Yamaha FJR1300R User manual

LIT-11616-16-18 5JW-28197-10
FJR1300R
FJR1300RC
SERVICE MANUAL

EAS00001
FJR1300R/FJR1300RC
SERVICE MANUAL
©2002 by Yamaha Motor Corporation, U.S.A.
First edition, June 2002
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-16-18

EAS00003
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.
This model has been designed and manufactured to perform within certain specifications in regard
to performance and emissions. Proper service with the correct tools is necessary to ensure that the
vehicle will operate as designed. If there is any question about a service procedure, it is imperative
that you contact a Yamaha dealer for any service information changes that apply to this model. This
policy is intended to provide the customer with the most satisfaction from his vehicle and to conform
to federal environmental quality objectives.
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

EAS00013
TABLE OF CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC 2
PERIODIC CHECKS AND
ADJUSTMENTS CHK
ADJ 3
CHASSIS CHAS 4
ENGINE ENG 5
COOLING SYSTEM COOL 6
FUEL INJECTION SYSTEM FI 7
ELECTRICAL SYSTEM ELEC 8
TROUBLESHOOTING TRBL
SHTG 9
–+

CONTENTS
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION ..................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL CODE...........................................................................................1-1
FEATURES ......................................................................................................1-2
OUTLINE ...................................................................................................1-2
FI SYSTEM................................................................................................1-3
COMPONENTS .........................................................................................1-5
FUEL INJECTION SYSTEM....................................................................1-17
THREE-WAY CATALYTIC CONVERTER SYSTEM ...............................1-26
AIR INDUCTION SYSTEM ......................................................................1-30
COMPONENTS .......................................................................................1-31
IMPORTANT INFORMATION........................................................................1-35
PREPARATION FOR REMOVAL AND DISASSEMBLY.........................1-35
REPLACEMENT PARTS.........................................................................1-35
GASKETS, OIL SEALS AND O-RINGS ..................................................1-35
LOCK WASHERS/PLATES AND COTTER PINS ...................................1-36
BEARINGS AND OIL SEALS ..................................................................1-36
CIRCLIPS ................................................................................................1-36
CHECKING THE CONNECTIONS ..........................................................1-37
SPECIAL TOOLS ..........................................................................................1-38
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS.........................................................................2-1
ENGINE SPECIFICATIONS ...........................................................................2-2
CHASSIS SPECIFICATIONS ........................................................................2-11
ELECTRICAL SPECIFICATIONS .................................................................2-15
CONVERSION TABLE ..................................................................................2-18
GENERAL TIGHTENING TORQUE SPECIFICATIONS ...............................2-18

TIGHTENING TORQUES ..............................................................................2-19
ENGINE TIGHTENING TORQUES .........................................................2-19
CHASSIS TIGHTENING TORQUES .......................................................2-23
LUBRICATION POINTS AND LUBRICANT TYPES.....................................2-25
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES.................2-25
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES ..............2-27
OIL FLOW DIAGRAMS .................................................................................2-28
COOLING SYSTEM DIAGRAMS ..................................................................2-38
CABLE ROUTING .........................................................................................2-42
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION..............................................................................................3-1
PERIODIC MAINTENANCE CHART FOR
THE EMISSION CONTROL SYSTEM ...........................................................3-1
GENERAL MAINTENANCE AND LUBRICATION CHART ...........................3-1
SEATS AND FUEL TANK ...............................................................................3-4
SEATS .......................................................................................................3-4
FUEL TANK ...............................................................................................3-5
T-BAR ........................................................................................................3-6
REMOVING THE FUEL TANK ..................................................................3-7
REMOVING THE FUEL PUMP .................................................................3-7
INSTALLING THE FUEL PUMP ................................................................3-8
INSTALLING THE FUEL HOSE ................................................................3-8
INSTALLING THE T-BAR ..........................................................................3-8
AIR FILTER CASE...........................................................................................3-9
COWLINGS AND COVERS...........................................................................3-11
COWLINGS .............................................................................................3-11
COVERS..................................................................................................3-15

