Yamaha 2013 FJR1300AS User manual

2013
SERVICE MANUAL
FJR1300AS
1MD-28197-E0

EAS20040
FJR1300AS 2013
SERVICE MANUAL
©2013 by Yamaha Motor Co., Ltd.
First edition, February 2013
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.

EAS20071
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. 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 vehi-
cle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP
Designs and specifications are subject to change without notice.
EAS20081
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential person-
al injury hazards. Obey all safety messages that follow this symbol to
avoid possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid
damage to the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
WARNING
NOTICE
TIP

EAS20090
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.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
1
7
3
5
4
6
2

EAS20101
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil
Filling fluid Molybdenum disulfide oil
Lubricant Brake fluid
Special tool Wheel bearing grease
Tightening torque Lithium-soap-based grease
Wear limit, clearance Molybdenum disulfide grease
Engine speed Silicone grease
Electrical data Apply locking agent (LOCTITE®).
Engine oil Replace the part with a new one.
G
M
BF
B
T
R
.
.
LS
M
S
LT
E
New

EAS20110 TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
COOLING SYSTEM 6
FUEL SYSTEM 7
ELECTRICAL SYSTEM 8
TROUBLESHOOTING 9

1
GENERAL INFORMATION
IDENTIFICATION ............................................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL..........................................................................................1-1
FEATURES......................................................................................................1-2
OUTLINE OF THE FI SYSTEM.................................................................1-2
FI SYSTEM................................................................................................1-3
OUTLINE OF THE YCC-S (Yamaha Chip Controlled-Shift) SYSTEM
AND YCC-T (Yamaha Chip Controlled-Throttle) ......................................1-4
OUTLINE OF THE CRUISE CONTROL SYSTEM....................................1-9
OUTLINE OF THE UNIFIED BRAKE SYSTEM ...................................... 1-17
OUTLINE OF THE ABS........................................................................... 1-19
ABS COMPONENT FUNCTIONS ...........................................................1-23
ABS OPERATION ...................................................................................1-29
ABS SELF-DIAGNOSIS FUNCTION.......................................................1-32
ABS WARNING LIGHT AND OPERATION.............................................1-35
OUTLINE OF THE TCS (Traction Control System).................................1-36
MULTI-FUNCTION METER UNIT ...........................................................1-39
IMPORTANT INFORMATION ....................................................................... 1-50
PREPARATION FOR REMOVAL AND DISASSEMBLY......................... 1-50
REPLACEMENT PARTS.........................................................................1-50
GASKETS, OIL SEALS AND O-RINGS ..................................................1-50
LOCK WASHERS/PLATES AND COTTER PINS ...................................1-50
BEARINGS AND OIL SEALS ..................................................................1-51
CIRCLIPS ................................................................................................1-51
RUBBER PARTS.....................................................................................1-51
BASIC SERVICE INFORMATION.................................................................1-52
QUICK FASTENERS...............................................................................1-52
ELECTRICAL SYSTEM...........................................................................1-53
SPECIAL TOOLS ..........................................................................................1-57

IDENTIFICATION
1-1
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is stamped
into the right side of the steering head pipe.
EAS20150
MODEL LABEL
The model label “1” is affixed to the frame. This
information will be needed to order spare parts.
1

FEATURES
1-2
EAS20170
FEATURES
ET2C01025
OUTLINE OF THE FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum
air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In
the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion
chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the
respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating con-
ditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter the
fuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-
fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the en-
gine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases increase,
it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accom-
modate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place
of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by
the engine at all times by using a microprocessor that regulates the fuel injection volume according to
the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response,
better fuel economy, and reduced exhaust emissions. Furthermore, the air induction system (AI sys-
tem) has been placed under computer control together with the FI system in order to realize cleaner
exhaust gases.
4
67 8 9 10,11
12
13
14
15,16,17
18
19,20
5
1,2
3
1. ECU (engine control unit)
2. Battery
3. Lean angle sensor
4. Air temperature sensor
5. Engine trouble warning light
6. Coolant temperature sensor
7. Cylinder identification sensor
8. Fuel pump
9. Air induction system solenoid
10. Intake air pressure sensor
11.Atmospheric pressure sensor
12. Injectors
13.Rear wheel sensor
14. O2sensor
15. Throttle position sensor
16.Accelerator position sensor
17.Throttle servo motor
18.Crankshaft position sensor
19. Spark plugs
20.Ignition coils

