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FJR 1300 AE 2014
Yamaha FJR 1300 AE 2014 Manuals
Manuals and User Guides for Yamaha FJR 1300 AE 2014. We have
1
Yamaha FJR 1300 AE 2014 manual available for free PDF download: Service Manual
Yamaha FJR 1300 AE 2014 Service Manual (694 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 21.8 MB
Table of Contents
Table of Contents
7
General Information
9
Identification
10
Vehicle Identification Number
10
Model Label
10
Outline of the Fi System
11
Fi System
12
YCC-T (Yamaha Chip Controlled Throttle)
13
Outline of the Cruise Control System
15
Outline of the Unified Brake System
22
Outline of the Abs
24
Abs Component Functions
28
Abs Operation
34
Abs Self-Diagnosis Function
37
Abs Warning Light and Operation
40
OUTLINE of the TCS (Traction Control System)
41
Multi-Function Meter Unit
44
Important Information
55
Preparation for Removal and Disassembly
55
Replacement Parts
55
Gaskets, Oil Seals and O-Rings
55
Lock Washers/Plates and Cotter Pins
55
Rubber Parts
56
Circlips
56
Bearings and Oil Seals
56
Basic Service Information
57
Quick Fasteners
57
Electrical System
58
Special Tools
62
Specifications
71
General Specifications
72
Engine Specifications
73
Chassis Specifications
81
Electrical Specifications
84
General Tightening Torque Specifications
87
Tightening Torques
87
Engine Tightening Torques
88
Chassis Tightening Torques
93
Engine
99
Lubrication Points and Lubricant Types
99
Chassis
101
Engine Oil Lubrication Chart
102
Lubrication System Chart and Diagrams
102
Lubrication Diagrams
104
Cooling System Diagrams
114
Cable Routing
118
Periodic Checks and Adjustments
139
General Maintenance and Lubrication Chart
142
Introduction
142
Periodic Maintenance
142
Periodic Maintenance Chart for the Emission Control System
142
Checking the Fuel Line
145
Checking the Spark Plugs
145
Adjusting the Valve Clearance
146
Checking the Engine Idling Speed
148
Synchronizing the Throttle Bodies
149
Checking the Exhaust System
150
Adjusting the Exhaust Gas Volume
151
Checking the Air Induction System
152
Checking the Crankcase Breather Hose
152
Cleaning the Air Filter Element
152
Adjusting the Clutch Lever
153
Checking the Clutch Fluid Level
153
Adjusting the Front Disc Brake
154
Bleeding the Hydraulic Clutch System
154
Checking the Brake Fluid Level
155
Bleeding the Hydraulic Brake System (Abs)
156
Adjusting the Rear Disc Brake
157
Checking the Front Brake Pads
157
Checking the Brake Hoses
158
Checking the Rear Brake Pads
158
Checking the Tires
158
Checking the Wheels
158
Checking and Adjusting the Steering Head
160
Checking the Swingarm Pivot
160
Checking the Wheel Bearings
160
Lubricating the Swingarm Pivot
160
Checking the Chassis Fasteners
161
Lubricating the Levers
161
Lubricating the Pedals
161
Lubricating the Steering Head
161
Adjusting the Damping Force of the Front Fork Legs and Rear Shock Absorber Assembly
162
Checking the Centerstand
162
Checking the Front Fork
162
Checking the Sidestand
162
Checking the Sidestand Switch
162
Lubricating the Centerstand
162
Lubricating the Sidestand
162
Adjusting the Preload of the Rear Shock Absorber Assembly
163
Checking the Rear Suspension
163
Checking the Engine Oil Level
165
Lubricating the Rear Suspension
165
Changing the Engine Oil
166
Measuring the Engine Oil Pressure
167
Checking the Coolant Level
168
Checking the Cooling System
168
Changing the Coolant
169
Checking the Final Gear Oil Level
170
Adjusting the Rear Brake Light Switch
171
Changing the Final Gear Oil
171
Checking the Brake Light Switches
171
Checking and Lubricating the Cables
172
Checking the Throttle Grip Operation
172
Adjusting the Headlight Beams
173
Checking the Switches, Lights and Signals
173
Replacing the Headlight Bulbs
173
Chassis
175
General Chassis
178
Installing the Center Rear Cowling
179
Installing the Rear Cowlings
179
Removing the Center Rear Cowling
179
Removing the Rear Cowlings
179
Installing the Seats
180
Installing the Side Covers
180
Removing the Side Covers
180
Adjusting the Side Panels
184
Removing the Front Cowling Inner Panel
184
Installing the Front Cowling Inner Panel
185
Installing the Side Cowlings
186
Removing the Side Cowlings
186
Installing the Center Covers
189
