlip 1 4 washer 1 5 clutch master cylinder kit 1 6 clutch master cylinder body 1 for assembly, reverse the disassembly pr...

  • Page 353: Clutch

    Clutch 5-52 * apply silicon grease disassembling the clutch master cylinder (fjr13ae) order job/parts to remove q’ty remarks 1 clutch master cylinder kit 1 2 clutch master cylinder body 1 for assembly, reverse the disassembly pro- cedure. 1 2 new ∗.

  • Page 354: Clutch

    Clutch 5-53 removing the clutch release cylinder (fjr13a) order job/parts to remove q’ty remarks clutch fluid drain. Refer to “bleeding the hydraulic clutch system (fjr13a)” on page 3-18. 1 clutch hose union bolt 1 2 copper washer 2 3 clutch hose 1 disconnect. 4 clutch release cylinder 1 5 dowel pin...

  • Page 355: Clutch

    Clutch 5-54 removing the clutch release cylinder (fjr13ae) order job/parts to remove q’ty remarks clutch fluid drain. Refer to “bleeding the hydraulic clutch system (fjr13ae)” on page 3-19. 1 clutch hose union bolt 1 2 copper washer 2 3 clutch hose 1 disconnect. 4 clutch release cylinder 1 5 dowel p...

  • Page 356: Clutch

    Clutch 5-55 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 357: Clutch

    Clutch 5-56 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 5-127. 3. Remove: • c...

  • Page 358: Clutch

    Clutch 5-57 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 359: Clutch

    Clutch 5-58 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 360: Clutch

    Clutch 5-59 • 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. 4. Bend the lock washer tab ...

  • Page 361: Clutch

    Clutch 5-60 b. Apply the rear brake forcefully. C. Shift the transmission into 1st gear. D. Turn the throttle grip to 1/4 “a” of the fully open position ten times, each time for less than 0.5 second. Note: it is not unusual for the engine to stall when per- forming this procedure. If the engine stal...

  • Page 362: Clutch

    Clutch 5-61 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 master cylinder kit rust/scratches/wear → re...

  • Page 363: Clutch

    Clutch 5-62 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 364: Clutch

    Clutch 5-63 • refill with the same type of clutch fluid that is already in the system. Mixing clutch flu- ids may result in a harmful chemical reac- tion, leading to poor clutch performance. • when refilling, be careful that water does not enter the clutch fluid reservoir. Water will significantly l...

  • Page 365: Clutch

    Clutch 5-64 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 (fjr13ae only)” on ...

  • Page 366: Clutch

    Clutch 5-65 eas25330 checking the clutch release cylinder 1. Check: • clutch release cylinder body cracks/damage → replace the clutch re- lease cylinder. 2. Check: • clutch release cylinder “1” • clutch release cylinder piston “2” rust/scratches/wear → replace the clutch release cylinder and clutch ...

  • Page 367: Clutch

    Clutch 5-66 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 368

    Shift actuator and shift rod (fjr13ae only) 5-67 et3p66037 shift actuator and shift rod (fjr13ae 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 sen...

  • Page 369

    Shift actuator and shift rod (fjr13ae only) 5-68 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 f...

  • Page 370

    Shift actuator and shift rod (fjr13ae only) 5-69 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. Remove ...

  • Page 371

    Shift actuator and shift rod (fjr13ae only) 5-70 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 footrest assembly. 3. Install: • ...

  • Page 372

    Shift actuator and shift rod (fjr13ae only) 5-71 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 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” and ...

  • Page 373

    Shift actuator and shift rod (fjr13ae only) 5-72 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 374: Shift Shaft

    Shift shaft 5-73 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 5-44. Shift rod fjr13ae refer to “shift actuator and shift rod (fjr13ae only)” on page 5-67. 1 oil baffle plate 1 1 2 shift arm 1 3 circlip...

  • Page 375: Shift Shaft

    Shift shaft 5-74 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 376: Shift Shaft

    Shift shaft 5-75 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 377: Oil Pump

    Oil pump 5-76 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 7-5. Exhaust pipe assembly refer to “engine removal” on page 5-1. Sidestand r...

  • Page 378: Oil Pump

    Oil pump 5-77 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 379: Oil Pump

    Oil pump 5-78 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 380: Oil Pump

    Oil pump 5-79 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 381: Oil Pump

    Oil pump 5-80 eas24980 checking the oil delivery pipes the following procedure applies to all of the oil delivery pipes. 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 → replac...

  • Page 382: Middle Gear

    Middle gear 5-81 eas25710 middle gear removing the middle gear (fjr13a) 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 5-76. 1 middle gear case cover 1 2 middle gear case cover gasket 1 3 dowel pin 2 4 damper cover 1 ...

  • Page 383: Middle Gear

    Middle gear 5-82 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 (fjr13a) order job/parts to remove q’ty remarks.

  • Page 384: Middle Gear

    Middle gear 5-83 removing the middle gear (fjr13ae) 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 5-76. 1 middle gear case cover 1 2 middle gear case cover gasket 1 3 dowel pin 2 4 damper cover 1 5 damper 1 6 middle ...

  • Page 385: Middle Gear

    Middle gear 5-84 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 (fjr13ae) order job/parts to remove q’ty remarks.

  • Page 386: Middle Gear

    Middle gear 5-85 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 387: Middle Gear

    Middle gear 5-86 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 388: Middle Gear

    Middle gear 5-87 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 389: Middle Gear

    Middle gear 5-88 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 390: Middle Gear

    Middle gear 5-89 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 391: Middle Gear

    Middle gear 5-90 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 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 inward as shown in the illustration...

  • Page 392: Middle Gear

    Middle gear 5-91 eas25880 measuring the middle gear backlash 1. Measure: • middle gear backlash out of specification → refer to “adjusting the middle gear backlash” on page 5-91. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Hold the middle drive shaft “1”. B. Install the gear lash measuremen...

  • Page 393: Middle Gear

    Middle gear 5-92 6. Measure: • crankcase-to-middle-driven-shaft-bearing- housing clearance (with a thickness gauge) 7. Select: • middle driven pinion gear shim(s) “1” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Shims can only be selected in 0.05 mm incre- ments, therefore round off to the h...

  • Page 394: Middle Gear

    Middle gear 5-93 “a”= 65.00 “b”= 18.94 “c”= a numeral on the lower crankcase, to be divided by 100 and added to “84” example: “a” is 65.00 “b” is 18.94 if the lower crankcase is marked “45” “c” is 84.45 (i.E., 84.00 + 0.45 = 84.45) “a” = 84.45 - 65.00 - 18.94 = 0.51 round off to the hundredths digit...

  • Page 395: Crankcase

    Crankcase 5-94 eas25540 crankcase separating the crankcase (fjr13a) 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 5-21. Starter clutch refer to “generator and starter clutch” on page 5-31. Pickup rotor refer to “pi...

  • Page 396: Crankcase

    Crankcase 5-95 9 lower crankcase 1 10 dowel pin 3 for installation, reverse the removal proce- dure. Separating the crankcase (fjr13a) 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 397: Crankcase

    Crankcase 5-96 separating the crankcase (fjr13ae) 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 5-21. Starter clutch refer to “generator and starter clutch” on page 5-31. Pickup rotor refer to “pickup rotor” on pag...

  • Page 398: Crankcase

    Crankcase 5-97 11 dowel pin 3 for installation, reverse the removal proce- dure. Separating the crankcase (fjr13ae) 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 m •...

  • Page 399: Crankcase

    Crankcase 5-98 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 5-104. Crankshaft/crankshaft journal bearings refer to “crankshaft” on page 5-112. Transmission refer to “transmission” on page 5-116. 1 oi...

  • Page 400: Crankcase

    Crankcase 5-99 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 • i...

  • Page 401: Crankcase

    Crankcase 5-100 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 402: Crankcase

    Crankcase 5-101 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 journal bear- ings. Do not apply sealant to within 2–3 mm (0.08–0.12 in) of the crankshaft journal bearings. 3. Insta...

  • Page 403: Crankcase

    Crankcase 5-102 7. Tighten: • crankcase bolts (m9 × 115 mm) “1”–“10” warning ew3p61013 replace the bolts with new ones. Note: the tightening procedure of crankcase bolts “1”– “10” is angle controlled, therefore tighten the bolts using the following procedure. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ...

  • Page 404: Crankcase

    Crankcase 5-103 note: tighten the crankcase bolts in the proper tight- ening sequence as shown. T r . . Crankcase bolt “11”, “12” 24 nm (2.4 m·kg, 17 ft·lb) crankcase bolt “13”, “14” 12 nm (1.2 m·kg, 8.7 ft·lb) crankcase bolt “15”–“31” 10 nm (1.0 m·kg, 7.2 ft·lb) 13 21 18 15 16 17 20 19 22 14 24 29 ...

  • Page 405: Connecting Rods and Pistons

    Connecting rods and pistons 5-104 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 5-94. 1 connecting rod cap 4 2 big end lower bearing 4 3 piston pin clip 8 4 piston pin 4 5 piston ...

