OWNER’S MANUAL FJR1300S(C) FJR1300AS(C) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.05-1.
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5JW11.book Page 1 Friday, May 9, 2003 4:03 PM INTRODUCTION EAU10080 Congratulations on your purchase of the Yamaha FJR1300S(C)/FJR1300AS(C). This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle.
5JW11.book Page 1 Friday, May 9, 2003 4:03 PM IMPORTANT MANUAL INFORMATION EAU10130 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
JW11.book Page 2 Friday, May 9, 2003 4:03 PM IMPORTANT MANUAL INFORMATION EAU10191 AFFIX DEALER LABEL HERE FJR1300S(C)/FJR1300AS(C) OWNER’S MANUAL ©2003 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan.
5JW11.book Page 1 Friday, May 9, 2003 4:03 PM TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 Location of important labels ............1-5 DESCRIPTION ..................................2-1 Left view ..........................................2-1 Right view ........................................2-2 Controls and instruments.................2-3 INSTRUMENT AND CONTROL FUNCTIONS .......................................3-1 Main switch/steering lock ................3-1 Indicator and warning lights ....
5JW11.book Page 2 Friday, May 9, 2003 4:03 PM TABLE OF CONTENTS Checking the wheel bearings .......6-30 Battery ..........................................6-30 Replacing the fuses ......................6-31 Replacing a headlight bulb ...........6-33 Replacing a rear turn signal light bulb or a tail/brake light bulb .....6-34 Troubleshooting ............................6-35 Troubleshooting charts .................6-36 MOTORCYCLE CARE AND STORAGE ..........................................7-1 Care ............
5JW11.book Page 1 Friday, May 9, 2003 4:03 PM SAFETY INFORMATION EAU10250 1 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: ● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION.
5JW11.book Page 2 Friday, May 9, 2003 4:03 PM SAFETY INFORMATION ● ● wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). • Always obey the speed limit and never travel faster than warranted by road and traffic conditions. • Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control.
5JW11.book Page 3 Friday, May 9, 2003 4:03 PM SAFETY INFORMATION 1 Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of FJR1300 200.0 kg (441 lb) (CAL) FJR1300 201.0 kg (443 lb) (U49) FJR1300A 193.0 kg (426 lb) (CAL) FJR1300A 194.0 kg (428 lb) (U49). When loading within this weight limit, keep the following in mind: ● Cargo and accessory weight should be kept as low and close to the motorcycle as possible.
5JW11.book Page 4 Friday, May 9, 2003 4:03 PM SAFETY INFORMATION ● tor and may limit control ability, therefore, such accessories are not recommended. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the motorcycle’s electrical system, an electric failure could result, which could cause a dangerous loss of lights or engine power. Gasoline and exhaust gas ● GASOLINE IS HIGHLY FLAMMABLE: • Always turn the engine off when refueling.
5JW11.book Page 5 Friday, May 9, 2003 4:03 PM SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.
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5JW11.book Page 7 Friday, May 9, 2003 4:03 PM SAFETY INFORMATION 1 5 8 6 9 7 CAUTION Cleaning with alkaline or acid cleaner, gasoline or solvent will damage windshield. Use neutral detergent.
5JW11.book Page 1 Friday, May 9, 2003 4:03 PM DESCRIPTION EAU10410 Left view 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.Final gear oil filler bolt (page 6-14) 11.Final gear oil drain bolt (page 6-14) 12.Shock absorber assembly rebound damping force adjusting knob (page 3-15) 13.Shock absorber assembly spring preload adjusting lever (page 3-15) 14.Air filter element (page 6-16) 15.Shift pedal (page 3-7) 16.Engine oil filter cartridge (page 6-11) 17.
5JW11.book Page 2 Friday, May 9, 2003 4:03 PM DESCRIPTION EAU10420 Right view 2 1. 2. 3. 4. 5. 6. 7. 8.
5JW11.book Page 3 Friday, May 9, 2003 4:03 PM DESCRIPTION EAU10430 Controls and instruments 2 1. 2. 3. 4. 5. 6. 7. 8. 9. Main switch/steering lock (page 3-1) 10.