Installing the Windshield Bracket Covers
189
Removing the Center Covers
189
Removing the Windshield Bracket Covers
189
Installing the Front Cowling Assembly
190
Installing the Headlight Beam Adjusting Knob Joints
190
Installing the Windshield Drive Unit
193
Front Wheel
199
Checking the Front Wheel
201
Disassembling the Front Wheel
201
Removing the Front Wheel
201
Maintenance of the Front Wheel Sensor and Sensor Rotor
202
Assembling the Front Wheel
203
Adjusting the Front Wheel Static Balance
204
Installing the Front Wheel (Front Brake Discs)
205
Rear Wheel
207
Disassembling the Rear Wheel
209
Removing the Rear Wheel
209
Assembling the Rear Wheel
210
Checking the Rear Wheel
210
Maintenance of the Rear Wheel Sensor and Sensor Rotor
210
Adjusting the Rear Wheel Static Balance
211
Installing the Rear Wheel (Rear Brake Disc)
212
Front Brake
214
Checking the Front Brake Discs
219
Introduction
219
Replacing the Front Brake Pads
220
Disassembling the Front Brake Calipers
221
Removing the Front Brake Calipers
221
Assembling the Front Brake Calipers
222
Checking the Front Brake Calipers
222
Installing the Front Brake Calipers
222
Removing the Front Brake Master Cylinder
223
Assembling the Front Brake Master Cylinder
224
Checking the Front Brake Master Cylinder
224
Installing the Front Brake Master Cylinder
224
Rear Brake
226
Checking the Rear Brake Disc
232
Introduction
232
Replacing the Rear Brake Pads
232
Removing the Rear Brake Caliper
233
Assembling the Rear Brake Caliper
234
Checking the Rear Brake Caliper
234
Disassembling the Rear Brake Caliper
234
Installing the Rear Brake Caliper
235
Checking the Rear Brake Master Cylinder
236
Removing the Rear Brake Master Cylinder
236
Assembling the Rear Brake Master Cylinder
237
Installing the Rear Brake Master Cylinder
237
Abs (Anti-Lock Brake System)
239
Abs Components Chart
239
Removing the Hydraulic Unit Assembly
243
Checking the Brake Pipes
244
Checking the Hydraulic Unit Assembly
244
Checking the Proportioning Valve and Metering Valve
244
Installing the Hydraulic Unit Assembly
244
Hydraulic Unit Operation Tests
247
Checking the Abs Warning Light
250
Handlebars
251
Adjusting the Handlebar Position
253
Removing the Handlebars
253
Checking the Handlebars
254
Installing the Handlebars
254
Front Fork
257
Disassembling the Front Fork Legs
259
Removing the Front Fork Legs
259
Checking the Front Fork Legs
260
Assembling the Front Fork Legs
261
Installing the Front Fork Legs
265
Steering Head
266
Checking the Steering Head
268
Installing the Steering Head
268
Removing the Lower Bracket
268
Rear Shock Absorber Assembly
270
Handling the Rear Shock Absorber
275
Removing the Rear Fender Assembly
275
Checking the Connecting Arm and Relay Arm
276
Checking the Rear Shock Absorber Assembly
276
Disposing of a Rear Shock Absorber
276
Removing the Rear Shock Absorber Assembly
276
Adjusting the Rear Shock Absorber Assembly DC Motor
277
Installing the Rear Shock Absorber Assembly
277
Replacing the Stepping Motor
277
Installing the Rear Fender Assembly
278
Swingarm
280
Checking the Swingarm
282
Installing the Swingarm
282
Removing the Swingarm
282
Shaft Drive
284
Troubleshooting
288
Checking the Final Drive Oil for Contamination and Checking the Shaft Drive for Leaks
290
Measuring the Final Gear Backlash
290
Adjusting the Final Gear Backlash
291
Adjusting the Ring-Gear-To-Stopper-Bolt Clearance
292
Measuring the Ring-Gear-To-Stopper-Bolt Clearance
292
Disassembling the Final Drive Assembly
293
Removing and Installing the Bearings
293
Aligning the Final Drive Pinion Gear and Ring Gear
294
Checking the Drive Shaft
297
Installing the Drive Shaft and Final Drive Assembly
297
Engine
301
Engine Inspection
304
Measuring the Compression Pressure
304
Engine Removal
306
Engine
310
Installing the Engine
311
Removing the Engine
311
Camshafts
314
Removing the Camshafts
316
Checking the Camshafts
317
Checking the Camshaft Sprockets
318
Checking the Timing Chain Guides
318
Checking the Timing Chain Tensioner
318
Installing the Camshafts
319
Cylinder Head
323
Checking the Cylinder Head
324
Installing the Cylinder Head
324
Removing the Cylinder Head
324
Checking the Valves and Valve Guides
327
Removing the Valves
327
Valves and Valve Springs
327
Checking the Valve Seats
