Yamaha FJR13AG User manual

2016
SERVICE MANUAL
FJR13AG
FJR13ESG
B88-28197-70-E0

EAS20002
FJR13AG/FJR13ESG
SERVICE MANUAL
©2016 by Yamaha Motor Co., Ltd.
First edition, January 2016
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.

EAS20003
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.
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 vehi-
cle 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 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
• This Service Manual contains information regarding periodic maintenance to the emission control sys-
tem. Please read this material carefully.
• Designs and specifications are subject to change without notice.
EAS30001
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 personal inju-
ry 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

EAS20004
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

EAS20005
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

EAS10003 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 YCC-T (Yamaha Chip Controlled-Throttle).................1-2
OUTLINE OF THE CRUISE CONTROL SYSTEM....................................1-3
OUTLINE OF THE UNIFIED BRAKE SYSTEM ...................................... 1-11
OUTLINE OF THE TCS (Traction Control System).................................1-12
MULTI-FUNCTION METER UNIT ...........................................................1-16
IMPORTANT INFORMATION .......................................................................1-27
PREPARATION FOR REMOVAL AND DISASSEMBLY......................... 1-27
REPLACEMENT PARTS.........................................................................1-27
GASKETS, OIL SEALS AND O-RINGS ..................................................1-27
LOCK WASHERS/PLATES AND COTTER PINS ...................................1-27
BEARINGS AND OIL SEALS ..................................................................1-28
CIRCLIPS ................................................................................................1-28
RUBBER PARTS.....................................................................................1-28
BASIC SERVICE INFORMATION.................................................................1-29
QUICK FASTENERS...............................................................................1-29
ELECTRICAL SYSTEM...........................................................................1-30
SPECIAL TOOLS ..........................................................................................1-34

IDENTIFICATION
1-1
EAS20007
IDENTIFICATION
EAS30002
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is stamped
into the right side of the steering head pipe.
EAS30003
MODEL LABEL
The model label “1” is affixed to the frame. This
information will be needed to order spare parts.
1

FEATURES
1-2
EAS20008
FEATURES
EAS32018
OUTLINE OF THE 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
1-3
YCC-T system outline
EAS30940
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.
5
6
7
8
9
32
1
4
1. Throttle position sensor
2. Throttle servo motor
3. Accelerator position sensor
4. ECU (electronic control unit)
5. Sensor input
6. Gear position switch
7. Crankshaft position sensor
8. Rear wheel sensor
9. Coolant temperature sensor

FEATURES
1-4
WARNING
EWA17451
• 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.
GEAR
N
25
A.TEMP ˚C
Lo
C.TEMP ˚C
0:06
TIME TRIP
16
15 14
13 10
11
12
9
8
76
5
4
3
2
1
1. Battery
2. Main switch
3. Meter assembly
4. ECU (Engine Control Unit)
5. Clutch switch
6. Cruise control setting switch
7. Cruise control power switch
8. Front brake light switch
9. Start/engine stop switch
10.Grip cancel switch
11.Accelerator position sensor
12.Throttle servo motor
13. Throttle position sensor
14.Rear brake light switch
15.Crankshaft position sensor
16.Rear wheel sensor

FEATURES
1-5
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
The cruise control system operates only when riding in 3rd, 4th or 5th gear at speeds between about
50 km/h (31 mph) and 160 km/h (100 mph), or 6th gear at speeds between about 55 km/h (34 mph)
and 160 km/h (100 mph).
Operating range of cruise control system
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.
• Apply the clutch lever.
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.
500160
(31)
55
(34)
5
4
3
2
1
(100)
km/h
mph
AB
C
6
A. Gear position
B. Cruising speed cannot be set
C. Cruising speed can be set

FEATURES
1-6
TIP
Traveling speed decreases as soon as the cruise control system is deactivated; unless the throttle grip
is turned.
Using the resume function
Push the “RES+” side of the cruise control setting switch to reactivate the cruise control system. The
traveling speed will return to the previously set cruising speed. The cruise control setting indicator light
“SET” will come on.
If the “SET–” side of the cruise control setting switch is pushed during the resume operation, the current
traveling speed will be set as the new cruising speed.
WARNING
EWA17460
It is dangerous to use the resume function when the previously set cruising speed is too high
for current conditions.
TIP
Pushing the power switch while the system is operating will turn the system off completely and erase
the previously set cruising speed. You will not be able to use the resume function until a new cruising
speed has been set.
ba
a. Closed position
b. Cruise control cancel direction

FEATURES
1-7
Operation chart
Automatic deactivation of the cruise control system
The cruise control system for this model is electronically controlled and is linked with the other control
systems. The cruise control system will automatically become deactivated under the following condi-
tions:
• The cruise control system is not able to maintain the set cruising speed. (If the traveling speed de-
creases by approximately 10 km/h (6 mph) or more than the set cruising speed.)
• The traction control system is turned on and has been activated. (Traction control system indica-
tor/warning light flashes.)
• Traction control system is turned off and wheel slip or wheel spin is detected. (The changes in the
vehicle speed signals exceed a preset value.)
• The start/engine stop switch is set to the “ ” position.
• The engine stalls.
• The sidestand is extended.
SET SET SET SET
RES
SET
RES
SET
A
C
D
E
F
B
ab dcebfgb
j
hi
A. Operation
B. Indication
C. Speed
D. 160 km/h (100 mph)
E. 50 km/h (31 mph) or 55 km/h (34 mph) (6th
gear)
F. T i m e
a. Cruise control power switch “ ” “ON”
b. Manual acceleration
c. Push the “SET–” side of the cruise control
setting switch
d. Currently set cruising speed increases
e. Currently set cruising speed decreases
f. New cruising speed is set
g. Currently set cruising speed is canceled
h. Resume operation starts
i. Resume operation finishes
j. Currently set cruising speed

