Yamaha 2006 FJR1300AS Service Manual
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Yamaha 2006 FJR1300AS Service Manual

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2006
FJR1300AS(V)
SUPPLEMENTARY
SERVICE MANUAL
3P6-28197-E1
Table of Contents
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Summary of Contents for Yamaha 2006 FJR1300AS

  • Page 1 2006 FJR1300AS(V) SUPPLEMENTARY SERVICE MANUAL 3P6-28197-E1...
  • Page 2 Service Manual together with the following manual. FJR1300A(V) SERVICE MANUAL: 3P6-28197-E0 EAS20040 FJR1300AS(V) 2006 SUPPLEMENTARY SERVICE MANUAL ©2006 by Yamaha Motor Co., Ltd. First edition, February 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
  • Page 3 EAS20070 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 man- ual. 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.

  • Page 4: How To Use This Manual

    EAS20090 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. •...

  • Page 5: Symbols

    EAS20100 1. Serviceable with engine mounted SYMBOLS 2. Filling fluid The following symbols are used in this manual 3. Lubricant for easier understanding. 4. Special tool NOTE: 5. Tightening torque The following symbols are not relevant to every 6. Wear limit, clearance vehicle.

  • Page 6: Table Of Contents

    EAS20110 CONTENTS FEATURES......................1 OUTLINE OF THE YCC-S (Yamaha Chip Controlled-Shift) SYSTEM ..1 SPECIAL TOOLS ....................4 GENERAL SPECIFICATIONS ................6 ENGINE SPECIFICATIONS ................7 CHASSIS SPECIFICATIONS ................8 ELECTRICAL SPECIFICATIONS ..............9 TIGHTENING TORQUES ................. 10 ENGINE TIGHTENING TORQUES............10 CHASSIS TIGHTENING TORQUES............
  • Page 7 SHAFT DRIVE ....................46 INSTALLING THE DRIVE SHAFT AND FINAL DRIVE ASSEMBLY ..46 ENGINE REMOVAL ..................47 REMOVING THE GEAR POSITION SENSOR .......... 49 REMOVING THE ENGINE ................. 49 INSTALLING THE GEAR POSITION SENSOR......... 49 ADJUSTING THE GEAR POSITION SENSOR ......... 50 CLUTCH ......................
  • Page 8 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM......... 85 CIRCUIT DIAGRAM (1/2)................85 CIRCUIT DIAGRAM (2/2)................87 TROUBLESHOOTING ................89 MAINTENANCE OF THE MCU ..............90 MCU (motor control unit) SELF-DIAGNOSTIC FUNCTION ....... 90 SELF-DIAGNOSTIC FUNCTION TABLE ........... 91 TROUBLESHOOTING METHOD............... 94 DIAGNOSTIC MODE ................. 95 TROUBLESHOOTING DETAILS ...............

  • Page 10: Features

    FEATURES EAS20170 FEATURES ET2D21013 OUTLINE OF THE YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Concept YCC-S offers more enjoyable and easy riding by eliminating the need for the user to operate the clutch, which also reduces fatigue during long touring. YCC-S is not an automatic transmission, although it allows the user to shift gears by foot or hand ac- cording to preference.
  • Page 11 FEATURES 1. YCC-S test coupler 8. MCU (motor control unit) 2. YCC-S control relay 9. Shift actuator 3. YCC-S indicator and warning light 10. Clutch actuator 4. YCC-S motor control fuse 11. Foot shift switch 5. Hand shift switch 12. YCC-S speed sensor 6.
  • Page 12 • If the YCC-S indicator and warning light come on while riding, stop the vehicle, park it in a safe place, and then contact a Yamaha dealer. Because the YCC-S system stops automatically when the YCC-S indicator and warning light come on, it is impossible to shift since clutch operation is stopped.

  • Page 13: Special Tools

    SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.

  • Page 14: Tool Name/Tool No

    SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pivot shaft wrench adapter 90890-01476 Digital circuit tester 50, 60 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Test coupler adapter 90890-03149 Pocket tester 129, 130, 132, 90890-03112 133, 134 Analog pocket tester YU-03112-C –...

  • Page 15: General Specifications

    GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 2D21(Europe except (B)and(F))(ZA) 2D22(B)(F) 2D23(AUS) Weight With oil and fuel 295.0 kg (650 lb) Maximum load 208 kg (459 lb) – 6 –...

  • Page 16: Engine Specifications

    ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Clutch Clutch type Wet, multiple-disc Clutch release method Hydraulic inner push Clutch lever free play 1.9–20.7 mm (0.07–0.81 in) Friction plate thickness 2.90–3.10 mm (0.114–0.122 in) Wear limit 2.80 mm (0.1102 in) Plate quantity 9 pcs Clutch plate thickness 1.90–2.10 mm (0.075–0.083 in) Plate quantity...