5JW11.book Page 1 Friday, May 9, 2003 4:03 PM INSTRUMENT AND CONTROL FUNCTIONS EAU10460 Main switch/steering lock EAU10660 OFF All electrical systems are off. The key can be removed. To unlock the steering EAU10690 LOCK The steering is locked, and all electrical systems are off. The key can be removed. 3 To lock the steering The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. 1. Push. 2. Turn.
5JW11.book Page 2 Friday, May 9, 2003 4:03 PM INSTRUMENT AND CONTROL FUNCTIONS EAU11001 Indicator and warning lights EAU11060 EAU11510 Neutral indicator light “ ” This indicator light comes on when the transmission is in the neutral position. Engine trouble warning light “ ” This warning light comes on when an electrical circuit monitoring the engine is defective. When this occurs, have a Yamaha dealer check the self-diagnosis system. This warning light also comes on when the fuel tank is empty.
5JW11.book Page 3 Friday, May 9, 2003 4:03 PM INSTRUMENT AND CONTROL FUNCTIONS EWA10081 WARNING 3 EAU11601 EAU11871 Speedometer Tachometer 1. Tachometer 2. Speedometer 3. Multi-function display 1. Tachometer 2. Tachometer red zone If the ABS warning light comes on or flashes while riding, the brake system reverts to conventional braking. Therefore, be careful not to cause the wheels to lock during emergency braking.
5JW11.book Page 4 Friday, May 9, 2003 4:03 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12250 Multi-function display 1. Multi-function display 2. “SELECT” button 3.
5JW11.book Page 5 Friday, May 9, 2003 4:03 PM INSTRUMENT AND CONTROL FUNCTIONS 3 Clock mode To set the clock: 1. Push the “SELECT” button and “RESET” button together for at least two seconds. 2. When the hour digits start flashing, push the “RESET” button to set the hours. 3. Push the “SELECT” button, and the minute digits will start flashing. 4. Push the “RESET” button to set the minutes. 5. Push the “SELECT” button and then release it to start the clock.
5JW11.book Page 6 Friday, May 9, 2003 4:03 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12492 EAU12660 Windshield position adjusting switch “ ” To move the windshield up, push this switch in direction (a). To move the windshield down, push the switch in direction (b). Engine stop switch “ / ” Set this switch to “ ” before starting the engine. Set this switch to “ ” to stop the engine in case of an emergency, such as when the vehicle overturns or when the throttle cable is stuck.
5JW11.book Page 7 Friday, May 9, 2003 4:03 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12830 Clutch lever Make sure that the appropriate setting on the adjusting dial is aligned with the arrow mark on the clutch lever. The clutch lever is equipped with a clutch switch, which is part of the ignition circuit cut-off system. (See page 3-17.) EAU12870 Shift pedal 3 1. 2. 3. 4. Clutch lever Arrow mark Clutch lever position adjusting dial Distance between clutch lever and handlebar grip 1.
5JW11.book Page 8 Friday, May 9, 2003 4:03 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12930 Brake lever EAU12941 Brake pedal EAU26791 ABS (For FJR1300A only) The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip. The Yamaha ABS (Anti-lock Brake System) features a dual electronic control system, which acts on the front and rear brakes independently.
5JW11.book Page 9 Friday, May 9, 2003 4:03 PM INSTRUMENT AND CONTROL FUNCTIONS ● 3 This ABS has a test mode which allows the owner to experience the pulsating at the brake lever or brake pedal when the ABS is operating. However, special tools are required, so please consult your Yamaha dealer when performing this test. EAU13070 NOTE: The fuel tank cap cannot be closed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked.
5JW11.book Page 10 Friday, May 9, 2003 4:03 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13210 Fuel ECA10070 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EAU13360 1. Fuel tank filler tube 2. Fuel level Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity: 25.0 L (6.61 US gal) (5.50 Imp.