ENGINE..........................................................................................................3-16
ADJUSTING THE VALVE CLEARANCE.................................................3-16
SYNCHRONIZING THE THROTTLE BODIES ........................................3-22
ADJUSTING THE ENGINE IDLING SPEED ...........................................3-25
ADJUSTING THE THROTTLE CABLE FREE PLAY...............................3-26
CHECKING THE SPARK PLUGS ...........................................................3-28
CHECKING THE IGNITION TIMING .......................................................3-29
MEASURING THE COMPRESSION PRESSURE ..................................3-31
CHECKING THE ENGINE OIL LEVEL ....................................................3-33
CHANGING THE ENGINE OIL................................................................3-35
MEASURING THE ENGINE OIL PRESSURE ........................................3-37
ADJUSTING THE CLUTCH LEVER ........................................................3-39
CHECKING THE CLUTCH FLUID LEVEL ..............................................3-39
BLEEDING THE HYDRAULIC CLUTCH SYSTEM .................................3-40
CLEANING THE AIR FILTER ELEMENT ................................................3-42
CHECKING THE THROTTLE BODY JOINTS.........................................3-43
CHECKING THE FUEL AND VACUUM HOSES.....................................3-44
CHECKING THE CRANKCASE BREATHER HOSE...............................3-44
CHECKING THE EXHAUST SYSTEM ....................................................3-45
CHECKING THE COOLANT LEVEL .......................................................3-46
CHECKING THE COOLING SYSTEM ....................................................3-47
CHANGING THE COOLANT ...................................................................3-48
CHASSIS .......................................................................................................3-51
ADJUSTING THE FRONT BRAKE..........................................................3-51
ADJUSTING THE REAR BRAKE ............................................................3-52
CHECKING THE BRAKE FLUID LEVEL .................................................3-53
CHECKING THE BRAKE PADS..............................................................3-54
ADJUSTING THE REAR BRAKE LIGHT SWITCH .................................3-54
CHECKING THE BRAKE HOSES ...........................................................3-55
BLEEDING THE HYDRAULIC BRAKE SYSTEM....................................3-56
ADJUSTING THE SHIFT PEDAL ............................................................3-57
CHECKING THE FINAL DRIVE OIL LEVEL ...........................................3-58
CHANGING THE FINAL DRIVE OIL .......................................................3-58
CHECKING AND ADJUSTING THE STEERING HEAD .........................3-59
CHECKING THE FRONT FORK .............................................................3-61
ADJUSTING THE FRONT FORK LEGS .................................................3-62
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ..................3-64
CHECKING THE TIRES ..........................................................................3-65
CHECKING THE WHEELS .....................................................................3-67
CHECKING AND LUBRICATING THE CABLES.....................................3-68
LUBRICATING THE LEVERS AND PEDALS .........................................3-68
LUBRICATING THE SIDESTAND ...........................................................3-68
LUBRICATING THE CENTERSTAND ....................................................3-69
LUBRICATING THE REAR SUSPENSION .............................................3-69
ELECTRICAL SYSTEM.................................................................................3-70
CHECKING AND CHARGING THE BATTERY .......................................3-70
CHECKING THE FUSES.........................................................................3-75
REPLACING THE HEADLIGHT BULBS .................................................3-77
ADJUSTING THE HEADLIGHT BEAMS .................................................3-78

CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISCS ............................................................4-1
REMOVING THE FRONT WHEEL............................................................4-3
CHECKING THE FRONT WHEEL ............................................................4-3
CHECKING THE BRAKE DISCS ..............................................................4-5
INSTALLING THE FRONT WHEEL ..........................................................4-6
ADJUSTING THE FRONT WHEEL STATIC BALANCE............................4-7
REAR WHEEL AND BRAKE DISC .................................................................4-9
REMOVING THE REAR WHEEL ............................................................4-11
CHECKING THE REAR WHEEL.............................................................4-11
INSTALLING THE REAR WHEEL...........................................................4-12
ADJUSTING THE REAR WHEEL STATIC BALANCE............................4-12
FRONT AND REAR BRAKES.......................................................................4-13
FRONT BRAKE PADS ............................................................................4-13
REAR BRAKE PADS...............................................................................4-14
REPLACING THE FRONT BRAKE PADS ..............................................4-15
REPLACING THE REAR BRAKE PADS.................................................4-17
FRONT BRAKE MASTER CYLINDER ....................................................4-20
REAR BRAKE MASTER CYLINDER ......................................................4-23
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER..............4-26
DISASSEMBLING THE REAR BRAKE MASTER CYLINDER................4-26
CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS ..4-27
ASSEMBLING AND INSTALLING THE FRONT BRAKE
MASTER CYLINDER..............................................................................4-28
ASSEMBLING THE REAR BRAKE MASTER CYLINDER......................4-30
FRONT BRAKE CALIPERS ....................................................................4-33
REAR BRAKE CALIPER .........................................................................4-35
DISASSEMBLING THE FRONT BRAKE CALIPERS..............................4-37
DISASSEMBLING THE REAR BRAKE CALIPER...................................4-38
CHECKING THE FRONT AND REAR BRAKE CALIPERS.....................4-39
ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS .....4-40
ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER ..........4-42
HYDRAULIC CLUTCH ..................................................................................4-46
CLUTCH MASTER CYLINDER ...............................................................4-46
DISASSEMBLING THE CLUTCH MASTER CYLINDER.........................4-49
CHECKING THE CLUTCH MASTER CYLINDER...................................4-50
ASSEMBLING AND INSTALLING THE CLUTCH
MASTER CYLINDER..............................................................................4-51
CLUTCH RELEASE CYLINDER .............................................................4-54
DISASSEMBLING THE CLUTCH RELEASE CYLINDER.......................4-56
CHECKING THE CLUTCH RELEASE CYLINDER .................................4-57
ASSEMBLING AND INSTALLING THE CLUTCH
RELEASE CYLINDER ............................................................................4-57

FRONT FORK................................................................................................4-60
REMOVING THE FRONT FORK LEGS ..................................................4-63
DISASSEMBLING THE FRONT FORK LEGS ........................................4-63
CHECKING THE FRONT FORK LEGS...................................................4-65
ASSEMBLING THE FRONT FORK LEGS ..............................................4-66
INSTALLING THE FRONT FORK LEGS.................................................4-70
HANDLEBARS ..............................................................................................4-72
LEFT HANDLEBAR .................................................................................4-72
RIGHT HANDLEBAR...............................................................................4-73
REMOVING THE HANDLEBARS............................................................4-74
CHECKING THE HANDLEBARS ............................................................4-74
INSTALLING THE HANDLEBARS ..........................................................4-75
STEERING HEAD..........................................................................................4-78
REMOVING THE LOWER BRACKET.....................................................4-80
CHECKING THE STEERING HEAD .......................................................4-80
INSTALLING THE STEERING HEAD .....................................................4-81
REAR SHOCK ABSORBER ASSEMBLY AND RELAY ARM .....................4-83
HANDLING THE REAR SHOCK ABSORBER ........................................4-85
DISPOSING OF A REAR SHOCK ABSORBER......................................4-85
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY...................4-85
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY....................4-86
CHECKING THE CONNECTING ARM AND RELAY ARM .....................4-86
INSTALLING THE RELAY ARM..............................................................4-87
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY..................4-87
SWINGARM ...................................................................................................4-88
REMOVING THE SWINGARM................................................................4-90
CHECKING THE SWINGARM ................................................................4-90
INSTALLING THE SWINGARM ..............................................................4-91
SHAFT DRIVE ...............................................................................................4-93
TROUBLESHOOTING.............................................................................4-93
CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION
AND CHECKING THE SHAFT DRIVE FOR LEAKS ..............................4-96
MEASURING THE RING GEAR BACKLASH .........................................4-97
ADJUSTING THE RING GEAR BACKLASH...........................................4-98
MEASURING THE RING-GEAR-TO-STOPPER-BOLT CLEARANCE ...4-99
ADJUSTING THE RING-GEAR-TO-STOPPER-BOLT CLEARANCE.....4-99
REMOVING THE LEFT FOOTREST BRACKET...................................4-105
DISASSEMBLING THE FINAL DRIVE ASSEMBLY..............................4-105
REMOVING AND INSTALLING THE RING GEAR BEARINGS............4-106
ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR........4-108
CHECKING THE DRIVE SHAFT...........................................................4-113
INSTALLING THE UNIVERSAL JOINT
AND FINAL DRIVE ASSEMBLY...........................................................4-113

