wheel YAMAHA FJR1300A 2004 Owners Manual

EAU26941
DECLARATION of CONFORMITY
We
Hereby declare that the product:
is in compliance with following norm(s) or documents: Type-designation:
5SL-00, 5VS-00, 5VX-00, 3HT-00, 5UX-00, 5UX-10, 5KS-00 and 5KS-10
R&TTE Directive(1999/5/EC)
EN300 330-2 v1.1.1(2001-6), EN60950(2000)
Two or Three-Wheel Motor Vehicles Directive(97/24/EC: Chapter 8, EMC)
Place of issue: Shizuoka, Japan
Date of issue: Aug. 1
st 2002 Kind of equipment: IMMOBILIZER Address: 1450-6 Mori Mori-Machi Shuchi-gun Shizuoka 437-0292 Japan Company: MORIC CO., LTD.
Kazuji Kawai
representative name and signature
5JWE3.book Page 1 Friday, September 5, 2003 3:08 PM

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Immobilizer system .........................3-1
Main switch/steering lock ................3-2
Indicator and warning lights ............3-3
Speedometer ..................................3-5
Tachometer ....................................3-5
Multi-function display ......................3-6
Anti-theft alarm (optional) ...............3-7
Handlebar switches ........................3-8
Clutch lever .....................................3-9
Shift pedal .....................................3-10
Brake lever ...................................3-10
Brake pedal ..................................3-11
ABS (For FJR1300A only) .............3-11
Fuel tank cap ................................3-12
Fuel ...............................................3-12
Fuel tank breather hose ................3-13
Catalytic converter ........................3-14
Seats ............................................3-14
Storage compartment ...................3-15
Accessory box ..............................3-15
Adjusting the front fork ..................3-16Adjusting the shock absorber
assembly ................................... 3-18
Locks for the optional side
cases and travel trunk ............... 3-19
Sidestand ..................................... 3-19
Ignition circuit cut-off system ........ 3-20
PRE-OPERATION CHECKS............. 4-1
Pre-operation check list .................. 4-2
OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting the engine ......................... 5-1
Shifting ........................................... 5-2
Tips for reducing fuel
consumption ............................... 5-3
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
Owner’s tool kit ............................... 6-1
Periodic maintenance and
lubrication chart .......................... 6-2
Removing and installing panels ..... 6-5
Checking the spark plugs ............... 6-7
Engine oil and oil filter cartridge ..... 6-8
Final gear oil ................................. 6-10
Coolant ......................................... 6-11
Cleaning the air filter element ...... 6-13Checking the engine idling
speed ........................................ 6-14
Adjusting the throttle cable
free play .................................... 6-15
Adjusting the valve clearance ...... 6-15
Tires ............................................. 6-15
Cast wheels ................................. 6-18
Clutch lever free play ................... 6-18
Adjusting the brake pedal
position ..................................... 6-19
Adjusting the rear brake light
switch ....................................... 6-19
Checking the front and rear
brake pads ................................ 6-20
Checking the brake and
clutch fluid levels ...................... 6-20
Changing the brake and
clutch fluids ............................... 6-22
Checking and lubricating the
cables ....................................... 6-22
Checking and lubricating the
throttle grip and cable ............... 6-22
Checking and lubricating the
brake and shift pedals .............. 6-23
Checking and lubricating the
brake and clutch levers ............ 6-23
Checking and lubricating the
centerstand and sidestand ....... 6-24
Lubricating the swingarm
pivots ........................................ 6-245JWE3.book Page 1 Friday, September 5, 2003 3:08 PM

TABLE OF CONTENTS
Lubricating the rear
suspension ................................ 6-25
Checking the front fork ................. 6-25
Checking the steering ................... 6-26
Checking the wheel bearings ....... 6-26
Battery .......................................... 6-27
Replacing the fuses ...................... 6-28
Replacing a headlight bulb ........... 6-30
Replacing a rear turn signal light
bulb or a tail/brake light bulb ..... 6-31
Replacing an auxiliary light
bulb ........................................... 6-31
Troubleshooting ............................ 6-32
Troubleshooting charts ................. 6-33
MOTORCYCLE CARE AND
STORAGE.......................................... 7-1
Care ................................................ 7-1
Storage ...........................................7-3
SPECIFICATIONS ............................. 8-1
CONSUMER INFORMATION............. 9-1
Identification numbers .................... 9-1
5JWE3.book Page 2 Friday, September 5, 2003 3:08 PM

SAFETY INFORMATION
1-2
1 due to EXCESSIVE SPEED or un-
dercornering (insufficient lean an-
gle for the speed).
Always obey the speed limit and
never travel faster than warrant-
ed 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.
The operator should keep both
hands on the handlebar and
both feet on the operator foot-
rests during operation to main-
tain control of the motorcycle.
The passenger should always
hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep both
feet on the passenger footrests.
Never carry a passenger unless
he or she can firmly place both
feet on the passenger footrests.


