2004 YAMAHA FJR1300A suspension

TABLE OF CONTENTS
Lubricating the rear
suspension ................................ 6-25
Checking the front fork ................. 6-25
Checking the steering ................... 6-26
Checking the wheel bearings ....... 6-26
Battery .......................................... 6-27
Replacing the fuses ...................... 6-28
Replacing a headlight bulb ........... 6-30
Replacing a rear turn signal light
bulb or a tail/brake light bulb ..... 6-31
Replacing an auxiliary light
bulb ........................................... 6-31
Troubleshooting ............................ 6-32
Troubleshooting charts ................. 6-33
MOTORCYCLE CARE AND
STORAGE.......................................... 7-1
Care ................................................ 7-1
Storage ...........................................7-3
SPECIFICATIONS ............................. 8-1
CONSUMER INFORMATION............. 9-1
Identification numbers .................... 9-1
5JWE3.book Page 2 Friday, September 5, 2003 3:08 PM

SAFETY INFORMATION
1-3
1Loading
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit of
FJR1300 201 kg (443 lb)
FJR1300A 194 kg (428 lb). When load-
ing within this weight limit, keep the fol-
lowing in mind:

Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Make
sure to distribute the weight as
evenly as possible on both sides of
the motorcycle to minimize imbal-
ance or instability.


Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories and cargo are securely
attached to the motorcycle before
riding. Check accessory mounts
and cargo restraints frequently.


Never attach any large or heavy
items to the handlebar, front fork,
or front fender. These items, in-
cluding such cargo as sleeping
bags, duffel bags, or tents, can
create unstable handling or a slow
steering response.Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be re-
sponsible for the proper selection, in-
stallation and use of non-Yamaha
accessories. Use extreme caution
when selecting and installing any ac-
cessories.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.

Never install accessories or carry
cargo that would impair the perfor-
mance of your motorcycle. Care-
fully inspect the accessory before
using it to make sure that it does
not in any way reduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or ob-
scure lights or reflectors.
Accessories fitted to the handle-
bar or the front fork area can
create instability due to improper
weight distribution or aerody-
namic changes. If accessoriesare added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become un-
stable in cross winds. These ac-
cessories may also cause
instability when passing or being
passed by large vehicles.
Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.


Use caution when adding electri-
cal accessories. If electrical acces-
sories exceed the capacity of the
motorcycle’s electrical system an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
5JWE3.book Page 3 Friday, September 5, 2003 3:08 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-16
3
WARNING
EWA11421


Do not exceed the load limit of
0.3 kg (0.66 lb) for the accessory
box.


Do not exceed the maximum
load of FJR1300 201 kg (443 lb)
FJR1300A 194 kg (428 lb) for thevehicle.
EAU14731
Adjusting the front fork This front fork is equipped with spring
preload adjusting bolts, rebound damp-
ing force adjusting knobs and compres-
sion damping force adjusting screws.
WARNING
EWA10180
Always adjust both fork legs equal-
ly, otherwise poor handling and lossof stability may result.
Spring preload
To increase the spring preload and
thereby harden the suspension, turn
the adjusting bolt on each fork leg in di-
rection (a). To decrease the spring pre-load and thereby soften the
suspension, turn the adjusting bolt on
each fork leg in direction (b).
NOTE:Align the appropriate groove on the ad-
justing mechanism with the top of thefront fork cap bolt.
1. Spring preload adjusting bolt
1. Current setting
2. Front fork cap boltSpring preload setting:
Minimum (soft):
6
Standard:
4
Maximum (hard):
1
5JWE3.book Page 16 Friday, September 5, 2003 3:08 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
9*WheelsCheck runout and for damage.√√√√
10*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
11*Wheel bearingsCheck bearing for looseness or damage.√√√√
12*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50000 km
13*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20000 km
14*Chassis fastenersMake sure that all nuts, bolts and screws are properly
tightened.√√√√ √
15 Sidestand, centerstandCheck operation.
Lubricate.√√√√ √
16*Sidestand switchCheck operation.√√√√√ √
17*Front forkCheck operation and for oil leakage.√√√√
18*Shock absorber assem-
blyCheck operation and shock absorber for oil leakage.√√√√
19*Rear suspension relay
arm and connecting
arm pivoting pointsCheck operation.√√√√
Lubricate with lithium-soap-based grease.√√
20*Electronic fuel injectionAdjust engine idling speed and synchronization.√√√√√ √
21 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
22Engine oil filter car-
tridgeReplace.√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
5JWE3.book Page 3 Friday, September 5, 2003 3:08 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6
WARNING
EWA11020
Because loading has an enormous
impact on the handling, braking,
performance and safety characteris-
tics of your motorcycle, you should
keep the following precautions in
mind.


NEVER OVERLOAD THE
MOTORCYCLE! Operation of an
overloaded motorcycle may re-
sult in tire damage, loss of con-
trol, or severe injury. Make sure
that the total weight of rider,
passenger, cargo, and accesso-
ries does not exceed the speci-
fied maximum load for the
vehicle.


Do not carry along loosely
packed items, which can shift
during a ride.


Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.


Adjust the suspension and tire
air pressure with regard to the
load.


