YAMAHA FJR1300A 2003 Repair Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6 Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
NOTE:_ If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible. _
Specified spark plug:
CR8E (NGK) or
U24ESR-N (DENSO)
a. Spark plug gapSpark plug gap:
0.7–0.8 mm
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf)
U5JWE2.book Page 8 Wednesday, November 6, 2002 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
EAU05018
Engine oil and oil filter
cartridge The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the motorcycle on the cen-
terstand.NOTE:_ Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. _2. Start the engine, warm it up for
several minutes, and then turn it
off.3. Wait a few minutes until the oil set-
tles, and then check the oil level
through the check window located
at the bottom-left side of the crank-
case.
NOTE:_ The engine oil should be between the
minimum and maximum level marks. _4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.To change the engine oil
(with or without oil filter cartridge
replacement)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
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.
NOTE:_ Skip steps 4–6 if the oil filter cartridge is
not being replaced. _
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
1. Engine oil filler cap
2. Engine oil filter cartridge
3. Engine oil drain bolt
U5JWE2.book Page 9 Wednesday, November 6, 2002 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 4. Remove the oil filter cartridge with
an oil filter wrench.
NOTE:_ An oil filter wrench is available at a
Yamaha dealer. _
5. Apply a thin coat of engine oil to
the O-ring of the new oil filter car-
tridge.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.
7. Install the engine oil drain bolt, and
then tighten it to the specified
torque.NOTE:_ Check the washer for damage and re-
place it if necessary. _
1. Oil filter cartridge
2. Oil filter wrench
1. O-ring
1. Oil filter cartridge
2. Torque wrenchTightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf)
U5JWE2.book Page 10 Wednesday, November 6, 2002 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
68. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
ECA00133
CAUTION:_

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
higher 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,
immediately 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 the
oil level is sufficient. _
EC000067
CAUTION:_ If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha deal-
er check the vehicle. _10. Turn the engine off, and then
check the oil level and correct it if
necessary. Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge
replacement:
3.8 L
With oil filter cartridge
replacement:
4 L
Total amount (dry engine):
4.9 L
U5JWE2.book Page 11 Wednesday, November 6, 2002 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6
EAU04067
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 motorcycle. In
addition, the final gear oil must be
changed as follows at the intervals
specified in the periodic maintenance
and lubrication chart.
EW000066
WARNING
_

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


Make sure that no oil gets on
the tire or wheel.
_
To check the final gear oil level
1. Place the motorcycle on the cen-
terstand.NOTE:_

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


Make sure that the motorcycle is
positioned straight up when
checking the oil level. A slight tilt to
the side can result in a false read-
ing.
_2. Remove the oil filler bolt, and then
check the oil level in the final gear
case.
NOTE:_ The oil level should be at the brim of
the filler hole. _3. If the oil is below the brim of the fill-
er hole, add sufficient oil of the rec-
ommended type to raise it to the
correct level.
To change the final gear oil
1. Place an oil pan under the final
gear case to collect the used oil.
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.
4. Add the recommended final gear
oil to the brim of the filler hole.
1. Final gear oil filler bolt
2. Final gear oil drain bolt
3. Correct oil level
Tightening torque:
Final gear oil drain bolt:
23 Nm (2.3 m·kgf)
U5JWE2.book Page 12 Wednesday, November 6, 2002 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
65. Install and tighten the filler bolt.
6. Check the final gear case for oil
leakage. If oil is leaking, check for
the cause.
EAU04861
Checking the coolant level The coolant level should be checked as
follows before each ride. In addition,
the coolant must be changed at the in-
tervals specified in the periodic mainte-
nance and lubrication chart.
1. Place the motorcycle on the cen-
terstand.NOTE:_

The coolant level must be checked
on a cold engine since the level
varies with engine temperature.


Make sure that the motorcycle is
positioned straight up when
checking the coolant level. A slight
tilt to the side can result in a false
reading.
_
2. Check the coolant level in the
coolant reservoir.NOTE:_ The coolant should be between the
minimum and maximum level marks. _
Recommended final gear oil:
Shaft drive gear oil
(Part No.: 9079E-SH001-00)
Oil quantity:
0.2 L
1. Maximum level mark
2. Minimum level mark
U5JWE2.book Page 13 Wednesday, November 6, 2002 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6 3. If the coolant is at or below the
minimum level mark, remove the
bolt, the coolant reservoir cap cov-
er and the reservoir cap.
4. Add coolant or distilled water to
raise the coolant to the maximum
level mark, install the coolant res-
ervoir cap, the coolant reservoir
cap cover and the bolt.
EC000080
CAUTION:_

If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.


If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the cool-
ing system will not be protected
against frost and corrosion.


If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
_
EW000067
WARNING
_ Never attempt to remove the radia-
tor cap when the engine is hot. _
NOTE:_

The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.


If the engine overheats, see page
6-38 for further instructions.
_
1. Bolt
2. Coolant reservoir cap cover
3. Coolant reservoir cap
Coolant reservoir capacity
(up to the maximum level mark):
0.25 L
U5JWE2.book Page 14 Wednesday, November 6, 2002 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
6
EAU04509*
Cleaning the air filter element The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
1. Remove panel E. (See page 6-7
for panel removal and installation
procedures.)
2. Remove the intake air shroud by
removing the quick fastener
screws.3. Remove the air filter case cover by
removing the screws.4. Pull the air filter element out.1. Intake air shroud
2. Quick fastener screw (× 4)
1. Air filter case cover
2. Screw (× 4)
1. Air filter element
U5JWE2.book Page 15 Wednesday, November 6, 2002 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6 5. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as shown.
If the air filter element is damaged,
replace it.
6. Insert the air filter element into the
air filter case.
EC000082*
CAUTION:_

Make sure that the air filter ele-
ment is properly seated in the
air filter case.


The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
pistons and/or cylinders may
become excessively worn.
_7. Install the air filter case cover by
installing the screws.
8. Install the intake air shroud by in-
stalling the quick fastener screws.
9. Install the panel.
EAU04033
Checking the engine idling
speed The engine idling speed must be
checked as follows and, if necessary,
adjusted by a Yamaha dealer at the in-
tervals specified in the periodic mainte-
nance and lubrication chart.
Start the engine and warm it up for
several minutes at 1,000–2,000 r/min
while occasionally revving it to
4,000–5,000 r/min.NOTE:_ The engine is warm when it quickly re-
sponds to the throttle. _Engine idling speed:
1,000–1,100 r/min
U5JWE2.book Page 16 Wednesday, November 6, 2002 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
EAU00635
Adjusting the throttle cable
free play The throttle cable free play should
measure 3–5 mm at the throttle grip.
Periodically check the throttle cable
free play and, if necessary, have a
Yamaha dealer adjust it.
EAU00637
Adjusting the valve clearance 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.
EAU00658
Tires To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
EW000082
WARNING
_

The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).


The tire air pressure must be
adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approved
for this model.
_
a. Throttle cable free playU5JWE2.book Page 17 Wednesday, November 6, 2002 3:32 PM