  • Page 17: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Tire air pressure (measured on cold tires) Loading condition 0–90 kg (0–198 lb) Front 270 kPa (39 psi) (2.70 kgf/cm²) Rear 290 kPa (42 psi) (2.90 kgf/cm²) Loading condition 90–208 kg (198–459 lb) Front 270 kPa (39 psi) (2.70 kgf/cm²) Rear 290 kPa (42 psi) (2.90 kgf/cm²) High-speed riding...

  • Page 18: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Gear position sensor Output voltage (at neutral position) 0.71–0.91 V Resistance 4.0–6.0 kΩ Foot shift switch Output voltage 2.4–2.6 V Resistance 4.0–6.0 kΩ Grip warmer 1.21–1.48 Ω at 20 °C (68 °F) Resistance Fuses Main fuse 50.0 A Headlight fuse 25.0 A...

  • Page 19: Tightening Torques

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Clutch fluid reservoir bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Clutch actuator bracket bolt 19 Nm (1.9 m·kg, 13 ft·lb) Clutch actuator bracket bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Gear position sensor cover 10 Nm (1.0 m·kg, 7.2 ft·lb)

  • Page 20: Chassis Tightening Torques

    TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Shift pedal bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Shift pedal pivot bolt 16 Nm (1.6 m·kg, 11 ft·lb) Pivot shaft locknut retainer bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) –...
  • Page 21 TIGHTENING TORQUES – 12 –...

  • Page 22: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING 12 11 – 13 –...
  • Page 23 CABLE ROUTING 1. Brake hose (front brake master cylinder to M. Fasten the right handlebar switch lead, right grip hydraulic unit) warmer lead, and main switch lead with a plastic locking tie at the location shown in the illustration. 2. Right handlebar switch lead Position the buckle of the plastic locking tie under 3.
  • Page 24 CABLE ROUTING 41 42 14 15 – 15 –...
  • Page 25 CABLE ROUTING 1. O sensor lead F. Route the positive battery lead between the battery stay and the battery box. 2. Engine idling speed adjusting cable G. To front cowling wire harness 3. Starter motor lead H. Align the rear end of the right radiator fan motor 4.
  • Page 26 CABLE ROUTING – 17 –...
  • Page 27 CABLE ROUTING 1. Rear wheel sensor lead 2. Rear brake fluid reservoir 3. Rear brake light switch lead 4. Clutch actuator motor lead 5. Clutch actuator sensor lead 6. Hydraulic unit 7. Brake hose (front brake master cylinder to hydraulic unit) 8.
  • Page 28 CABLE ROUTING – 19 –...
  • Page 29 CABLE ROUTING 1. Auxiliary DC jack 2. Left radiator fan motor lead 3. Accessory box solenoid 4. Wire harness 5. Front cowling wire harness 6. Radiator inlet hose 7. Grip warmer control unit leads 8. Left radiator fan 9. Coolant reservoir breather hose 10.
  • Page 30 CABLE ROUTING 31 32 12 13 – 21 –...
  • Page 31 CABLE ROUTING 1. Grip warmer couplers E. Fasten the sidestand switch lead, stator coil lead, and oil level switch lead with a plastic locking tie, 2. Hand shift switch coupler making sure to bundle and fasten the sidestand 3. Handlebar switch couplers switch lead so that the coupler is positioned to the 4.
  • Page 32 CABLE ROUTING – 23 –...
  • Page 33 CABLE ROUTING 1. Wire harness L. Route the leads between the left tail/brake light bulb socket and the rear left turn signal light bulb 2. ECU (engine control unit) socket. 3. ABS ECU (electronic control unit) M. Route the tail/brake light assembly lead between 4.
  • Page 34 CABLE ROUTING 3 4 5 6 7 8 9 – 25 –...
  • Page 35 CABLE ROUTING 1. Spark plug lead #1 L. Route the stator coil lead to the inside of the engine bracket (top) and under the crankcase 2. Spark plug lead #2 breather hose. 3. Front wheel sensor lead M. Route the wire harness (to sub-wire harness) 4.
  • Page 36 CABLE ROUTING – 27 –...
  • Page 37 CABLE ROUTING 1. Clutch actuator motor lead 2. Clutch actuator sensor lead 3. License plate light lead 4. Tail/brake light assembly lead 5. Seat lock cable 6. Intake air temperature sensor A. Connect the clutch actuator motor lead and clutch actuator sensor lead, install the rubber cover around the leads, and then place the cover between the hydraulic unit and the frame.

  • Page 38: Periodic Maintenance

    • From 50000 km, repeat the maintenance intervals starting from 10000 km. • Items marked with an asterisk should be performed by a -Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1000 km)
  • Page 39 PERIODIC MAINTENANCE ODOMETER READING (× 1000 km) ANNU- ITEM CHECK OR MAINTENANCE JOB CHECK Shock absorber as- √ √ √ √ 18 * • Check operation and shock absorber for oil leakage. sembly √ √ √ √ Rear suspension re- •...