CHAPTER 5
ENGINE
ENGINE............................................................................................................5-1
MUFFLERS AND EXHAUST PIPE ASSEMBLY .......................................5-1
LEADS AND HOSES.................................................................................5-2
ENGINE .....................................................................................................5-4
INSTALLING THE ENGINE.......................................................................5-6
CAMSHAFTS...................................................................................................5-8
CYLINDER HEAD COVER........................................................................5-8
CAMSHAFTS.............................................................................................5-9
REMOVING THE CAMSHAFTS..............................................................5-11
CHECKING THE CAMSHAFTS ..............................................................5-12
CHECKING THE CAMSHAFT SPROCKETS..........................................5-13
CHECKING THE TIMING CHAIN TENSIONER......................................5-14
INSTALLING THE CAMSHAFTS ............................................................5-14
CYLINDER HEAD..........................................................................................5-19
REMOVING THE CYLINDER HEAD.......................................................5-20
CHECKING THE CYLINDER HEAD .......................................................5-20
INSTALLING THE CYLINDER HEAD .....................................................5-21
VALVES AND VALVE SPRINGS ..................................................................5-23
REMOVING THE VALVES ......................................................................5-24
CHECKING THE VALVES AND VALVE GUIDES...................................5-25
CHECKING THE VALVE SEATS ............................................................5-27
CHECKING THE VALVE SPRINGS........................................................5-29
CHECKING THE VALVE LIFTERS .........................................................5-30
INSTALLING THE VALVES.....................................................................5-31
GENERATOR AND STARTER CLUTCH......................................................5-33
GENERATOR ROTOR AND STARTER CLUTCH ..................................5-33
STATOR ASSEMBLY..............................................................................5-35
REMOVING THE GENERATOR .............................................................5-36
REMOVING THE STARTER CLUTCH....................................................5-37
CHECKING THE STARTER CLUTCH ....................................................5-37
INSTALLING THE STARTER CLUTCH ..................................................5-38
INSTALLING THE GENERATOR............................................................5-38
PICKUP COIL ROTOR ..................................................................................5-40
REMOVING THE PICKUP COIL ROTOR ...............................................5-42
INSTALLING THE PICKUP COIL ROTOR..............................................5-42

