2004 FJR1300(S) FJR1300A(S) 5JW1-AE5 SUPPLEMENTARY SERVICE MANUAL
FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the FJR1300(S)/FJR1300A(S) 2004. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manuals.
EAS00002 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one 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.
EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”. 2 Each chapter is divided into sections.
EAS00008 1 2 GEN INFO SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. SPEC 3 4 CHK ADJ 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system 7 Fuel injection system 8 Electrical system 9 Troubleshooting CHAS 5 6 ENG COOL 7 8 FI – ELEC 9 Symbols 0 to G indicate the following.
CONTENTS GENERAL INFORMATION ..............................................................................1 FEATURES ...............................................................................................1 OUTLINE ...............................................................................................1 FI SYSTEM ...........................................................................................2 SPECIFICATIONS ..........................................................................
FEATURES GEN INFO GENERAL INFORMATION FEATURES OUTLINE The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion 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 carburetor.
FEATURES GEN INFO FI SYSTEM The fuel pump delivers fuel to the injector via the fuel filter. The fuel pump maintains the fuel pressure that is applied to the injector at only 324 kPa (3.24 kg/cm2, 46.08 psi). 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.
GENERAL SPECIFICATIONS/ ENGINE SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Model code Standard FJR1300: 5JWG (for Europe) 5JWH (for F) 5JWJ (for Oceania) FJR1300A: 5VS7 (for Europe) 5VS8 (for F) 5VS9 (for Oceania) Limit ------------------- ENGINE SPECIFICATIONS Item Fuel pump Pump type Model (manufacturer) Maximum consumption amperage Output pressure Throttle bodies Model (manufacturer) × quantity Intake vacuum pressure Throttle cable free play (at the flange of the throttle grip) ID
ELECTRICAL SPECIFICATIONS SPEC ELECTRICAL SPECIFICATIONS Item Ignition system Ignition system type Ignition timing Advancer type Pickup coil resistance/color Transistorized coil ignition unit model (manufacturer) Starting circuit cut-off relay Model (manufacturer) Coil resistance Fuel injection system relay Model (manufacturer) Standard Limit Transistorized coil ignition (digital) 5° BTDC at 1,050 r/min Electric 420.8 ~ 569.
INTRODUCTION/ PERIODIC MAINTENANCE AND LUBRICATION CHART CHK ADJ EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a 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.
PERIODIC MAINTENANCE AND LUBRICATION CHART No. 15 ITEM CHECK OR MAINTENANCE JOB CHK ADJ ODOMETER READING (× 1,000 km) 1 Sidestand, center- • Check operation. • Lubricate. stand √ 10 20 30 40 ANNUAL CHECK √ √ √ √ √ √ 16 * Sidestand switch • Check operation. √ √ √ √ 17 * Front fork • Check operation and for oil leakage. √ √ √ √ • Check operation and shock absorber for oil leakage. √ √ √ √ √ √ √ √ 18 * Shock absorber assembly 19 * • Check operation.
SEATS AND FUEL TANK CHK ADJ SEATS AND FUEL TANK EAS00040 FUEL TANK Order 1 2 3 4 5 6 7 8 9 Job/Part Removing the fuel tank Rider seat Fuel Fuel tank side panel (left and right) Bolt Nut Fuel sender coupler Fuel pump coupler Fuel tank overflow hose Fuel tank breather hose Hose holder Fuel hose holder Q’ty 1/1 2 1 1 1 1 1 1 1 –7– Remarks Remove the parts in the order listed. Refer to “SEATS AND FUEL TANK” in chapter 3. (Manual No.: 5JW1-AE1) Drain.
SEATS AND FUEL TANK Order 10 Fuel hose Job/Part 11 12 Bolt Fuel tank CHK ADJ Q’ty Remarks 1 Refer to “REMOVING THE FUEL TANK”. Refer to “INSTALLING THE FUEL HOSE” in chapter 3. (Manual No.: 5JW1AE1) 1 1 Refer to “REMOVING THE FUEL TANK”. For installation, reverse the removal procedure.
SEATS AND FUEL TANK a CHK ADJ REMOVING THE FUEL TANK 1. Remove the fuel in the fuel tank through the fuel tank filler hole with a pump. 2. Remove: • fuel hose CAUTION: Although the fuel has been removed from the fuel tank, be careful when removing the fuel hose since there may be fuel remaining in it. NOTE: • To remove the fuel hose from the fuel injection pipe, slide the cover a on the end of the hose in the direction of the arrow shown, and then remove the hose.