  • Page 40: Engine

    ENGINE EAS20470 NOTE: ENGINE In order to ensure a correct reading of the clutch fluid level, make sure the top of the reservoir is EAS20890 CHECKING THE CLUTCH FLUID LEVEL horizontal. 1. Stand the vehicle on a level surface. 4. Install: NOTE: •...

  • Page 41: Vacuum/Pressure Pump Gauge Set

    ENGINE b. Turn the main switch to “ON” and check that l. Repeat steps (i) to (k) until all of the air bub- the transmission is in neutral. bles have disappeared from the clutch fluid in c. Add the recommended clutch fluid to the the plastic hose of the vacuum/pressure proper level.

  • Page 42: Checking The Vehicle After Bleeding The Hydraulic Clutch System

    ENGINE g. If the pressure plate stroke is out of specifica- tion, repeat steps (j) to (l) in the procedure for step “2. Bleed” until clutch pressure plate stroke is within specification. L LLL L LLL L LLL L LLL L LLL 4.

  • Page 43: Cleaning The Air Filter Element

    ENGINE b. Start the engine. • Left side cover c. Shift the transmission from neutral to 1st gear Refer to “GENERAL CHASSIS” on page 37. and back to neutral ten times. • Shift actuator d. Shift the transmission into 1st gear, and then Refer to “SHIFT ACTUATOR AND SHIFT apply the rear brake.

  • Page 44: Chassis

    CHASSIS EAS21140 CHASSIS ET2D21002 ADJUSTING THE SHIFT PEDAL 1. Check: • Shift pedal position NOTE: The shift pedal “1” can be adjusted to three po- sitions to suit the rider’s preference as shown. 2. Adjust: • Shift pedal position M MMM M MMM M MMM M MMM...

  • Page 45: Electrical System

    ELECTRICAL SYSTEM EAS21750 ECA13690 ELECTRICAL SYSTEM CAUTION: Avoid touching the glass part of the head- EAS21790 light bulb to keep it free from oil, otherwise REPLACING THE HEADLIGHT BULBS the transparency of the glass, the life of the The following procedure applies to both of the bulb and the luminous flux will be adversely headlight bulbs.

  • Page 46: General Chassis

    GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the front cowling assembly 10 Nm (1.0 m kg, 7.2 ft • • 32 Nm (3.2 m kg, 23 ft • • Order Job/Parts to remove Q’ty Remarks Open the accessory box lid. Left side panel Left side cowling Front left turn signal light coupler Disconnect.
  • Page 47 GENERAL CHASSIS Removing the front cowling assembly 10 Nm (1.0 m kg, 7.2 ft • • 32 Nm (3.2 m kg, 23 ft • • Order Job/Parts to remove Q’ty Remarks Front cowling left inner panel 2 Plastic band Disconnect. Plastic holder Disconnect.
  • Page 48 GENERAL CHASSIS Removing the air filter case 18 Nm (1.8 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft • • (11) 8 Nm (0.8 m kg, 5.8 ft • • 4 Nm (0.4 m kg, 2.9 ft •...
  • Page 49 GENERAL CHASSIS Removing the air filter case 18 Nm (1.8 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft • • (11) 8 Nm (0.8 m kg, 5.8 ft • • 4 Nm (0.4 m kg, 2.9 ft •...

  • Page 50: Handlebars

    HANDLEBARS EAS22850 HANDLEBARS Removing the left handlebar Order Job/Parts to remove Q’ty Remarks Left handlebar Left grip warmer lead Hand shift switch lead Left handlebar switch lead Lead holder 1 Hand shift switch Lead holder 2 Left handlebar switch Grip end Handlebar grip For installation, reverse the removal proce- dure.
  • Page 51 HANDLEBARS Removing the right handlebar Order Job/Parts to remove Q’ty Remarks Front brake light switch connector Disconnect. Front brake master cylinder holder Front brake master cylinder assembly Grip end Throttle cable housing Throttle cable Disconnect. Throttle grip Right handlebar Right grip warmer lead Right handlebar switch lead Lead holder Right handlebar switch...

  • Page 52: Installing The Handlebars

    HANDLEBARS EAS22900 INSTALLING THE HANDLEBARS 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Install: • Handlebar grip • Grip end “1” 4. Install: M MMM M MMM M MMM...
  • Page 53 HANDLEBARS es to the rear of the other section of the lead, NOTE: and route the lead through the throttle cable Fit the projections on each handlebar into the housing. holes in the upper bracket, making sure that the • When installing the throttle cable housing, handlebars are installed in the same position.
  • Page 54 HANDLEBARS • First, tighten the upper bolt, then the lower bolt. 11.Adjust: • Throttle cable free play Refer to “ADJUSTING THE THROTTLE CA- BLE FREE PLAY” in chapter 3. (Manual No.: 3P6-28197-E0) Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) –...