329
Checking the Valve Springs
330
Checking the Valve Lifters
331
Installing the Valves
331
Generator and Starter Clutch
334
Checking the Starter Clutch
335
Removing the Generator
335
Removing the Starter Clutch
335
Installing the Generator
336
Installing the Starter Clutch
336
Pickup Rotor
338
Installing the Pickup Rotor
339
Removing the Pickup Rotor
339
Electric Starter
341
Checking the Starter Motor
343
Assembling the Starter Motor
344
Clutch
345
Removing the Clutch
351
Checking the Clutch Plates
352
Checking the Clutch Spring Plate
352
Checking the Friction Plates
352
Checking the Clutch Boss
353
Checking the Clutch Housing
353
Checking the Clutch Push Rods
353
Checking the Pressure Plate
353
Checking the Primary Driven Gear
353
Installing the Clutch
354
Checking the Clutch Master Cylinder
355
Disassembling the Clutch Master Cylinder
355
Assembling the Clutch Master Cylinder
356
Installing the Clutch Master Cylinder
356
Assembling the Clutch Release Cylinder
357
Checking the Clutch Release Cylinder
357
Removing the Clutch Release Cylinder
357
Installing the Clutch Release Cylinder
358
Shift Shaft
359
Adjusting the Shift Pedal
360
Checking the Shift Shaft
360
Checking the Stopper Lever
360
Installing the Shift Shaft
360
Oil Pump
362
Checking the Oil Delivery Pipes
365
Checking the Oil Pump
365
Checking the Relief Valve
365
Assembling the Oil Pump
366
Checking the Oil Strainer
366
Installing the Oil Pan
366
Middle Gear
367
Disassembling the Middle Drive Shaft Assembly
371
Disassembling the Middle Driven Shaft Assembly
371
Removing the Middle Drive Shaft Assembly
371
Assembling the Middle Drive Shaft Assembly
372
Assembling the Middle Driven Shaft Assembly
372
Checking the Middle Drive Shaft Assembly
372
Checking the Middle Driven Shaft Assembly
372
Installing the Middle Drive Shaft Assembly
373
Installing the Middle Driven Shaft Assembly
374
Installing the Middle Gear Case Cover
374
Adjusting the Middle Gear Backlash
375
Measuring the Middle Gear Backlash
375
Aligning the Middle Gear
376
Crankcase
379
Assembling the Crankcase
383
Checking the Bearings and Oil Seal
383
Checking the Crankcase
383
Checking the Oil Delivery Pipes
383
Checking the Timing Chain and Oil Pump Drive Chain
383
Disassembling the Crankcase
383
Installing the Oil Pump Drive Sprocket
386
Checking the Cylinders and Pistons
388
Connecting Rods and Pistons
388
Removing the Connecting Rods and Pistons
388
Checking the Piston Rings
389
Checking the Piston Pin
390
Checking the Connecting Rods
391
Installing the Connecting Rods and Pistons
392
Crankshaft
395
Checking the Crankshaft
396
Checking the Oil Nozzles
396
Removing the Crankshaft Journal Bearings
396
Installing the Crankshaft
397
Transmission
399
Checking the Shift Drum Assembly
404
Checking the Shift Forks
404
Checking the Transmission
404
Removing the Transmission
404
Assembling the Main Axle and Drive Axle
405
Installing the Transmission
406
Balancers
410
Checking the Balancers
410
Installing the Front Balancer
410
Installing the Rear Balancer
411
Cooling System
415
Radiator
416
Checking the Radiator
418
Installing the Radiator
418
Removing the Radiator
418
Oil Cooler
419
Checking the Oil Cooler
420
Installing the Oil Cooler
420
Thermostat
421
Checking the Thermostat
423
Installing the Thermostat Assembly
423
Water Pump
425
Assembling the Water Pump
427
Checking the Water Pump
427
Disassembling the Water Pump
427
Installing the Water Pump
428
Fuel System
431
Fuel Tank
432
Checking the Fuel Pump Body
433
Installing the Fuel Pump
433
Installing the Fuel Tank
433
Removing the Fuel Pump
433
Removing the Fuel Tank
433
Throttle Bodies
435
Checking and Cleaning the Throttle Bodies
438
Checking the Injectors
438
Checking the Injectors (before Removing)
438
Removing the Injectors
438
Checking the Injector Pressure
440
Checking the Throttle Body Joints
440
Installing the Injectors
440
Replacing the Throttle Bodies
440
Checking the Fuel Pressure
441
Adjusting the Accelerator Position Sensor
442
Adjusting the Throttle Position Sensor
442
Air Induction System
444
Checking the Air Induction System
448
Installing the Air Induction System
448
Electrical System
449
Troubleshooting
667
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