AIR FILTER CASE CHK ADJ EAS00043 AIR FILTER CASE Order Job/Part Removing the air filter case Seats Q’ty Fuel tank Side covers (left and right) 1 2 3 4 5 6 7 8 9 Air shroud Air filter case cover Air filter element Tray Fuel tank bracket Plastic locking tie Intake air temperature sensor coupler Bypass air unit inlet hose Crankcase breather hose 1 1 1 1 1 1 1 1 1 – 10 – Remarks Remove the parts in the order listed. Refer to “SEATS AND FUEL TANK” in chapter 3. (Manual No.
AIR FILTER CASE Order 10 11 12 13 Job/Part Air induction system hose 5 Clamp screw Air filter case Air filter case breather hose CHK ADJ Q’ty Remarks 1 Disconnect. 4 Loosen. 1 1 For installation, reverse the removal procedure.
FI FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 Ignition coil 2 Air filter case 3 Intake air temperature sensor 4 Fuel delivery hose 5 Fuel tank 6 Fuel pump C Coolant temperature sensor D Spark plug E Cylinder identification sensor F Battery G ECU H Fuel injection system relay 7 Intake air pressure sensor 8 Throttle position sensor 9 Fuel injector 0 O2 sensor A Catalytic converter B Crankshaft position sensor I Engine trouble warning light J Lean angle cut-off switch K Air cut-of
– 13 – B L G/Y G/Y A G/Y L A L B å L G/Y L R/W R/B R Br/L ON OFF P 2 B B L/R Br/R Br/L R G/L BB B R/G R/W Y/L 1 R Br/R Br/L Br/L Br/L R Br/L Br/R ¢ £ § B W W W Br/G Br/G A Br/G Br/G R/W R/Y Br BB2 BB1 BB3 BB4 BB B2 3 Br/W Br/G BB3 BB2 BB4 BB1 B B B B B2 B1 B2 BB R Br/L Br/R ® • (BLACK) B R W 4 Y Br Y W R R (GRAY) W L/R W W W R R R B/R R/B B/R R/B Sb B Sb Lg B Lg Sb Br/Y R B Lg Br/R Sb Lg R/B B/R B R Br Sb Br/R Lg B Br/Y Br/R Br/Y
– 14 – B L G/Y G/Y A G/Y L A L B © L G/Y L R/W R/B R Br/L ON OFF P 2 B B R Br/R Br/L Br/L Br/L R Br/L Br/R µ º æ R B W W W Br/W Br/G Br/G A Br/G Br/G R/W R/Y Br BB2 BB1 BB3 BB4 BB B2 3 Br/W Br/G BB3 BB2 BB4 BB1 B B B B B2 B1 B2 BB R Br/L Br/R … ø (BLACK) B ¥ L/R Br/R Br/L R G/L BB B R/G R/W Y/L 1 W 4 W R R Y Br (GRAY) W L/R W W W R R Br/L Y R Sb Br/Y R B Lg Br/R B/R R/B Sb B Sb Lg B Lg B/R R/B Sb Lg R/B B/R B R Br Sb Br/R Lg B
FUEL INJECTION SYSTEM FI * Table of self-diagnostic fault code numbers displayed on meter No. 11 12 13 Symptom No normal signals are received from the cylinder identification sensor. No normal signals are received from the crankshaft position sensor. Intake air pressure sensor - open or short circuit detected.
FUEL INJECTION SYSTEM FI 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.
FUEL INJECTION SYSTEM FI Self-diagnostic fault codes, symptoms, and probable causes Diagnostic code indication Code No. Symptom No normal signals are received from the cylinder identification sensor. Open or short circuit in wiring sub lead. Open or short circuit in wiring harness. Defective cylinder identification sensor. Malfunction in ECU. Improperly installed sensor. — • • • • • Open or short circuit in wiring harness. Defective crankshaft position sensor. Malfunction in pickup rotor.
FUEL INJECTION SYSTEM Code No. Symptom FI Probable cause of malfunction Diagnostic code No normal signals are received from the O2 sensor. • • • • The motorcycle has overturned. • Overturned. • Malfunction in ECU. 08 The amount of air-fuel ratio feedback compensation is maintained continuously in the vicinity of the upper limit (lean air-fuel ratio). • • • • • • Open or short circuit in wiring harness. Fuel pressure too low. Clogged injectors.
FI FUEL INJECTION SYSTEM Sensor operation data display verification table NOTE: • Check the intake air 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 the intake temperature, use the ambient temperature as reference (use the compared values for reference). Diag code Item Description of action Data displayed on meter (reference value) Throttle angle Displays the throttle angle.
