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2001-YAMAHA FJR 1300 SERVICE MANUAL – PDF DOWNLOAD
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2001-YAMAHA FJR 1300 SERVICE MANUAL – PDF DOWNLOAD
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Description
2001-YAMAHA FJR 1300 SERVICE MANUAL – PDF DOWNLOAD
DESCRIPTION:
2001-YAMAHA FJR 1300 SERVICE MANUAL – PDF DOWNLOAD
NOTICE
- This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual.
- Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
- Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. Yamaha Motor Company, Ltd. is continually striving to improve all of its models.
- Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal- ers and will appear in future editions of this manual where applicable
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS
”. 2 Each chapter is divided into sections. The current section title is shown at the top of each page, except in chapter
3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s) appears. 3 Sub-section titles appear in smaller print than the section title.
4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.
5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step.
6 Symbols indicate parts to be lubricated or replaced. Refer to “SYMBOLS”.
7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.
8 Jobs requiring more information (such as special tools and technical data) are described sequen- tially.
TABLE OF CONTENTS:
2001-YAMAHA FJR 1300 SERVICE MANUAL – PDF DOWNLOAD
Cover..................................................................... 1 TABLE OF CONTENTS..................................................... 7 GENERAL INFORMATION................................................... 10 Identification.................................................... 12 Features.......................................................... 13 FI System......................................................... 14 Fuel Control Block............................................ 15 ECU........................................................... 16 Fuel pump..................................................... 18 Pressure Regulator............................................ 19 Fuel Injector................................................. 20 Crankshaft Position Sensor.................................... 21 Cylinder identification sensor................................ 22 Throttle position sensor...................................... 23 Intake air pressure sensor and atmospheric pressure sensor.... 24 Coolant temperature and Intake temperature sensors............ 25 O2 sensor..................................................... 26 Lean angle cut-off switch..................................... 27 Operation and control......................................... 28 Three-way Catalytic Converter System.............................. 37 Air Induction System.............................................. 41 Instrument Panel.................................................. 43 Important Information............................................. 46 Special Tools..................................................... 49 SPECIFICATIONS........................................................ 55 General Specifications............................................ 57 Engine Specifications............................................. 58 Chassis Specifications............................................ 67 Electrical Specifications......................................... 71 General Tightening Torque Specifications.......................... 74 Engine Tightening Torques......................................... 75 Tightening Sequences.............................................. 78 Chassis Tightening Torques........................................ 79 Lubrication Points and Lubricant Types............................ 81 Oil Flow Diagrams................................................. 84 Cooling System Diagrams........................................... 94 Cable Routing..................................................... 98 PERIODIC CHECKS AND ADJUSTMENTS.......................................114 Introduction and Intervals........................................116 Seats and Fuel Tank...............................................118 Air Filter Case...................................................123 Cowlings and Covers...............................................125 Valve clearance...................................................130 Synchronizing the throttle bodies.................................136 Exhaust gas at idle...............................................138 Exhaust gas volume................................................140 Engine idling speed...............................................143 Throttle cable free play..........................................145 Spark plugs.......................................................147 Ignition timing...................................................148 Compression pressure..............................................150 Engine oil level..................................................152 Changing the engine oil...........................................154 Measuring the engine oil pressure.................................156 Adjusting and checking the clutch.................................158 Bleeding the clutch system........................................159 Cleaning the air filter element...................................161 Throttle body joints..............................................162 Fuel, vacuum and crankcase breather hoses.........................163 Exhaust system....................................................164 Coolant level.....................................................165 Cooling system....................................................166 Changing coolant..................................................167 Front brake adjustment............................................170 Rear brake adjustment.............................................171 Brake fluid level.................................................172 Brake pads........................................................173 Rear brake light switch...........................................173 Brake hoses.......................................................174 Bleeding the brake system.........................................175 Shift pedal adjustment............................................176 Final drive oil...................................................177 Steering head.....................................................178 Front fork........................................................180 Rear shock absorber...............................................183 Tires.............................................................184 Wheels............................................................186 Chassis lubrication...............................................187 Checking and Charging the battery.................................189 Fuses.............................................................194 Headlight bulbs...................................................196 CHASSIS...............................................................201 Front wheel and brake disks.......................................203 Rear wheel and brake disk.........................................211 Front and rear brakes.............................................215 Front brake pads..............................................215 Rear brake pads...............................................216 Replacing front pads..........................................217 Replacing rear pads...........................................219 Front master cylinder.........................................222 Rear master cylinder..........................................225 Disassembling the master cylinders............................228 Checking master cylinders.....................................229 Assembling and installing the front master cylinder...........230 Assembling and installing the rear master cylinder............232 Front brake calipers..........................................235 Rear brake caliper............................................237 Disassembling brake calipers..................................239 Checking the brake calipers...................................241 Assembling and installing the front calipers..................242 Assembling and installing the rear caliper....................244 Hydraulic clutch..................................................248 Disassembling the master cylinder.............................251 Checking the master cylinder..................................252 Assembling and installing the master cylinder.................253 Clutch release cylinder.......................................256 Disassembling the release cylinder............................258 Checking and assembling the release cylinder..................259 Front fork........................................................262 Removing and disassembling fork legs..........................265 Checking the fork legs........................................267 Assembling the fork legs......................................268 