  • Page 55: Shaft Drive

    SHAFT DRIVE EAS23550 SHAFT DRIVE EAS23660 INSTALLING THE DRIVE SHAFT AND FINAL Installed depth “a” DRIVE ASSEMBLY 8.5–10.0 mm (0.33–0.39 in) 1. Lubricate: • Drive shaft spline (final drive pinion gear side) Recommended lubricant Molybdenum disulfide grease 2. Lubricate: • Drive shaft spline (universal joint side) Recommended lubricant Lithium-soap-based grease 3.

  • Page 56: Engine Removal

    ENGINE REMOVAL EAS23710 ENGINE REMOVAL Disconnecting the leads and hoses 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “FRONT WHEEL” in chapter 4. Front fender (Manual No.: 3P6-28197-E0) Air filter case...
  • Page 57 ENGINE REMOVAL Disconnecting the leads and hoses 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “SHIFT ACTUATOR AND SHIFT Gear position sensor cover ROD”...

  • Page 58: Removing The Gear Position Sensor

    ENGINE REMOVAL ET2D21003 REMOVING THE GEAR POSITION SENSOR 1. Disconnect: • Gear position sensor coupler 2. Remove: • Gear position sensor NOTE: Remove only the screws “1” when removing the gear position sensor. Do not remove the screws “2”. ET2D21004 INSTALLING THE GEAR POSITION SENSOR 1.

  • Page 59: Adjusting The Gear Position Sensor

    ENGINE REMOVAL 3. Check: ET2D21005 ADJUSTING THE GEAR POSITION SENSOR • Gear position setting 1. Check: Refer to “Diagnostic code table (Diagnostic • Gear position sensor code No. Sh_ _65)”. Refer to “CHECKING THE GEAR POSITION SENSOR” on page 132. 2.

  • Page 60: Clutch

    CLUTCH EAS25060 CLUTCH Removing the clutch actuator and clutch master cylinder 7 Nm (0.7 m kg, 5.1 ft • • 19 Nm (1.9 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft •...
  • Page 61 CLUTCH Removing the clutch actuator and clutch master cylinder 7 Nm (0.7 m kg, 5.1 ft • • 19 Nm (1.9 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft •...
  • Page 62 CLUTCH Disassembling the clutch master cylinder ∗ Order Job/Parts to remove Q’ty Remarks Clutch master cylinder kit Clutch master cylinder body For assembly, reverse the disassembly pro- cedure. * Apply silicon grease – 53 –...
  • Page 63 CLUTCH Removing the clutch release cylinder Order Job/Parts to remove Q’ty Remarks Drain. Clutch fluid Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” on page 31. Clutch hose union bolt Copper washer Clutch hose Disconnect. Clutch release cylinder Dowel pin Plate For installation, reverse the removal proce- dure.

  • Page 64: Breaking In The Friction Plates After Replacement

    CLUTCH ET2D21037 BREAKING IN THE FRICTION PLATES AFTER REPLACEMENT 1. If the friction plates are replaced, perform the following procedure to break them in. M MMM M MMM M MMM M MMM M MMM a. Start the engine and warm it up until at least three segments appear on the coolant tem- perature meter “1”...

  • Page 65: Installing The Clutch Actuator

    CLUTCH ET2D21039 Pressure plate INSTALLING THE CLUTCH ACTUATOR Action stroke 1. Install: • Clutch actuator Pressure plate stroke • Clutch master cylinder before replacing the • Clutch hose clutch master cylin- Select diagnostic der kit was 2.90 mm code No. Sh_ _66 in •...

  • Page 66: Shift Actuator And Shift Rod

    SHIFT ACTUATOR AND SHIFT ROD ET2D21006 SHIFT ACTUATOR AND SHIFT ROD Removing the shift actuator, shift rod and foot shift switch 4 Nm (0.4 m kg, 2.9 ft • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 67 SHIFT ACTUATOR AND SHIFT ROD Removing the shift actuator, shift rod and foot shift switch 4 Nm (0.4 m kg, 2.9 ft • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 68: Removing The Shift Actuator

    SHIFT ACTUATOR AND SHIFT ROD ET2D21007 REMOVING THE SHIFT ACTUATOR 1. Remove: • Shift actuator M MMM M MMM M MMM M MMM M MMM a. Pass a suitable 5 mm diameter rod “1” through the holes in the rear shift arm and shift actuator to secure the shift rod.

  • Page 69: Adjusting The Foot Shift Switch

    SHIFT ACTUATOR AND SHIFT ROD 4. Adjust: Shift pedal pivot bolt • Foot shift switch 16 Nm (1.6 m·kg, 11 ft·lb) Refer to “ADJUSTING THE FOOT SHIFT ® LOCTITE SWITCH” on page 60. NOTE: ET2D21010 ADJUSTING THE FOOT SHIFT SWITCH •...