FUEL INJECTION SYSTEM FI Troubleshooting details Troubleshooting the self-diagnostic fault code Code No. 19 Symptom A break or disconnection of the black/red lead of the ECU is detected. Used diagnostic code No. 20 (sidestand switch) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective sidestand switch Replace if defective. If the transmission Refer to “CHECKING THE SWITCHES” in is in gear, it is reinchapter 8. (Manual No.
FUEL INJECTION SYSTEM FI THROTTLE BODIES 7 7 5 3 5 5 5 10 10 10 10 6 4 2 8 1 9 Order Job/Part Removing the throttle bodies Seats/T-bar/rubber sheet Q’ty Fuel tank Air filter case Coolant 1 2 3 4 5 6 O2 sensor coupler Cylinder identification sensor coupler Sub-wire harness 2 coupler Throttle stop screw Throttle body joint clamp screw Throttle bodies 1 1 2 1 8 1 – 21 – Remarks Remove the parts in the order listed. Refer to “SEATS AND FUEL TANK” in chapter 3. (Manual No.
FUEL INJECTION SYSTEM FI 7 7 5 3 5 5 5 10 10 10 10 6 4 2 8 1 9 Order 7 8 9 10 Job/Part Throttle cable Plunger control unit hose 1 Plunger control unit hose 2 Throttle body joint Q’ty Remarks 2 Disconnect. 1 Disconnect. 1 Disconnect. 4 For installation, reverse the removal procedure.
FI FUEL INJECTION SYSTEM 2 3 7 4 5 11 6 1 10 8 9 12 10 13 14 Order 1 2 3 4 5 6 7 8 9 10 Job/Part Removing the injectors Throttle position sensor coupler Intake air pressure sensor coupler Cylinder #1-injector coupler Cylinder #2-injector coupler Cylinder #3-injector coupler Cylinder #4-injector coupler Sub-wire harness 2 Negative pressure hose Bypass air unit Bypass air unit outlet hose Q’ty 1 1 1 1 1 1 1 1 1 4 – 23 – 10 Remarks Remove the parts in the order listed. Disconnect. Disconnect.
FI FUEL INJECTION SYSTEM 2 3 7 4 5 11 6 1 10 8 9 12 10 13 14 Order 11 12 13 14 Job/Part Intake air pressure sensor Fuel injection pipe Injector Throttle position sensor Q’ty 1 1 4 1 10 Remarks For installation, reverse the removal procedure.
AIR INDUCTION SYSTEM FI AIR INDUCTION SYSTEM a INSTALLING THE REED VALVES 1. Install: • plate 1 b 1 NOTE: Align the notch a in each plate with the projection b of each reed valve seat on the cylinder head cover.
ELECTRICAL COMPONENTS ELEC – + EAS00729 ELECTRICAL ELECTRICAL COMPONENTS 1 Windshield drive unit 2 Battery 3 Starter relay 4 Fuel injection system fuse 5 Front brake light switch 6 Clutch switch 7 Fuse box 8 Radiator fan motor 9 Wire harness 0 Neutral switch A Sidestand switch B Oil level switch C Rear brake light switch D Horn – 26 – E Ignition coil F Main fuse G ABS motor fuse (FJR1300A)
ELECTRICAL COMPONENTS 1 Coolant temperature sensor 2 Intake air pressure sensor 3 Intake air temperature sensor 4 Relay unit 5 Lean angle cut-off switch 6 Hydraulic unit (FJR1300A) 7 Fail-safe relay (FJR1300A) 8 ECU (engine) 9 ECU (ABS) (FJR1300A) 0 Speed sensor A Cylinder identification sensor B O2 sensor C Crankshaft position sensor – 27 – ELEC – D Accessory box solenoid E Accessory box relay F Headlight relay 1 G Radiator fan motor relay H Turn signal relay I Headlight relay 2 +