5JW11.book Page 11 Friday, May 9, 2003 4:03 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13430 Catalytic converter EAU14080 Seats This model is equipped with a catalytic converter in the exhaust chamber. Rider seat EWA10860 WARNING 3 The exhaust system is hot after operation. Make sure that the exhaust system has cooled down before doing any maintenance work. To remove the rider seat 1. Insert the key into the seat lock, and then turn it as shown. 1. Projection 2.
5JW11.book Page 12 Friday, May 9, 2003 4:03 PM INSTRUMENT AND CONTROL FUNCTIONS EAU14461 Storage compartment EAU26881 Accessory box 3 1. Receptacle 2. Seat holder 2. Install the rider seat. NOTE: Make sure that the seats are properly secured before riding. 1. Storage compartment 1. Accessory box The storage compartment is located under the passenger seat. (See page 3-11.) The accessory box is located beside the meter panel.
5JW11.book Page 13 Friday, May 9, 2003 4:03 PM INSTRUMENT AND CONTROL FUNCTIONS EWA11420 ● ● 3 EAU14731 WARNING Adjusting the front fork Do not exceed the load limit of 0.3 kg (0.7 lb) for the accessory box. Do not exceed the maximum load of FJR1300 200.0 kg (441 lb) (CAL) FJR1300 201.0 kg (443 lb) (U49) FJR1300A 193.0 kg (426 lb) (CAL) FJR1300A 194.0 kg (428 lb) (U49) for the vehicle.
5JW11.book Page 14 Friday, May 9, 2003 4:03 PM INSTRUMENT AND CONTROL FUNCTIONS Rebound damping force Compression damping force ECA10100 CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings. 1. Rebound damping force adjusting knob 1. Compression damping force adjusting screw To increase the rebound damping force and thereby harden the rebound damping, turn the adjusting knob on each fork leg in direction (a).
5JW11.book Page 15 Friday, May 9, 2003 4:03 PM INSTRUMENT AND CONTROL FUNCTIONS EAU14911 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjusting lever and a rebound damping force adjusting knob. For riding solo, move the spring preload adjusting lever in direction (b). For riding with a passenger, move the spring preload adjusting lever in direction (a).
5JW11.book Page 16 Friday, May 9, 2003 4:03 PM INSTRUMENT AND CONTROL FUNCTIONS ● ● Do not deform or damage the gas cylinder in any way, as this will result in poor damping performance. Always have a Yamaha dealer service the shock absorber. EAU15290 Locks for the optional side cases and travel trunk EAU15300 Sidestand The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the vehicle upright.
5JW11.book Page 17 Friday, May 9, 2003 4:03 PM INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer repair it if it does not function properly. 3 EAU15321 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. ● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled.
5JW11.book Page 18 Friday, May 9, 2003 4:03 PM INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is turned on. 3. Turn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? YES NOTE: This check is most reliable if performed with a warmed-up engine. NO The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer.
5JW11.book Page 1 Friday, May 9, 2003 4:03 PM PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.
5JW11.book Page 2 Friday, May 9, 2003 4:03 PM PRE-OPERATION CHECKS EAU15601 Pre-operation check list ITEM CHECKS PAGE Fuel • Check fuel level in fuel tank. • Refuel if necessary. • Check fuel line for leakage. 3-10 Engine oil • Check oil level in engine. • If necessary, add recommended oil to specified level. • Check vehicle for oil leakage. 6-11 Final gear oil • Check vehicle for oil leakage. 6-14 Coolant • Check coolant level in reservoir.
5JW11.book Page 3 Friday, May 9, 2003 4:03 PM PRE-OPERATION CHECKS ITEM CHECKS PAGE Throttle grip • Make sure that operation is smooth. • Check cable free play. • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. 6-18, 6-26 Control cables • Make sure that operation is smooth. • Lubricate if necessary. Wheels and tires • • • • Brake and shift pedals • Make sure that operation is smooth. • Lubricate pedal pivoting points if necessary.
5JW11.book Page 1 Friday, May 9, 2003 4:03 PM OPERATION AND IMPORTANT RIDING POINTS EAU15950 EAU31950 Starting the engine EWA10270 WARNING ● ● ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. Never start the engine or operate it in a closed area for any length of time.