  • Page 406: Connecting Rods and Pistons

    Connecting rods and pistons 5-105 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 407: Connecting Rods and Pistons

    Connecting rods and pistons 5-106 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 of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. C. Measur...

  • Page 408: Connecting Rods and Pistons

    Connecting rods and pistons 5-107 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 409: Connecting Rods and Pistons

    Connecting rods and pistons 5-108 et3p61028 checking the connecting rods 1. Measure: • crankshaft-pin-to-big-end-bearing clearance out of specification → replace the big end bearings. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ the following procedure applies to all of the connecting rods. Cau...

  • Page 410: Connecting Rods and Pistons

    Connecting rods and pistons 5-109 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Select: • big end bearings (p 1 –p 4 ) note: • the numbers “a” stamped into the crankshaft web and the numbers “b” on the connecting rods are used to determine the replacement big end bearing sizes. • p 1 –p 4 ref...

  • Page 411: Connecting Rods and Pistons

    Connecting rods and pistons 5-110 • reinstall each piston into its original cylinder (numbering order starting from the left: #1 to #4). 3. Offset: • piston ring end gaps 4. Lubricate: • piston • piston rings • cylinder (with the recommended lubricant) 5. Lubricate: • bolt threads • nut seats (with ...

  • Page 412: Connecting Rods and Pistons

    Connecting rods and pistons 5-111 8. Tighten: • connecting rod nuts “1” warning ew3p61019 replace the connecting rod bolts and nuts with new ones. Note: tighten the connecting rod nuts using the follow- ing procedure. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Tighten the connecting rod nu...

  • Page 413: Crankshaft

    Crankshaft 5-112 eas25950 crankshaft removing the crankshaft order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-94. Front balancer weight refer to “balancers” on page 5-127. Connecting rod caps refer to “connecting rods and pis- tons” on page 5-104. 1 crankshaf...

  • Page 414: Crankshaft

    Crankshaft 5-113 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 415: Crankshaft

    Crankshaft 5-114 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 416: Crankshaft

    Crankshaft 5-115 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 417: Transmission

    Transmission 5-116 eas26240 transmission removing the transmission, shift drum assembly, and shift forks (fjr13a) order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-94. Stopper lever refer to “shift shaft” on page 5-73. 1 drive axle assembly 1 2 bearing 1 3 was...

  • Page 418: Transmission

    Transmission 5-117 13 main axle assembly 1 for installation, reverse the removal proce- dure. Removing the transmission, shift drum assembly, and shift forks (fjr13a) order job/parts to remove q’ty remarks.

  • Page 419: Transmission

    Transmission 5-118 removing the transmission, shift drum assembly, and shift forks (fjr13ae) order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-94. Stopper lever refer to “shift shaft” on page 5-73. 1 gear position sensor bracket 1 2 oil seal 1 3 drive axle ass...

  • Page 420: Transmission

    Transmission 5-119 15 main axle assembly 1 for installation, reverse the removal proce- dure. Removing the transmission, shift drum assembly, and shift forks (fjr13ae) order job/parts to remove q’ty remarks.

  • Page 421: Transmission

    Transmission 5-120 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 422: Transmission

    Transmission 5-121 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 423: Transmission

    Transmission 5-122 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 424: Transmission

    Transmission 5-123 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 425: Transmission

    Transmission 5-124 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 426: Transmission

    Transmission 5-125 3. Install: • 2nd pinion gear “1” note: install the 2nd pinion gear with its chamfered side facing inward as shown in the illustration. Eas26350 installing the transmission 1. Install: • main axle assembly “1” • main axle bearing housing bolts note: • when installing the main axle...

  • Page 427: Transmission

    Transmission 5-126 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. 1 2.

  • Page 428: Balancers

    Balancers 5-127 et3p61031 balancers removing the front balancer order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-94. 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 429: Balancers

    Balancers 5-128 removing the rear balancer order job/parts to remove q’ty remarks throttle bodies refer to “throttle bodies” on page 7-5. Pickup rotor cover refer to “pickup rotor” on page 5-37. Clutch cover refer to “clutch” on page 5-44. 1 rear balancer cover 1 2 rear balancer cover gasket 1 3 rea...

  • Page 430: Balancers

    Balancers 5-129 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 431: Balancers

    Balancers 5-130 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 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 432: Balancers

    Balancers 5-131 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 433: Balancers

    Balancers 5-132 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 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 434: Balancers

    Balancers 5-133.

  • Page 435: Cooling System

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

  • Page 436: 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 7-5. 1 radiator cap 1 2 coolant reservoir hose 1 3 coolant reservoir breather hose 1 4 coolant r...

  • Page 437: 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 438: 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 439: 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 440: 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 441: 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 7-5. 1 radiator cap 1 2 coolant reservoir hose 1 disconnect. 3 radiator inlet hos...

  • Page 442: 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) t r . . 7 nm (...

  • Page 443: 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 444: 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 445: 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 446: 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 447: 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 448: 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 449: 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 450: Water Pump

    Water pump 6-15.

  • Page 451: Fuel System

    7 fuel system fuel tank .................................................................................................... 7-1 removing the fuel tank.................................................................. 7-3 removing the fuel pump ..........................................................

  • Page 452: 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 except for california 5 fuel tank br...

  • Page 453: Fuel Tank

    Fuel tank 7-2 removing the rollover valve and canister (for california only) order job/parts to remove q’ty remarks side cowlings refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. 1 canister purge hose (throttle body-#1 to 3-way joint) 1 2 3-way joint 1 3 canister p...

  • Page 454: Fuel Tank

    Fuel tank 7-3 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 455: Fuel Tank

    Fuel tank 7-4 et3p61018 installing the fuel tank 1. Install: • fuel hose (fuel rail side) caution: ec3p61007 when installing the fuel hose, make sure that it is securely connected, and that the fuel hose connector cover on the fuel hose is in the correct position, otherwise the fuel hose will not be...

  • Page 456: Throttle Bodies

    Throttle bodies 7-5 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 7-11. Coolant drain. Re...

  • Page 457: Throttle Bodies

    Throttle bodies 7-6 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 458: Throttle Bodies

    Throttle bodies 7-7 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 459: Throttle Bodies

    Throttle bodies 7-8 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 460: Throttle Bodies

    Throttle bodies 7-9 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 461: Throttle Bodies

    Throttle bodies 7-10

  • Page 462: Air Induction System

    Air induction system 7-11 eas27040 air induction system 1 2 3 4 5 1 1 1 1 2 2 5 2 3 3 4 7 8 6.

  • Page 463: Air Induction System

    Air induction system 7-12 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 464: Air Induction System

    Air induction system 7-13 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 465: Air Induction System

    Air induction system 7-14 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 466: Air Induction System

    Air induction system 7-15 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 467: Electrical System

    8 electrical system ignition system ......................................................................................... 8-1 circuit diagram (1/2) (fjr13a) ......................................................... 8-1 circuit diagram (2/2) (fjr13a) .................................................

  • Page 468

    Fuel injection system ......................................................................... 8-57 circuit diagram (1/2) (fjr13a) ....................................................... 8-57 circuit diagram (2/2) (fjr13a) ....................................................... 8-59 circuit diagram...

  • Page 469

    [c-2] the abs warning light and all other indicator lights fail to come on................................................................ 8-139 [c-3] the abs warning light fail to come on while the start switch is being pushed.................................................. 8-139 [c-4] the abs wa...

  • Page 470

    Checking the air induction system solenoid.................... 8-232 checking the cylinder identification sensor .................. 8-232 checking the intake air pressure sensor ......................... 8-233 checking the intake air temperature sensor.................. 8-233 checking the accessory ...

  • Page 472: Ignition System

    Ignition system 8-1 eas27090 ignition system eas27110 circuit diagram (1/2) (fjr13a) r br / l l / g r b / r b br / b br / b br / b br / b l / y l l / y l / y l b b r lg / w b b g / w r / l b / w b3 l / g b l / r b b dg ch y / g l / r g / y br / b br r / b r / w r / w w / l r / w w / g w / y b / w b ...

  • Page 473: Ignition System

    Ignition system 8-2 1. Main switch 7. Main fuse 8. Battery 12.Gear position switch 13.Coupler 1 (wire harness–front cowling wire harness) 16.Coupler 2 (wire harness–front cowling wire harness) 30.Coupler 3 (wire harness–front cowling wire harness) 31.Sidestand switch 32.Cylinders-#1/#4 ignition coil...

  • Page 474: Ignition System

    Ignition system 8-3 et3p61001 circuit diagram (2/2) (fjr13a) front cowling wire harness g y b g y b r br r / wg / l l / w r / y r / b l / r br / b g / l y l / b g (black) b b b ( gray ) ( gray ) ( gray ) b / l b / w ( gray ) ly / ly / wb / y g / ww / ly / gl / w pb / rg / bg / r b / yy / wy / ll l /...

