![Yamaha FJR1300(N) (2001) [222/617] Front master cylinder](/img/pdf.png)
Yamaha FJR1300(N) (2001) [222/617] Front master cylinder
![Yamaha FJR1300(N) (2001) [222/617] Front master cylinder](/views2/1121433/page222/bgde.png)
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CHAS
FRONT AND REAR BRAKES
EAS00584
FRONT BRAKE MASTER CYLINDER
Order Job/Part Q’ty Remarks
Removing the front brake master
cylinder
Remove the parts in the order listed.
Brake fluid Drain.
1 Brake master cylinder reservoir cap 1
2 Brake master cylinder reservoir dia-
phragm holder
1
3 Brake master cylinder reservoir dia-
phragm
1
4Brake lever 1
5 Front brake light switch connector 2 Disconnect.
Содержание
- Caution 4
- Important manual information 4
- Notice 4
- Warning 4
- How to use this manual 5
- Chk adj 6
- Gen info 6
- Symbols 6
- Trbl shtg 6
- Chassis 7
- Cooling system 7
- Electrical system 7
- Engine 7
- Fuel injection system 7
- General information 7
- Periodic checks and adjustments 7
- Specifications 7
- Table of contents 7
- Troubleshooting 7
- Chapter 1 general information 10
- Gen info 10
- General information 10
- Gen info 12
- General information 12
- Identification 12
- Motorcycle identification 12
- Features 13
- Gen info 13
- Outline the main function of a fuel supply system is to provide fuel to the combustion chamber at the opti mum air fuel ratio in accordance with the engine operating conditions and the atmospheric tempera ture in the conventional carburetor system the air fuel ratio of the mixture that is supplied to the com bustion chamber is created by the volume of the intake air and the fuel that is metered by the jet that is used in the respective chamber despite the same volume of intake air the fuel volume requirement varies by the engine operating conditions such as acceleration deceleration or operating under a heavy load carburetors that meter the fuel through the use of jets have been provided with various auxiliary devices so that an optimum air fuel ratio can be achieved to accommodate the constant changes in the operating con ditions of the engine as the requirements for the engine to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel 13
- 4 3 2 1 14
- Features 14
- Fi system 14
- Fi system the fuel pump delivers fuel to the injector via the fuel filter the pressure regulator maintains the fuel pressure that is applied to the injector at only 2 5 kg c 14
- Gen info 14
- Higher than the intake manifold pres sure accordingly when the energizing signal from the ecu energizes the injector the fuel passage opens causing the fuel to be injected into the intake manifold only during the time the passage remains open therefore the longer the length of time the injector is energized injection duration the greater the volume of fuel that is supplied conversely the shorter the length of time the injector is energized injection duration the lesser the volume of fuel that is supplied 14
- Illustration is for reference only 14
- Sensor enable the ecu to determine the injection duration the injection timing is determined through the signals from the crankshaft position sensor and the cylinder identification sensor as a result the volume of fuel that is required by the engine can be supplied at all times in accordance with the driving conditions 14
- The injection duration and the injection timing are controlled by the ecu signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor atmospheric pressure sensor intake temperature sensor coolant temperature sensor and 14
- Features 15
- Fuel control block 15
- Gen info 15
- Components ecu electronic control unit the ecu is mounted underneath the seat below the toolbox the main functions of the ecu are ignition control fuel control self diagnosis and load control ecu s internal construction and functions the main components and functions of the ecu can be broadly divided into the following four items a power supply circuit the power supply circuit obtains power from the battery 12 v to supply the power 5 v that is required for operating the ecu b input interface circuits the input interface circuits convert the signals output by all the sensors into digital signals which can be processed by the cpu and input them into the cpu c cpu central processing unit the cpu determines the condition of the sensors in accordance with the level of the signal that is output by the respective sensor then the signals are temporarily stored on the ram in the cpu based on those stored signals and the basic processing program on the rom the cpu calculates the fuel injection d 16
- Features 16
- Gen info 16
- Features 17
- Gen info 17
- Features 18
- Fuel pump 18
- Gen info 18
- Features 19
- Gen info 19
- Pressure regulator 19
- Pressure regulator it regulates the fuel pressure that is applied to the injectors that are provided in the cylinders in order to maintain a constant pressure difference with the pressure in the intake manifold the fuel that is delivered by the fuel pump fills the fuel chamber through the fuel inlet of the regulator and exerts pressure on the diaphragm in the direction for opening the valve a spring that is provided in the spring chamber exerts pressure on the diaphragm in the direction for closing the valve in contrast to the pressure of the fuel thus the valve cannot open unless the fuel pressure overcomes the spring force an intake vacuum is applied to the spring chamber via a pipe when the pressure of the fuel exceeds the sum of the intake vacuum and the spring force the valve that is integrated with the dia phragm opens allowing the fuel to return from the fuel outlet to the fuel tank via the fuel return hose as a result because the intake vacuum fluctuates in accordance with the 19
- Features 20
- Fuel injector 20
- Fuel injector upon receiving injection signals from the ecu the fuel injector injects fuel in the normal state the core is pressed downward by the force of the spring as illustrated the needle that is integrated with the bottom of the core keeps the fuel passage closed when the current flows to the coil in accordance with the signal from the ecu the core is drawn upward allowing the flange that is integrated with the needle to move to the spacer since the dis tance of the movement of the needle is thus kept constant the opening area of the fuel passage also becomes constant because the pressure difference of the fuel to the intake manifold pressure is kept constant by the pressure regulator the fuel volume varies in proportion to the length of time the coil is energized the injector that has been recently adopted has a four hole type injection ori fice that enhances the atomization of fuel and improves combustion efficiency 20
- Gen info 20
- Crankshaft position sensor 21
- Features 21
- Gen info 21
- 180 180 180 22
- Cylinder identification sensor 22
- Cylinder identification sensor the cylinder identification sensor is mounted on the exhaust head cover of the 4 cylinder when the exhaust cam of the 4 cylinder rotates and the lift of the cam passes by the sensor the sensor generates a signal and sends it to the ecu based on this signal and the signal from the crankshaft position sensor the ecu then actuates the injector of the cylinder that is currently in order to supply fuel 22
- Features 22
- Gen info 22
- Features 23
- Gen info 23
- Throttle position sensor 23
- Throttle position sensor the throttle position sensor measures the intake air volume by detecting the position of the throttle valve it detects the mechanical angle of the throttle valve through the positional relationship between the moving contact that moves in unison with the throttle shaft and the resistor board in actual operation the ecu supplies 5 v power to both ends of the resistor board and the voltage that is output by the throttle position sensor is used to determine the angle of the throttle valve 23
- Features 24
- Gen info 24
- Intake air pressure sensor and atmospheric pressure sensor 24