  • Page 70: Installing The Left Footrest Assembly

    SHIFT ACTUATOR AND SHIFT ROD Shift actuator rear bolt 20 Nm (2.0 m·kg, 14 ft·lb) Shift actuator front bolt 20 Nm (2.0 m·kg, 14 ft·lb) L LLL L LLL L LLL L LLL L LLL ET2D21011 INSTALLING THE LEFT FOOTREST ASSEMBLY 1.
  • Page 71 SHIFT ACTUATOR AND SHIFT ROD Shift rod front locknut 7 Nm (0.7 m·kg, 5.1 ft·lb) Shift rod rear locknut 10 Nm (1.0 m·kg, 7.2 ft·lb) h. Pull out the rod from the holes. L LLL L LLL L LLL L LLL L LLL –...

  • Page 72: Shift Shaft

    SHIFT SHAFT EAS25410 SHIFT SHAFT EAS25450 INSTALLING THE SHIFT SHAFT 1. Install: • Stopper lever “1” • Stopper lever spring “2” NOTE: • Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss “3”. •...

  • Page 73: Middle Gear

    MIDDLE GEAR EAS25710 MIDDLE GEAR Removing the middle gear Order Job/Parts to remove Q’ty Remarks Refer to “ENGINE REMOVAL” in chapter 5. Engine (Manual No.: 3P6-28197-E0) Refer to “OIL PUMP” in chapter 5. (Manual Oil pan/Oil pump No.: 3P6-28197-E0) Middle gear case cover Middle gear case cover gasket Dowel pin Damper cover...
  • Page 74 MIDDLE GEAR Removing the middle gear Order Job/Parts to remove Q’ty Remarks Middle drive shaft assembly Spacer Middle driven gear Bearing retainer Bearing Middle drive pinion gear shim Bearing For installation, reverse the removal proce- dure. – 65 –...

  • Page 75: Crankcase

    CRANKCASE EAS25540 CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft 20 Nm (2.0 m kg, 14 ft • • • • 2nd 20 Nm (2.0 m kg, 14 ft • • (10) 24 Nm (2.4 m kg, 17 ft •...
  • Page 76 CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft 20 Nm (2.0 m kg, 14 ft • • • • 2nd 20 Nm (2.0 m kg, 14 ft (10) • • 24 Nm (2.4 m kg, 17 ft •...

  • Page 77: Transmission

    TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” in chapter 5. (Man- ual No.: 3P6-28197-E0) Refer to “SHIFT SHAFT” in chapter 5. (Man- Stopper lever ual No.: 3P6-28197-E0) Gear position sensor bracket Oil seal...
  • Page 78 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Shift drum assembly Shift fork-C Main axle assembly For installation, reverse the removal proce- dure. – 69 –...
  • Page 79 TRANSMISSION – 70 –...

  • Page 80: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM (1/2) – 71 –...
  • Page 81 ELECTRIC STARTING SYSTEM 1. Main switch 7. Main fuse 8. Battery 10.Starter relay 11.Starter motor 12.Diode 1 17.Coupler 2 (wire harness–front cowling wire harness) 18.Neutral switch 25.Rear brake light switch 27.Brake light relay 33.Coupler 3 (wire harness–front cowling wire harness) 34.Sidestand switch 56.MCU (motor control unit) 64.YCC-S control relay...

  • Page 82: Circuit Diagram (2/2)

    ELECTRIC STARTING SYSTEM ET3P61003 CIRCUIT DIAGRAM (2/2) Front cowling wire harness – 73 –...
  • Page 83 ELECTRIC STARTING SYSTEM 17.Coupler 2 (front cowling wire harness–wire harness) 33.Coupler 3 (front cowling wire harness–wire harness) 65.Coupler 6 (front cowling wire harness–wire harness) 82.Front brake light switch 83.Engine stop switch 84.Start switch 92.Relay unit 93.Starting circuit cut-off relay – 74 –...

  • Page 84: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” (the switch circuit is closed), the main switch is turned “ON” (the switch circuit is closed), and the brake lever is squeezed (the front brake light switch circuit is open) or the brake pedal is depressed (the rear brake light switch circuit is open), the starter motor can only op- erate if at least one of the following conditions is met: •...

  • Page 85: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar 4. Throttle bodies NG → 1. Check the fuses. (Main, signaling system, and igni- tion) Replace the fuse(s).
  • Page 86 ELECTRIC STARTING SYSTEM NG → 7. Check the starter relay. Refer to “CHECKING THE RE- Replace the starter relay. LAYS” on page 130. OK ↓ NG → 8. Check the brake light relay. Refer to “CHECKING THE RE- Replace the brake light relay. LAYS”...
  • Page 87 ELECTRIC STARTING SYSTEM NG → 17.Check the entire starting system wiring. Properly connect or repair the starting sys- Refer to “CIRCUIT DIAGRAM (1/2)” tem wiring. on page 71 and “CIRCUIT DIA- GRAM (2/2)” on page 73. OK ↓ Replace the MCU or diode 1. –...

