Yamaha FJR1300(S) Manuale
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
© 2003 by Yamaha Motor Co., Ltd.
First edition, September 2003
All rights reserved.
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
12
34
56
78
90
AB
CD
EFG
HIJ
KLM
NO
GEN
INFO
SPEC
CHK
ADJ
CHAS
ENG
COOL
FI –+
ELEC
TRBL
SHTG
T
R
.
.
EGM
BLS M
LT
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
6
8
4523GH
J
7
A
90
B
D
C
K
1
IF
E
–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
57
4
6
3
A
8
2
0
9
È
É
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