Yamaha 2002 FJR1300 Manual

FJR1300(P)
5JW1-AE2
SUPPLEMENTARY
SERVICE MANUAL
2002

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
FJR1300(P) 2002. For complete service information procedures it is necessary to use this Supple-
mentary Service Manual together with the following manual.
FJR1300(N) 2001 SERVICE MANUAL: 5JW1-AE1
FJR1300(P) 2002
SUPPLEMENTARY
SERVICE MANUAL
© 2001 by Yamaha Motor Co., Ltd.
First edition, November 2001
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.

EAS00002
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-
ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in
one manual. 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. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-
ers and will appear in future editions of this manual where applicable.
NOTE:
@
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person checking or repairing the
motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:

EAS00007
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.
1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter.
Refer to “SYMBOLS”.
2Each chapter is divided into sections. The current section title is shown at the top of each page,
except in chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s)
appears.
3Sub-section titles appear in smaller print than the section title.
4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8Jobs requiring more information (such as special tools and technical data) are described sequen-
tially.

EAS00008
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1to 9indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Chassis
5Engine
6Cooling system
7Fuel injection system
8Electrical system
9Troubleshooting
Symbols 0to Gindicate the following.
0Serviceable with engine mounted
AFilling fluid
BLubricant
CSpecial tool
DTightening torque
EWear limit, clearance
FEngine speed
GElectrical data
Symbols Hto Min the exploded diagrams
indicate the types of lubricants and lubrication
points.
HEngine oil
IGear oil
JMolybdenum disulfide oil
KWheel bearing grease
LLithium soap base grease
MMolybdenum disulfide grease
Symbols Nto Oin the exploded diagrams
indicate the following.
NApply locking agent (LOCTITE®)
OReplace the part
12
34
56
78
90
AB
CD
EFG
HIJ
KLM
NO
GEN
INFO
SPEC
CHK
ADJ
CHAS
ENG
COOL
FI –+
ELEC
TRBL
SHTG
T
R
.
.
EGM
BLS M
LT
New

CONTENTS
SPECIFICATIONS ............................................................................................1
GENERAL SPECIFICATIONS ..................................................................1
ENGINE SPECIFICATIONS .....................................................................1
CHASSIS SPECIFICATIONS ....................................................................2
ELECTRICAL SPECIFICATIONS .............................................................4
TIGHTENING TORQUES .........................................................................5
ENGINE TIGHTENING TORQUES ......................................................5
CHASSIS TIGHTENING TORQUES ....................................................5
LUBRICATION POINTS AND LUBRICANT TYPES .................................6
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES ...........6
CABLE ROUTING .....................................................................................7
PERIODIC CHECKS AND ADJUSTMENTS ..................................................10
INTRODUCTION .....................................................................................10
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS .............10
COWLINGS AND COVERS ....................................................................12
COWLINGS .........................................................................................12
COVERS .............................................................................................15
CHASSIS ........................................................................................................16
FRONT AND REAR BRAKES .................................................................16
REAR BRAKE PADS ..........................................................................16
REAR BRAKE CALIPER .....................................................................17
FRONT FORK .........................................................................................19
INSTALLING THE FRONT FORK LEGS ............................................20
SHAFT DRIVE .........................................................................................22
ENGINE ..........................................................................................................24
CAMSHAFTS ..........................................................................................24
CAMSHAFTS ......................................................................................24
FUEL INJECTION SYSTEM ...........................................................................26
FUEL INJECTION SYSTEM ...................................................................26
ECU’S SELF-DIAGNOSTIC FUNCTION ............................................26

– 1 –
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
ENGINE SPECIFICATIONS
Item Standard Limit
Model code 5JW4 (for Europe)
5JW5 (for F)
5JW6 (for Oceania)
----
----
----
Item Standard Limit
Fuel
Recommended fuel Regular unleaded gasoline only
(for Europe)
Unleaded gasoline only (for Oceania)
----
----
Fuel tank capacity
Total (including reserve) 25 L ----
Reserve only 5 L ----
Oil filter
Oil filter type Cartridge (paper) ----
Bypass valve opening pressure 78.4 ~ 117.6 kPa
(0.78 ~ 1.18 kg/cm2, 0.78 ~ 1.18 bar)
----
Cooling system
Radiator capacity 3.2 L ----
Radiator cap opening pressure 93.3 ~ 122.7 kPa
(0.93 ~ 1.23 kg/cm2, 0.93 ~ 1.23 bar)
----
Valve relief pressure 4.9 kPa (0.05 kg/cm2, 0.05 bar) ----
Radiator core
Width 360 mm ----
Height 295.8 mm ----
Depth 27 mm ----
Coolant reservoir
Capacity 0.25 L ----
<From low to full level> 0.15 L ----
Water pump
Water pump type Single-suction centrifugal pump ----
Reduction ratio 75/48 ×25/28 (1.395) ----
Max. impeller shaft tilt ---- 0.15 mm
Measurement B 24.997 ~ 25.097 mm 23.997 mm
Fuel injectors
Model INP-732 ----
Manufacturer NIPPON INJECTOR ----
Quantity 4 ----
GENERAL SPECIFICATIONS/
ENGINE SPECIFICATIONS