  • Page 88: Grip Warmer System

    GRIP WARMER SYSTEM ET2D21014 GRIP WARMER SYSTEM ET2D21015 CIRCUIT DIAGRAM (1/2) – 79 –...
  • Page 89 GRIP WARMER SYSTEM 1. Main switch 7. Main fuse 8. Battery 43.ECU (engine control unit) 65.Coupler 6 (wire harness–front cowling wire harness) 66.Headlight (on/off)/grip warmer relay 68.Signaling system fuse 69.Headlight fuse 72.Grip warmer control unit – 80 –...

  • Page 90: Circuit Diagram (2/2)

    GRIP WARMER SYSTEM ET2D21016 CIRCUIT DIAGRAM (2/2) Front cowling wire harness R L/W L/W L/Y R/W L/G B/R S W/L R/W R/W L/W Br/G B R/B R/B B Br/W Ch G/Y R/W G/L G/L R/W Br/B L/R R/B L/Y Br/R R/B L/R Br/B Br/B Br/G...
  • Page 91 GRIP WARMER SYSTEM 65.Coupler 6 (front cowling wire harness–wire harness) 122.Right grip warmer 123.Left grip warmer – 82 –...

  • Page 92: Troubleshooting

    GRIP WARMER SYSTEM ET2D21017 TROUBLESHOOTING • The grip warmers do not become warm at all. • The grip warmers are abnormally hot while the engine is idling. • The grip warmers do not become very warm while the vehicle is traveling. NOTE: •...
  • Page 93 GRIP WARMER SYSTEM NG → 2. Disconnect the grip warmer control unit coupler (white/yellow and black/green) and check that the Replace the ECU. temperature does not drop while the engine is running. OK ↓ Replace the grip warmer control unit. The grip warmers do not become very warm while the vehicle is traveling.

  • Page 94: Ycc-S (Yamaha Chip Controlled-Shift) System

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM ET2D21018 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM ET2D21019 CIRCUIT DIAGRAM (1/2) – 85 –...
  • Page 95 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM 1. Main switch 7. Main fuse 8. Battery 14.Coupler 1 (wire harness–front cowling wire harness) 17.Coupler 2 (wire harness–front cowling wire harness) 20.ABS ECU (electronic control unit) 25.Rear brake light switch 27.Brake light relay 33.Coupler 3 (wire harness–front cowling wire harness) 34.Sidestand switch...

  • Page 96: Circuit Diagram (2/2)

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM ET2D21020 CIRCUIT DIAGRAM (2/2) Front cowling wire harness – 87 –...
  • Page 97 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM 14.Coupler 1 (front cowling wire harness–wire harness) 17.Coupler 2 (front cowling wire harness–wire harness) 33.Coupler 3 (front cowling wire harness–wire harness) 58.Coupler 4 (front cowling wire harness–wire harness) 60.Coupler 5 (front cowling wire harness–wire harness) 65.Coupler 6 (front cowling wire harness–wire...

  • Page 98: Troubleshooting

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM ET2D21035 TROUBLESHOOTING • The hand shift select indicator light fails to come on. • The transmission gear display on the multi-function meter fails to indicate the selected gear. NOTE: • Before troubleshooting, remove the following part(s): 1.

  • Page 99: Maintenance Of The Mcu

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM The transmission gear display on the multi-function meter fails to indicate the selected gear. NG → 1. Check the gear position sensor. Refer to “CHECKING THE GEAR POSITION SENSOR” on page 132 Replace the gear position sensor.

  • Page 100: Self-Diagnostic Function Table

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM SHIFT Checking the YCC-S indicator and warning light The YCC-S indicator and warning light come on for 1.4 seconds after the main switch has been turned to “ON” and they come on while the start switch is being pushed. If the YCC-S indicator and warning light does not come on under these conditions, the warning light (LED) may be defective.
  • Page 101 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Able/un- Fault Able/un- able to Symptom Malfunction detecting condition code No. able to start change the shift Overcurrent to clutch Detected current in clutch actuator Sh_ _13* Unable Unable actuator motor motor is too high.
  • Page 102 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Able/un- Fault Able/un- able to Symptom Malfunction detecting condition code No. able to start change the shift Engine speed signal from ECU Engine speed signal Sh_ _31 does not match multi-function Unable Unable is abnormal.

  • Page 103: Troubleshooting Method

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Able/un- Fault Able/un- able to Symptom Malfunction detecting condition code No. able to start change the shift Braking signal is not No braking signal is received by Sh_ _47 detected while brak- MCU (motor control unit) when ve-...