- Intake air pressure sensor and atmospheric pressure sensor intake air pressure sensor the intake air pressure sensor is used for measuring the intake air volume the intake air volume of every intake stroke is proportionate to the intake air pressure therefore the intake air volume can be measured by measuring the intake air pressure the intake air pressure sensor converts the mea sured intake air pressure into electrical signals and sends those signals to the ecu when the intake air pressure is introduced into the sensor unit which contains a vacuum chamber on one side of the silicon diaphragm the silicon chip that is mounted on the silicon diaphragm converts the intake air pressure into electrical signals then an integrated circuit ic amplifies and adjusts the signals and makes temperature compensations in order to generate electrical signals that are proportionate to the pressure atmospheric pressure sensor the atmospheric pressure sensor is used for making compensations to the chang 24
- Coolant temperature and intake temperature sensors 25
- Coolant temperature sensor the signals from the coolant temperature sensor are used primarily for making fuel volume compen sations during starting and warm up the coolant temperature sensor converts the temperature of the coolant into electrical signals and sends them to the ecu 25
- Features 25
- Gen info 25
- Intake temperature sensor the intake temperature sensor corrects the deviation of the air fuel mixture that is associated with the changes in the intake air density which are created by the changes in the intake air temperature that occur due to atmospheric temperatures this sensor uses a semi conductor thermistor that has a large resistance at low temperatures and a small resistance at high temperatures the thermistor converts the temperature dependent changes in resistance into electrical resistance values which are then input into the ecu 25
- Features 26
- Gen info 26
- O2 sensor 26
- Sensor has been adopted to enable the catalyst to function at a high degree of efficiency by maintaining the air fuel mixture near the stoichiometric ratio 14 1 this sensor which is a zirco nia type utilizes the oxygen ion conductivity of the solid electrolyte for detecting the oxygen concen tration levels in actual operation a zirconia tube made of solid electrolyte is exposed in the exhaust gas so that the exterior of the zirconia tube is in contact with the exhaust gas and the interior is in contact with the atmosphere whose oxygen concentration level is known when a difference in the oxygen concentration level is created between the outside and the inside of the zirconia tube the oxygen ion passes through the zirconia element and generates an electromotive force the electro motive force increases when the oxygen concentration level is low rich air fuel ratio and the elec tromotive force decreases when the oxygen concentration level is high lean air fuel ratio as electromotive force 26
- Sensor the 26
- Features 27
- Gen info 27
- Lean angle cut off switch 27
- Lean angle cut off switch the lean angle cut off switch stops the supply of fuel to the engine in case the motorcycle overturns when the motorcycle is in the normal state the cut off switch outputs a constant voltage of approxi mately 1 v low level when the motorcycle tilts the float in the switch tilts in proportion to the tilt of the motorcycle however the voltage output to the ecu remains unchanged at the low level when the tilt of the motorcycle exceeds 70 degrees according to the tilt of the float the signal from the sensor increases to approximately 4 v high level when the ecu receives the high level volt age it determines that the motorcycle has overturned and stops the delivery of fuel to the engine by turning off the fuel injection system relay that powers the fuel pump and the injectors once the cut off switch is tripped the ecu maintains this state therefore even if the motorcycle has recov ered its upright position this state will not be canceled unless the main switch is t 27
- Detection of intake air volume the intake air volume is detected primarily through the signals from the throttle position sensor and the intake air pressure sensor the intake air volume is determined in accordance with the signals from the atmospheric pressure sensor intake temperature sensor and the engine speed data composition of basic injection duration 28
- Features 28
- Fuel injection system operation and control the fuel injection timing injection duration ignition timing and the coil energizing duration are con trolled by the ecu to determine the basic injection timing the ecu calculates the intake air volume through the signals from the intake air pressure sensor throttle position sensor cylinder identifica tion sensor and crankshaft position sensor furthermore the ecu calculates the final injection timing by adding the following compensations to the aforementioned basic injection duration those obtained from the state of acceleration as well as those based on the signals from various sensors such as the coolant temperature intake tem perature atmospheric and exhaust pipe oxygen concentration level at the same time the ecu assesses the crankshaft position through the signals from the cylinder identification sensor and the crankshaft position sensor then when the ecu determines that it is time to inject fuel it sends an injection command to the inje 28
- Gen info 28
- Operation and control 28
- Determining the final injection duration the intake air volume determines the basic injection duration however at a given intake air vol ume the volume of fuel that is required varies by the engine operating conditions such as accelera tion or deceleration or by weather conditions this system uses various sensors to precisely check these conditions applies compensations to the basic injection duration and determines the final injection duration based on the operating condition of the engine 29
- Features 29
- Gen info 29
- The fuel is cut off under conditions that do not require fuel in order to stop the injection 29
- Acceleration compensation decelera tion compensation 5 intake air pressure intake air pressure sensor 30
- After start enrichment 2 coolant temperature coolant temperature sensor 30
- After start injection 30
- Air fuel ratio feedback compensation 6 exhaust gas residual oxy gen concentration 30
- Compensation item check item sensor used 30
- Composition of final injection duration 30
- Coolant temperature coolant temperature sensor 30
- Features 30
- Gen info 30
- Intake temperature compensation 4 intake temperature intake temperature sensor 30
- List of fuel injection compensations 30
- Reactive injection duration a lag is created between the time the ecu outputs a fuel injection signal to the injector and the time the injector actually opens therefore the ecu calculates this lag in advance before sending the actuation signal to the injector the battery voltage determines the reactive injection duration high voltage short reactive injection duration low voltage long reactive injection duration 30
- Sensor 30
- Starting injection 1 coolant temperature coolant temperature sensor 30
- Throttle position throttle position sensor 30
- Warm up enrichment 3 coolant temperature coolant temperature sensor 30
- 2 4 3 1 2 4 3 1 31
- Features 31
- Fuel control during normal driving in synchronous injection during normal driving fuel is injected on a cylinder by cylinder basis when all of the conditions below are met 31
- Fuel injection control during normal driving 31
- Gen info 31
- Sensor is added to determine the final injection duration as a result fuel is supplied to the cylinders normal synchronous injection 31
- To determine the injection timing the ecu calculates the injection timing through the use of the 3d control map provided in the ecu which is based on the throttle position and the engine speed the injection duration is based on the basic injection duration obtained through the throttle position intake air pressure and engine speed to which injection duration compensation based on the sig nals from various sensors such as the intake temperature sensor atmospheric pressure sensor and 31
- Features 32
- Gen info 32
- After start enrichment after start enrichment provides enrichment compensation during a prescribed duration following the starting firing of the engine while the amount of fuel enrichment is determined by the after start enrichment coefficient the coefficient varies by the coolant temperature although the coolant tem perature determines the initial starting enrichment coefficient the coefficient subsequently changes in accordance with the damping factor the enrichment ratio is the highest immediately after the engine is started and diminishes gradually the enrichment of fuel in this manner ensures a stable engine operation immediately after the engine is started 33