CLUTCH.........................................................................................................5-44
CLUTCH COVER ....................................................................................5-44
CLUTCH ..................................................................................................5-45
REMOVING THE CLUTCH .....................................................................5-47
CHECKING THE FRICTION PLATES.....................................................5-48
CHECKING THE CLUTCH PLATES .......................................................5-49
CHECKING THE CLUTCH SPRING PLATE...........................................5-49
CHECKING THE CLUTCH HOUSING ....................................................5-49
CHECKING THE CLUTCH BOSS ...........................................................5-50
CHECKING THE PRESSURE PLATE ....................................................5-50
CHECKING THE CLUTCH PUSH RODS................................................5-50
CHECKING THE PRIMARY DRIVEN GEAR...........................................5-50
INSTALLING THE CLUTCH ....................................................................5-51
SHIFT SHAFT ................................................................................................5-54
CHECKING THE SHIFT SHAFT .............................................................5-56
CHECKING THE STOPPER LEVER.......................................................5-56
INSTALLING THE SHIFT SHAFT ...........................................................5-56
OIL PAN AND OIL PUMP..............................................................................5-58
OIL PUMP................................................................................................5-60
REMOVING THE OIL PAN......................................................................5-61
CHECKING THE OIL PUMP ...................................................................5-61
CHECKING THE RELIEF VALVE ...........................................................5-62
CHECKING THE OIL DELIVERY PIPES ................................................5-62
CHECKING THE OIL STRAINER............................................................5-62
ASSEMBLING THE OIL PUMP ...............................................................5-62
INSTALLING THE OIL PUMP .................................................................5-63
INSTALLING THE OIL STRAINER..........................................................5-63
INSTALLING THE OIL PAN ....................................................................5-63
MIDDLE GEAR ..............................................................................................5-65
REMOVING THE MIDDLE GEAR ...........................................................5-69
DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY................5-70
DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY.............5-70
CHECKING THE MIDDLE DRIVE SHAFT ASSEMBLY..........................5-70
CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY .......................5-71
ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY......................5-71
ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY...................5-71
INSTALLING THE MIDDLE DRIVE SHAFT ASSEMBLY........................5-72
INSTALLING THE MIDDLE DRIVEN SHAFT ASSEMBLY .....................5-73
MEASURING THE MIDDLE GEAR BACKLASH.....................................5-74
ADJUSTING THE MIDDLE GEAR BACKLASH ......................................5-75
ALIGNING THE MIDDLE GEAR..............................................................5-78
CRANKCASE ................................................................................................5-81
DISASSEMBLING THE CRANKCASE....................................................5-85
CHECKING THE CRANKCASE ..............................................................5-86
CHECKING THE BEARINGS AND OIL SEALS ......................................5-86
CHECKING THE TIMING CHAIN AND OIL PUMP DRIVE CHAIN.........5-87
ASSEMBLING THE CRANKCASE..........................................................5-87

CONNECTING RODS AND PISTONS ..........................................................5-91
REMOVING THE CONNECTING RODS AND PISTONS .......................5-92
CHECKING THE CYLINDERS AND PISTONS.......................................5-93
CHECKING THE PISTON RINGS...........................................................5-94
CHECKING THE PISTON PINS..............................................................5-95
CHECKING THE CONNECTING RODS .................................................5-97
INSTALLING THE CONNECTING RODS AND PISTONS......................5-99
CRANKSHAFT ............................................................................................5-103
REMOVING THE CRANKSHAFT..........................................................5-104
CHECKING THE CRANKSHAFT ..........................................................5-104
INSTALLING THE CRANKSHAFT ........................................................5-107
TRANSMISSION..........................................................................................5-108
REMOVING THE TRANSMISSION.......................................................5-114
CHECKING THE SHIFT FORKS...........................................................5-114
CHECKING THE SHIFT DRUM ASSEMBLY ........................................5-115
CHECKING THE TRANSMISSION .......................................................5-115
INSTALLING THE TRANSMISSION .....................................................5-117
BALANCERS...............................................................................................5-118
FRONT BALANCER ..............................................................................5-118
REAR BALANCER ................................................................................5-119
CHECKING THE BALANCER ...............................................................5-120
INSTALLING THE FRONT BALANCER................................................5-120
INSTALLING THE REAR BALANCER ..................................................5-122
CHAPTER 6
COOLING SYSTEM
RADIATOR ......................................................................................................6-1
CHECKING THE RADIATOR ....................................................................6-3
INSTALLING THE RADIATOR ..................................................................6-4
OIL COOLER ...................................................................................................6-5
CHECKING THE OIL COOLER.................................................................6-6
INSTALLING THE OIL COOLER...............................................................6-6
THERMOSTAT ................................................................................................6-8
CHECKING THE THERMOSTAT............................................................6-10
ASSEMBLING THE THERMOSTAT ASSEMBLY ...................................6-11
INSTALLING THE THERMOSTAT ASSEMBLY .....................................6-11
WATER PUMP...............................................................................................6-12
DISASSEMBLING THE WATER PUMP..................................................6-15
CHECKING THE WATER PUMP ............................................................6-15
ASSEMBLING THE WATER PUMP........................................................6-16
INSTALLING THE WATER PUMP ..........................................................6-18