5JW11.book Page 2 Friday, May 9, 2003 4:03 PM OPERATION AND IMPORTANT RIDING POINTS ECA11130 CAUTION: EAU16671 Shifting ECA10260 CAUTION: ● For maximum engine life, always warm the engine up before starting off. Never accelerate hard when the engine is cold! NOTE: The engine is warm when it quickly responds to the throttle. 5 1. Shift pedal 2. Neutral position ● Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc.
5JW11.book Page 3 Friday, May 9, 2003 4:03 PM OPERATION AND IMPORTANT RIDING POINTS 4. At the recommended shift points shown in the following table, close the throttle, and at the same time, quickly pull the clutch lever in. 5. Shift the transmission into second gear. (Make sure not to shift the transmission into the neutral position.) 6. Open the throttle part way and gradually release the clutch lever. 7. Follow the same procedure when shifting to the next higher gear.
5JW11.book Page 4 Friday, May 9, 2003 4:03 PM OPERATION AND IMPORTANT RIDING POINTS ECA10331 EAU17211 CAUTION: Parking After 1000 km (600 mi) of operation, the engine oil and final gear oil must be changed, and the oil filter cartridge or element replaced. When parking, stop the engine, and then remove the key from the main switch. 1600 km (1000 mi) and beyond The vehicle can now be operated normally.
5JW11.book Page 1 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17231 EAU17300 PERIODIC MAINTENANCE Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of motorcycle inspection, adjustment, and lubrication are explained on the following pages.
5JW11.book Page 2 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10340 WARNING Modifications not approved by Yamaha may cause loss of performance, excessive emissions, and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any changes.
chapter6 Page 3 Tuesday, May 13, 2003 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17600 Periodic maintenance chart for the emission control system INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months Fuel line • Check fuel hose for cracks or damage. • Replace if necessary.
5JW11.book Page 4 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32181 General maintenance and lubrication chart INITIAL No. 6 ITEM ROUTINE 1 * Air filter element • Clean with compressed air. • Replace if necessary. 2 * Clutch • Check operation and fluid leakage. • Correct if necessary.
5JW11.book Page 5 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE Swingarm pivot bearings • Check bearing assemblies for looseness. • Moderately repack with lithiumsoap-based grease. 10 * Steering bearings • Check bearing assembly for looseness. • Moderately repack with lithiumsoap-based grease every 16000 mi (25000 km) or 24 months.
5JW11.book Page 6 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month 18 * Rear suspension link pivots • Apply lithium-soap-based grease lightly. 19 Engine oil • Change (warm engine before draining). √ 20 * Engine oil filter cartridge • Replace.
5JW11.book Page 7 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. EAU17660 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 cylinder, always change the fluid.
5JW11.book Page 8 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU18770 Removing and installing panels 1. Panel F 6 1. 2. 3. 4. Panel A Panel B Panel C Panel D The panels shown above need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. 1. Screw 2.
5JW11.book Page 9 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR 2. Install panel A (to complete the installation of panel B) or panel D (to complete the installation of panel C). EAU19210 Panel D 1. Screw 2. Quick fastener To remove the panel Remove the screws, and then take the panel off. EAU19450 Panels E and F To remove one of the panels 1. Remove the seats. (See page 3-11.) 2. Remove the screws, the quick fastener screw and the quick fasteners, and then take the panel off.
5JW11.book Page 10 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19640 Checking the spark plugs 6 The spark plugs are important engine components, which should be checked periodically, preferably by a Yamaha dealer. Since heat and deposits will cause any spark plug to slowly erode, they should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plugs can reveal the condition of the engine.
5JW11.book Page 11 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19680 Canister (for California only) ● ● ● Check each hose connection. Check each hose and canister for cracks or damage. Replace if damaged. Make sure that the canister breather is not blocked, and if necessary, clean it. EAU19881 Engine oil and oil filter cartridge The engine oil level should be checked before each ride.