  • Page 104: Diagnostic Mode

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM 5. Erase the malfunction history in the diagnos- tic mode. Refer to “Diagnostic code table (Di- agnostic code No. Sh_ _62)”. NOTE: Turning the main switch to “OFF” will not erase the malfunction history. ET2D21031...
  • Page 105 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Diagnostic code table Diagnos- Data displayed on tic code Item meter (reference Checking method value) Sh_ _61 Malfunction history code display • No history Sh_ _61 — • History exists Fault code numbers If fault codes are stored in the malfunction Sh_ _11–Sh_ _52...
  • Page 106 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Diagnos- Data displayed on tic code Item meter (reference Checking method value) Sh_ _63 Clutch actuation op- Sh_ _63 The clutch actuator can be operated in this eration mode. 1. The hand shift select indicator light NOTE: comes on when the clutch is engaged.
  • Page 107 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Diagnos- Data displayed on tic code Item meter (reference Checking method value) Sh_ _65 Gear position setting Sh_ _65 The gear position can be set in this mode. 1. Make sure that the transmission is in neutral.

  • Page 108: Troubleshooting Details

    YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Diagnos- Data displayed on tic code Item meter (reference Checking method value) Sh_ _66 Adjust the clutch en- Sh_ _66 This mode adjust the clutch engagement gagement position point manually. The clutch engagement point while the ve-...
  • Page 109 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _11 Symptom Too low or too high voltage is supplied to the YCC-S system. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •...
  • Page 110 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _13 Symptom Over current to clutch actuator motor. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the • Wire harness MCU (motor control that may be pulled out.
  • Page 111 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _14 Symptom Over current to shift actuator motor. Order Item/components and probable Check or maintenance job Reinstatement cause method • Connections • Check the coupler for any pins Turning the • Wire harness MCU (motor control that may be pulled out.
  • Page 112 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _15 Symptom Abnormal current is detected in clutch or shift actuator motor drive circuit. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 113 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _16 Symptom Malfunction of clutch or shift actuator motor drive circuit in the MCU (motor control unit). Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 114 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _17 Symptom Detected clutch actuator position is incorrect. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the • Wire harness MCU (motor control that may be pulled out.
  • Page 115 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _18 Symptom Detected shift actuator position is incorrect. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the • Wire harness MCU (motor control that may be pulled out.
  • Page 116 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _19 Symptom Output signal of shift actuator sensor is abnor- mal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 117 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _21 Symptom Output signal of gear position sensor is abnor- mal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •...
  • Page 118 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _23 Symptom No input signal from sidestand switch. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the • Wire harness MCU (motor control that may be pulled out.
  • Page 119 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _26 Symptom Abnormal clutch movement is detected during check when main switch is turned to “ON”. Order Item/components and probable Check or maintenance job Reinstatement cause method Clutch fluid • Check for clutch fluid leakage.
  • Page 120 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _31 Symptom Engine speed signal is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the • Wire harness MCU (motor control that may be pulled out.
  • Page 121 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _34 Symptom TPS (throttle position sensor) signal is abnor- mal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •...
  • Page 122 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _36 Symptom Output signal of clutch actuator sensor is ab- normal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •...
  • Page 123 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _37 Symptom Power supply to clutch or shift actuator motor is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 124 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _38 Symptom Malfunction of hand shift lever switch (shift up or shift down). Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •...
  • Page 125 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _41 Symptom Coolant temperature sensor signal is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the • Wire harness MCU (motor control that may be pulled out.
  • Page 126 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _43 Symptom Communication between MCU (motor control unit) and ABS ECU is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •...
  • Page 127 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _45 Symptom Shift operation and gear position do not match. Order Item/components and probable Check or maintenance job Reinstatement cause method Shift rod • Check the shift rod pin hole lo- Turning the cation.
  • Page 128 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _47 Symptom Braking signal is not detected while braking. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the • Wire harness MCU (motor control that may be pulled out.
  • Page 129 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _49 Symptom Engine idling speed is too high when vehicle is started. Order Item/components and probable Check or maintenance job Reinstatement cause method Clutch operation. • Check the clutch stroke. Turning the Refer to “BLEEDING THE HY-...
  • Page 130 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _52 Symptom Main switch signal is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the • Wire harness MCU (motor control that may be pulled out.
  • Page 131 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM – 122 –...

  • Page 132: Electrical Components

    ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS – 123 –...
  • Page 133 ELECTRICAL COMPONENTS 1. Windshield drive unit 2. Battery 3. Starter relay 4. ABS motor fuse 5. Front brake light switch 6. Fuse box 2 7. Fuse box 1 8. Right radiator fan motor 9. Left radiator fan motor 10. Neutral switch 11.
  • Page 134 ELECTRICAL COMPONENTS – 125 –...
  • Page 135 ELECTRICAL COMPONENTS 1. Coolant temperature sensor 2. Throttle position sensor 3. Intake air pressure sensor 4. Intake air temperature sensor 5. ABS motor relay 6. Hydraulic unit 7. MCU (motor control unit) 8. ECU (engine control unit) 9. ABS (ECU) 10.