– 28 – B L G/Y G/Y A G/Y L A L B å L G/Y L R/W R/B R Br/L ON OFF P 2 B B L/R Br/R Br/L R G/L BB B R/G R/W Y/L 1 R Br/R Br/L Br/L Br/L R Br/L Br/R ¢ £ § B W W W Br/G Br/G A Br/G Br/G R/W R/Y Br BB2 BB1 BB3 BB4 BB B2 3 Br/W Br/G BB3 BB2 BB4 BB1 B B B B B2 B1 B2 BB R Br/L Br/R ® • (BLACK) B R W 4 Y Br Y W R R (GRAY) W L/R W W W R R R B/R R/B B/R R/B Sb B Sb Lg B Lg Sb Br/Y R B Lg Br/R Sb Lg R/B B/R B R Br Sb Br/R Lg B Br/Y Br/R Br/Y
– 29 – B L G/Y G/Y A G/Y L A L B © L G/Y L R/W R/B R Br/L ON OFF P 2 B B R Br/R Br/L Br/L Br/L R Br/L Br/R µ º æ R B W W W Br/W Br/G Br/G A Br/G Br/G R/W R/Y Br BB2 BB1 BB3 BB4 BB B2 3 Br/W Br/G BB3 BB2 BB4 BB1 B B B B B2 B1 B2 BB R Br/L Br/R … ø (BLACK) B ¥ L/R Br/R Br/L R G/L BB B R/G R/W Y/L 1 W 4 W R R Y Br (GRAY) W L/R W W W R R Br/L Y R Sb Br/Y R B Lg Br/R B/R R/B Sb B Sb Lg B Lg B/R R/B Sb Lg R/B B/R B R Br Sb Br/R Lg B
FUEL INJECTION SYSTEM ELEC – + EAS00819 CHECKING THE FUEL PUMP WARNING @ Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire. Be extremely careful and note the following points: • Stop the engine before refueling. • Do not smoke, and keep away from open flames, sparks, or any other source of fire. • If you do accidentally spill gasoline, wipe it up immediately with dry rags. • If gasoline touches the engine when it is hot, a fire may occur.
FJR1300 WIRING DIAGRAM 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O P Q R S T U V W X Y Z [ \ ] _ a b c d e f g h i j k l m n o p q r s t u v w x y z { | } ~ å ç † ¢ £ Immobilizer unit Main switch Rectifier/regulator Generator Backup fuse (odometer, clock and windshield) Main fuse Battery Fuel injection system fuse Starter relay Starter motor Relay unit Starting circuit cut-off relay Fuel injection system relay Neutral switch Sidestand switch Accessory box solenoid Accessory box relay Fuel pump O2 sen
FJR1300A WIRING DIAGRAM 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O P Q R S T U V W X Y Z [ \ ] _ a b c d e f g h i j k l m n o p q r s t u v w x y z { | } ~ å ç † ¢ £ Immobilizer unit Main switch Rectifier/regulator Generator ABS fuse Backup fuse (odometer, clock and windshield) Main fuse ABS motor fuse Battery Fuel injection system fuse Starter relay Starter motor Relay unit Starting circuit cut-off relay Fuel injection system relay Neutral switch Sidestand switch Accessory box solenoid Accessory b
YAMAHA MOTOR CO., LTD.
FJR1300 WIRING DIAGRAM G Ch B B BB R/G Y/L G/L R/W 1 R/G B2 B R/W Lg Y/L B Br/G L B SUB-WIRE HARNESS 1 E F SUB-WIRE HARNESS 3 Dg W/B Y Gy/G P/W B/L Gy/G Y W/B B/L P/W (BLACK) (BLACK) WIRE HARNESS SUB-WIRE HARNESS 2 Br/G L B SUB-WIRE HARNESS 1 SUB-WIRE HARNESS 3 D C A B R/L R/B G/B L/B O/B L G/B R/B R/L L O/B L/B W Y/L O/W R/G G/L O/W Y/L W G/L R/G Sb/W G/W Dg B Br/Y Br L/R Ch Sb Lg Br/Y B Dg G/W Sb/W Lg Sb Ch L/R Br Y/B Br/B R/Y Y Lg Br/W G/B Br/G R/W B2 G/Y L Lg Y R/Y Br/B
FJR1300A WIRING DIAGRAM B BB R/G Y/L G/L R/W 1 R/G B2 B R/W Lg Y/L E D C B A 5 Br/L Br/W G/L BB B R/G R/W Y/L 6 R R/G L/W R R C 7 R W W W 3 (BLACK) W W W R R/L 4 R W W ON OFF P R Br/L WIRE HARNESS O/W Y/L W G/L G/R R/G (BLACK) (BLACK) SUB-WIRE HARNESS 2 WIRE HARNESS SUB-WIRE HARNESS 1 Sb/W G/W Dg B Br/Y Br L/R Ch Sb Lg Br/Y B Dg G/W Sb/W Lg Sb Ch L/R Br Y/B Br/B R/Y Y Lg Br/W G/B Br/G R/W B2 G/Y L Lg Y R/Y Br/B Y/B L G/Y B2 R/W Br/G G/B Br/W WIRE HARNESS SUB-WIRE HARN