- Changes in compensation coefficient and compensation injection duration 33
- Features 33
- Gen info 33
- Starting cylinder control 33
- Changes in compensation coefficient and compensation injection duration 34
- Features 34
- Gen info 34
- Warm up enrichment when the coolant temperature is low a warm up coefficient is applied in accordance with the sig nals from the coolant temperature sensor in order to effect fuel enrichment because the coolant temperature determines the coefficient the coefficient changes with the fluctuations in the coolant temperature the coefficient increases with the decrease in the coolant temperature and decreases with the increase in the coolant temperature the ratio of fuel enrichment also changes with the changes in the coefficient 34
- Features 35
- Gen info 35
- Features 36
- Gen info 36
- Features 37
- Gen info 37
- Sensor and the three way catalytic converter system by effecting com prehensive control of the air fuel ratio in this manner this system reduces the co hc and nox in the exhaust gases the fi system controls the mixture to an optimal air fuel ratio basic air fuel ratio that matches the operating condition of the engine in order to realize an ideal combustion furthermore an 37
- Sensor that detects the concentration of oxygen that remains in the exhaust gas is provided in the exhaust pipe for the purpose of maximizing the performance of the three way cat alytic converter and to clean the exhaust gas at a high degree of efficiency based on this data the ecu applies more precise compensation to the basic air fuel ratio in order to maintain the mixture in the vicinity of the stoichiometric air fuel ratio of 14 1 through the joint effort of these control systems the exhaust gas is cleaned in a highly efficient manner without sacrificing engine performance 37
- Three way catalytic converter system 37
- Three way catalytic converter system diagram 37
- Three way catalytic converter system system outline this is a highly efficient exhaust gas cleaning system that effects air fuel control through a joint effort by the fi system 37
- Features 38
- Gen info 38
- Features 39
- Gen info 39
- Large amounts of both co and hc are generated when the mixture is rich as indicated by insuffi cient 39
- Region a conversely large amounts of nox are generated when the mixture is lean as indicated by excessive 39
- Region b under these conflicting characteristics the system maintains the mixture within an extremely narrow range c of stoichiometric ratio 14 1 as a result the function of the catalyst is maximized making it possible to clean the exhaust gases at a high degree of efficiency 39
- Air fuel ratio compensation equipment an 40
- Features 40
- Gen info 40
- Illustration is for reference only 40
- Sensor detects the level of concentration of the oxy gen remaining in the exhaust gases a high level of oxygen concentration signifies a lean air fuel mixture and when the 40
- Sensor detects this condition it inputs a lean signal into the ecu conversely when the level of oxygen concentration is low the 40
- Sensor inputs a rich signal into the ecu the ecu system applies minute corrections to these signals so that the injection volume the dura tion of the current applied to the injectors comes to be within the vicinity of the stoichiometric ratio thus the system is designed to maximize the cleaning function of the catalyst feedback compensation circuit 40
- Sensor is provided in the exhaust pipe upstream of the catalyst to enable the catalyst to operate at a high degree of efficiency the 40
- Air induction system 41
- Features 41
- Gen info 41
- Components 1 air cut off valve the air cut off valve consists of a plunger that is mounted inside the core of a solenoid coil and a valve at the end of the plunger for opening and closing the air passage due to the force of a spring the valve is in constant contact with valve block a and thus keeps the air passage open as a result the air from the air cleaner passes through the air passage and flows into the reed valves of the cyl inders when the current flows to the solenoid coil in accordance with a signal from the ecu the plunger in the core becomes attracted towards the coil when this attraction force overcomes the pressure of the spring the valve is pulled in along with the plunger comes in contact with valve block b and closes the air passage the ecu controls the operation of the air cut off valve so that it operates in an optimal condition to suit the driving conditions 42
- Features 42
- Gen info 42
- Features 43
- Gen info 43
- Instrument panel 43
- Features 44
- Gen info 44
- Features 45
- Gen info 45
- Gen info 46
- Important information 46
- Caution 47
- Gen info 47
- Important information 47
- Gen info 48
- Important information 48
- Gen info 49
- Special tools 49
- 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 inappropri ate tools or improvised techniques special tools part numbers or both may differ depending on the country when placing an order refer to the list provided below to avoid any mistakes 49
- Tool no tool name function illustration 49
- Gen info 50
- Special tools 50
- Tool no tool name function illustration 50
- Gen info 51
- Special tools 51
- Tool no tool name function illustration 51
- Gen info 52
- Special tools 52
- Tool no tool name function illustration 52
- Gen info 53
- Special tools 53
- Tool no tool name function illustration 53
- Chapter 2 specifications 55
- Specifications 55
- General specifications 57
- Specifications 57
- Engine specifications 58
- Engine specifications 59
- Engine specifications 60
- Engine specifications 61
- Engine specifications 62
- Engine specifications 63
- Engine specifications 64
- Engine specifications 65
- Engine specifications 66
- Chassis specifications 67
- Chassis specifications 68
- Chassis specifications 69
- Chassis specifications 70
- Electrical specifications 71
- Electrical specifications 72
- Electrical specifications 73
- A nut b bolt 74
- A width across flats b thread diameter 74
- All specification data in this manual are listed in si and metric units use this table to convert metric unit data to imperial unit data 74
- Conversion table 74
- Conversion table general tightening torque specifications 74
- General tightening torque specifications 74
- General tightening torques 74
- Metric multiplier imperial 74
- Mm 0 3937 0 8 in 74
- Mm 0 3937 in 74
- Mm 10 mm 30 3 22 74
- Mm 12 mm 55 5 40 74
- Mm 14 mm 85 8 61 74
- Mm 16 mm 130 13 94 74
- Mm 6 mm 6 0 4 74
- Mm 8 mm 15 1 11 74
- Nm m kg ft lb 74
- This chart specifies tightening torques for stan dard fasteners with a standard iso thread pitch tightening torque specifications for spe cial components or assemblies are provided for each chapter of this manual to avoid warpage tighten multi fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached unless otherwise specified tightening torque specifications require clean dry threads com ponents should be at room temperature 74
- Engine tightening torques 75
- Tightening torques 75
- Tightening torques 76
- Tightening torques 77
- Tightening sequences 78
- Chassis tightening torques 79
- Tightening torques 79
- Tightening torques 80
- Lubrication points and lubricant types 81
- Lubrication points and lubricant types 82
- Lubrication points and lubricant types 83
- Oil flow diagrams 84
- Oil flow diagrams 85
- Oil flow diagrams 86
- Oil flow diagrams 87
- Oil flow diagrams 88
- Oil flow diagrams 89
- Oil flow diagrams 90
- Oil flow diagrams 91
- Oil flow diagrams 92
- Oil flow diagrams 93
- Cooling system diagrams 94
- Cooling system diagrams 95
- Cooling system diagrams 96
- Cooling system diagrams 97
- Cable routing 98
- Cable routing 99
- Cable routing 100
- Cable routing 101
- Cable routing 102
- Cable routing 104
- Cable routing 105
- Cable routing 106
- Cable routing 107
- Cable routing 108
- Cable routing 109
- Cable routing 110
- Cable routing 111
- Chapter 3 periodic checks and adjustments 114
- Chk adj 114
- Periodic checks and adjustments 114
- Chk adj 115
- Chk adj 116
- Introduction 116
- Introduction and intervals 116
- Introduction periodic maintenance and lubrication intervals 116
