Yamaha FJR1300(S) Manual

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.

FJR1300(N) 2001 SERVICE MANUAL: 5JW1-AE1

FJR1300(P) 2002 SUPPLEMENTARY SERVICE MANUAL: 5JW1-AE2

FJR1300(R)/FJR1300A(R) 2003 SUPPLEMENTARY SERVICE MANUAL: 5JW1-AE4

FJR1300(S)/FJR1300A(S) 2004

SUPPLEMENTARY

SERVICE MANUAL

First edition, September 2003

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

EAS00002

NOTICE

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.

NOTE:

Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to

the motorcycle operator, a bystander or a person checking or repairing the

motorcycle.

A CAUTION indicates special precautions that must be taken to avoid damage

to the motorcycle.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

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.

1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of

each page indicate the current chapter.

Refer to “SYMBOLS”.

2Each chapter is divided into sections. The current section title is shown at the top of each page,

except in chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s)

appears.

3Sub-section titles appear in smaller print than the section title.

4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of

each removal and disassembly section.

5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a

disassembly step.

6Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

8Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

EAS00008

SYMBOLS

The following symbols are not relevant to

every vehicle.

Symbols 1to 9indicate the subject of each

chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Chassis

5Engine

6Cooling system

7Fuel injection system

8Electrical system

9Troubleshooting

Symbols 0to Gindicate the following.

0Serviceable with engine mounted

AFilling fluid

BLubricant

CSpecial tool

DTightening torque

EWear limit, clearance

FEngine speed

GElectrical data

Symbols Hto Min the exploded diagrams

indicate the types of lubricants and lubrication

points.

HEngine oil

IGear oil

JMolybdenum disulfide oil

KWheel bearing grease

LLithium soap base grease

MMolybdenum disulfide grease

Symbols Nto Oin the exploded diagrams

indicate the following.

NApply locking agent (LOCTITE®)

OReplace the part

EFG

HIJ

KLM

GEN

INFO

SPEC

CHK

ADJ

CHAS

ENG

COOL

FI –+

ELEC

TRBL

SHTG

EGM

BLS M

New

CONTENTS

GENERAL INFORMATION ..............................................................................1

FEATURES ...............................................................................................1

OUTLINE ...............................................................................................1

FI SYSTEM ...........................................................................................2

SPECIFICATIONS ............................................................................................3

GENERAL SPECIFICATIONS ..................................................................3

ENGINE SPECIFICATIONS ......................................................................3

ELECTRICAL SPECIFICATIONS .............................................................4

PERIODIC CHECKS AND ADJUSTMENTS ....................................................5

INTRODUCTION .......................................................................................5

PERIODIC MAINTENANCE AND LUBRICATION CHART .......................5

SEATS AND FUEL TANK .........................................................................7

FUEL TANK ..........................................................................................7

REMOVING THE FUEL TANK ..............................................................9

AIR FILTER CASE ..................................................................................10

FUEL INJECTION SYSTEM ...........................................................................12

FUEL INJECTION SYSTEM ...................................................................12

WIRING DIAGRAM (FJR1300) ...........................................................13

WIRING DIAGRAM (FJR1300A) .........................................................14

SUBSTITUTE CHARACTERISTICS OPERATION CONTROL

(FAIL-SAFE ACTION) .........................................................................16

THROTTLE BODIES ...........................................................................21

AIR INDUCTION SYSTEM ......................................................................25

INSTALLING THE REED VALVES .....................................................25

ELECTRICAL .................................................................................................26

ELECTRICAL COMPONENTS ...............................................................26

FUEL INJECTION SYSTEM ...................................................................28

CIRCUIT DIAGRAM (FJR1300) ..........................................................28

CIRCUIT DIAGRAM (FJR1300A) .......................................................29

CHECKING THE FUEL PUMP ...........................................................30

FJR1300 WIRING DIAGRAM

FJR1300A WIRING DIAGRAM

–1 –

GEN

INFO

FEATURES

GENERAL INFORMATION

FEATURES

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 carburetor.

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 ratio in a more precise and finely tuned man-

ner. To accommodate this need, this model has adopted an electronically controlled fuel injection

(FI) system, in place of the conventional carburetor system. This system can achieve an optimum

air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel

injection volume according to the engine operating conditions detected by various sensors.

The adoption of the FI system has resulted in a highly precise fuel supply, improved engine

response, better fuel economy, and reduced exhaust emissions. Furthermore, the air induction sys-

tem (AI system) has been placed under computer control together with the FI system in order to

realize cleaner exhaust gases.

1Ignition coil

2Air filter case

3Intake air tempera-

ture sensor

4Fuel delivery hose

5Fuel tank

6Fuel pump

7Intake air pressure

sensor

8Throttle position sensor

9Fuel injector

0O2sensor

ACatalytic converter

BCrankshaft position

sensor

CCoolant temperature

sensor

DSpark plug

ECylinder identifica-

tion sensor

FBattery

GECU

HFuel injection system

relay

IEngine trouble warn-

ing light

JLean angle cut-off

switch

KAir cut-off valve

4523GH

–2 –

GEN

INFO

FEATURES

FI SYSTEM

The fuel pump delivers fuel to the injector via the fuel filter. The fuel pump maintains the fuel pres-

sure 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. 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 dura-

tion), the lesser the volume of fuel that is supplied.

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, intake air tem-

perature sensor, coolant temperature sensor, and O2sensor enable the ECU to determine the

injection duration. The injection timing is determined through the signals from the crankshaft posi-

tion 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.

1Fuel pump

2Fuel injector

3Throttle body

4Intake air temperature

sensor

5Throttle position sen-

sor

6Intake air pressure

sensor

7ECU

8Coolant temperature

sensor

9O2sensor

0Cylinder identification

sensor

ACrankshaft position

sensor

ÈFuel system

ÉControl system

Illustration is for reference only.

#4 #3 #2 #1 1

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