CHAPTER 7
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM ............................................................................7-1
WIRING DIAGRAM....................................................................................7-2
ECU’S SELF-DIAGNOSTIC FUNCTION...................................................7-3
SUBSTITUTE CHARACTERISTICS OPERATION CONTROL
(FAIL-SAFE ACTION)...............................................................................7-7
TROUBLESHOOTING...............................................................................7-8
THROTTLE BODIES ...............................................................................7-33
CHECKING THE INJECTOR...................................................................7-37
CHECKING THE THROTTLE BODY ......................................................7-37
CHECKING THE PRESSURE REGULATOR..........................................7-37
CHECKING THE FUEL PUMP AND
PRESSURE REGULATOR OPERATION...............................................7-38
AIR INDUCTION SYSTEM ............................................................................7-40
AIR INJECTION.......................................................................................7-40
AIR CUT-OFF VALVE .............................................................................7-40
AIR INDUCTION SYSTEM DIAGRAMS..................................................7-41
AIR CUT-OFF VALVE ASSEMBLY AND
AIR INDUCTION SYSTEM HOSES........................................................7-42
REED VALVES........................................................................................7-43
CHECKING THE AIR INDUCTION SYSTEM..........................................7-44
CANISTER (FOR CALIFORNIA ONLY)........................................................7-45
CHAPTER 8
ELECTRICAL
ELECTRICAL COMPONENTS........................................................................8-1
CHECKING SWITCH CONTINUITY ................................................................8-3
CHECKING THE SWITCHES ..........................................................................8-4
CHECKING THE BULBS AND BULB SOCKETS ..........................................8-6
TYPES OF BULBS ....................................................................................8-6
CHECKING THE CONDITION OF THE BULBS........................................8-6
CHECKING THE CONDITION OF THE BULB SOCKETS........................8-8
IGNITION SYSTEM..........................................................................................8-9
CIRCUIT DIAGRAM ..................................................................................8-9
TROUBLESHOOTING.............................................................................8-10

ELECTRIC STARTING SYSTEM ..................................................................8-14
CIRCUIT DIAGRAM ................................................................................8-14
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ........................8-15
TROUBLESHOOTING.............................................................................8-16
STARTER MOTOR ........................................................................................8-20
CHECKING THE STARTER MOTOR .....................................................8-23
ASSEMBLING THE STARTER MOTOR .................................................8-25
CHARGING SYSTEM ....................................................................................8-26
CIRCUIT DIAGRAM ................................................................................8-26
TROUBLESHOOTING.............................................................................8-27
LIGHTING SYSTEM ......................................................................................8-29
CIRCUIT DIAGRAM ................................................................................8-29
TROUBLESHOOTING.............................................................................8-30
CHECKING THE LIGHTING SYSTEM....................................................8-32
SIGNALING SYSTEM....................................................................................8-36
CIRCUIT DIAGRAM ................................................................................8-36
TROUBLESHOOTING.............................................................................8-38
CHECKING THE SIGNALING SYSTEM .................................................8-39
COOLING SYSTEM.......................................................................................8-46
CIRCUIT DIAGRAM ................................................................................8-46
TROUBLESHOOTING.............................................................................8-47
FUEL INJECTION SYSTEM ..........................................................................8-51
CIRCUIT DIAGRAM ................................................................................8-51
TROUBLESHOOTING.............................................................................8-52
CHECKING THE FUEL PUMP ................................................................8-58
CHECKING AND ADJUSTING THE THROTTLE
POSITION SENSOR...............................................................................8-59
WINDSHIELD DRIVE SYSTEM.....................................................................8-63
CIRCUIT DIAGRAM ................................................................................8-63
TROUBLESHOOTING.............................................................................8-64
CHAPTER 9
TROUBLESHOOTING
STARTING PROBLEMS..................................................................................9-1
ENGINE .....................................................................................................9-1
FUEL SYSTEM..........................................................................................9-1
ELECTRICAL SYSTEMS ..........................................................................9-2