- Note the annual checks must be performed every year except if a kilometer based maintenance is performed instead from 50 000 km repeat the maintenance intervals starting from 10 000 km items marked with an asterisk should be performed by a yamaha dealer as they require special tools data and technical skills 116
- Periodic checks and adjustments 116
- Periodic maintenance and lubrication intervals 116
- 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 longer service life and reduce the need for costly overhaul work this information applies to vehicles already in service as well as to new vehicles that are being prepared for sale all service technicians should be familiar with this entire chapter 116
- Chk adj 117
- Note the air filter needs more frequent service if you are riding in unusually wet or dusty areas hydraulic brake and clutch systems after disassembling the brake or clutch master cylinders caliper cylinders or clutch release cylin der always change the fluid regularly check the brake and clutch fluid levels and fill the reser voirs as required replace the oil seals on the inner parts of the brake or clutch master cylinders caliper cylinders and clutch release cylinder every two years replace the brake and clutch hoses every four years or if cracked or damaged 117
- Periodic maintenance and lubrication intervals 117
- Chk adj 118
- Seats and fuel tank 118
- Chk adj 119
- Seats and fuel tank 119
- Chk adj 120
- Seats and fuel tank 120
- Caution 121
- Chk adj 121
- Seats and fuel tank 121
- Caution 122
- Chk adj 122
- Seats and fuel tank 122
- Air filter case 123
- Chk adj 123
- Air filter case 124
- Chk adj 124
- Chk adj 125
- Cowlings and covers 125
- Chk adj 126
- Cowlings and covers 126
- Chk adj 127
- Cowlings and covers 127
- 8 7 4 6 5 3 128
- Chk adj 128
- Cowlings and covers 128
- Chk adj 129
- Cowlings and covers 129
- Adjusting the valve clearance 130
- Chk adj 130
- Engine 130
- Valve clearance 130
- Adjusting the valve clearance 131
- Chk adj 131
- Adjusting the valve clearance 132
- Chk adj 132
- Adjusting the valve clearance 133
- Chk adj 133
- Adjusting the valve clearance 134
- Chk adj 134
- Adjusting the valve clearance 135
- Chk adj 135
- Exhaust 135
- Intake 135
- Valve clearance cold 0 5 0 2 mm example installed is pad 150 measured clearance is 0 0 mm replace pad 150 with pad 160 pad number example pad no 150 1 0 mm pad no 160 1 0 mm always install pad with number down 135
- Valve clearance cold 0 8 0 5 mm example installed is pad 175 measured clearance is 0 2 mm replace pad 175 with pad 185 pad number example pad no 175 1 5 mm pad no 185 1 5 mm always install pad with number down 135
- Adjusting the valve clearance synchronizing the throttle bodies 136
- Chk adj 136
- Synchronizing the throttle bodies 136
- Caution 137
- Chk adj 137
- Synchronizing the throttle bodies 137
- Chk adj 138
- Exhaust gas at idle 138
- Note on north american models the ecu jumper must be relocated prior to performing the following proceedure please refer to http www micapeak com bike fjr1300 howto jumper html 138
- Synchronizing the throttle bodies checking and adjusting the exhaust gas at idle 138
- Checking and adjusting the exhaust gas at idle 139
- Chk adj 139
- Note not all bikes are equipped with the exhaust ports on the headers refer to http www micapeak com bike fjr1300 howto rivnut html for directions on how to add them 139
- Checking and adjusting the exhaust gas at idle adjusting the exhaust gas volume 140
- Chk adj 140
- Exhaust gas volume 140
- Adjusting the exhaust gas volume 141
- Chk adj 141
- Checking the exhaust gas at idle 142
- Chk adj 142
- Checking the exhaust gas at idle adjusting the engine idling speed 143
- Chk adj 143
- Engine idling speed 143
- Adjusting the engine idling speed 144
- Chk adj 144
- Adjusting the engine idling speed adjusting the throttle cable free play 145
- Chk adj 145
- Throttle cable free play 145
- Adjusting the throttle cable free play 146
- Chk adj 146
- Adjusting the throttle cable free play checking the spark plugs 147
- Caution 147
- Chk adj 147
- Spark plugs 147
- Warning 147
- Checking the spark plugs checking the ignition timing 148
- Chk adj 148
- Ignition timing 148
- Checking the ignition timing 149
- Chk adj 149
- Caution 150
- Checking the ignition timing measuring the compression pressure 150
- Chk adj 150
- Compression pressure 150
- Chk adj 151
- Measuring the compression pressure 151
- Warning 151
- Chk adj 152
- Engine oil level 152
- Measuring the compression pressure checking the engine oil level 152
- Caution 153
- Checking the engine oil level 153
- Chk adj 153
- Caution 154
- Changing the engine oil 154
- Chk adj 154
- Changing the engine oil 155
- Chk adj 155
- A slightly loosen the oil gallery bolt 1 b start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt if no engine oil comes out after one minute turn the engine off so that it will not seize c check the engine oil passages the oil filter cartridge and the oil pump for damage or leakage refer to oil pan and oil pump in chapter 5 d start the engine after solving the problem s and check the engine oil pressure again e tighten the oil gallery bolt to specification 156
- Caution 156
- Changing the engine oil measuring the engine oil pressure 156
- Check engine oil pressure 156
- Chk adj 156
- Measuring the engine oil pressure 156
- Measuring the engine oil pressure 1 check engine oil level below the minimum level mark add the recommended engine oil to the proper level 2 remove side cowlings 3 start the engine warm it up for several min utes and then turn it off 156
- Oil gallery bolt 20 nm 2 m kg 156
- When the engine is cold the engine oil will have a higher viscosity causing the engine oil pressure to increase therefore be sure to measure the engine oil pressure after warming up the engine 156
- Chk adj 157
- Measuring the engine oil pressure 157
- Warning 157
- Adjusting and checking the clutch 158
- Adjusting the clutch lever checking the clutch fluid level 158
- Chk adj 158
- Warning 158
- Bleeding the clutch system 159
- Caution 159
- Checking the clutch fluid level bleeding the hydraulic clutch system 159
- Chk adj 159
- Warning 159
- Bleeding the hydraulic clutch system 160
- Chk adj 160
- Bleeding the hydraulic clutch system cleaning the air filter element 161
- Chk adj 161
- Cleaning the air filter element 161
- Warning 161
- Caution 162
- Chk adj 162
- Cleaning the air filter element checking the throttle body joints 162
- Throttle body joints 162
- Caution 163
- Checking the fuel and vacuum hoses checking the crankcase breather hose 163
- Chk adj 163
- Fuel vacuum and crankcase breather hoses 163
- Checking the exhaust system 164
- Chk adj 164
- Exhaust system 164
- Caution 165
- Checking the coolant level 165
- Chk adj 165
- Coolant level 165
- Checking the cooling system 166
- Chk adj 166
- Cooling system 166
- Changing coolant 167
- Changing the coolant 167
- Chk adj 167
- Warning 167
- Changing the coolant 168
- Chk adj 168
- Warning 168
- Caution 169
- Changing the coolant 169
- Chk adj 169
- Adjusting the front brake 170
- Caution 170
- Chassis 170
- Chk adj 170
- Front brake adjustment 170
- Warning 170
- Adjusting the rear brake 171
- Caution 171
- Chk adj 171
- Rear brake adjustment 171
- Warning 171
- Adjusting the rear brake checking the brake fluid level 172
- Brake fluid level 172
- Chk adj 172
- Warning 172
- Brake pads 173
- Caution 173
- Chk adj 173
- Rear brake light switch 173
- Adjusting the rear brake light switch checking the brake hoses 174
- Brake hoses 174
- Chk adj 174
- Bleeding the brake system 175
- Bleeding the hydraulic brake system 175
- Chk adj 175
- Warning 175
- Bleeding the hydraulic brake system adjusting the shift pedal 176
- Chk adj 176
- Shift pedal adjustment 176
- Warning 176
- Adjusting the shift pedal checking the final drive oil level changing the final drive oil 177
- Chk adj 177
- Final drive oil 177
- Changing the final drive oil checking and adjusting the steering head 178
- Chk adj 178
- Steering head 178
- Warning 178
- Checking and adjusting the steering head 179
- Chk adj 179
- Warning 179
- Checking and adjusting the steering head checking the front fork 180
- Chk adj 180
- Front fork 180
- Warning 180
- Adjusting the front fork legs 181
- Caution 181
- Chk adj 181
- Warning 181
- A turn the adjusting knob 1 in direction a or b 182
- A turn the adjusting screw 1 in direction a or b 182
- Adjust compression damping 182
- Adjusting positions minimum 17 clicks out standard 12 clicks out maximum 1 click out 182
