2001 Yamaha FJR1300N Service Manual
Video Preview:
Image Preview:
Table Of Contents:
2001 Yamaha FJR1300N Service Manual
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
Description:
2001 Yamaha FJR1300N Service Manual
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.
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]