2003 YAMAHA FJR1300A brake pads

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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_

The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.


From 50,000 km, repeat the maintenance intervals starting from 10,000 km.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_CP-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×
1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line
Check fuel hoses for cracks or damage.√√√√ √
2*Spark plugsCheck condition.
Clean and regap.√√
Replace.√√
3*ValvesCheck valve clearance.
Adjust.Every 40,000 km
4 Air filter elementClean.√√
Replace.√√
5*ClutchCheck operation, fluid level and vehicle for fluid leakage. (See
NOTE on page 6-4.)√√ √ √ √
6*Front brakeCheck operation, fluid level and vehicle for fluid leakage. (See
NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation, fluid level and vehicle for fluid leakage. (See
NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
8*Brake hosesCheck for cracks or damage.√√√√ √
Replace. (See NOTE on page 6-4.) Every 4 years
U5JWE2.book Page 2 Wednesday, November 6, 2002 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
EAU00713
Adjusting the rear brake light
switch The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction
a. To
make the brake light come on later,
turn the adjusting nut in direction
b.
EAU00721
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU00725
Front brake pads
Each front brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator groove. If a brake
pad has worn to the point that the wear
indicator groove has almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
1. Rear brake light switch
2. Rear brake light switch adjusting nut
1. Brake pad wear indicator grooveFront
U5JWE2.book Page 22 Wednesday, November 6, 2002 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
EAU04510
Rear brake pads
Check each rear brake pad for damage
and measure the lining thickness. If a
brake pad is damaged or if the lining
thickness is less than 0.8 mm, have a
Yamaha dealer replace the brake pads
as a set.
EAU05024
Checking the brake and clutch
fluid levels Insufficient brake fluid may allow air to
enter the brake or clutch systems, pos-
sibly causing them to become ineffec-
tive.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake flu-
id level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
NOTE:_ The rear brake fluid reservoir is located
behind panel F. (See page 6-7 for pan-
el removal and installation proce-
dures.) _
a. Lining thickness
Rear
1. Minimum level markFront brake
1. Minimum level markRear brake
U5JWE2.book Page 23 Wednesday, November 6, 2002 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6 Observe these precautions:


When checking the fluid level,
make sure that the top of the brake
or clutch fluid reservoir is level.


Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking or clutch
performance.


Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking or clutch per-
formance.


The brake or clutch fluid reservoir
diaphragm will lose its shape from
the negative pressure if the fluid
level goes down too far. Be sure to
return the diaphragm to its original
shape before installing it into the
brake or clutch fluid reservoir.


Be careful that water does not en-
ter the brake or clutch fluid reser-
voir when refilling. Water will
significantly lower the boiling point
of the fluid and may result in vapor
lock, and dirt may clog the ABS
hydraulic unit valves.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
1. Minimum level mark
Recommended brake and clutch
fluid: DOT 4 brake fluidClutch
U5JWE2.book Page 24 Wednesday, November 6, 2002 3:32 PM

INDEXAABS (For FJR1300A only)...................... 3-13
ABS warning light
(For FJR1300A only) .............................3-5
Accessory box ....................................... 3-19
Air filter element, cleaning ...................... 6-15
Anti-theft alarm ........................................3-9
Auxiliary light bulb, replacing .................. 6-35BBattery ................................................... 6-31
Brake and clutch fluid levels,
checking .............................................. 6-23
Brake and clutch fluids, changing........... 6-25
Brake and clutch levers,
checking and lubricating ...................... 6-27
Brake and shift pedals,
checking and lubricating ...................... 6-26
Brake lever............................................. 3-12
Brake light switch (rear), adjusting ......... 6-22
Brake pads, checking............................. 6-22
Brake pedal............................................ 3-12
Brake pedal position, adjusting .............. 6-21CCables, checking and lubricating............ 6-25
Care.........................................................7-1
Catalytic converter ................................. 3-16
Centerstand and sidestand,
checking and lubricating ...................... 6-27
Clutch lever ........................................... 3-11
Clutch lever free play ............................. 6-21
Conversion table ..................................... 8-5
Coolant level, checking .......................... 6-13DDimmer switch ......................................... 3-9EEngine break-in ....................................... 5-3
Engine idling speed, checking ............... 6-16
Engine oil and oil filter cartridge ............... 6-9
Engine stop switch................................. 3-10
Engine trouble warning light .................... 3-5FFinal gear oil .......................................... 6-12
Front fork, adjusting ............................... 3-19
Front fork, checking ............................... 6-29
Fuel ....................................................... 3-15
Fuel consumption, tips for reducing ......... 5-3
Fuel tank breather hose ......................... 3-16
Fuel tank cap ......................................... 3-14
Fuses, replacing .................................... 6-32HHandlebar switches ................................. 3-9
Hazard switch ........................................ 3-10
Headlight bulb, replacing ....................... 6-33
High beam indicator light ......................... 3-5
Horn switch ............................................. 3-9
IIdentification numbers ..............................9-1
Ignition circuit cut-off system ..................3-24
Immobilizer system..................................3-1
Immobilizer system indicator light.............3-4
Indicator and warning lights......................3-4KKey identification number .........................9-1LLocks for optional side cases and
travel trunk ...........................................3-23MMain switch/steering lock .........................3-2
Model label ..............................................9-2
Multi-function display................................3-7NNeutral indicator light ...............................3-5OOil level warning light ...............................3-5PPanels, removing and installing ................6-5
Parking.....................................................5-4
Part locations ...........................................2-1
Pass switch ..............................................3-9
Periodic maintenance and
lubrication chart .....................................6-2
Pre-operation check list ............................4-1
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