  • Page 475: Ignition System

    Ignition system 8-4 13.Coupler 1 (front cowling wire harness–wire harness) 16.Coupler 2 (front cowling wire harness–wire harness) 30.Coupler 3 (front cowling wire harness–wire harness) 50.Coupler 5 (front cowling wire harness–wire harness) 67.Engine stop switch 76.Relay unit 91.Lean angle sensor.

  • Page 476: Ignition System

    Ignition system 8-5 et3p66001 circuit diagram (1/2) (fjr13ae) on off g / w b r / lb e e e e e e c b b b c f c c c c b b c b c e e e e e e d a a a a d l br / r br / l br / l br / w r r r / g r w w w w w w r r br / l l / g b / r br / b br / b br / b l / y r / b l l / y l b r b r g / y br / l br / l r ...

  • Page 477: Ignition System

    Ignition system 8-6 1. Main switch 7. Main fuse 8. Battery 13.Coupler 1 (wire harness–front cowling wire harness) 16.Coupler 2 (wire harness–front cowling wire harness) 17.Neutral switch 32.Coupler 3 (wire harness–front cowling wire harness) 33.Sidestand switch 34.Cylinders-#1/#4 ignition coil 35.Sp...

  • Page 478: Ignition System

    Ignition system 8-7 et3p66002 circuit diagram (2/2) (fjr13ae) front cowling wire harness shift down shift up push up down lg r / b l / rb r / g br br / lb r / l r / bb r r br / b b g / l yy gg bb br b b / l r / w r / w r / b w / l b br g / y r / y lg sb / w o / wo / bg / rg / b r / b br / lb b / l d...

  • Page 479: Ignition System

    Ignition system 8-8 13.Coupler 1 (front cowling wire harness–wire harness) 16.Coupler 2 (front cowling wire harness–wire harness) 32.Coupler 3 (front cowling wire harness–wire harness) 63.Coupler 5 (front cowling wire harness–wire harness) 81.Engine stop switch 89.Relay unit 103.Lean angle sensor.

  • Page 480: 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 481: 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 ng → ok ↓ ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng →...

  • Page 482: 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 8-211. Replace the main switch. 9. Check the engine stop switch. Refer to “checking the switches” on page 8-211. Replace the right h...

  • Page 483: Ignition System

    Ignition system 8-12.

  • Page 484: Electric Starting System

    Electric starting system 8-13 eas27160 electric starting system eas27170 circuit diagram (1/2) (fjr13a) r br / l l / g r b / r b br / b br / b br / b br / b l / y l l / y l / y l b b r lg / w b b g / w r / l b / w b3 l / g b l / r b b dg ch y / g l / r g / y br / b br r / b r / w r / w w / l r / w w...

  • Page 485: Electric Starting System

    Electric starting system 8-14 1. Main switch 7. Main fuse 8. Battery 10.Starter relay 11.Starter motor 12.Gear position switch 16.Coupler 2 (wire harness–front cowling wire harness) 30.Coupler 3 (wire harness–front cowling wire harness) 31.Sidestand switch 50.Coupler 5 (wire harness–front cowling wi...

  • Page 486: Electric Starting System

    Electric starting system 8-15 et3p61003 circuit diagram (2/2) (fjr13a) front cowling wire harness g y b g y b r br r / wg / l l / w r / y r / b l / r br / b g / l y l / b g (black) b b b ( gray ) ( gray ) ( gray ) b / l b / w ( gray ) ly / ly / wb / y g / ww / ly / gl / w pb / rg / bg / r b / yy / w...

  • Page 487: Electric Starting System

    Electric starting system 8-16 16.Coupler 2 (front cowling wire harness–wire harness) 30.Coupler 3 (front cowling wire harness–wire harness) 50.Coupler 5 (front cowling wire harness–wire harness) 67.Engine stop switch 68.Start switch 71.Clutch switch 76.Relay unit 77.Starting circuit cut-off relay.

  • Page 488: Electric Starting System

    Electric starting system 8-17 et3p66005 circuit diagram (1/2) (fjr13ae) on off g / w b r / lb e e e e e e c b b b c f c c c c b b c b c e e e e e e d a a a a d l br / r br / l br / l br / w r r r / g r w w w w w w r r br / l l / g b / r br / b br / b br / b l / y r / b l l / y l b r b r g / y br / l...

  • Page 489: Electric Starting System

    Electric starting system 8-18 1. Main switch 7. Main fuse 8. Battery 10.Starter relay 11.Starter motor 12.Diode 1 16.Coupler 2 (wire harness–front cowling wire harness) 17.Neutral switch 24.Rear brake light switch 26.Brake light relay 32.Coupler 3 (wire harness–front cowling wire harness) 33.Sidesta...

  • Page 490: Electric Starting System

    Electric starting system 8-19 et3p66006 circuit diagram (2/2) (fjr13ae) front cowling wire harness shift down shift up push up down lg r / b l / rb r / g br br / lb r / l r / bb r r br / b b g / l yy gg bb br b b / l r / w r / w r / b w / l b br g / y r / y lg sb / w o / wo / bg / rg / b r / b br / ...

  • Page 491: Electric Starting System

    Electric starting system 8-20 16.Coupler 2 (front cowling wire harness–wire harness) 32.Coupler 3 (front cowling wire harness–wire harness) 63.Coupler 5 (front cowling wire harness–wire harness) 80.Front brake light switch 81.Engine stop switch 82.Start switch 89.Relay unit 90.Starting circuit cut-o...

  • Page 492: Electric Starting System

    Electric starting system 8-21 eas27180 starting circuit cut-off system operation (fjr13a) 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 transmi...

  • Page 493: Electric Starting System

    Electric starting system 8-22 et3p66007 starting circuit cut-off system operation (fjr13ae) 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 is ...

  • Page 494: Electric Starting System

    Electric starting system 8-23 eas27190 troubleshooting (fjr13a) 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 ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. C...

  • Page 495: 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 8-211. Replace the main switch. 9. Check the engine stop switch. Refer to “checking the switches” on page 8-211. Replace the right ha...

  • Page 496: Electric Starting System

    Electric starting system 8-25 et3p66008 troubleshooting (fjr13ae) 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 ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1....

  • Page 497: 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 8-221. Replace the brake light relay. 9. Check the ycc-s control relay. Refer to “checking the re- lays” on...

  • Page 498: Electric Starting System

    Electric starting system 8-27 ng → ok ↓ 17.Check the entire starting system wiring. Refer to “circuit diagram (1/2) (fjr13ae)” on page 8-17 and “circuit diagram (2/2) (fjr13ae)” on page 8-19. Properly connect or repair the starting sys- tem wiring. Replace the mcu or diode 1..

  • Page 499: Electric Starting System

    Electric starting system 8-28.

  • Page 500: Charging System

    Charging system 8-29 eas27200 charging system eas27210 circuit diagram r br / l l / g r br / b br / b br / b l / y l l / y l / y l b b r lg / w b b g / w r / l r r r b b b b b b b / w r r / l l / w r / w r b w w g / l r / b l / r br / r g / y r / w br / l br / l br / l l / r br r / y r / y r / y g /...

  • Page 501: Charging System

    Charging system 8-30 2. Rectifier/regulator 3. Ac magneto 7. Main fuse 8. Battery.

  • Page 502: 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 8-217...

  • Page 503: Charging System

    Charging system 8-32.

  • Page 504: Lighting System

    Lighting system 8-33 eas27240 lighting system eas27250 circuit diagram (1/2) r br / l l / g r b / r b br / b br / b br / b br / b l / y l l / y l / y l b b r lg / w b b g / w r / l b / w b3 l / g b l / r b b dg ch y / g l / r g / y br / b br r / b r / w r / w w / l r / w w / g w / y b / w b / w b / ...

  • Page 505: Lighting System

    Lighting system 8-34 1. Main switch 7. Main fuse 8. Battery 25.License plate light 27.Tail/brake light 30.Coupler 3 (wire harness–front cowling wire harness) 40.Ecu (engine control unit) 50.Coupler 5 (wire harness–front cowling wire harness) 51.Headlight relay (on/off) 52.Hazard lighting fuse 54.Hea...

  • Page 506: Lighting System

    Lighting system 8-35 et3p61004 circuit diagram (2/2) front cowling wire harness l / g g y b g y b r br r / wg / l l / w r / y r / b l / r br / b g / l y l / b g (black) b b b ( gray ) ( gray ) ( gray ) b / l b / w ( gray ) ly / ly / wb / y g / ww / ly / gl / w pb / rg / bg / r b / yy / wy / ll l / w...

  • Page 507: Lighting System

    Lighting system 8-36 30.Coupler 3 (front cowling wire harness–wire harness) 50.Coupler 5 (front cowling wire harness–wire harness) 72.Dimmer switch 86.Meter light 87.High beam indicator light 93.Front left turn signal light 94.Front right turn signal light 95.Headlight relay (dimmer) 97.Headlight.

