2003 YAMAHA FJR1300A check engine

4-1
4
EAU01114
4-PRE-OPERATION CHECKSThe condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-
tion, to check the following points before each ride.
EAU03439
Pre-operation check list
CO-01E
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-15
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-9
Final gear oilCheck vehicle for oil leakage. 6-12
CoolantCheck coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-13–6-14
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-22–6-24
Rear brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-21–6-24
ClutchCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended fluid to specified level.
Check hydraulic system for leakage.6-21, 6-24
U5JWE2.book Page 1 Wednesday, November 6, 2002 3:32 PM

5-1
5
EAU00372
5-OPERATION AND IMPORTANT RIDING POINTS
EAU00373
WARNING
_

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


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


Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
_
EAU26800
Starting the engine In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

The transmission is in the neutral
position.


The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EWA10290
WARNING
_

Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-25.


Never ride with the sidestand
down.
_1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.
ECA11780
CAUTION:_ The following warning lights and in-
dicator light should come on for a
few seconds, then go off.

Oil level warning light


Engine trouble warning light


Immobilizer system indicator
light


ABS warning light
If a warning or indicator light does
not go off, see pages 3-4–3-6 for the
corresponding warning and indica-
tor light circuit check.
_2. Shift the transmission into the neu-
tral position.NOTE:_ When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical cir-
cuit. _3. Start the engine by pushing the
start switch.
U5JWE2.book Page 1 Wednesday, November 6, 2002 3:32 PM

OPERATION AND IMPORTANT RIDING POINTS
5-4
5
EAU04032*
0–1,000 km
Avoid prolonged operation above
5,000 r/min.
1,000–1,600 km
Avoid prolonged operation above
6,000 r/min.
EC000056*
CAUTION:_ After 1,000 km of operation, the en-
gine oil and final gear oil must be
changed, and the oil filter cartridge
replaced. _1,600 km and beyond
The vehicle can now be operated nor-
mally.
EC000053
CAUTION:_

Keep the engine speed out of
the tachometer red zone.


If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehicle.
_
EAU00461
Parking When parking, stop the engine, and
then remove the key from the main
switch.
EW000058
WARNING
_

Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.


Do not park on a slope or on
soft ground, otherwise the
motorcycle may overturn.
_
EC000062
CAUTION:_ Never park in an area where there
are fire hazards such as grass or
other flammable materials. _
U5JWE2.book Page 4 Wednesday, November 6, 2002 3:32 PM

6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-2
Removing and installing panels ........................... 6-5
Checking the spark plugs .................................... 6-7
Engine oil and oil filter cartridge .......................... 6-9
Final gear oil ...................................................... 6-12
Checking the coolant level ................................. 6-13
Cleaning the air filter element ............................ 6-15
Checking the engine idling speed ...................... 6-16
Adjusting the throttle cable free play .................. 6-17
Adjusting the valve clearance ............................ 6-17
Tires ................................................................... 6-17
Cast wheels ....................................................... 6-20
Clutch lever free play ......................................... 6-21
Adjusting the brake pedal position ..................... 6-21
Adjusting the rear brake light switch .................. 6-22
Checking the front and rear brake pads ............. 6-22
Checking the brake and clutch fluid levels ......... 6-23
Changing the brake and clutch fluids ................. 6-25
Checking and lubricating the cables .................. 6-25Checking and lubricating the throttle grip and
cable ............................................................... 6-25
Checking and lubricating the brake and
shift pedals ...................................................... 6-26
Checking and lubricating the brake and
clutch levers .................................................... 6-27
Checking and lubricating the centerstand and
sidestand ......................................................... 6-27
Lubricating the swingarm pivots ........................ 6-28
Checking the front fork ...................................... 6-29
Checking the steering ....................................... 6-29
Checking the wheel bearings ............................ 6-30
Battery ............................................................... 6-31
Replacing the fuses .......................................... 6-32
Replacing a headlight bulb ................................ 6-33
Replacing an auxiliary light bulb ....................... 6-35
Replacing a rear turn signal light bulb or
a tail/brake light bulb ....................................... 6-36
Troubleshooting ................................................. 6-36
Troubleshooting charts ...................................... 6-37
U5JWE2.book Page 1 Wednesday, November 6, 2002 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
9
*Wheels
Check runout and for damage.√√√√
10*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
11*Wheel bearings
Check bearing for looseness or damage.√√√√
12*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50,000 km
13*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20,000 km
14*Chassis fasteners
Make sure that all nuts, bolts and screws are properly tightened.√√√√ √
15 Sidestand/centerstandCheck 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 leakage.√√√√
19*Rear suspension relay
arm and connecting arm
pivoting pointsCheck operation.√√√√
20*Electronic fuel injection
Adjust engine idling speed and synchronization.√√√√√ √
21 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×
1,000 km)
ANNUAL
CHECK
1 10203040
U5JWE2.book Page 3 Wednesday, November 6, 2002 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU04408
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.
_22 Engine oil filter cartridge
Replace.√√√
23
*Cooling systemCheck coolant level and vehicle for coolant leakage.√√√√ √
Change.Every 3 years
24 Final gear oilCheck oil level and vehicle for oil leakage.
Change.√√√√√
25*Front and rear brake
switchesCheck operation.√√√√√ √
26 Moving parts and cables
Lubricate.√√√√ √
27*Throttle grip housing and
cableCheck 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
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×
1,000 km)
ANNUAL
CHECK
1 10203040
U5JWE2.book Page 4 Wednesday, November 6, 2002 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6
EAU01315
Panel D
To remove the panelRemove the screws, and then take the
panel off.
To install the panelPlace the panel in the original position,
and then install the screws.
EAU04506
Panels E and F
To remove one of the panels1. Remove the seats. (See page 3-17
for seat removal and installation
procedures.)
2. Remove the screws, the quick fas-
tener screw and the quick fasten-
ers, and then take the panel off.
To install the panel1. Place the panel in the original po-
sition, and then install the quick
fasteners and quick fastener
screw, and tighten the screws.
2. Install the seats.
EAU01880
Checking the spark plugs The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal col-
or when the motorcycle is ridden nor-
mally), and all spark plugs installed in
the engine should have the same color.
If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.
1. Screw (× 3)
1. Screw (× 2)
2. Quick fastener screw
3. Quick fastener (× 3)
U5JWE2.book Page 7 Wednesday, November 6, 2002 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
EAU05018
Engine oil and oil filter
cartridge The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the motorcycle on the cen-
terstand.NOTE:_ Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. _2. Start the engine, warm it up for
several minutes, and then turn it
off.3. Wait a few minutes until the oil set-
tles, and then check the oil level
through the check window located
at the bottom-left side of the crank-
case.
NOTE:_ The engine oil should be between the
minimum and maximum level marks. _4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.To change the engine oil
(with or without oil filter cartridge
replacement)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
NOTE:_ Skip steps 4–6 if the oil filter cartridge is
not being replaced. _
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
1. Engine oil filler cap
2. Engine oil filter cartridge
3. Engine oil drain bolt
U5JWE2.book Page 9 Wednesday, November 6, 2002 3:32 PM