YAMAHA FJR1300A 2004 Repair Manual
Manufacturer: YAMAHA, Model Year: 2004, Model line: FJR1300A, Model: YAMAHA FJR1300A 2004Pages: 90, PDF Size: 6.9 MB
Page 61 of 90
PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6
EAU22240
Adjusting the brake pedal
position The top of the brake pedal should be
positioned approximately 42.0 mm
(1.65 in) below the top of the footrest as
shown. Periodically check the brake
pedal position and, if necessary, have a
Yamaha dealer adjust it.
WARNING
EWA10690
A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the hydraulic system. If there is
air in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the motorcycle. Air in
the hydraulic system will diminishthe braking performance, which may
result in loss of control and an acci-
dent.
EAU22270
Adjusting the rear brake light
switch The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction (a). To
make the brake light come on later, turn
the adjusting nut in direction (b).
1. Distance between brake pedal and footrest
1. Rear brake light switch
2. Rear brake light switch adjusting nut
5JWE3.book Page 19 Friday, September 5, 2003 3:08 PM
Page 62 of 90
PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
EAU22390
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU22420
Front brake pads
Each front brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator groove. If a brake
pad has worn to the point that the wearindicator groove has almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU22500
Rear brake pads
Check each rear brake pad for damage
and measure the lining thickness. If a
brake pad is damaged or if the lining
thickness is less than 0.8 mm (0.03 in),
have a Yamaha dealer replace the
brake pads as a set.
EAU22680
Checking the brake and clutch
fluid levels Front brake
Rear brake
1. Brake pad wear indicator groove
1. Lining thickness
1. Minimum level mark
1. Minimum level mark
5JWE3.book Page 20 Friday, September 5, 2003 3:08 PM
Page 63 of 90
PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6 Clutch
Insufficient brake fluid may allow air to
enter the brake or clutch systems, pos-
sibly causing them to become ineffec-
tive.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake level is low, be sure to check the
brake pads for wear and the brake sys-
tem for leakage.
NOTE:The rear brake fluid reservoir is locatedbehind panel F. (See page 6-5.)
Observe these precautions:
When checking the fluid level,
make sure that the top of the brake
or clutch fluid reservoir is level.
Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking or clutch
performance.
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking or clutch per-
formance.
The brake or clutch fluid reservoir
diaphragm will lose its shape from
the negative pressure if the fluid
level goes down too far. Be sure to
return the diaphragm to its original
shape before installing it into the
brake or clutch fluid reservoir.
Be careful that water does not en-
ter the brake or clutch fluid reser-
voir when refilling. Water willsignificantly lower the boiling point
of the fluid and may result in vapor
lock.
Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.
As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
1. Minimum level mark
Recommended brake and clutch flu-
id:
DOT 4 brake fluid
5JWE3.book Page 21 Friday, September 5, 2003 3:08 PM
Page 64 of 90
PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
EAU22750
Changing the brake and
clutch fluids Have a Yamaha dealer change the
brake and clutch fluids at the intervals
specified in the NOTE after the periodic
maintenance and lubrication chart. In
addition, have the oil seals of the brake
and clutch master cylinders and cali-
pers as well as the brake and clutch
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.
Oil seals: Replace every two
years.
Brake and clutch hoses: Replace
every four years.
EAU23100
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING
EWA10720
Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafeconditions.
EAU23110
Checking and lubricating the
throttle grip and cable The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated or
replaced at the intervals specified in the
periodic maintenance chart.
Recommended lubricant:
Engine oil
5JWE3.book Page 22 Friday, September 5, 2003 3:08 PM
Page 65 of 90
PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
EAU23131
Checking and lubricating the
brake and shift pedals The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
EAU23140
Checking and lubricating the
brake and clutch levers Brake lever
Clutch lever
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
5JWE3.book Page 23 Friday, September 5, 2003 3:08 PM
Page 66 of 90
PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6
EAU23210
Checking and lubricating the
centerstand and sidestand The operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and metal-to-
metal contact surfaces should be lubri-
cated if necessary.
WARNING
EWA10740
If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or re-pair it.
EAUM1650
Lubricating the swingarm
pivots The swingarm pivots must be lubricat-
ed at the intervals specified in the peri-
odic maintenance and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
Recommended lubricant:
Lithium-soap-based grease
5JWE3.book Page 24 Friday, September 5, 2003 3:08 PM
Page 67 of 90
PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EAU23250
Lubricating the rear
suspension The pivoting points of the rear suspen-
sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU23271
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
WARNING
EWA10750
Securely support the vehicle so thatthere is no danger of it falling over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
CAUTION:
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-pair it.
Recommended lubricant:
Lithium-soap-based grease
5JWE3.book Page 25 Friday, September 5, 2003 3:08 PM
Page 68 of 90
PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU23280
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
WARNING
EWA10750
Securely support the vehicle so thatthere is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
EAU23290
Checking the wheel bearings The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.
5JWE3.book Page 26 Friday, September 5, 2003 3:08 PM
Page 69 of 90
PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
EAU23400
Battery The battery is located under panels C
and D. (See page 6-5.)
This vehicle is equipped with a sealed-
type (MF) battery, which does not re-
quire any maintenance. There is no
need to check the electrolyte or to add
distilled water.
To charge the battery
Have a Yamaha dealer charge the bat-
tery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quickly
if the vehicle is equipped with optional
electrical accessories.
WARNING
EWA10760
Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al-
ways shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
EXTERNAL: Flush with plenty
of water.
INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a physician.
EYES: Flush with water for 15
minutes and seek prompt
medical attention.
Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed
space.
KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OFCHILDREN.
To store the battery
1. If the vehicle will not be used for
more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place.
2. If the battery will be stored for more
than two months, check it at least
once a month and fully charge it if
necessary.
3. Fully charge the battery before in-
stallation.
4. After installation, make sure that
the battery leads are properly con-
nected to the battery terminals.
CAUTION:
ECA10630
Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.
To charge a sealed-type (MF)
battery, a special (constant-volt-
age) battery charger is required.
Using a conventional battery
1. Battery
5JWE3.book Page 27 Friday, September 5, 2003 3:08 PM
Page 70 of 90
PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6charger will damage the battery.
If you do not have access to a
sealed-type (MF) battery charg-
er, have a Yamaha dealer
charge your battery.
EAU23652
Replacing the fuses The fuse box, which contains the fuses
for the individual circuits, is located un-
der panel A. Both the electronic fuel in-
jection fuse and the main fuse are
located under panel D. The main fuse is
located beside the battery. (See page
6-5.)1. Electronic fuel injection fuse
2. Electronic fuel injection spare fuse
1. Headlight fuse
2. Signaling system fuse
3. Ignition fuse
4. Windshield motor fuse
5. Radiator fan fuse
6. Backup fuse (for odometer, clock and
immobilizer system)
7. Spare fuse
8. Hazard fuse
9. ABS control unit fuse
10.Parking lighting fuse
5JWE3.book Page 28 Friday, September 5, 2003 3:08 PM