  • Page 508: Lighting System

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

  • Page 509: Lighting System

    Lighting system 8-38 ng → ok ↓ 8. Check the entire lighting system wiring. Refer to “circuit diagram (1/2)” on page 8-33 and “circuit dia- gram (2/2)” on page 8-35. Properly connect or repair the lighting sys- tem wiring. Replace the ecu..

  • Page 510: Signaling System

    Signaling system 8-39 eas27270 signaling system eas27280 circuit diagram (1/2) (fjr13a) r br / l l / g r b / r b br / b br / b br / b br / b l / y l l / y l / y l b b r lg / w b b g / w r / l b / w b3 l / g b l / r b b dg ch y / g l / r g / y br / b br r / b r / w r / w w / l r / w w / g w / y b / w...

  • Page 511: Signaling System

    Signaling system 8-40 1. Main switch 4. Abs ecu fuse 7. Main fuse 8. Battery 12.Gear position switch 13.Coupler 1 (wire harness–front cowling wire harness) 15.Fuel sender 16.Coupler 2 (wire harness–front cowling wire harness) 18.Abs ecu (electronic control unit) 20.Rear wheel sensor 23.Rear brake li...

  • Page 512: Signaling System

    Signaling system 8-41 et3p61005 circuit diagram (2/2) (fjr13a) front cowling wire harness g y b g y b r br r / wg / l l / w r / y r / b l / r br / b g / l y l / b g (black) b b b ( gray ) ( gray ) ( gray ) b / l b / w ( gray ) ly / ly / wb / y g / ww / ly / gl / w pb / rg / bg / r b / yy / wy / ll l...

  • Page 513: Signaling System

    Signaling system 8-42 13.Coupler 1 (front cowling wire harness–wire harness) 16.Coupler 2 (front cowling wire harness–wire harness) 30.Coupler 3 (front cowling wire harness–wire harness) 48.Coupler 4 (front cowling wire harness–wire harness) 50.Coupler 5 (front cowling wire harness–wire harness) 63....

  • Page 514: Signaling System

    Signaling system 8-43 et3p66009 circuit diagram (1/2) (fjr13ae) on off g / w b r / lb e e e e e e c b b b c f c c c c b b c b c e e e e e e d a a a a d l br / r br / l br / l br / w r r r / g r w w w w w w r r br / l l / g b / r br / b br / b br / b l / y r / b l l / y l b r b r g / y br / l br / l ...

  • Page 515: Signaling System

    Signaling system 8-44 1. Main switch 4. Abs ecu fuse 7. Main fuse 8. Battery 13.Coupler 1 (wire harness–front cowling wire harness) 15.Fuel sender 16.Coupler 2 (wire harness–front cowling wire harness) 17.Neutral switch 19.Abs ecu (electronic control unit) 21.Rear wheel sensor 24.Rear brake light sw...

  • Page 516: Signaling System

    Signaling system 8-45 et3p66010 circuit diagram (2/2) (fjr13ae) front cowling wire harness shift down shift up push up down lg r / b l / rb r / g br br / lb r / l r / bb r r br / b b g / l yy gg bb br b b / l r / w r / w r / b w / l b br g / y r / y lg sb / w o / wo / bg / rg / b r / b br / lb b / l...

  • Page 517: Signaling System

    Signaling system 8-46 13.Coupler 1 (front cowling wire harness–wire harness) 16.Coupler 2 (front cowling wire harness–wire harness) 32.Coupler 3 (front cowling wire harness–wire harness) 57.Coupler 4 (front cowling wire harness–wire harness) 63.Coupler 5 (front cowling wire harness–wire harness) 78....

  • Page 518: 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 519: 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 8-211. Replace the left handlebar switch. 2. Ch...

  • Page 520: 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. (fjr13ae) refer to “checking the diode 2 (fjr13ae only)” on page 8-236. Replace the diode 2. 6. Check the entire signaling...

  • Page 521: 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. (fjr13a) ng → ok ↓ 5. Check the entire signaling system wiring. Refer to “circuit diagram (1/2) (fjr13a)” on page 8-39, “circuit diagram (2/2) (...

  • Page 522: 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) (fjr13a)” on page 8-39 and “cir- cuit diagram (2/2) (fjr13a)” on page 8-...

  • Page 523: 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 and abs ecu coupler. (white–white) (black–black) • between abs ecu coupler and ecu coupler. (white/yellow–white/yellow) • between ecu ...

  • Page 524: Cooling System

    Cooling system 8-53 eas27300 cooling system eas27310 circuit diagram r br / l l / g r b / r b br / b br / b br / b br / b l / y l l / y l / y l b b r lg / w b b g / w r / l b / w b3 l / g b l / r b b dg ch y / g l / r g / y br / b br r / b r / w r / w w / l r / w w / g w / y b / w b / w b / w r / l ...

  • Page 525: Cooling System

    Cooling system 8-54 1. Main switch 7. Main fuse 8. Battery 40.Ecu (engine control unit) 43.Coolant temperature sensor 55.Ignition fuse 58.Radiator fan motor relay 59.Left radiator fan motor fuse 60.Left radiator fan motor 61.Right radiator fan motor fuse 62.Right radiator fan motor.

  • Page 526: 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 527: Cooling System

    Cooling system 8-56.

  • Page 528: Fuel Injection System

    Fuel injection system 8-57 eas27330 fuel injection system eas27340 circuit diagram (1/2) (fjr13a) r br / l l / g r b / r b br / b br / b br / b br / b l / y l l / y l / y l b b r lg / w b b g / w r / l b / w b3 l / g b l / r b b dg ch y / g l / r g / y br / b br r / b r / w r / w w / l r / w w / g w...

  • Page 529: Fuel Injection System

    Fuel injection system 8-58 1. Main switch 4. Abs ecu fuse 5. Fuel injection system fuse 7. Main fuse 8. Battery 12.Gear position switch 13.Coupler 1 (wire harness–front cowling wire harness) 14.Fuel pump 16.Coupler 2 (wire harness–front cowling wire harness) 18.Abs ecu (electronic control unit) 20.R...

  • Page 530: Fuel Injection System

    Fuel injection system 8-59 et3p61006 circuit diagram (2/2) (fjr13a) front cowling wire harness g y b g y b r br r / wg / l l / w r / y r / b l / r br / b g / l y l / b g (black) b b b ( gray ) ( gray ) ( gray ) b / l b / w ( gray ) ly / ly / wb / y g / ww / ly / gl / w pb / rg / bg / r b / yy / wy /...

  • Page 531: Fuel Injection System

    Fuel injection system 8-60 13.Coupler 1 (front cowling wire harness–wire harness) 16.Coupler 2 (front cowling wire harness–wire harness) 30.Coupler 3 (front cowling wire harness–wire harness) 50.Coupler 5 (front cowling wire harness–wire harness) 67.Engine stop switch 72.Dimmer switch 76.Relay unit ...

  • Page 532: Fuel Injection System

    Fuel injection system 8-61 et3p66012 circuit diagram (1/2) (fjr13ae) on off g / w b r / lb e e e e e e c b b b c f c c c c b b c b c e e e e e e d a a a a d r l br / r br / l br / l br / w r r r / g r w w w w w w r r br / l l / g b / r br / b br / b br / b l / y r / b l l / y l b r b r g / y br / l ...

  • Page 533: Fuel Injection System

    Fuel injection system 8-62 1. Main switch 4. Abs ecu fuse 5. Fuel injection system fuse 7. Main fuse 8. Battery 13.Coupler 1 (wire harness–front cowling wire harness) 14.Fuel pump 16.Coupler 2 (wire harness–front cowling wire harness) 17.Neutral switch 19.Abs ecu (electronic control unit) 21.Rear wh...

  • Page 534: Fuel Injection System

    Fuel injection system 8-63 et3p66013 circuit diagram (2/2) (fjr13ae) front cowling wire harness shift down shift up push up down lg r / b l / rb r / g br br / lb r / l r / bb r r br / b b g / l yy gg bb br b b / l r / w r / w r / b w / l b br g / y r / y lg sb / w o / wo / bg / rg / b r / b br / lb ...

  • Page 535: Fuel Injection System

    Fuel injection system 8-64 13.Coupler 1 (front cowling wire harness–wire harness) 16.Coupler 2 (front cowling wire harness–wire harness) 32.Coupler 3 (front cowling wire harness–wire harness) 63.Coupler 5 (front cowling wire harness–wire harness) 81.Engine stop switch 85.Dimmer switch 89.Relay unit ...

  • Page 536: 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 537: 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 538: 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 539: 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 540: 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. 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 doe...

  • Page 541: 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 542: 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 front cowling wire harness. • open or short circuit in wire harness. • malfunction in ecu. • defective relay unit (diode). 20 21 coolant temperature sen- sor: open or short...

  • Page 543: Fuel Injection System

    Fuel injection system 8-72 33 malfunction detected in the primary wire of the cylin- ders-#1/#4 ignition coil. • open or short circuit in front cowling wire harness. • open or short circuit in wire harness. • malfunction in cylinders-#1/#4 ignition coil. • malfunction in ecu. 30 34 malfunction detec...