–2 –
SPEC
CHASSIS SPECIFICATIONS
CHASSIS SPECIFICATIONS
Item Standard Limit
Front wheel
Wheel type Cast wheel ----
Rim
Size 17M/C ×MT3.50
17 ×MT3.50
----
----
Material Aluminum ----
Wheel travel 135 mm ----
Wheel runout
Max. radial wheel runout ---- 1 mm
Max. lateral wheel runout ---- 0.5 mm
Rear wheel
Wheel type Cast wheel ----
Rim
Size 17M/C ×MT5.50
17 ×MT5.50
----
----
Material Aluminum ----
Wheel travel 125 mm ----
Wheel runout
Max. radial wheel runout ---- 1 mm
Max. lateral wheel runout ---- 0.5 mm
Front tire
Tire type Tubeless ----
Size 120/70ZR 17M/C (58W)
120/70ZR 17 (58W)
----
----
Model (manufacturer) MEZ4J FRONT (METZELER)/
BT020F N (BRIDGESTONE)
----
Tire pressure (cold)
0 ~ 90 kg 250 kPa (2.5 kgf/cm2, 2.5 bar) ----
90 ~ 208 kg 250 kPa (2.5 kgf/cm2, 2.5 bar) ----
High-speed riding 250 kPa (2.5 kgf/cm2, 2.5 bar) ----
Min. tire tread depth ---- 1.6 mm
Rear tire
Tire type Tubeless ----
Size 180/55ZR 17M/C (73W)
180/55ZR 17 (73W)
----
----
Model (manufacturer) MEZ4J (METZELER)/
BT020R N (BRIDGESTONE)
----
Tire pressure (cold)
0 ~ 90 kg 250 kPa (2.5 kgf/cm2, 2.5 bar) ----
90 ~ 208 kg 290 kPa (2.9 kgf/cm2, 2.9 bar) ----
High-speed riding 290 kPa (2.9 kgf/cm2, 2.9 bar) ----
Min. tire tread depth ---- 1.6 mm

– 3 –
SPEC
CHASSIS SPECIFICATIONS
Rear suspension
Suspension type Swingarm (link suspension) ----
Rear shock absorber assembly type Coil spring/gas-oil damper ----
Rear shock absorber assembly travel 60 mm ----
Upper spring
Free length 159 mm 155.82 mm
Installed length 138.1 mm ----
Lower spring
Free length 74 mm 72.52 mm
Installed length 65.4 mm ----
Spring rate (K1) 71.6 N/mm (7.16 kgf/mm) ----
Spring stroke (K1) 0 ~ 31.3 mm ----
Spring rate (K2) 102 N/mm (10.2 kgf/mm) ----
Spring stroke (K2) 31.3 ~ 60.0 mm ----
Optional spring available No ----
Standard spring preload gas/air pres-
sure
1,200 kPa (12.0 kg/cm2, 12.0 bar) ----
Spring preload adjusting positions
Rider only SOFT ----
With passenger or cargo HARD ----
Rebound damping adjusting posi-
tions
Minimum* 20 ----
Standard* 10 ----
Maximum* 3 ----
*from the fully turned-in position
Item Standard Limit

