check engine YAMAHA FJR1300A 2007 User Guide

PRE-OPERATION CHECKS
4-2
4
EAU15605
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-18
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-8
Final gear oilCheck vehicle for oil leakage. 6-10
CoolantCheck coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-12
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-19, 6-20
Rear brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-19, 6-20
ClutchCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended fluid to specified level.
Check hydraulic system for leakage.6-19, 6-20
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OPERATION AND IMPORTANT RIDING POINTS
5-1
5
EAU15950
WARNING
EWA10270


Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.


Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.


Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible lossof control.
EAU39890
Starting the engine In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

The transmission is in the neutral
position.


The transmission is in gear with
the clutch lever pulled and the sid-
estand up.WARNING
EWA10290


Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-31.


Never ride with the sidestanddown.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.
CAUTION:
ECA15450
The following warning lights and in-
dicator light should come on for a
few seconds, then go off.

Oil level warning light


Engine trouble warning light


Immobilizer system indicator
light


ABS warning light
If a warning or indicator light does
not go off, see page 3-4 for the corre-
sponding warning and indicator
light circuit check.
2. Shift the transmission into the neu-
tral position.NOTE:When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical cir-cuit.
3. Start the engine by pushing the
start switch.NOTE:If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any oneattempt.
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OPERATION AND IMPORTANT RIDING POINTS
5-3
5
EAU16810
Tips for reducing fuel con-
sumption Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:

Shift up swiftly, and avoid high en-
gine speeds during acceleration.


Do not rev the engine while shifting
down, and avoid high engine
speeds with no load on the engine.


Turn the engine off instead of let-
ting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
EAU16841
Engine break-in There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU17121
0–1000 km (0–600 mi)
Avoid prolonged operation above 4500
r/min.
1000–1600 km (600–1000 mi)
Avoid prolonged operation above 5400
r/min.
CAUTION:
ECA10331
After 1000 km (600 mi) of operation,
the engine oil and final gear oil must
be changed, and the oil filter car-tridge or element replaced.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.CAUTION:
ECA10310


Keep the engine speed out of
the tachometer red zone.


If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehi-cle.
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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*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
U3P6E1E0.book Page 3 Thursday, October 5, 2006 10:13 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6
EAU19642
Checking the spark plugs The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal color
when the vehicle is ridden normally),
and all spark plugs installed in the en-
gine should have the same color. If any
spark plug shows a distinctly different
color, the engine could be operating im-
properly. Do not attempt to diagnose
such problems yourself. Instead, have
a Yamaha dealer check the vehicle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.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:
NGK/CR8E
DENSO/U24ESR-N
1. Spark plug gap
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6
EAU19881
Engine oil and oil filter car-
tridge 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 vehicle on the center-
stand.NOTE:
Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in afalse 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 theminimum 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 replace-
ment)
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 isnot being replaced.
4. Remove the oil filter cartridge with
an oil filter wrench.
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
1. Engine oil filler cap
2. Oil filter cartridge
3. Engine oil drain bolt
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
NOTE:An oil filter wrench is available at aYamaha 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 properlyseated.
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.
8. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler cap.
1. Oil filter cartridge
2. Oil filter wrench
1. O-ring
1. Oil filter cartridge
2. Torque wrench
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf, 12 ft·lbf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge replace-
ment:
3.80 L (4.02 US qt) (3.34 Imp.qt)
With oil filter cartridge replacement:
4.00 L (4.23 US qt) (3.52 Imp.qt)
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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.
EAU20011
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.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6
EAU20070
Coolant The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU39511
To check 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 vehicle on the center-
stand.NOTE:

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


Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to theside can result in a false reading.
2. Check the coolant level in the cool-
ant reservoir.
NOTE:The coolant should be between theminimum and maximum level marks.
3. If the coolant is at or below the
minimum level mark, remove the
reservoir cap.4. Add coolant or distilled water to
raise the coolant to the maximum
level mark, install the coolant res-
ervoir cap.
CAUTION:
ECA10471


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-
1. Maximum level mark
2. Minimum level mark
1. Coolant reservoir capCoolant reservoir capacity (up to the
maximum level mark):
0.25 L (0.26 US qt) (0.22 Imp.qt)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6 wise the cooling 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 ofthe coolant will be reduced.WARNING
EWA10380
Never attempt to remove the radiatorcap when the engine is hot.NOTE:

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


If the engine overheats, see page6-32 for further instructions.
EAU33030
Changing the coolant
WARNING
EWA10380
Never attempt to remove the radiatorcap when the engine is hot.The coolant must be changed at the in-
tervals specified in the periodic mainte-
nance and lubrication chart. Have a
Yamaha dealer change the coolant.
EAU20471
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 B. (See page 6-5.)
2. Remove the intake air shroud by
removing the screw and the quick
fastener screws.
3. Remove the air filter case cover by
removing the screws.1. Intake air shroud
2. Screw
3. Quick fastener screw
U3P6E1E0.book Page 13 Thursday, October 5, 2006 10:13 AM