INCORRECT ENGINE IDLING SPEED...........................................................9-2
ENGINE .....................................................................................................9-2
FUEL SYSTEM..........................................................................................9-2
ELECTRICAL SYSTEMS ..........................................................................9-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE .................................9-3
ENGINE .....................................................................................................9-3
FUEL SYSTEM..........................................................................................9-3
FAULTY GEAR SHIFTING ..............................................................................9-3
SHIFTING IS DIFFICULT ..........................................................................9-3
SHIFT PEDAL DOES NOT MOVE ............................................................9-3
JUMPS OUT OF GEAR.............................................................................9-3
FAULTY CLUTCH ...........................................................................................9-4
CLUTCH SLIPS .........................................................................................9-4
CLUTCH DRAGS ......................................................................................9-4
OVERHEATING ...............................................................................................9-4
ENGINE .....................................................................................................9-4
COOLING SYSTEM ..................................................................................9-4
FUEL SYSTEM..........................................................................................9-4
CHASSIS ...................................................................................................9-4
ELECTRICAL SYSTEMS ..........................................................................9-4
POOR BRAKING PERFORMANCE................................................................9-5
FAULTY FRONT FORK LEGS........................................................................9-5
LEAKING OIL ............................................................................................9-5
MALFUNCTION.........................................................................................9-5
UNSTABLE HANDLING..................................................................................9-6
FAULTY LIGHTING OR SIGNALING SYSTEM..............................................9-6
HEADLIGHT DOES NOT LIGHT...............................................................9-6
HEADLIGHT BULB BURNT OUT..............................................................9-6
TAIL/BRAKE LIGHT DOES NOT LIGHT ...................................................9-6
TAIL/BRAKE LIGHT BULB BURNT OUT ..................................................9-6
TURN SIGNAL DOES NOT LIGHT ...........................................................9-6
TURN SIGNAL BLINKS SLOWLY.............................................................9-6
TURN SIGNAL REMAINS LIT ...................................................................9-6
TURN SIGNAL BLINKS QUICKLY ............................................................9-7
HORN DOES NOT SOUND ......................................................................9-7

1 - 1
GEN
INFO
MOTORCYCLE IDENTIFICATION
EAS00014
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1is
stamped into the right side of the steering head
pipe.
EAS00018
MODEL CODE
The model code label 1is affixed to the
frame. This information will be needed to order
spare parts.
1

1 - 2
GEN
INFO
FEATURES
FEATURES
OUTLINE
The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti-
mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera-
ture.
In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the com-
bustion chamber is created by the volume of the intake air and the fuel that is metered by the jet that
is used in the respective chamber.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating
conditions, 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 con-
ditions of the engine.
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 man-
ner. To accommodate 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 sys-
tem (AI system) has been placed under computer control together with the FI system in order to
realize cleaner exhaust gases.
1Ignition coil
2Air filter case
3Intake temperature
sensor
4Fuel delivery hose
5Fuel tank
6Fuel pump
7Fuel return hose
8Intake air pressure
sensor
9Throttle position sensor
0Fuel injector
AO2sensor
BCatalytic converter
CCrankshaft position
sensor
DCoolant temperature
sensor
ESpark plug
FCylinder identifica-
tion sensor
GPressure regulator
HBattery
IECU
JAtmospheric pressure
sensor
KFuel injection system
relay
LEngine trouble warn-
ing light
MLean angle cut-off
switch
NAir cut-off valve