  • Page 544: Fuel Injection System

    Fuel injection system 8-73 sensor operation table er-1 no signals are received from the ecu. • open or short circuit in front cowling wire harness. • open or short circuit in wire harness. • malfunction in meter assembly. • malfunction in ecu. • defective wire connection of the ecu cou- pler. — er-2...

  • Page 545: Fuel Injection System

    Fuel injection system 8-74 07 vehicle speed pulse 0–999 check that the number in- creases when the rear wheel is rotated. The num- ber is cumulative and does not reset each time the wheel is stopped. 08 lean angle sensor remove the lean angle sensor and incline it more than 65 degrees. • upright 0.4...

  • Page 546: 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 61 malfunction history code display — • no history 00 • history exists fault codes 11-50 • (if more than one...

  • Page 547: Fuel Injection System

    Fuel injection system 8-76 37 injector #2 actuates the injector #2 five times at one-second inter- vals. Illuminates the engine trou- ble warning light. Check the operating sound of the injector #2 five times. 38 injector #3 actuates the injector #3 five times at one-second inter- vals. Illuminates ...

  • Page 548: Fuel Injection System

    Fuel injection system 8-77 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 549: 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 550: 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. 03 intake air pressure sensor order item/components and probable cause check or maintenance job reinstatement method 1 connections • intake air pressure sensor coupler...

  • Page 551: Fuel Injection System

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

  • Page 552: Fuel Injection System

    Fuel injection system 8-81 fault code no. 16 symptom stuck throttle position sensor is detected. Diagnostic code no. 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 loosene...

  • Page 553: 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. 20 sidestand switch order item/components and probable cause check or maintenance job reinstatement method 1 connections • wire harness ecu coupler • front ...

  • Page 554: 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. 06 coolant temperature sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of coolant tempera- ture s...

  • Page 555: 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. 05 intake air temperature sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of intake air tem- p...

  • Page 556: 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 557: 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. 08 lean angle sensor order item/components and probable cause check or maintenance job reinstatement method 1 the vehicle has overturned. Raise the veh...

  • Page 558: 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. 01 throttle position sensor order item/components and probable cause check or maintenance j...

  • Page 559: 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 7-3. • check the d...

  • Page 560: 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. 01 throttle position sensor order item/components and probable cause check or maintenance j...

  • Page 561: Fuel Injection System

    Fuel injection system 8-90 5 the fuel pressure is too high. • compare the fuel pressures at idle and with throttle open. About the same → normal too high → refer to the follow- ing table. • checking the pressure regula- tor. • replace if defective. Refer to “checking the fuel pressure” on page 7-8. ...

  • Page 562: Fuel Injection System

    Fuel injection system 8-91 fault code no. 33 symptom malfunction detected in the primary wire of the cylinders- #1/#4 ignition coil. Diagnostic code no. 30 cylinders-#1/#4 ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinders-#...

  • Page 563: Fuel Injection System

    Fuel injection system 8-92 fault code no. 34 symptom malfunction detected in the primary wire of the cylinders- #2/#3 ignition coil. Diagnostic code no. 31 cylinders-#2/#3 ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinders-#...

  • Page 564: Fuel Injection System

    Fuel injection system 8-93 fault code no. 41 symptom lean angle sensor: open or short circuit detected. Diagnostic code no. 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 coupler...

  • Page 565: Fuel Injection System

    Fuel injection system 8-94 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. (fjr13a) open or short circuit is detected in the neutral switch. (fjr13ae) diagnostic code no. ...

  • Page 566: Fuel Injection System

    Fuel injection system 8-95 b-1 connections • gear position switch coupler (fjr13a) • neutral switch coupler (fjr13ae) • wire harness ecu coupler • front cowling wire harness coupler • check the coupler for any pins that may be pulled out. • check the locking condition of the coupler. • if there is a...

  • Page 567: Fuel Injection System

    Fuel injection system 8-96 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. 09 fuel system voltage order item/components and probable cause check or maintenance job reinstatement method 1 connections • r...

  • Page 568: Fuel Injection System

    Fuel injection system 8-97 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 569: Fuel Injection System

    Fuel injection system 8-98 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 570: Fuel Injection System

    Fuel injection system 8-99 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 571: Fuel Injection System

    Fuel injection system 8-100

  • Page 572: Fuel Pump System

    Fuel pump system 8-101 eas27550 fuel pump system eas27560 circuit diagram (1/2) r br / l l / g r b / r b br / b br / b br / b br / b l / y l l / y l / y l b b r lg / w b b g / w r / l b / w b3 l / g b l / r b b dg ch y / g l / r g / y br / b br r / b r / w r / w w / l r / w w / g w / y b / w b / w b...

  • Page 573: Fuel Pump System

    Fuel pump system 8-102 1. Main switch 5. Fuel injection system fuse 7. Main fuse 8. Battery 14.Fuel pump 16.Coupler 2 (wire harness–front cowling wire harness) 40.Ecu (engine control unit) 50.Coupler 5 (wire harness–front cowling wire harness) 55.Ignition fuse.

  • Page 574: Fuel Pump System

    Fuel pump system 8-103 et3p61007 circuit diagram (2/2) front cowling wire harness g y b g y b r br r / wg / l l / w r / y r / b l / r br / b g / l y l / b g (black) b b b ( gray ) ( gray ) ( gray ) b / l b / w ( gray ) ly / ly / wb / y g / ww / ly / gl / w pb / rg / bg / r b / yy / wy / ll l / w g /...

  • Page 575: Fuel Pump System

    Fuel pump system 8-104 16.Coupler 2 (front cowling wire harness–wire harness) 50.Coupler 5 (front cowling wire harness–wire harness) 67.Engine stop switch 76.Relay unit 78.Fuel pump relay.

  • Page 576: Fuel Pump System

    Fuel pump system 8-105 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 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition, ...

  • Page 577: Fuel Pump System

    Fuel pump system 8-106.

  • Page 578: Windshield Drive System

    Windshield drive system 8-107 eas27610 windshield drive system eas27620 circuit diagram (1/2) r br / l l / g r b / r b br / b br / b br / b br / b l / y l l / y l / y l b b r lg / w b b g / w r / l b / w b3 l / g b l / r b b dg ch y / g l / r g / y br / b br r / b r / w r / w w / l r / w w / g w / y...

  • Page 579: Windshield Drive System

    Windshield drive system 8-108 1. Main switch 6. Backup fuse (odometer, clock, and windshield drive system) 7. Main fuse 8. Battery 16.Coupler 2 (wire harness–front cowling wire harness) 50.Coupler 5 (wire harness–front cowling wire harness) 53.Signaling system fuse.

  • Page 580: Windshield Drive System

    Windshield drive system 8-109 et3p61008 circuit diagram (2/2) front cowling wire harness g y b g y b r br r / wg / l l / w r / y r / b l / r br / b g / l y l / b g (black) b b b ( gray ) ( gray ) ( gray ) b / l b / w ( gray ) ly / ly / wb / y g / ww / ly / gl / w pb / rg / bg / r b / yy / wy / ll l ...

  • Page 581: Windshield Drive System

    Windshield drive system 8-110 16.Coupler 2 (front cowling wire harness–wire harness) 50.Coupler 5 (front cowling wire harness–wire harness) 73.Windshield position switch 100.Windshield drive unit.

  • Page 582: Windshield Drive System

    Windshield drive system 8-111 eas27630 troubleshooting the windshield fails to operate. 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 ↓ 1. Check the fuses. (main, signaling system, and bac...

  • Page 583: Windshield Drive System

    Windshield drive system 8-112.

  • Page 584: Accessory Box System

    Accessory box system 8-113 et3p61009 accessory box system et3p61010 circuit diagram (1/2) r br / l l / g r br / b br / b br / b l / y l l / y l / y l b b r lg / w b b g / w r / l r r r b b b b b b b / w r r / l l / w r / w r b w w g / l r / b l / r br / r g / y r / w br / l br / l br / l l / r br r ...

  • Page 585: Accessory Box System

    Accessory box system 8-114 1. Main switch 7. Main fuse 8. Battery 50.Coupler 5 (wire harness–front cowling wire harness) 53.Signaling system fuse.

  • Page 586: Accessory Box System

    Accessory box system 8-115 et3p61011 circuit diagram (2/2) front cowling wire harness g y b g y b r br r / wg / l l / w r / y r / b l / r br / b g / l y l / b g (black) b b b ( gray ) ( gray ) ( gray ) b / l b / w ( gray ) ly / ly / wb / y g / ww / ly / gl / w pb / rg / bg / r b / yy / wy / ll l / w...

  • Page 587: Accessory Box System

    Accessory box system 8-116 50.Coupler 5 (front cowling wire harness–wire harness) 79.Accessory box solenoid.

  • Page 588: Accessory Box System

    Accessory box system 8-117 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 589: Accessory Box System

    Accessory box system 8-118.