FEATURES
1-3
ET3P61042
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm², 47.0 psi). Accordingly,
when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing
the fuel to be injected into the intake manifold only during the time the passage remains open. There-
fore, the longer the length of time the fuel injector is energized (injection duration), the greater the vol-
ume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized
(injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from the
throttle position sensor, accelerator position sensor, coolant temperature sensor, cylinder identification
sensor, lean angle sensor, crankshaft position sensor, intake air pressure sensor, atmospheric pres-
sure sensor, air temperature sensor, rear wheel sensor and O2sensor enable the ECU to determine
the injection duration. The injection timing is determined through the signals from the crankshaft posi-
tion sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times in
accordance with the driving conditions.
#3#1 #2 #4
1
17
B
15
16
14
3
13
A
2412
5
C9
6
10
11
78
1. Fuel pump
2. Injector
3. Coolant temperature sensor
4. Cylinder identification sensor
5. ECU (engine control unit)
6. Throttle position sensor
7. Accelerator position sensor
8. Atmospheric pressure sensor
9. Rear wheel sensor
10.Lean angle sensor
11.Air temperature sensor
12.O2sensor
13.Catalytic converter
14.Crankshaft position sensor
15. Throttle body
16. Intake air pressure sensor
17.Air filter case
A. Fuel system
B. Air system
C. Control system

FEATURES
1-4
EAS1MD1015
OUTLINE OF THE YCC-S (Yamaha Chip Controlled-Shift) SYSTEM AND YCC-T (Yamaha Chip
Controlled-Throttle)
Mechanism characteristics of the YCC-T
Yamaha developed the YCC-T system employing the most advanced electronic control technologies.
Electronic control throttle systems have been used on automobiles, but Yamaha has developed a fast-
er, more compact system specifically for the needs of a sports motorcycle. The Yamaha-developed
system has a high-speed calculating capacity that produces computations of running conditions every
1/1000th of a second.
The YCC-T system is designed to respond to the throttle action of the rider by having the ECU instan-
taneously calculate the ideal throttle valve opening and generate signals to operate the motor-driven
throttle valves and thus actively control the intake air volume.
The ECU contains two CPUs with a capacity about five times that of conventional units, making it pos-
sible for the system to respond extremely quickly to the slightest adjustments made by the rider. In par-
ticular, optimized control of the throttle valve opening provides the optimum volume of intake air for
easy-to-use torque, even in a high-revving engine.
Aims and advantages of using YCC-T
• Increased engine power
By shortening the air intake path, higher engine speed is possible →Increased engine power.
• Improved driveability
Air intake volume is controlled according to the operating conditions →Improved throttle response to
meet engine requirement.
Driving force is controlled at the optimal level according to the transmission gear position and engine
speed →Improved throttle control.
• Engine braking control
Due to the throttle control, optimal engine braking is made possible.
• Simplified idle speed control (ISC) mechanism
The bypass mechanism and ISC actuator are eliminated →A simple mechanism is used to maintain
a steady idle speed.
• Reduced weight
Compared to using a sub-throttle mechanism, weight is reduced.
4
123
1. Accelerator position sensor
2. Throttle servo motor
3. Throttle position sensor
4. Throttle valves