Installing the fork legs......................................272 Handlebars........................................................273 Steering head.....................................................279 Rear shock absorber and relay arm.................................284 Swingarm..........................................................289 Shaft drive.......................................................294 Troubleshooting...............................................294 Checking for contamination and leaks..........................297 Ring gear backlash............................................298 Ring gear to stopper bolt clearance...........................300 Removal and disassembly.......................................302 Removing and installing ring gear bearings....................307 Aligning the final drive pinion gear and ring gear............309 Reassembling the final drive..................................312 Installing the U-joint and final drive assembly...............314 ENGINE................................................................316 Mufflers and exhaust pipe assembly................................320 Leads and hoses...................................................321 Removing the engine...............................................323 Installing the engine.............................................325 Camshafts.........................................................327 Removing......................................................330 Checking......................................................331 Camshaft sprockets............................................332 Timing chain tensioner........................................333 Installing ...................................................333 Cylinder head.....................................................338 Removing......................................................338 Checking......................................................339 Installing....................................................340 Valves and valve springs..........................................343 Removing......................................................343 Checking......................................................345 Installing....................................................351 Generator and starter clutch......................................353 Pickup coil rotor.................................................360 Clutch............................................................364 Shift shaft.......................................................374 Oil pan and oil pump..............................................378 Middle gear.......................................................385 Removing......................................................385 Disassembling.................................................387 Checking and assembly.........................................391 Installing the middle drive shaft assembly....................392 Installing the middle driven shaft assembly...................393 Measuring and adjusting backlash..............................394 Aligning the middle gear......................................398 Crankcase.........................................................401 Separating the crankcase......................................401 Disassembling and checking the crankcase......................405 Assembling the crankcase......................................407 Connecting rods and pistons.......................................411 Removing connecting rods and pistons..........................411 Checking the cylinders and pistons............................413 Checking the piston rings and pins............................414 Checking the connecting rods..................................417 Installing the connecting rods and pistons....................419 Crankshaft........................................................423 Transmission......................................................428 Removing the transmission, shift drum and forks...............428 Disassembling the axle assemblies.............................430 Checking and reassembly.......................................434 Installing the transmission...................................437 Balancers.........................................................438 Removal.......................................................438 Checking and installation.....................................440 Adjusting balancer gear lash..................................444 COOLING SYSTEM........................................................447 Radiator..........................................................449 Oil Cooler........................................................453 Thermostat........................................................456 Water pump........................................................460 FUEL INJECTION SYSTEM.................................................468 Components locations..............................................470 Wiring diagram....................................................471 ECU self diagnostic function......................................472 Table of fault code numbers.......................................475 Fail-safe operation...............................................476 Troubleshooting...................................................477 Codes, symptoms and probably causes...........................480 Sensor operation verification table...........................482 Actuator operation verification table.........................483 Troubleshooting basic proceedure..............................484 Troubleshooting the fault code................................485 Diagnosis mode (malfunction not detected).....................497 Throttle bodies...................................................502 Fuel pump and pressure regulator..................................507 Air induction system..............................................509 ELECTRICAL............................................................515 Electrical components locations...................................517 Checking switches.................................................519 Checking bulbs and sockets........................................523 Ignition system...................................................526 Electric starting system..........................................531 Starter motor.....................................................537 Charging system...................................................543 Lighting system...................................................546 Signaling system..................................................553 Cooling system....................................................563 Fuel Injection system.............................................568 1. Main, fuel injection system and ignition fuses ............569 2. Battery....................................................569 3. Main switch................................................569 4. Engine stop switch.........................................569 5. Fuel injection system relay................................570 6. Fuel pump resistance.......................................570 7. Crankshaft position sensor resistance......................570 8. Cylinder identification sensor output voltage..............571 9. Speed sensor output voltage................................571 10.Coolant temperature sensor.................................572 11.Intake air temperature sensor resistance...................573 12.Intake air pressure sensor output voltage..................573 13.Atmospheric pressure sensor output voltage.................574 14.AI system solenoid.........................................574 CHECKING THE FUEL PUMP........................................575 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR...........576 Windshield drive system...........................................580 TROUBLESHOOTING.......................................................584 Starting problems.................................................586 Incorrect engine idling speed.....................................587 Poor medium and high speed performance............................588 Faulty gear shifting..............................................588 Faulty clutch.....................................................589 Overheating.......................................................589 Poor braking performance..........................................590 Faulty front fork legs............................................590 Unstable handling.................................................591 Faulty lighting or signaling system...............................591 WIRING DIAGRAM (for Europe)...........................................596 WIRING DIAGRAM (for Oceania)..........................................597 WIRING DIAGRAM (for North America)....................................598 micapeak.com.............................................................. 0 The "Barbarian Jumper Mod"............................................599 Installing Riv-Nut ports in the FJR's Headers.........................608
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