- Adjusting positions minimum 21 clicks out standard 12 clicks out maximum 1 click out 182
- Adjusting the front fork legs 182
- Caution 182
- Chk adj 182
- Compression damping 182
- Direction a compression damping is increased suspension is harder 182
- Direction a rebound damping is increased suspension is harder 182
- Direction b compression damping is decreased suspension is softer 182
- Direction b rebound damping is decreased suspension is softer 182
- From the fully turned in position 182
- Never go beyond the maximum or mini mum adjustment positions 182
- Adjusting the rear shock absorber assembly 183
- Caution 183
- Chk adj 183
- Rear shock absorber 183
- Warning 183
- Adjusting the rear shock absorber assembly checking the tires 184
- Chk adj 184
- Warning 184
- Checking the tires 185
- Chk adj 185
- Warning 185
- Checking the tires checking the wheels 186
- Chk adj 186
- Warning 186
- Wheels 186
- Chassis lubrication 187
- Chk adj 187
- Warning 187
- Chk adj 188
- Lubricating the centerstand lubricating the rear suspension 188
- Caution 189
- Checking and charging the battery 189
- Chk adj 189
- Electrical system 189
- Warning 189
- Caution 190
- Checking and charging the battery 190
- Chk adj 190
- Caution 191
- Checking and charging the battery 191
- Chk adj 191
- Warning 191
- Charging method using a variable voltage charger 192
- Checking and charging the battery 192
- Chk adj 192
- Charging method using a constant voltage charger 193
- Checking and charging the battery 193
- Chk adj 193
- Caution 194
- Checking and charging the battery checking the fuses 194
- Chk adj 194
- Checking the fuses 195
- Chk adj 195
- Checking the fuses replacing the headlight bulbs 196
- Chk adj 196
- Headlight bulbs 196
- Warning 196
- Caution 197
- Chk adj 197
- Replacing the headlight bulbs adjusting the headlight beams 197
- A turn the adjusting screw 1 in direction a or b left headlight 198
- Adjust headlight beam horizontally 198
- Adjusting the headlight beams 198
- Chk adj 198
- Direction a headlight beam moves to the right 198
- Direction b headlight beam moves to the left 198
- Right headlight 198
- Chapter 4 chassis 201
- Chassis 201
- Chassis 203
- Front wheel and brake discs 203
- Front wheel and brake disks 203
- Front wheel and brake discs 204
- Front wheel and brake discs 205
- Warning 205
- Caution 206
- Front wheel and brake discs 206
- Front wheel and brake discs 207
- A remove the brake disc b rotate the brake disc by one bolt hole c install the brake disc 208
- Adjust brake disc deflection 208
- Before tightening the wheel axle nut push down hard on the handlebars several times and check if the front fork rebounds smoothly 208
- Brake disc bolt 18 nm 1 m kg loctit 208
- Caution 208
- 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 208
- Front wheel and brake discs 208
- Installing the front wheel the following procedure applies to both brake discs 1 lubricate wheel axle oil seal lips 208
- Recommended lubricant lithium soap base grease 208
- Tighten the brake disc bolts in stages and in a crisscross pattern 208
- Tighten wheel axle 1 wheel axle pinch bolt 2 208
- A spin the front wheel b when the front wheel stops put an x mark at the bottom of the wheel c turn the front wheel 90 so that the x mark is positioned as shown d release the front wheel e when the wheel stops put an x mark at the bottom of the wheel f repeat steps d through f several times until all the marks come to rest at the same spot g the spot where all the marks come to rest is the front wheel s heavy spot x 209
- Adjusting the front wheel static balance 209
- After replacing the tire wheel or both the front wheel static balance should be adjusted adjust the front wheel static balance with the brake discs installed 209
- Front wheel and brake discs 209
- Install brake caliper 209
- Make sure the brake hose is routed prop erly 209
- Place the front wheel on a suitable balancing stand 209
- Remove balancing weight s 2 find front wheel s heavy spot 209
- Warning 209
- A install a balancing weight 1 onto the rim exactly opposite the heavy spot x 210
- A turn the front wheel and make sure it stays at each position shown b if the front wheel does not remain stationary at all of the positions rebalance it 210
- Adjust front wheel static balance 210
- B turn the front wheel 90 so that the heavy spot is positioned as shown 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 210
- Check front wheel static balance 210
- Front wheel and brake discs 210
- Start with the lightest weight 210
- Rear wheel and brake disc 211
- Rear wheel and brake disk 211
- Rear wheel and brake disc 212
- Rear wheel and brake disc 213
- Warning 213
- Rear wheel and brake disc 214
- Front and rear brakes 215
- Front brake pads 215
- Front and rear brakes 216
- Rear brake pads 216
- Caution 217
- Front and rear brakes 217
- Replacing front pads 217
- Front and rear brakes 218
- Front and rear brakes 219
- Replacing rear pads 219
- Front and rear brakes 220
- Front and rear brakes 221
- Front and rear brakes 222
- Front master cylinder 222
- Front and rear brakes 223
- Front and rear brakes 224
- Front and rear brakes 225
- Rear master cylinder 225
- Front and rear brakes 226
- Front and rear brakes 227
- Disassembling the master cylinders 228
- Front and rear brakes 228
- Checking master cylinders 229
- Front and rear brakes 229
- Assembling and installing the front master cylinder 230
- Front and rear brakes 230
- Warning 230
- Caution 231
- Front and rear brakes 231
- Warning 231
- Assembling and installing the rear master cylinder 232
- Caution 232
- Front and rear brakes 232
- Warning 232
- Caution 233
- Front and rear brakes 233
- Warning 233
- Front and rear brakes 234
- Front and rear brakes 235
- Front brake calipers 235
- Front and rear brakes 236
- Front and rear brakes 237
- Rear brake caliper 237
- Front and rear brakes 238
- Disassembling brake calipers 239
- Front and rear brakes 239
- Warning 239
- A blow compressed air into the brake hose joint opening a to force out the piston from the brake caliper 240
- B remove the brake caliper piston seals 240
- Before disassembling the brake caliper drain the brake fluid from the entire brake system 240
- Cover the brake caliper piston with a rag be careful not to get injured when the pis ton is expelled from the brake caliper never try to pry out the brake caliper pis ton 240
- Disassembling the rear brake caliper 240
- Front and rear brakes 240
- Put the end of the brake hose into a container and pump out the brake fluid carefully 240
- Remove brake caliper piston 1 brake caliper piston seals 2 240
- Remove union bolt 1 copper washers 2 brake hose 3 240
- Warning 240
- Checking the brake calipers 241
- Front and rear brakes 241
- Warning 241
- Assembling and installing the front calipers 242
- Caution 242
- Front and rear brakes 242
- Warning 242
- Caution 243
- Front and rear brakes 243
- Warning 243
- Assembling and installing the rear caliper 244
- Front and rear brakes 244
- Warning 244
- Caution 245
- Front and rear brakes 245
- Warning 245
- Caution 246
- Front and rear brakes 246
- Warning 246
- Front and rear brakes 247
- Hydraulic clutch 248
- Hydraulic clutch 249
- Hydraulic clutch 250
- Caution 251
- Disassembling the master cylinder 251
- Hydraulic clutch 251
- Checking the master cylinder 252
- Hydraulic clutch 252
- Assembling and installing the master cylinder 253
- Hydraulic clutch 253
- Warning 253
- Caution 254
- Hydraulic clutch 254
- Warning 254
- Hydraulic clutch 255
- Clutch release cylinder 256
- Hydraulic clutch 256
- Hydraulic clutch 257
- Disassembling the release cylinder 258
- Hydraulic clutch 258
- Warning 258
- Caution 259
- Checking and assembling the release cylinder 259
- Hydraulic clutch 259
- Warning 259
- Caution 260
- Hydraulic clutch 260
- Warning 260
- Hydraulic clutch 261
- Front fork 262
- Front fork 263
- Front fork 264
- Front fork 265
- Removing and disassembling fork legs 265
- Warning 265
- Caution 266
- Front fork 266
- Caution 267
- Checking the fork legs 267
- Front fork 267
- Warning 267
- Assembling the fork legs 268
- Caution 268
- Front fork 268
- Warning 268
- Caution 269
- Front fork 269
- Caution 270
- Front fork 270
- Front fork 271
- Warning 271
- Front fork 272
- Installing the fork legs 272
- Warning 272
- Handlebars 273
- Handlebars 274
- Handlebars 275
- Warning 275
- Handlebars 276
- Warning 276