FEATURES
1-5
Mechanism characteristics of the YCC-S
YCC-S offers more enjoyable and easy riding by eliminating the need for the user to operate the clutch,
which also reduces fatigue during long touring.
YCC-S is not an automatic transmission, although it allows the user to shift gears by foot or hand ac-
cording to preference.
When shifting, a signal is sent to the MCU (motor control unit), which ensures optimum clutch operation,
shifting, and engine control. Therefore, the user never needs to operate the clutch, which in turn, reduc-
es fatigue and allows the user to concentrate while riding.
YCC-S is equipped with a stop mode function. When the stop mode function is activated, YCC-S auto-
matically shifts down according to the vehicle speed when the vehicle slows down. In addition, YCC-S
automatically shifts the transmission to 1st gear when the vehicle stops. As a result, the stop mode
function eliminates the need for the user to select the gear for starting off and prevents starting off using
a high gear.
YCC-S also operates the clutch instead of the user while the vehicle is stopped.
The ECU controls YCC-T in order to adjust the engine speed to the speed that is suitable for the next
gear. As a result, shift times are shortened and shift shocks are reduced.
Basic function of the YCC-S
When the engine is started and the shift pedal or the shift lever is moved, a signal is sent to the MCU
(Motor Control Unit) which disengages the clutch, the ECU (Engine Control Unit) then adjusts the elec-
tronic throttle valve, the gear shift is made and then the clutch is re-engaged once the engine is running
at the proper speed. Clutch engagement is controlled optimally by the MCU according to engine r/min,
engine requirements, and riding conditions.
This is not an automatic transmission, only the clutch system is automatic. The gears must be shifted
by the rider except when stopping the vehicle while the stop mode function is activated.
The YCC-S system will not shift up if the engine r/min is lower than a specified value. Even if the user
shifts up, if the specified value is not met (engine r/min is too low), the YCC-S system will not shift up
until the above-mentioned specified value is met.
Likewise, the YCC-S system will not shift down if the specified value is not met (engine r/min is too
high).
In this case, the throttle must be closed so that the MCU can disengage the clutch until the specified
value is met to prevent the engine from stopping. During this period, a coasting condition will be felt.
The YCC-S system is constantly performing a self-diagnosis when the engine is running. If any trouble
is detected, the MCU automatically stops the YCC-S system and shifting is impossible.

FEATURES
1-6
13
1,2,3
4
568
11
12
7
10 9
1. YCC-S warning light
2. Stop mode function indicator light
3. Shift down indicator light
4. Hand shift lever switch and stop mode
function switch
5. Gear position sensor
6. Neutral switch
7. MCU (motor control unit)
8. Shift actuator
9. YCC-S control relay
10. Clutch actuator
11.Foot shift sensor
12.YCC-S speed sensor
13.YCC-S motor control fuse

FEATURES
1-7
Shift pattern
This vehicle is equipped with a constant-mesh 5-speed transmission. The gears can be shifted using
either the shift pedal “1” or the hand shift switch “2”. The gear positions are shown in the illustration.
Attention
• Do not turn the main switch to “OFF” while the vehicle is moving, otherwise the electrical systems will
be switched off, including the YCC-S system, which may result in loss of control or an accident. Make
sure that the vehicle is stopped before turning the main switch to “OFF”.
• The clutch will be engaged for a few seconds after the engine is stopped using the main switch if the
transmission is not in neutral. This means that the vehicle cannot be moved by pushing or pulling it.
To move the vehicle, turn the main switch to “ON”, and then apply the front or rear brake to disengage
the clutch. A click will be heard when the clutch is disengaged.
• Always stop the engine and turn the main switch to “LOCK” when parking the vehicle.
YCC-S warning light
• The YCC-S system is constantly performing a self-diagnosis.
• The YCC-S system also performs a self-diagnosis when the main switch is turned to “ON”. The YCC-
S warning light “1” come on during this self-diagnosis. After the self-diagnosis is completed, if there
were no problems found, the YCC-S warning light will go off.
• If the YCC-S warning light come on while riding, stop the vehicle, park it in a safe place.
Because the YCC-S system stops automatically when the YCC-S warning light come on, it is impos-
sible to shift since clutch operation is stopped. To move the vehicle, turn the main switch to “OFF” and
place the vehicle on the centerstand. While rotating the rear wheel, operate the shift rod forward and
shift the transmission into neutral.
N
2
N
12345
GEAR
N
25
A.TEMP ˚C
Lo
C.TEMP ˚C
0:06
TIME TRIP
1

FEATURES
1-8
YCC-S and YCC-T system outline
4
10
9
3
5
6
7
8
2
1
14
11
12
13
15
1. Engine speed
2. Vehicle speed
3. Throttle grip
4. Electric throttle valve
5. Gear position sensor
6. Hand shift switch
7. Foot shift sensor
8. Stop mode function switch
9. ECU (engine control unit)
10.MCU (motor control unit)
11.Ignition coil
12.Electric throttle valve
13.Meter assembly
14. Clutch actuator sensor
15.Shift actuator sensor