  • Page 590: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-119 eas28790 abs (anti-lock brake system) eas27730 circuit diagram (1/2) (fjr13a) r br / l l / g r b / r b br / b br / b br / b br / b l / y l l / y l / y l b b r lg / w b b g / w r / l b / w b3 l / g b l / r b b dg ch y / g l / r g / y br / b br r / b r / w r / w w / ...

  • Page 591: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-120 1. Main switch 4. Abs ecu fuse 7. Main fuse 8. Battery 9. Abs motor fuse 10.Starter relay 13.Coupler 1 (wire harness–front cowling wire harness) 16.Coupler 2 (wire harness–front cowling wire harness) 17.Abs test coupler 18.Abs ecu (electronic control unit) 19.Front...

  • Page 592: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-121 et3p61021 circuit diagram (2/2) (fjr13a) front cowling wire harness g y b g y b r br r / wg / l l / w r / y r / b l / r br / b g / l y l / b g (black) b b b ( gray ) ( gray ) ( gray ) b / l b / w ( gray ) ly / ly / wb / y g / ww / ly / gl / w pb / rg / bg / r b / y...

  • Page 593: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-122 13.Coupler 1 (front cowling wire harness–wire harness) 16.Coupler 2 (front cowling wire harness–wire harness) 30.Coupler 3 (front cowling wire harness–wire harness) 50.Coupler 5 (front cowling wire harness–wire harness) 66.Front brake light switch 67.Engine stop sw...

  • Page 594: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-123 et3p66014 circuit diagram (1/2) (fjr13ae) on off g / w b r / lb e e e e e e c b b b c f c c c c b b c b c e e e e e e d a a a a d l br / r br / l br / l br / w r r r / g r w w w w w w r r br / l l / g b / r br / b br / b br / b l / y r / b l l / y l b r b r g / y b...

  • Page 595: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-124 1. Main switch 4. Abs ecu fuse 7. Main fuse 8. Battery 9. Abs motor fuse 10.Starter relay 12.Diode 1 13.Coupler 1 (wire harness–front cowling wire harness) 16.Coupler 2 (wire harness–front cowling wire harness) 18.Abs test coupler 19.Abs ecu (electronic control uni...

  • Page 596: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-125 et3p66015 circuit diagram (2/2) (fjr13ae) front cowling wire harness shift down shift up push up down lg r / b l / rb r / g br br / lb r / l r / bb r r br / b b g / l yy gg bb br b b / l r / w r / w r / b w / l b br g / y r / y lg sb / w o / wo / bg / rg / b r / b ...

  • Page 597: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-126 13.Coupler 1 (front cowling wire harness–wire harness) 16.Coupler 2 (front cowling wire harness–wire harness) 32.Coupler 3 (front cowling wire harness–wire harness) 63.Coupler 5 (front cowling wire harness–wire harness) 80.Front brake light switch 81.Engine stop sw...

  • Page 598: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-127 eas27740 abs components chart 4 5 6 7 8 9 10 11,12 13 14 1 2 3 a a 15 16 5 7 1. Abs test coupler 2. Abs warning light 3. Abs ecu fuse 4. Abs motor fuse 5. Abs motor relay 6. Abs ecu (electronic control unit) 7. Hydraulic unit (hu) 8. Rear wheel sensor 9. Rear wheel...

  • Page 599: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-128.

  • Page 600: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-129 eas27750 abs coupler location chart 4 r / w w / g w / l w / y r / w r / w 2 b g / r lg sb 3 r / l r / b r / w w / b w w w / b br / b w / l br / w b b b / w g / r g / y w / y lg r / b b w / g w / l w / y r / l y / g sb b2 l / w r / w 7 8 9 w b gy w 1 10 ch dg r / g ...

  • Page 601: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-130 1. Meter assembly coupler 2. Abs test coupler 3. Abs motor relay coupler 4. Hydraulic unit solenoid coupler 5. Abs motor coupler 6. Rear wheel sensor coupler 7. Abs ecu coupler 8. Wire harness–abs wire harness coupler 9. Front wheel sensor coupler 10. Wire harness–...

  • Page 602: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-131 eas27760 abs ecu and abs motor relay removing the abs ecu and abs motor relay order job/parts to remove q’ty remarks rear side cover refer to “general chassis” on page 4-1. Storage compartment refer to “general chassis” on page 4-1. 1 abs ecu cover 1 2 abs ecu coup...

  • Page 603: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-132 eas27770 maintenance of the abs ecu checking the abs ecu 1. Check: • terminals “1” of the abs ecu cracks/damages → replace the abs ecu. • terminals “2” of the abs ecu couplers connection defective, contaminated, come- off → correct or clean. Note: if the abs ecu co...

  • Page 604: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-133 b. Check the solenoid valve insulation. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Check: • abs motor continuity no continuity → replace the hydraulic unit. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester ( Ω × 1) to the abs...

  • Page 605: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-134 self-diagnosis and servicing the abs ecu has a self-diagnosis function. By utilizing this function, quick problem identification and service are possible. Previous malfunctions can be checked since the abs ecu also stores the mal- function history. In case malfunct...

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

    Abs (anti-lock brake system) 8-135 eas27810 basic process for troubleshooting check the fuse. Check the wire harness, connectors, and couplers. Check the main switch. Check the brake switch circuits. Check the battery. Check the meter assembly. For details, use the mal- function codes listed from [c...

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

    Abs (anti-lock brake system) 8-136 note: do not delete the malfunction codes during the troubleshooting procedures. Be sure to delete the codes when the service is finished. Warning ew3p61011 when maintenance or checks have been performed on components related to the abs, be sure to perform a final ...

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

    Abs (anti-lock brake system) 8-137 1. The malfunction code “1” is displayed on the multi-function display (example: malfunction code 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 malfunction code for a past malfunc...

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

    Abs (anti-lock brake system) 8-138 as an example, a “10 digits/1 digit pattern” of the tester reading is shown below. A b 5 6 7 8 9 9 3 2 4 1 10 11 11 1. Abs test coupler 2. Lock plate 3. Protective cap 4. Ground terminal (black) 5. T/c terminal (sky blue) 6. T/f terminal (light green) 7. Abs warnin...

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

    Abs (anti-lock brake system) 8-139 eas27840 [c-1] only the abs warning light fails to come on when the main switch is turned to “on” disconnect the abs ecu couplers and meter assembly coupler, and then connect the test coupler adapter to the abs test coupler. 1. Check for continuity between the whit...

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

    Abs (anti-lock brake system) 8-140 et3p61066 [c-4] the abs warning light flashes with the engine off, check the front and rear brake light switches. Check that the rear brake light switch is adjusted properly, and then check if the brake light comes on when the front or rear brake is applied. 1. The...

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

    Abs (anti-lock brake system) 8-141 • the vehicle was continuously ridden on extremely uneven roads. The system is normal. • the front or rear brake light switch is defective or improperly adjusted. Replace or adjust. Et3p61068 [c-6] the abs warning light remains on 1. The battery voltage is low. • c...

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

    Abs (anti-lock brake system) 8-142 eas27880 [c-7] diagnosis by the malfunction code connect the test coupler adapter to the abs test coupler, and then connect a pocket tester to the light green terminal of the adapter and the positive battery terminal to determine the malfunction code by the movemen...

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

    Abs (anti-lock brake system) 8-143 15/16 no continuity in the front or rear wheel sensor circuits. 15 16 • continuity of the sensor cir- cuits • wire harness and abs wire harness (abs circuit) • connection of the wheel sensor couplers malfunction codes 15 and 16 (see page 8-147.) 21 hydraulic unit s...

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

    Abs (anti-lock brake system) 8-144 42 rear wheel will not recover from the locking tendency even though the sig- nal is continuously transmitted from the abs ecu to release the hydraulic pressure (when the battery voltage is normal). 42 • brake dragging • hydraulic unit operation tests • rear wheel ...

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

    Abs (anti-lock brake system) 8-145 * malfunction code 11 is indicated if the rear wheel rotates for longer than about 20 seconds with the front wheel stopped (e.G., when the vehicle is on the centerstand). Note: malfunction codes 15 (front wheel) and 16 (rear wheel) are indicated if a defective conn...

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

    Abs (anti-lock brake system) 8-146 c. Front wheel sensor circuit is short-circuited. • front wheel sensor or lead is short-circuited. Refer to “maintenance of the front wheel sensor and sensor rotor” on page 4-20 and “installing the front wheel (front brake discs)” on page 4-22. • abs wire harness a...

  • Page 618: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-147 note: if the vehicle is continuously ridden on extremely uneven roads, the abs warning light may flash and malfunction code 11 or 12 may be recorded depending on the condition. Malfunction codes 13/26 (front wheel) and 14/27 (rear wheel) (incorrect signal from the ...

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

    Abs (anti-lock brake system) 8-148 • front or rear wheel sensor or lead is broken. Refer to “maintenance of the front wheel sensor and sensor rotor” on page 4-20, “installing the front wheel (front brake discs)” on page 4-22, “maintenance of the rear wheel sensor and sensor rotor” on page 4-26, and ...