- Handlebars 277
- Warning 277
- Handlebars 278
- Steering head 279
- Steering head 280
- Steering head 281
- Warning 281
- Caution 282
- Steering head 282
- Steering head 283
- 1014 13 284
- 4 13 11 284
- Rear shock absorber and relay arm 284
- Rear shock absorber assembly and relay arm 284
- Rear shock absorber assembly and relay arm 285
- Rear shock absorber assembly and relay arm 286
- Warning 286
- Rear shock absorber assembly and relay arm 287
- Rear shock absorber assembly and relay arm 288
- Swingarm 289
- Swingarm 290
- Swingarm 291
- Warning 291
- Swingarm 292
- Warning 292
- Swingarm 293
- Shaft drive 294
- Troubleshooting 294
- C a slight clunk evident at low speed opera tion not to be confused with normal motor cycle operation diagnosis possible broken gear teeth 295
- Inspection notes 1 investigate any unusual noises 295
- Insufficient gear backlash is extremely destructive to the gear teeth if a test ride following reassembly indicates these symptoms stop riding immediately to mini mize gear damage 295
- Shaft drive 295
- Stop riding immediately if broken gear teeth are suspected this condition could result in the shaft drive assembly locking up causing a loss of control and possible injury to the rider 295
- The following noises may indicate a mechanical defect a a rolling rumble during coasting accelera tion or deceleration increases with the rear wheel speed but does not increase with higher engine or transmission speeds diagnosis possible wheel bearing damage b a whining noise that varies with accelera tion and deceleration diagnosis possible incorrect reassembly or too little gear backlash 295
- Warning 295
- Shaft drive 296
- Checking for contamination and leaks 297
- Shaft drive 297
- Ring gear backlash 298
- Shaft drive 298
- Shaft drive 299
- Ring gear to stopper bolt clearance 300
- Shaft drive 300
- Caution 301
- Shaft drive 301
- Removal and disassembly 302
- Shaft drive 302
- Shaft drive 303
- Shaft drive 304
- Shaft drive 305
- Shaft drive 306
- Caution 307
- Removing and installing ring gear bearings 307
- Shaft drive 307
- Warning 307
- A heat the final drive housing to approxi mately 150 c b remove the bearing outer races with an appropriately shaped punch 2 c remove the inner race from the final drive pinion gear 308
- A heat the final gear case to approximately 150 c b install the bearing outer races with a socket or appropriate tool that matches the diame ter of the races c install the inner race onto the final drive pin ion gear 308
- Install bearing 308
- Install collar 1 oil seal 2 bearing 3 with a suitable press tool 4 and an appro priate support for the final drive housing 308
- Remove bearing 1 308
- Shaft drive 308
- The bearing can be reused but yamaha rec ommends installing a new one 308
- The removal of the final drive pinion gear bear ing is a difficult procedure and is rarely neces sary 308
- Aligning the final drive pinion gear and ring gear 309
- Shaft drive 309
- Shaft drive 310
- Shaft drive 311
- Caution 312
- Reassembling the final drive 312
- Shaft drive 312
- Shaft drive 313
- Installing the u joint and final drive assembly 314
- Shaft drive 314
- Chapter 5 engine 316
- Engine 316
- Engine 320
- Mufflers and exhaust pipe assembly 320
- Engine 321
- Leads and hoses 321
- Engine 322
- Engine 323
- Removing the engine 323
- Engine 324
- Order job part q ty remarks 11 nut 1 324
- Refer to installing the engine 324
- Spacer bolt 1 loosen 13 rear upper mounting bolt 1 14 rear lower mounting bolt 1 15 spacer 1 16 engine 1 for installation reverse the removal procedure 324
- Engine 325
- Installing the engine 325
- Engine 326
- Camshafts 327
- Camshafts 328
- Camshafts 329
- A turn the crankshaft clockwise b when piston 1 is at tdc on the compres sion stroke align the t mark a on the pickup coil rotor with the crankcase mating surface b 330
- Camshafts 330
- Caution 330
- Loosen cap bolt 1 3 remove timing chain tensioner 2 gasket 330
- Remove camshaft caps dowel pins 330
- Removing 330
- Removing the camshafts 1 align t mark on the pickup coil rotor with the crankcase mating surface 330
- Tdc on the compression stroke can be found when the camshaft lobes are turned away from each other 330
- To prevent damage to the cylinder head camshafts or camshaft caps loosen the camshaft cap bolts in stages and in a criss cross pattern working from the outside in 330
- Camshafts 331
- Checking 331
- Camshaft sprockets 332
- Camshafts 332
- Camshafts 333
- Installing 333
- Timing chain tensioner 333
- Camshafts 334
- Camshafts 335
- Caution 335
- Warning 335
- Camshafts 336
- Camshafts 337
- Cylinder head 338
- Removing 338
- Checking 339
- Cylinder head 339
- Cylinder head 340
- Installing 340
- Caution 341
- Cylinder head 341
- Warning 341
- Cylinder head 342
- Removing 343
- Valves and valve springs 343
- A pour a clean solvent a into the intake and exhaust ports b check that the valves properly seal 344
- Before removing the internal parts of the cylin der head e g valves valve springs valve seats make sure the valves properly seal 344
- Check valve for leakage leakage at the valve seat check the valve face valve seat and valve seat width refer to checking the valve seats 344
- Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place 344
- Remove valve lifter 1 valve pad 2 344
- Removing the valves the following procedure applies to all of the valves and related components 344
- There should be no leakage at the valve seat 1 344
- Valves and valve springs 344
- Checking 345
- Valves and valve springs 345
- Valves and valve springs 346
- Valves and valve springs 347
- A apply a coarse lapping compound a to the valve face 348
- A apply mechanic s blueing dye dykem b onto the valve face b install the valve into the cylinder head c press the valve through the valve guide and onto the valve seat to make a clear impres sion d measure the valve seat width 348
- After replacing the cylinder head or replacing the valve and valve guide the valve seat and valve face should be lapped 348
- B apply molybdenum disulfide oil onto the valve stem 348
- Caution 348
- Do not let the lapping compound enter the gap between the valve stem and the valve guide 348
- Lap valve face valve seat 348
- Measure valve seat width a out of specification replace the cylinder head 348
- Valves and valve springs 348
- Where the valve seat and valve face contacted one another the blueing will have been removed 348
- Valves and valve springs 349
- Valves and valve springs 350
- Installing 351
- Valves and valve springs 351
- Caution 352
- Valves and valve springs 352
- Generator and starter clutch 353
- Generator and starter clutch 354
- Generator and starter clutch 355
- Generator and starter clutch 356
- Generator and starter clutch 357
- Generator and starter clutch 358
- Generator and starter clutch 359
- Pickup coil rotor 360
- Pickup coil rotor 361
- Pickup coil rotor 362
- Pickup coil rotor 363
- Clutch 364
- Clutch 365
- Clutch 366
- Clutch 367
- Clutch 368
- Clutch 369
- Clutch 370
- Clutch 371
- Clutch 372
- Clutch 373
- Shift shaft 374
- Shift shaft 375
- Shift shaft 376
- Shift shaft 377
- Oil pan and oil pump 378
- Oil pan and oil pump 379
- Oil pan and oil pump 380
- Oil pan and oil pump 381
- Oil pan and oil pump 382
- Caution 383
- Oil pan and oil pump 383
- Warning 383
- Oil pan and oil pump 384
- Warning 384
- Middle gear 385
- Removing 385
- Middle gear 386
- Disassembling 387
- Middle gear 387
- Middle gear 388
- Middle gear 389
- Middle gear 390
- Checking and assembly 391
- Middle gear 391
- Installing the middle drive shaft assembly 392
- Middle gear 392
- Installing the middle driven shaft assembly 393
- Middle gear 393
- Measuring and adjusting backlash 394
- Middle gear 394
- Caution 395
- Middle gear 395
- Middle gear 396
- Middle gear 397
- Aligning the middle gear 398
- Middle gear 398
- Middle gear 399
- 4 5 6 7 5 400
- Hundredth rounded value 400
- Middle drive shaft shim 400
- Middle gear 400
- Shims are supplied in the following thick nesses 400
- Thickness mm 0 0 0 5 0 0 0 0 0 0 0 0 400
- Crankcase 401
- Separating the crankcase 401
- Crankcase 402
- Crankcase 403
- Crankcase 404
- Caution 405
- Crankcase 405
- Disassembling and checking the crankcase 405
- Crankcase 406
- Assembling the crankcase 407
- Crankcase 407
- Caution 408
- Crankcase 408
- Crankcase 409
- Caution 410
- Crankcase 410
- Warning 410
- Connecting rods and pistons 411