5JW11.book Page 12 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: The engine oil should be between the minimum and maximum level marks. 2. Place an oil pan under the engine to collect the used oil. 3. Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase. 1. Oil filter cartridge 2. Oil filter wrench 6 1. Engine oil level check window 2. Maximum level mark 3. Minimum level mark 4.
5JW11.book Page 13 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR ECA11620 Tightening torque: Oil filter cartridge: 17 Nm (1.7 m·kgf, 12 ft·lbf) CAUTION: ● 7. Install the engine oil drain bolt, and then tighten it to the specified torque. 1. O-ring NOTE: Make sure that the O-ring is properly seated. 6. Install the new oil filter cartridge, and then tighten it to the specified torque with a torque wrench. NOTE: Check the washer for damage and replace it if necessary.
5JW11.book Page 14 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR ECA10400 EAU20010 CAUTION: Final gear oil If the oil level warning light flickers or remains on, immediately turn the engine off and have a Yamaha dealer check the vehicle. The final gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the vehicle.
5JW11.book Page 15 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR 2. Remove the oil filler bolt and drain bolt to drain the oil from the final gear case. 3. Install the final gear oil drain bolt, and then tighten it to the specified torque. Tightening torque: Final gear oil drain bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 4. Add the recommended final gear oil to the brim of the filler hole. Recommended final gear oil: Shaft drive gear oil (Part No.: 9079ESH001-00) Oil quantity: 0.20 L (0.
5JW11.book Page 16 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● 1. Bolt 2. Coolant reservoir cap cover 3. Coolant reservoir cap 6 4. Add coolant or distilled water to raise the coolant to the maximum level mark, install the coolant reservoir cap, the coolant reservoir cap cover and the bolt. Coolant reservoir capacity (up to the maximum level mark): 0.25 L (0.26 US qt) (0.22 Imp.qt) ECA10470 CAUTION: ● If coolant is not available, use distilled water or soft tap water instead.
5JW11.book Page 17 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR out with compressed air as shown. If the air filter element is damaged, replace it. 9. Install the panel. 1. Air filter case cover 2. Screw 4. Pull the air filter element out. 6. Insert the air filter element into the air filter case. ECA10480 CAUTION: ● ● 1. Air filter element 5.
5JW11.book Page 18 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21380 Adjusting the throttle cable free play EAU21400 EAU21750 Adjusting the valve clearance Tires The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.
5JW11.book Page 19 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10510 Tire air pressure (measured on cold tires): 0.0–90.0 kg (0–198 lb): Front: 250 kPa (36 psi) (2.50 kgf/cm²) Rear: 250 kPa (36 psi) (2.50 kgf/cm²) FJR1300 90.0–200.0 kg (198–441 lb) (CAL) FJR1300 90.0–201.0 kg (198–443 lb) (U49) FJR1300A 90.0–193.0 kg (198–426 lb) (CAL) FJR1300A 90.0–194.0 kg (198–428 lb) (U49): Front: 250 kPa (36 psi) (2.50 kgf/cm²) Rear: 290 kPa (42 psi) (2.
5JW11.book Page 20 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10580 WARNING ● ● It is dangerous to ride with a worn-out tire. When a tire tread begins to show crosswise lines, have a Yamaha dealer replace the tire immediately. The replacement of all wheeland brake-related parts, including the tires, should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. This motorcycle is equipped with cast wheels and tubeless tires with valves.
5JW11.book Page 21 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● “broken in”. Therefore, it is advisable before doing any highspeed riding to ride conservatively for approximately 100 km (60 mi) after installing a new tire. The tires must be warmed up before a high-speed run. Always adjust the tire air pressure according to the operating conditions.
5JW11.book Page 22 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR any consequences caused by the use of items which have not been approved by Yamaha. 6 EAU22071 Clutch lever free play Since this model is equipped with a hydraulic clutch, adjusting the clutch lever free play is not needed. However, it is necessary to check the clutch fluid level and check the hydraulic system for leakage before each ride.
5JW11.book Page 23 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR the braking performance, which may result in loss of control and an accident. EAU22270 Adjusting the rear brake light switch EAU22390 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. EAU22420 Front brake pads 1. Rear brake light switch 2.