  • Page 620: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-149 malfunction code 23 (front or rear brake light switch is defective.) 1. Wire harness, abs wire harness, and front cowling wire harness • check the entire anti-lock brake system wiring. Refer to “circuit diagram (1/2) (fjr13a)” on page 8-119, “circuit diagram (2/2) ...

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

    Abs (anti-lock brake system) 8-150 malfunction code 25 (no signal is received from the front wheel sensor when the vehicle starts moving.) 1. If any of the following conditions have occurred, malfunction codes (past malfunctions) will be stored in the memory of the abs ecu, but the abs has not malfu...

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

    Abs (anti-lock brake system) 8-151 warning ew3p61005 only use genuine yamaha parts. Using other brake pipes, hoses and union bolts may close the brake hose lines. • check that the connections of the brake hose lines from the brake master cylinder to the hydraulic unit and from the hydraulic unit to ...

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

    Abs (anti-lock brake system) 8-152 malfunction code 42 (rear wheel will not recover from the locking tendency even though the signal is continuously transmitted from the abs ecu to release the hydraulic pressure (when the battery voltage is normal).) 1. Rotation of wheel • check that there is no bra...

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

    Abs (anti-lock brake system) 8-153 6. Hydraulic unit if the malfunction is not corrected after checking items (1) to (5), replace the hydraulic unit. Be sure to connect the brake hoses and couplers correctly and securely. Check the hydraulic unit operation. Refer to “hydraulic unit operation tests” ...

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

    Abs (anti-lock brake system) 8-154 3. Wire harness and abs wire harness • remove the abs motor relay and abs motor fuse, and then check for continuity between the red/blue terminal of abs wire harness and the starter relay abs motor fuse terminal “1” (abs wire harness side) shown in the illustration...

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

    Abs (anti-lock brake system) 8-155 3. Abs ecu • if the malfunction is not corrected after checking items (1) to (2), replace the abs ecu. Malfunction code 51 (front wheel will not recover from the locking tendency even though the signal is continuously transmitted from the abs ecu to release the hyd...

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

    Abs (anti-lock brake system) 8-156 5. The multi-function display switches to the odometer/tripmeter/fuel reserve tripmeter display and the abs warning light flashes in 0.5 second-intervals while the malfunction codes are being deleted. 6. Turn the main switch to “off”. 7. Turn the main switch to “on...

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

    Abs (anti-lock brake system) 8-157 b. Check for continuity between the abs ecu and the start switch lead. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 7. Check: • abs ecu voltage out of specification → replace the right han- dlebar switch. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Co...

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

    Abs (anti-lock brake system) 8-158.

  • Page 630

    Grip warmer system (fjr13ae only) 8-159 et3p66016 grip warmer system (fjr13ae only) et3p66017 circuit diagram (1/2) on off g / w b r / lb e e e e e e c b b b c f c c c c b b c b c e e e e e e d a a a a d l br / r br / l br / l br / w r r r / g r w w w w w w r r br / l l / g b / r br / b br / b br / ...

  • Page 631

    Grip warmer system (fjr13ae only) 8-160 1. Main switch 7. Main fuse 8. Battery 42.Ecu (engine control unit) 63.Coupler 5 (wire harness–front cowling wire harness) 64.Headlight (on/off)/grip warmer relay 66.Signaling system fuse 67.Headlight fuse 70.Grip warmer control unit.

  • Page 632

    Grip warmer system (fjr13ae only) 8-161 et3p66018 circuit diagram (2/2) front cowling wire harness lg r / b l / r br / g br br / l br / l r / b br r br / b b g / l y y g g b b br g / y r / y l / b r / g sb sb / w g l / b y b br r / w l / w r / y br / b g / l l / r r / b b / r b r / b b / r r br r / ...

  • Page 633

    Grip warmer system (fjr13ae only) 8-162 63.Coupler 5 (front cowling wire harness–wire harness) 117.Right grip warmer 118.Left grip warmer.

  • Page 634

    Grip warmer system (fjr13ae only) 8-163 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 foll...

  • Page 635

    Grip warmer system (fjr13ae only) 8-164 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 ...

  • Page 636

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-165 et3p66056 ycc-s (yamaha chip controlled-shift) system (fjr13ae only) et3p66057 circuit diagram (1/2) on off g / w b r / lb e e e e e e c b b b c f c c c c b b c b c e e e e e e d a a a a d g g g br / r br / l br / l br / w r r r / g r ...

  • Page 637

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-166 1. Main switch 7. Main fuse 8. Battery 13.Coupler 1 (wire harness–front cowling wire harness) 16.Coupler 2 (wire harness–front cowling wire harness) 19.Abs ecu (electronic control unit) 24.Rear brake light switch 26.Brake light relay 3...

  • Page 638

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-167 et3p66058 circuit diagram (2/2) front cowling wire harness shift down shift up push up down lg r / b l / rb r / g br br / lb r / l r / bb r r br / b b g / l yy gg bb br b b / l r / w r / w r / b w / l b br g / y r / y lg sb / w o / wo ...

  • Page 639

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-168 13.Coupler 1 (front cowling wire harness–wire harness) 16.Coupler 2 (front cowling wire harness–wire harness) 32.Coupler 3 (front cowling wire harness–wire harness) 57.Coupler 4 (front cowling wire harness–wire harness) 58.Coupler 6 (f...

  • Page 640

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-169 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 p...

  • Page 641

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-170 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. • te...

  • Page 642

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-171 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 indicator ...

  • Page 643

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-172 sh_ _13* overcurrent to clutch actuator motor detected current in shift actuator motor is too high. Unable unable sh_ _14* overcurrent to clutch actuator motor detected current in clutch actuator motor is too high. Unable unable sh_ _1...

  • Page 644

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-173 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-functi...

  • Page 645

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-174 *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 th...

  • Page 646

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-175 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 setti...

  • Page 647

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-176 diagnostic code table diagnos- tic code no. Item data displayed on meter (reference value) checking method sh_ _61 malfunction history code display • no history sh_ _61 — • history exists fault code numbers sh_ _11–sh_ _52 • (first dis...

  • Page 648

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-177 sh_ _63 clutch actuation op- eration note: the checking meth- od for the diagnostic code (sh_ _63) can- not be performed when any of the fol- lowing fault codes are detected. Sh_ _11, sh_ _12, sh_ _13, sh_ _15, sh_ 16, sh_ _17, sh_ _25...

  • Page 649

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-178 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 position,...

  • Page 650

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-179 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 651

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-180 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) co...

  • Page 652

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-181 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, n...

  • Page 653

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-182 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, n...

  • Page 654

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-183 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, n...

  • Page 655

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-184 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, n...

  • Page 656

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-185 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, n...

  • Page 657

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-186 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, n...

  • Page 658

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-187 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, n...

  • Page 659

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-188 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 660

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-189 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 • foot ...

  • Page 661

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-190 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, n...

  • Page 662

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-191 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, n...

  • Page 663

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-192 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, n...

  • Page 664

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-193 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 665

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-194 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, n...

  • Page 666

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-195 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 unit...

  • Page 667

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-196 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 h...

  • Page 668

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-197 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, n...

  • Page 669

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-198 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, n...

  • Page 670

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-199 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, n...

  • Page 671

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-200 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, n...

  • Page 672

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-201 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, n...

  • Page 673

    Ycc-s (yamaha chip controlled-shift) system (fjr13ae only) 8-202.

  • Page 674: Electrical Components

    Electrical components 8-203 eas27970 electrical components fjr13a 1 18 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17.

  • Page 675: Electrical Components

    Electrical components 8-204 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 676: Electrical Components

    Electrical components 8-205 fjr13a 1 17 16 18 19 3 2 4 5 6 7 8 9 10 11 12 13 14 15.

  • Page 677: Electrical Components

    Electrical components 8-206 1. Coolant temperature sensor 2. Throttle position sensor 3. Intake air pressure sensor 4. Intake air temperature sensor 5. Abs motor relay 6. Hydraulic unit 7. Ecu (engine control unit) 8. Abs (ecu) 9. Cylinder identification sensor 10. O 2 sensor 11. Crankshaft position...

  • Page 678: Electrical Components

    Electrical components 8-207 fjr13ae 1 2 3 4 5 6 7 8 9 10 11 12 13 15 14 16 18 19 20 17.

  • Page 679: Electrical Components

    Electrical components 8-208 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 680: Electrical Components

    Electrical components 8-209 fjr13ae 1 19 18 17 20 21 3 2 4 5 6 8 7 9 10 11 12 13 14 15 16.

  • Page 681: Electrical Components

    Electrical components 8-210 1. Coolant temperature sensor 2. Throttle position sensor 3. Intake air pressure sensor 4. Intake air temperature sensor 5. Abs motor relay 6. Hydraulic unit 7. Mcu (motor control unit) 8. Ecu (engine control unit) 9. Abs (ecu) 10. Cylinder identification sensor 11. O 2 s...