  • Page 136: Checking The Switches

    ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES Br/W R/Y Y Lg B Sb DOWN R/Y L/B Dg Br/W Ch O/W Br/L O/B B R/B G/R B/L G/B Shift down Shift up Br/L Br/L Br/R Br/R PUSH Br/L B Br/W Ch R/W R/B (BROWN) L/W B Br/W...
  • Page 137 ELECTRICAL COMPONENTS 1. Front brake light switch 2. Main switch 3. Rear brake light switch 4. Neutral switch 5. Sidestand switch 6. Hazard switch 7. Start switch 8. Engine stop switch 9. Hand shift select button 10. Hand shift lever switch (shift up) 11.
  • Page 138 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 CAUTION: Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

  • Page 139: Checking The Relays

    ELECTRICAL COMPONENTS EAS28040 CHECKING THE RELAYS Result Check each switch for continuity with the pocket Continuity tester. If the continuity reading is incorrect, re- (between “3” and “4”) place the relay. Relay unit (fuel pump relay) Pocket tester 90890-03112 Analog pocket tester YU-03112-C 1.
  • Page 140 ELECTRICAL COMPONENTS Headlight relay (dimmer) Brake light relay First step: First step: 1. Positive tester probe 1. Positive tester probe 2. Negative tester probe 2. Negative tester probe 3. Negative tester probe Result Continuity Result (between “1” and “2”) Continuity (between “1”...

  • Page 141: Checking The Ycc-S Speed Sensor

    ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM Result a. Connect the pocket tester (DC 20 V) to the No continuity YCC-S speed sensor coupler (wire harness (between “1” and “2”) side) as shown. Second step: Pocket tester 90890-03112 Analog pocket tester...

  • Page 142: Checking The Foot Shift Switch

    ELECTRICAL COMPONENTS • Positive tester probe → Resistance blue “1” 4.0–6.0 kΩ • Negative tester probe → black/blue “2” M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (Ω × 1k) to the gear position sensor terminals as shown.

  • Page 143: Checking The Grip Warmer Control Unit

    ELECTRICAL COMPONENTS ET2D21026 CHECKING THE DIODE 2 1. Check: • Diode 2 Out of specification → Replace. Pocket tester 90890-03112 Analog pocket tester YU-03112-C c. Measure the grip warmer resistance. NOTE: L LLL L LLL L LLL L LLL L LLL The pocket tester and the analog pocket tester readings are shown in the following table.
  • Page 144 ELECTRICAL COMPONENTS – 135 –...

  • Page 145: Wiring Diagram

    EAS28740 52. Shift actuator motor 107.Lean angle sensor WIRING DIAGRAM 53. Shift actuator sensor 108.Thermistor 54. Clutch actuator sensor 109.Hand shift switch FJR1300AS(V) 2006 55. Clutch actuator motor 110.Hand shift lever switch (shift 1. Main switch 56. MCU (motor control unit) 2.
  • Page 146 Pink/White Red/Black Red/Green Red/Blue Red/White Red/Yellow Sb/W Sky blue/White White/Black White/Green White/Blue White/Yellow Yellow/Black Yellow/Green Yellow/Blue Yellow/White...
  • Page 148 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...

  • Page 149: Fjr1300As(V) 2006 Wiring Diagram

    FJR1300AS(V) 2006 FJR1300AS(V) 2006 FJR1300AS(V) 2006 FJR1300AS(V) 2006 FJR1300AS(V) 2006 WIRING DIAGRAM (1/2) SCHALTPLAN (1/2) DIAGRAMA ELÉCTRICO (1/2) SCHÉMA DE CÂBLAGE (1/2) SCHEMA ELETTRICO (1/2) L R/L R/B G/B G/B R/B R/L L W/Y W Sb W Br/W Y/G W/L L/W Y Gy/W L/B O/B L/W W/L Y Br/W O/B L/B Gy/W Y...
  • Page 150 FJR1300AS(V) 2006 FJR1300AS(V) 2006 FJR1300AS(V) 2006 FJR1300AS(V) 2006 FJR1300AS(V) 2006 WIRING DIAGRAM (2/2) SCHALTPLAN (2/2) DIAGRAMA ELÉCTRICO (2/2) SCHÉMA DE CÂBLAGE (2/2) SCHEMA ELETTRICO (2/2) Front cowling wire harness Faisceau de fils au carénage avant Frontverkleidungs-Kabelbaum Cablaggio elettrico del cupolino Mazo de cables del carenado delantero Sb/W R L/W...

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