5JW11.book Page 24 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set. EAU22500 EAU22680 Checking the brake and clutch fluid levels Clutch Front brake Rear brake pads 1. Minimum level mark 1. Minimum level mark 6 1. Lining thickness Rear brake Check each rear brake pad for damage and measure the lining thickness. If a brake pad is damaged or if the lining thickness is less than 0.8 mm (0.
5JW11.book Page 25 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● When checking the fluid level, make sure that the top of the brake or clutch fluid reservoir is level. Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking or clutch performance. Recommended brake and clutch fluid: DOT 4 brake fluid ● ● ● Refill with the same type of brake fluid.
5JW11.book Page 26 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23090 EAU23110 Checking and lubricating the cables Checking and lubricating the throttle grip and cable The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it.
5JW11.book Page 27 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23140 Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Checking and lubricating the brake and clutch levers Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Brake lever Clutch lever 6 The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary.
5JW11.book Page 28 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23210 Checking and lubricating the centerstand and sidestand EAU23250 Lubricating the rear suspension EAU23271 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. To check the condition EWA10750 WARNING Securely support the vehicle so that there is no danger of it falling over.
5JW11.book Page 29 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23280 Checking the steering ECA10590 Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1. Place a stand under the engine to raise the front wheel off the ground.
5JW11.book Page 30 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23290 Checking the wheel bearings EAU23400 EWA10760 Battery WARNING The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. ● 1. Battery 6 The battery is located under panels C and D. (See page 6-8.
5JW11.book Page 31 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF CHILDREN. To store the battery 1. If the vehicle will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place. 2. If the battery will be stored for more than two months, check it at least once a month and fully charge it if necessary. 3. Fully charge the battery before installation. 4.
5JW11.book Page 32 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR 6 1. Headlight fuse 2. Signaling system fuse 3. Ignition fuse 4. Windshield motor fuse 5. Radiator fan fuse 6. Odometer and clock fuse (backup) 7. Spare fuse 8. Hazard fuse 9. ABS control unit fuse 10.Tail/position light fuse 1. Main fuse If a fuse is blown, replace it as follows. 1. Turn the key to “OFF” and turn off the electrical circuit in question. 2.
5JW11.book Page 33 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR ECA10640 EAU23900 CAUTION: Replacing a headlight bulb Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire. This model is equipped with quartz bulb headlights. If a headlight bulb burns out, replace it as follows. 1. Remove panel B (if replacing the left headlight bulb) or panel C (if replacing the right headlight bulb).
5JW11.book Page 34 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● 6 Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner. Headlight lens Do not affix any type of tinted film or stickers to the headlight lens.
5JW11.book Page 35 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25870 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting charts represent quick and easy procedures for checking these vital systems yourself.
5JW11.book Page 36 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25911 Troubleshooting charts Starting problems or poor engine performance EWA10840 WARNING Keep away open flames and do not smoke while checking or working on the fuel system. 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle. Check the fuel level in the fuel tank.
5JW11.book Page 37 Friday, May 9, 2003 4:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR Engine overheating EWA10400 WARNING ● ● Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
5JW11.book Page 1 Friday, May 9, 2003 4:03 PM MOTORCYCLE CARE AND STORAGE ucts onto seals, gaskets and wheel axles. Always rinse the dirt and degreaser off with water. EAU26060 Care While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appearance of a motorcycle.
5JW11.book Page 2 Friday, May 9, 2003 4:03 PM MOTORCYCLE CARE AND STORAGE After normal use Remove dirt with warm water, a mild detergent, and a soft, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bottlebrush for hard-to-reach areas. Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning.
5JW11.book Page 3 Friday, May 9, 2003 4:03 PM MOTORCYCLE CARE AND STORAGE EAU26240 NOTE: Consult a Yamaha dealer for advice on what products to use. Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover. ECA10810 CAUTION: ● ● 7 Storing the motorcycle in a poorly ventilated room or covering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust.
5JW11.book Page 4 Friday, May 9, 2003 4:03 PM MOTORCYCLE CARE AND STORAGE 4. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/centerstand. 5. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 6.