FEATURES
1-8
Because the automatic deactivation of the cruise control system is stored in the memory of the ECU,
the deactivation can be checked using the Yamaha diagnostic tool.
TIP
In some cases, the cruise control system may not be able to maintain the set cruising speed when the
vehicle is traveling uphill or downhill.
• When the vehicle is traveling uphill, the actual traveling speed may become lower than the set cruising
speed. If this occurs, accelerate to the desired traveling speed using the throttle.
• When the vehicle is traveling downhill, the actual traveling speed may become higher than the set
cruising speed. If this occurs, the setting switch cannot be used to adjust the set cruising speed. To
reduce the traveling speed, apply the brakes. When the brakes are applied, the cruise control system
will become deactivated.
• If the cruise control system turns off automatically while the cruising speed is not set, the cruise control
setting indicator light “SET” will not flash.
Automatic deactivation condi-
tion
Vehicle condition for de-
tection Multi-function meter indication
Unable to maintain the set
cruising speed
Cruise control system is
turned on and cruising
speed is set
Cruise control system indicator light “ ” goes
off and cruise control setting indicator light
“SET” flashes for 4 seconds
Traction control system is en-
gaged
Wheel slip or wheel spin is de-
tected
Start/engine stop switch is set
to the “ ” position
Cruise control system is
turned on
Engine stalls
Sidestand is extended

FEATURES
1-9
Meter displays during cruise control system operation
Self-diagnosis device
The cruise control system will also become deactivated when an irregularity with any of the vehicle sys-
tems is detected. The cruise control setting indicator light “SET” will go off and the cruise control system
indicator light “ ” will flash. You will not be able to use the cruise control system while the engine trou-
ble warning light, or while the cruise control system is malfunctioning.
C
D
B
A
d
c
b
aa
A. Cruise control system is activated (cruising
speed is set)
B. Cruise control system is turned off (cruise
control system indicator light “ ” flashes)
C. Cruise control system is turned off
D. Cruise control system is turned on (cruising
speed is not set)
a. Condition for automatically deactivating cruise
control system is detected
b. 4 seconds elapse (during this time, input from
the cruise control power switch “ ” will not be
received)
c. Cruise control power switch “ ” “ON”
d. Cruising speed is set
1 2 3
1. Engine trouble warning light “ ”
2. Cruise control system indicator light “ ”
3. Cruise control setting indicator light “SET”

FEATURES
1-10
NOTICE
ECA23590
If the engine trouble warning light come on, the vehicle should be checked as soon as possible
in order to avoid engine damage.
TIP
• If the cruise control system turned off because a malfunction was detected by the FI self-diagnosis,
the cruise control power switch “ ” must be pushed once before the system can return to the normal
operating condition.
• If a switch for the cruise control system is malfunctioning (fault code No. P056C and P0564), the en-
gine trouble warning light will not come on because the normal operation of the vehicle is not affected.
Meter displays during cruise control system operation
C
E
B
A
e
d
d
a
DD
c
cb b
F G
A. Cruise control system is activated (cruising
speed is set)
B. Cruise control system is turned off (engine
trouble warning light “ ” comes on, cruise
control system is deactivated, and cruise
control system indicator light “ ” flashes)
C. Cruise control system is turned off (engine
trouble warning light “ ” goes off, cruise
control system is deactivated, and cruise
control system indicator light “ ” flashes)
D. Cruise control system is turned off
E. Cruise control system is turned on (cruising
speed is not set)
F. Malfunction detected by FI self-diagnosis
G. Malfunction not detected by FI self-diagnosis
a. Malfunction occurs
b. Cruise control power switch “ ” “OFF”
c. Cruise control power switch “ ” “ON”
d. Delete the fault code on the yamaha
diagnostic tool
e. Cruising speed is set

FEATURES
1-11
EAS31836
OUTLINE OF THE UNIFIED BRAKE SYSTEM
The Yamaha unified brake system is a system that operates one set of pistons in the front brakes to-
gether with the rear brake when the brake pedal is depressed. Compared to conventional brake sys-
tems, the ability to slow the vehicle using the simple operation of the brake pedal is improved.
Unified brake system block diagram
When the brake lever is squeezed, both sets of pistons in the left front brake caliper are operated, but
only one set of pistons in the right front brake caliper is operated. When the brake pedal is depressed,
the rear brake caliper and one set of pistons in the right front brake caliper are operated. The brake line
from the rear brake master cylinder is split at the hydraulic unit to transmit brake fluid pressure to both
the rear brake caliper and part of the right front brake caliper in the unified brake system. The brake
fluid pressure transmitted to the rear brake caliper and part of the right front brake caliper is controlled
by the proportioning valve and metering valve respectively. The operation of these two valves ensures
that the braking feeling of conventional brakes is maintained when a small amount of force is applied
to the brake pedal, such as when making U-turns, and prevents early locking of the rear wheel when a
large amount of force is applied.
12
3
4
5
6
78
1. Rear brake master cylinder
2. Front brake master cylinder
3. Rear brake caliper
4. Proportioning valve
5. Hydraulic unit assembly (ABS ECU)
6. Metering valve
7. Front brake caliper (left)
8. Front brake caliper (right)