- Removing connecting rods and pistons 411
- Caution 412
- Connecting rods and pistons 412
- Checking the cylinders and pistons 413
- Connecting rods and pistons 413
- Checking the piston rings and pins 414
- Connecting rods and pistons 414
- Connecting rods and pistons 415
- Connecting rods and pistons 416
- Caution 417
- Checking the connecting rods 417
- Connecting rods and pistons 417
- And the crankshaft web 418
- Bearing color code 418
- Bearing size of 418
- Connecting rod 418
- Connecting rods and pistons 418
- Crank shaft web 6 1 5 yellow 418
- E tighten the connecting rod nuts refer to installing the connecting rods and pistons f remove the connecting rod and big end bearings refer to removing the connecting rods and pistons g measure the compressed plastigaug 418
- For example if the connecting rod 418
- Numbers are 6 and 1 respectively then the bearing size for 418
- Refer to the bearings shown in the crankshaft illustration 418
- Select big end bearings 418
- The numbers stamped into the crankshaft web and the numbers on the connecting rods are used to determine the replacement big end bearing sizes 418
- Width e on the crankshaft pin if the crankshaft pin to big end bearing clearance is out of specification select replacement big end bearings 418
- Yellow 418
- Connecting rods and pistons 419
- Installing the connecting rods and pistons 419
- Connecting rods and pistons 420
- Connecting rods and pistons 421
- Warning 421
- Caution 422
- Connecting rods and pistons 422
- Warning 422
- Crankshaft 423
- Crankshaft 424
- Caution 425
- Crankshaft 425
- And crank shaft web 426
- Are the same use the same size for all of the bearings 426
- Bearing color code 426
- Bearing size of 426
- Crankcase 426
- Crankshaft 426
- Crankshaft web 2 6 2 2 6 pink 426
- For example if the crankcase 426
- H measure the compressed plastigauge width c on each crankshaft journal if the crankshaft journal to crankshaft jour nal bearing clearance is out of specification select replacement crankshaft journal bear ings 426
- Numbers are 6 and 2 respec tively then the bearing size for 426
- Refer to the bearings shown in the crankshaft illustration if 426
- Select crankshaft journal bearings 426
- The numbers stamped into the crankshaft web and the numbers stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes 426
- Yellow 426
- Crankshaft 427
- Removing the transmission shift drum and forks 428
- Transmission 428
- Transmission 429
- Disassembling the axle assemblies 430
- Transmission 430
- Transmission 431
- Transmission 432
- Transmission 433
- Checking and reassembly 434
- Transmission 434
- Transmission 435
- Warning 435
- Transmission 436
- Installing the transmission 437
- Transmission 437
- Balancers 438
- Removal 438
- Balancers 439
- Balancers 440
- Checking and installation 440
- Balancers 441
- Balancers 442
- Balancers 443
- Adjusting balancer gear lash 444
- Balancers 444
- Chapter 6 cooling system 447
- Cooling system 447
- Cooling system 449
- Radiator 449
- Radiator 450
- Radiator 451
- Radiator 452
- Oil cooler 453
- Oil cooler 454
- Oil cooler 455
- Thermostat 456
- Thermostat 457
- Thermostat 458
- Thermostat 459
- Water pump 460
- Water pump 461
- Water pump 462
- Water pump 463
- Caution 464
- Water pump 464
- Caution 465
- Warning 465
- Water pump 465
- Warning 466
- Water pump 466
- Chapter 7 fuel injection system 468
- Fuel injection system 468
- Components locations 470
- Fuel injection system 470
- Fuel injection system 471
- L coolant temperature sensor m crankshaft position sensor n ecu o cylinder 1 injector p cylinder 2 injector q cylinder 3 injector r cylinder 4 injector s ai system solenoid w speed sensor å ignition fuse engine stop switch fuel injection system relay 471
- Main switch 5 main fuse 6 battery 7 fuel injection system fuse d fuel pump e 471
- Sensor f cylinder identification sensor g throttle position sensor h intake air pressure sensor i atmospheric pressure sensor j lean angle cut off switch k intake air temperature sensor 471
- Wiring diagram 471
- Ecu self diagnostic function 472
- Fuel injection system 472
- Fuel injection system 473
- Fuel injection system 474
- Fuel injection system 475
- How to erase the self diagnostic fault code from memory if the ecu detects a normal signal upon the completion of the repair of the malfunction the self diagnostic fault code disappears from the meter and is replaced by the normal clock display how ever the self diagnostic fault code of the previous malfunction remains in the ecu memory as part of the malfunction history to erase the self diagnostic fault code from the malfunction history the operation for diagnostic code 62 must be performed in the diagnosis mode 475
- Table of fault code numbers 475
- Table of self diagnostic fault code numbers displayed on meter 475
- Fail safe operation 476
- Fuel injection system 476
- Substitute characteristics operation control fail safe action if the ecu detects an abnormal signal from a sensor while the motorcycle is being driven the ecu illuminates the engine trouble warning light and provides the engine with substitute characteristic operation instructions that are appropriate for the type of the malfunction when an abnormal signal is received from a sensor the ecu processes the specified values that are programmed for every sensor in order to provide the engine with substitute characteristics operation instructions that enable the engine to continue to operate or to stop its operation depending on circumstances the ecu takes fail safe actions in two ways one in which the sensor output is set to a prescribed value and the other in which the ecu directly operates an actuator details on the fail safe actions are given in the table below 476
- Table of substitute characteristic operation control by self diagnostic fault code 476
- Fuel injection system 477
- Troubleshooting 477
- Fuel injection system 478
- Fuel injection system 479
- Codes symptoms and probably causes 480
- Fuel injection system 480
- Self diagnostic fault codes symptoms and probable causes diagnostic code indication 480
- Fuel injection system 481
- Fuel injection system 482
- Note check the intake temperature and coolant temperature as close as possible to the area in which the respective sensor is mounted if it is not possible to check it with an atmospheric pressure gauge judge it by using 760 mmhg as the standard if it is not possible to check the intake temperature use the ambient temperature as reference use the compared values for reference 482
- Sensor operation data display verification table 482
- Sensor operation verification table 482
- Actuator operation verification table 483
- Fuel injection system 483
- Fuel injection system 484
- Troubleshooting basic procedure 1 484
- Troubleshooting basic proceedure 484
- Fuel injection system 485
- Troubleshooting details troubleshooting the self diagnostic fault code 485
- Troubleshooting the fault code 485
- Fuel injection system 486
- Fuel injection system 487
- Fuel injection system 488
- Fuel injection system 489
- Fuel injection system 490
- Fuel injection system 491
- Fuel injection system 492
- Fuel injection system 493
- Fuel injection system 494
- Fuel injection system 495
- Fuel injection system 496
- Basic procedure 497
- Check the condition and the symptom of the malfunction of the motorcycle check the errors displayed on the meter 497
- Diagnosis mode malfunction not detected 497
- Diagnosis mode troubleshooting 2 self diagnostic malfunction not detected even if the malfunctions of some of the sensors do not appear on the meter because they are not detected by the self diagnostic function they can be inspected in the diagnosis mode 497
- Estimate the area of the malfunction by referring to the troubleshooting details refer to troubleshooting details 497
- Fuel injection system 497
- If there is a diagnostic code number for the inspection method for the probable location of the mal function check the operating condition of the affected sensor or actuator in the diagnosis mode 497
- Troubleshooting details troubleshooting the sensors with no malfunctions detected and special indications 497
- Using the results of the diagnosis mode inspection as reference estimate the cause of the mal function and carry out the inspection and repair of the affected area 497
- Fuel injection system 498
- Fuel injection system 499