5JW11.book Page 1 Friday, May 9, 2003 4:03 PM SPECIFICATIONS Dimensions: Overall length: 2195 mm (86.4 in) Overall width: 760 mm (29.9 in) Overall height: 1435 mm (56.5 in) Seat height: 805 mm (31.7 in) Wheelbase: 1515 mm (59.6 in) Ground clearance: 135 mm (5.31 in) Minimum turning radius: 3100 mm (122.0 in) Weight: With oil and fuel: FJR1300 275.0 kg (606 lb) (U49) FJR1300 276.0 kg (609 lb) (CAL) FJR1300A 282.0 kg (622 lb) (U49) FJR1300A 283.
5JW11.book Page 2 Friday, May 9, 2003 4:03 PM SPECIFICATIONS 3rd: 31/23 (1.348) 4th: 28/26 (1.077) 5th: 26/28 (0.929) Chassis: Frame type: Diamond Caster angle: 26.0 ° Trail: 109.0 mm (4.
5JW11.book Page 3 Friday, May 9, 2003 4:03 PM SPECIFICATIONS Spring/shock absorber type: Coil spring/gas-oil damper Wheel travel: 125.0 mm (4.92 in) Electrical system: Ignition system: Transistorized coil ignition (digital) Charging system: A.C. magneto Battery: Model: GT14B-4 Voltage, capacity: 12 V, 12.0 Ah Headlight: Bulb type: Halogen bulb Bulb voltage, wattage x quantity: 8 Headlight: 12 V, 60.0 W/55.0 W × 2 Tail/brake light: 12 V, 5.0 W/21.0 W × 2 Front turn signal/position light: 12 V, 21.
5JW11.book Page 1 Friday, May 9, 2003 4:03 PM CONSUMER INFORMATION EAU26351 Identification numbers EAU26380 EAU26400 Key identification number Vehicle identification number 1. Key identification number 1. Vehicle identification number The key identification number is stamped into the key tag. Record this number in the space provided and use it for reference when ordering a new key. The vehicle identification number is stamped into the steering head pipe. Record this number in the space provided.
5JW11.book Page 2 Friday, May 9, 2003 4:03 PM CONSUMER INFORMATION EAU26470 Model label 1. Model label The model label is affixed to the frame under the rider seat. (See page 3-11.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
5JW11.book Page 3 Friday, May 9, 2003 4:03 PM CONSUMER INFORMATION EAU26550 Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A.
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5JW11.book Page 5 Friday, May 9, 2003 4:03 PM CONSUMER INFORMATION EAU26631 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required. It is not acceptable proof of maintenance work.
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5JW11.book Page 7 Friday, May 9, 2003 4:03 PM CONSUMER INFORMATION EAU26661 YAMAHA MOTOR CORPORATION, U.S.A.
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5JW11.book Page 9 Friday, May 9, 2003 4:03 PM CONSUMER INFORMATION EAU26750 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.). In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost.
5JW11.book Page 10 Friday, May 9, 2003 4:03 PM CONSUMER INFORMATION We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your Yamaha Limited Warranty expires. A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need. Yamaha Service Marketing P.O.
5JW11.book Page 1 Friday, May 9, 2003 4:03 PM INDEX A ABS (For FJR1300A only) ...................... 3-8 ABS warning light ................................... 3-2 Accessories and replacement parts ..... 6-21 Accessory box ...................................... 3-12 Air filter element, cleaning .................... 6-16 Engine stop switch ..................................3-6 Engine trouble warning light ....................3-2 F Battery ..................................................
5JW11.book Page 2 Friday, May 9, 2003 4:03 PM INDEX Throttle cable free play, adjusting ......... 6-18 Throttle grip and cable, checking and lubricating ..................... 6-26 Tires ...................................................... 6-18 Tool kit .................................................... 6-1 Troubleshooting .................................... 6-35 Troubleshooting charts ......................... 6-36 Turn signal indicator lights ......................
OWNER’S MANUAL FJR1300S(C) FJR1300AS(C) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.05-1.