FEATURES
1-9
EAS1MC1087
OUTLINE OF THE CRUISE CONTROL SYSTEM
This model is equipped with a cruise control system designed to maintain a set cruising speed. Be-
cause the vehicle is equipped with the YCC-T system, the cruise control system can be controlled elec-
tronically. Based on the signals that are received from the sensors and switches, the ECU calculates
the required throttle valve opening and operates the throttle servo motor to control the throttle valves.
Because the system allows the rider to maintain a set cruising speed without operating the throttle, the
system reduces the burden of maintaining a constant speed during long-distance touring. In addition,
the cruise control system is equipped with a self-diagnosis function.
GEAR
N
25
A.TEMP ˚C
Lo
C.TEMP ˚ C
0:06
TIME TRIP
18
17 16
15 12
13
14
11
10
76
5
4
9
8
3
2
1
1. Battery
2. Main switch
3. Meter assembly
4. ECU (engine control unit)
5. Hand shift lever switch
6. Cruise control setting switch
7. Cruise control power switch
8. MCU (motor control unit)
9. Foot shift sensor
10.Front brake light switch
11.Start/engine stop switch
12.Grip cancel switch
13.Accelerator position sensor
14.Throttle servo motor
15. Throttle position sensor
16.Rear brake light switch
17.Crankshaft position sensor
18.Rear wheel sensor

FEATURES
1-10
WARNING
EWA1MC1006
• Improper use of the cruise control system may result in loss of control, which could lead to an
accident. Do not activate the cruise control system in heavy traffic, poor weather conditions,
or among winding, slippery, hilly, rough or gravel roads.
• When traveling uphill or downhill, the cruise control system may not be able to maintain the
set cruising speed.
• To prevent accidentally activating the cruise control system, turn it off when not in use. Make
sure that the cruise control system indicator light “ ” is off.
Activating and setting the cruise control system
1. Push the cruise control power switch “ ” located on the left handlebar. The cruise control system
indicator light “ ” will come on.
2. Push the “SET–” side of the cruise control setting switch to activate the cruise control system. Your
current traveling speed will become the set cruising speed. The cruise control setting indicator light
“SET” will come on.
TIP
• If the shift down indicator light “ ” is flashing, the cruise control system cannot be activated.
• The cruise control system operates only when riding in 3rd gear at speeds between about 50 km/h
(31 mph) and 160 km/h (100 mph), or 4th or 5th gear at speeds between about 50 km/h (31 mph) and
180 km/h (112 mph).
Operating range of cruise control system
321
1. Cruise control setting switch
2. Sift down indicator light
3. Cruise control setting indicator light
A. Gear position
B. Cruising speed cannot be set
C. Cruising speed can be set
500 160 180
(31)
5
4
3
2
1
(100) (112)
km/h
mph
AB
C

FEATURES
1-11
Adjusting the set cruising speed
While the cruise control system is operating, push the “RES+” side of the cruise control setting switch
to increase the set cruising speed or the “SET–” side to decrease the set speed.
TIP
• Pushing the setting switch once will change the speed in increments of approximately 2.0 km/h (1.2
mph). Holding the “RES+” or “SET–” side of the cruise control setting switch down will increase or de-
crease the speed continuously until the switch is released.
• The traveling speed can also be increased manually using the throttle. While the speed is being in-
creased manually or after the traveling speed has increased 4 km/h or higher than the set cruising
speed, a new cruising speed can be set by pushing the “SET–” side of the switch. If a new cruising
speed has not been set, the vehicle will automatically decelerate to the previously set cruising speed
when the throttle grip returns to the fully closed position.
Deactivating the cruise control system
Perform one of the following operations to cancel the set cruising speed. The cruise control setting in-
dicator light “SET” will go off.
• Turn the throttle grip past the closed position in the deceleration direction.
• Apply the front or rear brake.
• Operate the hand shift lever.
• Operate the shift pedal.
Push the power switch to turn off the cruise control system. The cruise control system indicator light
“ ” and the cruise control setting indicator light “SET” will go off.
TIP
Traveling speed decreases as soon as the cruise control system is deactivated; unless the throttle grip
is turned.
ba
a. Closed position
b. Cruise control cancel direction