- Fuel injection system 500
- Fuel injection system 501
- Fuel injection system 502
- Throttle bodies 502
- Fuel injection system 503
- Fuel injection system 504
- Fuel injection system 505
- A wash the throttle body in a petroleum based solvent do not use any caustic carburetor cleaning solution b blow out all of passages with compressed air 506
- Caution 506
- Check fuel passages obstruction clean 506
- Checking the injector 1 check injector damage replace 506
- Checking the pressure regulator 1 check pressure regulator damage replace 506
- Checking the throttle body 1 check throttle body cracks damage replace the throttle bodies 506
- Fuel injection system 506
- The throttle bodies should not be disas sembled unnecessarily 506
- Fuel injection system 507
- Fuel pump and pressure regulator 507
- Decrease the vacuum pressure fuel pressure is increased 508
- Faulty replace the pressure regulator 508
- Fuel injection system 508
- H use the vacuum pressure pump gauge set to adjust the fuel pressure in relation to the vacuum pressure as described below 508
- Increase the vacuum pressure fuel pressure is decreased 508
- Note the vacuum pressure should not exceed 100 kpa 1 mmhg 508
- Air induction system 509
- Air induction system 510
- Air induction system diagrams 510
- Air induction system 511
- Air induction system 512
- Air induction system 513
- Chapter 8 electrical 515
- Electrical 515
- Electrical 517
- Electrical components 517
- Electrical components locations 517
- Electrical components 518
- Caution 519
- Checking switch continuity 519
- Checking switches 519
- Check each switch for damage or wear proper connections and also for continuity between the ter minals refer to checking switch continuity damage wear repair or replace improperly connected properly connect incorrect continuity reading replace the switch 521
- Checking the switches 521
- On off p 521
- Checking the switches 522
- Checking bulbs and sockets 523
- Checking the bulbs and bulb sockets 523
- Caution 524
- Checking the bulbs and bulb sockets 524
- Warning 524
- A install a good bulb into the bulb socket b connect the pocket tester probes to the respective leads of the bulb socket c check the bulb socket for continuity if any of the readings indicate no continuity replace the bulb socket 525
- Check each bulb socket for continuity in the same manner as described in the bulb section however note the following 525
- Checking the bulbs and bulb sockets 525
- 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 525
- Pocket tester 90890 03112 525
- Circuit diagram 526
- Ignition system 526
- Main switch 5 main fuse 6 battery a starting circuit cut off relay c sidestand switch j lean angle cut off switch m crankshaft position sensor n ecu t cylinder 1 4 ignition coil u cylinder 2 3 ignition coil v spark plug å ignition fuse engine stop switch 526
- Ignition system 527
- Ignition system 528
- Ignition system 529
- Ignition system 530
- Circuit diagram 531
- Electric starting system 531
- Main switch 5 main fuse 6 battery 8 starter relay 9 starter motor 0 diode a starting circuit cut off relay b neutral switch c sidestand switch e clutch switch å ignition fuse engine stop switch start switch 531
- Electric starting system 532
- Electric starting system 533
- Warning 533
- Electric starting system 534
- Electric starting system 535
- Electric starting system 536
- Starter motor 537
- Starter motor 538
- Starter motor 539
- Starter motor 540
- Starter motor 541
- Starter motor 542
- Charging system 543
- Circuit diagram 543
- Rectifier regulator 3 generator 5 main fuse 6 battery 543
- Charging system 544
- Charging system 545
- Circuit diagram 546
- Lighting system 546
- Main switch 5 main fuse 6 battery n ecu high beam indicator light b meter light f pass switch g dimmer switch 546
- O headlight relay 1 p headlight relay 2 r auxiliary light s headlight u tail brake light parking lighting fuse ç headlight fuse ß light switch 546
- Lighting system 547
- Lighting system 548
- Lighting system 549
- Lighting system 550
- Lighting system 551
- Circuit diagram 553
- Signaling system 553
- Signaling system 554
- Signaling system 555
- Signaling system 556
- Signaling system 557
- Signaling system 558
- Signaling system 559
- Signaling system 560
- Signaling system 561
- Signaling system 562
- Circuit diagram 563
- Cooling system 563
- Main switch 5 main fuse 6 battery l coolant temperature sensor 563
- N ecu radiator fan motor radiator fan motor relay å ignition fuse radiator fan motor fuse 563
- Cooling system 564
- Cooling system 565
- Cooling system 566
- Warning 566
- Cooling system 567
- Circuit diagram 568
- Fuel injection system 568
- L coolant temperature sensor m crankshaft position sensor n ecu o cylinder 1 injector p cylinder 2 injector q cylinder 3 injector r cylinder 4 injector s ai system solenoid w speed sensor å ignition fuse engine stop switch fuel injection system relay 568
- Main switch 5 main fuse 6 battery 7 fuel injection system fuse d fuel pump e 568
- Sensor f cylinder identification sensor g throttle position sensor h intake air pressure sensor i atmospheric pressure sensor j lean angle cut off switch k intake air temperature sensor 568
- Battery 569
- Engine stop switch 569
- Fuel injection system 569
- Main fuel injection system and ignition fuses 569
- Main switch 569
- Crankshaft position sensor resistance 570
- Fuel injection system 570
- Fuel injection system relay 570
- Fuel pump resistance 570
- Cylinder identification sensor output voltage 571
- Fuel injection system 571
- Speed sensor output voltage 571
- Coolant temperature sensor 572
- Fuel injection system 572
- Warning 572
- Fuel injection system 573
- Intake air pressure sensor output voltage 573
- Intake air temperature sensor resistance 573
- Warning 573
- Ai system solenoid 574
- Atmospheric pressure sensor output voltage 574
- Fuel injection system 574
- Checking the fuel pump 575
- Fuel injection system 575
- Warning 575
- Checking and adjusting the throttle position sensor 576
- Fuel injection system 576
- Fuel injection system 577
- Fuel injection system 578
- Fuel injection system 579
- Circuit diagram 580
- Main switch 4 backup fuse odometer clock and windshield 5 main fuse 6 battery a starting circuit cut off relay b neutral switch z neutral indicator light h windshield position switch z windshield drive unit windshield motor fuse 580
- Windshield drive system 580
- Windshield drive system 581
- Windshield drive system 582
- Chapter 9 troubleshooting 584
- Trbl shtg 584
- Troubleshooting 584
- Trbl shtg 585
- Starting problems 586
- Trbl shtg 586
- Troubleshooting 586
- Incorrect engine idling speed 587
- Starting problems incorrect engine idling speed 587
- Trbl shtg 587
- Faulty gear shifting 588
- Poor medium and high speed performance 588
- Poor medium and high speed performance faulty gear shifting 588
- Trbl shtg 588
- Faulty clutch 589
- Faulty clutch overheating 589
- Overheating 589
- Trbl shtg 589
- Faulty front fork legs 590
- Poor braking performance 590
- Poor braking performance faulty front fork legs 590
- Trbl shtg 590
- Faulty lighting or signaling system 591
- Trbl shtg 591
- Unstable handling 591
- Unstable handling faulty lighting or signaling system 591
- Faulty lighting or signaling system 592
- Trbl shtg 592
- Color code 594
- Fjr1300 wiring diagram for europe 594
- Color code 595
- Fjr1300 wiring diagram for oceania 595
- Fjr1300 wirning diagram for europe 596
- J g h i 596
- On off p 596
- S r r q 596
- Wiring diagram for europe 596
- Fjr1300 wirning diagram for oceania 597
- J g h i 597
- On off 597
- Wiring diagram for oceania 597
- Atmos press 598
- Barbarian jumper 598
- Colour code b black br brown ch chocolate dg dark green g green gy gray l blue lg light green o orange p pink r red sb sky blue w white y yellow 598
- Crankshaft position sensor 598
- Cylinder id sensor 598
- Fjr1300r wiring diagram 598
- Front signal lights 598
- Fuel injection 598
- I f g h 598
- Ignition coils and spark plugs 598
- Intake air press 598
- Multi function meter 598
- On off 598
- Sidestand switch 598
- Turn signal relay 598
- Windshield drive unit 598
- Windshield position 598
- Wiring diagram for north america 598
- The barbarian jumper mod 599
- Installing riv nut ports in the fjr s headers 608
- The trimmed bolt no longer protrudes into the pipe 615
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