–4 –
SPEC
ELECTRICAL SPECIFICATIONS
ELECTRICAL SPECIFICATIONS
Item Standard Limit
Ignition system
Ignition system type Transistorized coil ignition (digital) ----
Ignition timing 5°BTDC at 1,050 r/min ----
Advancer type Electric ----
Pickup coil resistance/color 420.8 ~ 569.3 Ω/Gy–B ----
Transistorized coil ignition unit model
(manufacturer)
F8T911 (MITSUBISHI) (for Europe)
F8T912 (MITSUBISHI) (for F)
F8T913 (MITSUBISHI) (for Oceania)
----
----
----
Fuses (amperage ×quantity)
Main fuse 50 A ×1 ----
Fuel injection system fuse 15 A ----
Headlight fuse 25 A ×1 ----
Signaling system fuse 15 A ×1 ----
Ignition fuse 10 A ×1 ----
Radiator fan motor fuse 15 A ×1 ----
Hazard lighting fuse 7.5 A ----
Parking lighting fuse 10 A ----
Backup fuse (odometer and clock) 10 A ----
Windshield motor fuse 2 A ----
Reserve fuse 25 A, 15 A, 10 A ×1
7.5 A ×1 (for Europe)
2.0 A ×1 (for Oceania)
----
----
----

–5 –
SPEC
TIGHTENING TORQUES
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
CHASSIS TIGHTENING TORQUES
Part to be tightened Part name Thread
size Q’ty
Tightening
torque Remarks
Nm m·kgf
Timing chain tensioner cap Bolt M6 1 7 0.7
Part to be tightened Thread
size
Tightening
torque Remarks
Nm m·kgf
Rear brake caliper retaining bolt M10 27 2.7

–6 –
SPEC
LUBRICATION POINTS AND LUBRICANT TYPES
LUBRICATION POINTS AND LUBRICANT TYPES
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point Lubricant
Steering bearings and bearing races (upper and lower) LS
Front wheel oil seal (right and left) LS
Rear wheel oil seal LS
Rear wheel drive hub oil seal LS
Rear wheel drive hub mating surface LS
Rear brake pedal pivot LS
Footrest pivoting point LS
Centerstand pivoting point and sliding surface LS
Sidestand pivoting point and metal-to-metal moving parts LS
Throttle grip inner surface LS
Brake lever pivot bolt and contact surface LS
Clutch lever pivot bolt and contact surface LS
Rear shock absorber assembly oil seal LS
Rear shock absorber assembly bearing LS
Rear shock absorber assembly spacer LS
Pivot shaft LS
Connecting arm bearing LS
Spacer (relay arm and connecting arm) LS
Oil seal (relay arm and connecting arm) LS
Ring gear inner surface LS
Thrust washer (ring gear) E
Bearing (ring gear) LS
Bearing (final drive pinion gear) LS

–7 –
SPEC
CABLE ROUTING
1Air cut-off valve
2Clutch cable
3Left handlebar switch lead
4Headlight lead
5Main switch lead
6Throttle cable
7Right handlebar switch lead
8T-bar
9Spark plug lead #3
0Spark plug lead #2
ASpark plug lead #1
BSpark plug lead #4
CThrottle position sensor
DSidestand switch lead
ESpark plug lead #1
FSpark plug lead #4
CABLE ROUTING

–8 –
SPEC
ÈConnect the wire harness and right handlebar
switch lead.
ÉPass the left handlebar switch lead, main switch
lead, headlight lead, and clutch cable through
the hole on the left side of the frame.
ÊPass the right handlebar switch lead and throttle
cables through the hole on the right side of the
frame.
ËTo the lower left slit of the plate
ÌTo the cylinder identification sensor
ÍTo the fuel tank
ÎPass the cylinder identification sensor lead
through the lead guide of throttle body.
ÏTo the sidestand switch lead
ÐPass the cylinder identification sensor lead
under the fuel hose and then to the wire har-
ness.
CABLE ROUTING

–9 –
SPEC
ÑSupport the throttle cables with the T-bar located
behind the cable guide.
ÒPass the throttle cables under spark plug leads
#1, #2, #3, and #4, and the wire harness, head-
light lead, main switch lead, right handlebar
switch lead, and left handlebar switch lead.
Install the thermostat, heat protector, throttle
cables, spark plug leads, wire harnesses, and
air cut valve under the cable guide in the respec-
tive order.
ÓTo the left slit of the plate
CABLE ROUTING