Never ride under the influence of
alcohol or other drugs.


This motorcycle is designed for on-
road use only. It is not suitable for
off-road use.
Protective apparel
The majority of fatalities from motor-
cycle accidents are the result of head
injuries. The use of a safety helmet is
the single most critical factor in the pre-
vention or reduction of head injuries.


Always wear an approved helmet.


Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.


The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.


Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.


Never touch the engine or exhaust
system during or after operation.
They become very hot and cancause burns. Always wear protec-
tive clothing that covers your legs,
ankles, and feet.


A passenger should also observe
the above precautions.
Modifications
Modifications made to this motorcycle
not approved by Yamaha, or the re-
moval of original equipment, may ren-
der the motorcycle unsafe for use and
may cause severe personal injury.
Modifications may also make your
motorcycle illegal to use.
Loading and accessories
Adding accessories or cargo to your
motorcycle can adversely affect stabili-
ty and handling if the weight distribution
of the motorcycle is changed. To avoid
the possibility of an accident, use ex-
treme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
Here are some general guidelines to
follow if loading cargo or adding acces-
sories to your motorcycle:
5JWE3.book Page 2 Friday, September 5, 2003 3:08 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-4
3
EAU11060
Neutral indicator light “”
This indicator light comes on when the
transmission is in the neutral position.
EAU11080
High beam indicator light “”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU11120
Oil level warning light “”
This warning light comes on when the
engine oil level is low.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”.
If the warning light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.NOTE:Even if the oil level is sufficient, the
warning light may flicker when riding on
a slope or during sudden acceleration
or deceleration, but this is not a mal-function.
EAU11530
Engine trouble warning light “”
This warning light comes on or flashes
when an electrical circuit monitoring the
engine is defective. When this occurs,
have a Yamaha dealer check the self-
diagnosis system. (See page 3-6 for an
explanation of the self-diagnosis de-
vice.)
The electrical circuit of the warning light
can be checked by turning the key to
“ON”. If the warning light does not come
on for a few seconds, then go off, have
a Yamaha dealer check the electrical
circuit.
EAU11542
ABS warning light “”
(For FJR1300A only)
If this warning light comes on or flashes
while riding, the ABS may be defective.
If this occurs, have a Yamaha dealer
check the system as soon as possible.
(See page 3-11.)
WARNING
EWA10081
If the ABS warning light comes on or
flashes while riding, the brake sys-
tem reverts to conventional braking.
Therefore, be careful not to causethe wheels to lock during emergen-
cy braking. If the warning light
comes on or flashes while riding,
have a Yamaha dealer check the
brake system as soon as possible.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”.
If the warning light does not come on or
remains on, have a Yamaha dealer
check the electrical circuit.
EAU26871
Immobilizer system indicator light
“”
The electrical circuit of the indicator
light can be checked by turning the key
to “ON”.
If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.
When the key is turned to “OFF” and 30
seconds have passed, the indicator
light will start flashing indicating the im-
mobilizer system is enabled. After 24
hours have passed, the indicator light
will stop flashing, however the immobi-
lizer system is still enabled.
ABS
5JWE3.book Page 4 Friday, September 5, 2003 3:08 PM