  • Page 682: Electrical Components

    Electrical components 8-211 eas27980 checking the switches fjr13a 1 r br on off br l / b l / y r 2 (brown) b b 3 p b lg sb br / w l / b ch dg b / y r / y l / y lg b sb up down 12 dg br / w ch 13 b p 10 r / y l / b 11 b br / w ch dg r / b r / w g / y l / w br 8 l / w b r / w r / b 9 ch dg br / w 7 b ...

  • Page 683: Electrical Components

    Electrical components 8-212 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. Windshield position switch 13. Turn signal switc...

  • Page 684: Electrical Components

    Electrical components 8-213 fjr13ae 1 (brown) b b 3 lg b sb up down 14 dg br / w ch 15 b p 12 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 shift down g / r g / b b / l 11 10 shift up o / w o / b b / l br / l b / l 9 push b...

  • Page 685: Electrical Components

    Electrical components 8-214 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 686: Electrical Components

    Electrical components 8-215 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 687: Electrical Components

    Electrical components 8-216 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 688: Electrical Components

    Electrical components 8-217 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 689: Electrical Components

    Electrical components 8-218 warning ewa13310 never use a fuse with an amperage rating other than that specified. Improvising or us- ing a fuse with the wrong amperage rating may cause extensive damage to the electri- cal system, cause the lighting and ignition systems to malfunction and could possib...

  • Page 690: Electrical Components

    Electrical components 8-219 note: • the charge state of an mf battery can be checked by measuring its open-circuit voltage (i.E., the voltage when the positive battery ter- minal is disconnected). • no charging is necessary when the open-cir- cuit voltage equals or exceeds 12.8 v. B. Check the charg...

  • Page 691: Electrical Components

    Electrical components 8-220 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ charging method using a variable-current (voltage) charger a. Measure the open-circuit voltage prior to charging. Note: voltage should be measured 30 minutes after the engine is stopped. B. Connect a charger and ammeter to...

  • Page 692: Electrical Components

    Electrical components 8-221 10.Install: • front cowling right inner panel 1 refer to “general chassis” on page 4-1. 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...

  • Page 693: Electrical Components

    Electrical components 8-222 headlight relay (on/off) headlight relay (dimmer) first step: second step: brake light relay first step: 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe result continuity (between “3” and “4”) 1. Positive tester ...

  • Page 694: Electrical Components

    Electrical components 8-223 second step: ycc-s control relay (fjr13ae) first step: second step: radiator fan motor relay et3p61059 checking the abs motor relay 1. Remove: • abs motor relay 2. Check: • abs motor relay resistance out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ...

  • Page 695: Electrical Components

    Electrical components 8-224 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Check: • abs motor relay continuity no continuity → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester ( Ω × 1) to the abs motor relay terminal as shown. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ...

  • Page 696: Electrical Components

    Electrical components 8-225 b. Turn the main switch to “on”. C. Measure the turn signal/hazard relay output voltage. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28050 checking the relay unit (diode) 1. Check: • relay unit (diode) out of specification → replace. Note: the pocket tester and t...

  • Page 697: Electrical Components

    Electrical components 8-226 c. Check the relay unit (diode) for continuity. D. Check the relay unit (diode) for no continuity. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28070 checking the spark plug caps the following procedure applies to all of the spark plug caps. 1. Check: • spark plug...

  • Page 698: Electrical Components

    Electrical components 8-227 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 699: Electrical Components

    Electrical components 8-228 c. Turn the main switch to “on”. D. Turn the lean angle sensor to 65°. E. Measure the lean angle sensor output volt- age. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ et3p61016 checking the starter motor operation 1. Check: • starter motor operation does not operate ...

  • Page 700: Electrical Components

    Electrical components 8-229 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 701: Electrical Components

    Electrical components 8-230 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 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 702: Electrical Components

    Electrical components 8-231 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 703: Electrical Components

    Electrical components 8-232 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 704: Electrical Components

    Electrical components 8-233 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 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 705: Electrical Components

    Electrical components 8-234 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 706: Electrical Components

    Electrical components 8-235 et3p66021 checking the gear position sensor (fjr13ae only) 1. Remove: • gear position sensor note: remove only the screws “1” when removing the gear position sensor. Do not remove the screws “2”. 2. Check: • gear position sensor maximum resistance out of specification → r...

  • Page 707: Electrical Components

    Electrical components 8-236 1. Check: • grip warmer resistance out of specification → replace the grip warmer. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the grip warmer coupler from the front cowling wire harness. B. Connect the pocket tester ( Ω × 1) to the grip warmer coupler...

  • Page 708: Electrical Components

    Electrical components 8-237 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the diode 2 from the wire harness. B. Connect the pocket tester ( Ω × 1) to the diode 2 terminals as shown. C. Check the diode 2 for continuity. D. Check the diode 2 for no continuity. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲...

  • Page 709: Troubleshooting

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

  • Page 710: 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 711: 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 712: Troubleshooting

    Troubleshooting 9-3 • bent clutch push rod • damaged clutch boss • 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 pass...

  • Page 713: 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 714

    Eas28740 wiring diagram fjr13av(c) 2006 1. Main switch 2. Rectifier/regulator 3. Ac magneto 4. Abs ecu fuse 5. Fuel injection system fuse 6. Backup fuse (odometer, clock, and windshield drive system) 7. Main fuse 8. Battery 9. Abs motor fuse 10. Starter relay 11. Starter motor 12. Gear position swit...

  • Page 715

    Et3p66050 wiring diagram fjr13aev(c) 2006 1. Main switch 2. Rectifier/regulator 3. Ac magneto 4. Abs ecu fuse 5. Fuel injection system fuse 6. Backup fuse (odometer, clock, and windshield drive system) 7. Main fuse 8. Battery 9. Abs motor fuse 10. Starter relay 11. Starter motor 12. Diode 1 13. Coup...

  • Page 716

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

  • Page 718

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

  • Page 719

    Fjr13av(c) 2006 wiring diagram (1/2) r br / l l / g r b / r b br / b br / b br / b br / b l / y l l / y l / y l b b r lg / w b b g / w r / l b / w b3 l / g b l / r b b dg ch y / g l / r g / y br / b br r / b r / w r / w w / l r / w w / g w / y b / w b / w b / w r / l r / l r / b w / b r / w b b b b2...

  • Page 720

    Fjr13av(c) 2006 wiring diagram (2/2) g y b g y b r br r / w g / l l / w r / y r / b l / r br / b g / l y l / b g (black) b b b (gray) (gray) (gray) b / l b / w (gray) l y / l y / w b / y g / w w / l y / g l / w p b / r g / b g / r b / y y / w y / l l l / w g / r y / g w / l g / w p b / r b / w ch dg...

  • Page 721

    Fjr13av(c) 2006 wiring diagram (1/2) on off (gray) (gray) (blue) (blue) (blue) (blue) (red) (red) (gray) (black) (dark green) c c b c a a a a a a a c c c c c a a a a a b b b a sub-wire harness b d d (gray) (gray) b (gray) (black) (green) (gray) (gray) (gray) (black) (black) (black) (black) (black) (...

  • Page 722

    Fjr13av(c) 2006 wiring diagram (2/2) (black) (black) up down (black) (black) (black) (black) (black) (gray) (gray) (gray) (gray) (gray) (gray) 48 30 13 16 50 63 64 65 66 67 69 70 71 72 73 74 75 76 68 78 79 80 81 82 83 84 85 77 87 88 89 90 91 92 92 93 94 97 97 96 95 86 98 99 100

  • Page 723

    Fjr13aev(c) 2006 wiring diagram (1/2) on off g / w b r / l b e e e e e e c b b b c f c c c c b b c b c e e e e e e d a a a a d r l br / r br / l br / l br / w r r r / g r w w w w w w r r br / l l / g b / r br / b br / b br / b l / y r / b l l / y l b r b r g / y br / l br / l r / y r / w br / b br /...

  • Page 724

    Fjr13aev(c) 2006 wiring diagram (2/2) shift down shift up push up down lg r / b l / r br / g br br / l br / l r / b br r br / b b g / l y y g g b b br b b / l r / w r / w r / b w / l b br g / y r / y lg sb / w o / w o / b g / r g / b r / b br / l b b / l dg ch b b dg br / g l / b ch b dg br / g ch w...

  • Page 725

    Fjr13aev(c) 2006 wiring diagram (1/2) (black) (black) on off e e e e e e c b b b c f c c c c b b c b c e e e e e e d a a a a d g g g sub-wire harness 1 sub-lead 2 sub-lead 1 wire harness abs wire harness wire harness wire harness wire harness abs wire harness wire harness abs wire harness wire harne...

  • Page 726

    Fjr13aev(c) 2006 wiring diagram (2/2) (black) (gray) (gray) (gray) (gray) (black) (black) (black) (black) (black) (gray) (gray) shift down shift up push up down 57 32 13 16 63 78 77 79 80 81 83 84 85 86 87 88 89 82 91 92 93 94 95 96 97 98 90 100 101 102 58 104 103 110 110 111 112 115 99 114 114 113 ...