– 10 –
CHK
ADJ
INTRODUCTION/PERIODIC MAINTENANCE AND
LUBRICATION INTERVALS
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAS00037
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS
NOTE:
•The annual checks must be performed every year, except if a kilometer-based maintenance
is performed instead.
• From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
No. ITEM CHECK OR MAINTENANCE JOB ODOMETER READING (×1,000 km) ANNUAL
CHECK
1 10203040
1 * Fuel line • Check fuel hoses for cracks or damage. √√√√ √
2 Spark plugs
• Check condition.
• Clean and regap. √√
•Replace. √√
3 * Valves • Check valve clearance.
• Adjust. Every 40,000 km
4 Air filter element • Clean. √√
•Replace. √√
5*Clutch • Check operation, fluid level and vehicle for fluid
leakage. (See NOTE on page 11.) √√√√√
6 * Front brake
• Check operation, fluid level and vehicle for fluid
leakage. (See NOTE on page 11.) √√√√√ √
• Replace brake pads. Whenever worn to the limit
7 * Rear brake
• Check operation, fluid level and vehicle for fluid
leakage. (See NOTE on page 11.) √√√√√ √
• Replace brake pads. Whenever worn to the limit
8 * Brake hoses • Check for cracks or damage. √√√√ √
• Replace. (See NOTE on page 11.) Every 4 years
9 * Wheels • Check runout and for damage. √√√√
10 * Tires
• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
√√√√ √
11 * Wheel bearings • Check bearing for looseness or damage. √√√√
12 * Swingarm • Check operation and for excessive play. √√√√
• Lubricate with lithium-soap-based grease. Every 50,000 km
13 * Steering bearings • Check bearing play and steering for roughness. √√√√√
• Lubricate with lithium-soap-based grease. Every 20,000 km

–11 –
CHK
ADJ
PERIODIC MAINTENANCE AND LUBRICATION
INTERVALS
NOTE:
•The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
•Hydraulic brake and clutch service
•Regularly check and, if necessary, correct the brake and clutch fluid levels.
•Every two years replace the internal components of the brake master cylinders and calipers as
well as clutch master and release cylinders, and change the brake and clutch fluids.
•Replace the brake and clutch hoses every four years and if cracked or damaged.
14 * Chassis fasteners •Make sure that all nuts, bolts and screws are
properly tightened. √√√√ √
15 Sidestand/
centerstand
•Check operation.
•Lubricate. √√√√ √
16 * Sidestand switch •Check operation. √√√√√ √
17 * Front fork •Check operation and for oil leakage. √√√√
18 * Shock absorber
assembly
•Check operation and shock absorber for oil leak-
age. √√√√
19 *
Rear suspension
relay arm and con-
necting arm pivot-
ing points
•Check operation. √√√√
•Lubricate with lithium-soap-based grease. √√
20 * Electronic fuel
injection system •Adjust engine idling speed and synchronization. √√√√√ √
21 Engine oil •Change.
•Check oil level and vehicle for oil leakage. √√√√√ √
22 Engine oil filter
cartridge •Replace. √√√
23 * Cooling system
•Check coolant level and vehicle for coolant leak-
age. √√√√ √
•Change. Every 3 years
24 Final gear oil •Check oil level and vehicle for oil leakage.
•Change. √√√√√
25 * Front and rear
brake switches •Check operation. √√√√√ √
26 Moving parts and
cables •Lubricate. √√√√ √
27 * Throttle grip hous-
ing and cable
•Check operation and free play.
•Adjust the throttle cable free play if necessary.
•Lubricate the throttle grip housing and cable.
√√√√ √
28 * Muffler and
exhaust pipe •Check the screw clamp for looseness. √√√√√
29 * Lights, signals and
switches
•Check operation.
•Adjust headlight beam. √√√√√ √
No. ITEM CHECK OR MAINTENANCE JOB ODOMETER READING (×1,000 km) ANNUAL
CHECK
1 10203040

–12 –
CHK
ADJ
COWLINGS AND COVERS
EAS00041
COWLINGS AND COVERS
COWLINGS
1
2
3
4
5
6
7
8
9
10 11
12
13
T
R
.
.
10 Nm (1.0 m •kg)
Order Job/Part Q’ty Remarks
Removing the cowlings Remove the parts in the order listed.
Rider seat/fuel tank Refer to “SEATS AND FUEL TANK”.
(Manual No.: 5JW1-AE1)
1 Left side cowling 1
2 Right side cowling 1
3 Front bottom cowling 1
4 Front turn signal connector (left) 2
5 Front turn signal connector (right) 2
6 Left inner panel (front cowling) 1
7 Fuse box 1
8 Hazard switch 1
9 Right inner panel (front cowling) 1
10 Front-right inner panel (front cowling) 1
11 Front-left inner panel (front cowling) 1
12 Sub wire harness coupler 3
13 Front cowling assembly 1
For installation, reverse the removal
procedure.