PRE-OPERATION CHECKS
4-3
4
Throttle gripMake sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-15, 6-22
Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-22
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-15, 6-18
Brake and shift pedalsMake sure that operation is smooth.
Lubricate pedal pivoting points if necessary.6-23
Brake and clutch leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-23
Centerstand, sidestandMake sure that operation is smooth.
Lubricate pivots if necessary.6-24
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switchesCheck operation.
Correct if necessary.—
Sidestand switchCheck operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.3-19 ITEM CHECKS PAGE
5JWE3.book Page 3 Friday, September 5, 2003 3:08 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
9*WheelsCheck runout and for damage.√√√√
10*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
11*Wheel bearingsCheck bearing for looseness or damage.√√√√
12*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50000 km
13*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20000 km
14*Chassis fastenersMake sure that all nuts, bolts and screws are properly
tightened.√√√√ √
15 Sidestand, centerstandCheck operation.
Lubricate.√√√√ √
16*Sidestand switchCheck operation.√√√√√ √
17*Front forkCheck operation and for oil leakage.√√√√
18*Shock absorber assem-
blyCheck operation and shock absorber for oil leakage.√√√√
19*Rear suspension relay
arm and connecting
arm pivoting pointsCheck operation.√√√√
Lubricate with lithium-soap-based grease.√√
20*Electronic fuel injectionAdjust engine idling speed and synchronization.√√√√√ √
21 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
22Engine oil filter car-
tridgeReplace.√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
5JWE3.book Page 3 Friday, September 5, 2003 3:08 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6
CAUTION:
ECA11620


In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.


Make sure that no foreign mate-rial enters the crankcase.
9. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
NOTE:After the engine is started, the engine
oil level warning light should go off if theoil level is sufficient.
CAUTION:
ECA10400
If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha dealercheck the vehicle.
10. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU20010
Final gear oil The final gear case must be checked
for oil leakage before each ride. If any
leakage is found, have a Yamaha deal-
er check and repair the vehicle. In addi-
tion, the final gear oil must be changed
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
WARNING
EWA10370


Make sure that no foreign mate-
rial enters the final gear case.


Make sure that no oil gets on thetire or wheel.
To check the final gear oil level
1. Place the vehicle on the center-
stand.
NOTE:

The final gear oil level must be
checked on a cold engine.


Make sure that the vehicle is posi-
tioned straight up when checking
the oil level. A slight tilt to the sidecan result in a false reading.
5JWE3.book Page 10 Friday, September 5, 2003 3:08 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
WARNING
EWA10470


Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehi-
cle with excessively worn tires
decreases riding stability and
can lead to loss of control.


The replacement of all wheel
and brake related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-edge and experience.
Tire informationThis motorcycle is equipped with cast
wheels and tubeless tires with valves.
WARNING
EWA10480


The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the motor-
cycle cannot be guaranteed.


After extensive tests, only the
tires listed below have been ap-
proved for this model by
Yamaha Motor Co., Ltd.


Always make sure that the valve
caps are securely installed to
prevent air pressure leakage.


Use only the tire valves and
valve cores listed below to
avoid tire deflation during ahigh-speed ride.
WARNING
EWA10600
This motorcycle is fitted with super-
high-speed tires. Note the following
points in order to make the most ef-
ficient use of these tires.

Use only the specified replace-
ment tires. Other tires may run
the danger of bursting at super
high speeds.


Brand-new tires can have a rela-
tively poor grip on certain road
surfaces until they have been
1. Tire air valve
2. Tire air valve core
3. Tire air valve cap with seal
Front tire:
Size:
120/70 ZR17M/C (58W)
Manufacturer/model:
METZELER/MEZ4J FRONT
BRIDGESTONE/BT020F N
Rear tire:
Size:
180/55 ZR17M/C (73W)
Manufacturer/model:
METZELER/MEZ4J
BRIDGESTONE/BT020R N
FRONT and REAR:
Tire air valve:
TR412
Va l ve c o r e :
#9000A (original)
5JWE3.book Page 17 Friday, September 5, 2003 3:08 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6“broken in”. Therefore, it is ad-
visable before doing any high-
speed riding to ride conserva-
tively 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 pres-
sure according to the operatingconditions.
EAU21960
Cast wheels To maximize the performance, durabil-
ity, and safe operation of your vehicle,
note the following points regarding the
specified wheels.

The wheel rims should be checked
for cracks, bends or warpage be-
fore each ride. If any damage is
found, have a Yamaha dealer re-
place the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.


The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.


Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
EAU22071
Clutch lever free play Since this model is equipped with a hy-
draulic 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. If the clutch
lever free play does become excessive,
and shifting becomes rough or clutch
slippage occurs, causing poor acceler-
ation, there may be air in the clutch sys-
tem. If there is air in the hydraulic
system, have a Yamaha dealer bleed
the system before operating the motor-
cycle.
5JWE3.book Page 18 Friday, September 5, 2003 3:08 PM