2003 YAMAHA FJR1300A engine coolant

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

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
6-4
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
6-13
65. Install and tighten the filler bolt.
6. Check the final gear case for oil
leakage. If oil is leaking, check for
the cause.
EAU04861
Checking the coolant level The coolant level should be checked as
follows before each ride. In addition,
the coolant must be changed at the in-
tervals specified in the periodic mainte-
nance and lubrication chart.
1. Place the motorcycle on the cen-
terstand.NOTE:_

The coolant level must be checked
on a cold engine since the level
varies with engine temperature.


Make sure that the motorcycle is
positioned straight up when
checking the coolant level. A slight
tilt to the side can result in a false
reading.
_
2. Check the coolant level in the
coolant reservoir.NOTE:_ The coolant should be between the
minimum and maximum level marks. _
Recommended final gear oil:
Shaft drive gear oil
(Part No.: 9079E-SH001-00)
Oil quantity:
0.2 L
1. Maximum level mark
2. Minimum level mark
U5JWE2.book Page 13 Wednesday, November 6, 2002 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6 3. If the coolant is at or below the
minimum level mark, remove the
bolt, the coolant reservoir cap cov-
er and the reservoir cap.
4. Add coolant or distilled water to
raise the coolant to the maximum
level mark, install the coolant res-
ervoir cap, the coolant reservoir
cap cover and the bolt.
EC000080
CAUTION:_

If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.


If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the cool-
ing system will not be protected
against frost and corrosion.


If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
_
EW000067
WARNING
_ Never attempt to remove the radia-
tor cap when the engine is hot. _
NOTE:_

The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.


If the engine overheats, see page
6-38 for further instructions.
_
1. Bolt
2. Coolant reservoir cap cover
3. Coolant reservoir cap
Coolant reservoir capacity
(up to the maximum level mark):
0.25 L
U5JWE2.book Page 14 Wednesday, November 6, 2002 3:32 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
6 Engine overheating
EW000070
WARNING
_

Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.


After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hiss-
ing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
_NOTE:_ If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant
as soon as possible. _
Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.Add coolant. (See NOTE.)
Start the engine. If the engine overheats again,
have a
Yamaha dealer check
and repair the cooling system.
There is
leakage.
There is
no leakage.
U5JWE2.book Page 38 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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