Check the tire condition and airpressure before each ride.Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
NOTE:The tire tread depth limits may differ
from country to country. Always complywith the local regulations.
Tire air pressure (measured on cold
tires):
0–90 kg (0–198 lb):
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
250 kPa (36 psi) (2.50 kgf/cm²)
FJR1300 90–201 kg (198–443 lb)
FJR1300A 90–194 kg (198–428 lb):
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
290 kPa (42 psi) (2.90 kgf/cm²)
High-speed riding:
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
250 kPa (36 psi) (2.50 kgf/cm²)
Maximum load*:
FJR1300 201 kg (443 lb)
FJR1300A 194 kg (428 lb)
* Total weight of rider, passenger, car-
go and accessories
1. Tire sidewall
2. Tire tread depthMinimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
5JWE3.book Page 16 Friday, September 5, 2003 3:08 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EAU23250
Lubricating the rear
suspension The pivoting points of the rear suspen-
sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU23271
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
WARNING
EWA10750
Securely support the vehicle so thatthere is no danger of it falling over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
CAUTION:
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-pair it.
Recommended lubricant:
Lithium-soap-based grease
5JWE3.book Page 25 Friday, September 5, 2003 3:08 PM

SPECIFICATIONS
8-2
8
5th:
26/28 (0.929)
Chassis:Frame type:
Diamond
Caster angle:
26.0 °
Trail:
109.0 mm (4.29 in)Front tire:Type:
Tubeless
Size:
120/70 ZR17M/C (58W)
Manufacturer/model:
METZELER/MEZ4J FRONT
Manufacturer/model:
BRIDGESTONE/BT020F NRear tire:Type:
Tubeless
Size:
180/55 ZR17M/C (73W)
Manufacturer/model:
METZELER/MEZ4J
Manufacturer/model:
BRIDGESTONE/BT020R NLoading:Maximum load:
FJR1300 201 kg (443 lb)
FJR1300A 194 kg (428 lb)
(Total weight of rider, passenger, cargo and
accessories)
Tire air pressure (measured on cold
tires):Loading condition:
0–90 kg (0–198 lb)
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
250 kPa (36 psi) (2.50 kgf/cm²)
Loading condition:
FJR1300 90–201 kg (198–443 lb)
FJR1300A 90–194 kg (198–428 lb)
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
290 kPa (42 psi) (2.90 kgf/cm²)
High-speed riding:
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
250 kPa (36 psi) (2.50 kgf/cm²)Front wheel:Wheel type:
Cast wheel
Rim size:
17M/C x MT3.50Rear wheel:Wheel type:
Cast wheel
Rim size:
17M/C x MT5.50Front brake:Type:
Dual disc brakeOperation:
Right hand operation
Recommended fluid:
DOT 4
Rear brake:Type:
Single disc brake
Operation:
Right foot operation
Recommended fluid:
DOT 4Front suspension:Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
135.0 mm (5.31 in)Rear suspension:Type:
Swingarm (link suspension)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
125.0 mm (4.92 in)Electrical system:Ignition system:
Transistorized coil ignition (digital)
Charging system:
A.C. magnetoBattery:Model:
GT14B-4
5JWE3.book Page 2 Friday, September 5, 2003 3:08 PM

INDEXAABS (For FJR1300A only) .................... 3-11
ABS warning light
(For FJR1300A only) ............................ 3-4
Accessory box....................................... 3-15
Air filter element, cleaning..................... 6-13
Anti-theft alarm (optional)........................ 3-7
Auxiliary light bulb, replacing ................ 6-31BBattery................................................... 6-27
Brake and clutch fluid levels,
checking ............................................. 6-20
Brake and clutch fluids, changing ......... 6-22
Brake and clutch levers, checking
and lubricating .................................... 6-23
Brake and shift pedals, checking
and lubricating .................................... 6-23
Brake lever ............................................ 3-10
Brake pedal ........................................... 3-11
Brake pedal position, adjusting ............. 6-19CCables, checking and lubricating .......... 6-22
Care ........................................................ 7-1
Catalytic converter ................................ 3-14
Centerstand and sidestand,
checking and lubricating ..................... 6-24
Clutch lever ............................................. 3-9
Clutch lever free play ............................ 6-18
Coolant.................................................. 6-11DDimmer switch ........................................ 3-8EEngine break-in ....................................... 5-3
Engine idling speed, checking .............. 6-14Engine oil and oil filter cartridge ............. 6-8
Engine stop switch.................................. 3-9
Engine trouble warning light ................... 3-4
FFinal gear oil ......................................... 6-10
Front and rear brake pads, checking .... 6-20
Front fork, adjusting .............................. 3-16
Front fork, checking .............................. 6-25
Fuel....................................................... 3-12
Fuel consumption, tips for reducing........ 5-3
Fuel tank breather hose........................ 3-13
Fuel tank cap ........................................ 3-12
Fuses, replacing ................................... 6-28HHandlebar switches ................................ 3-8
Hazard switch ......................................... 3-9
Headlight bulb, replacing ...................... 6-30
High beam indicator light ........................ 3-4
Horn switch ............................................. 3-9IIdentification numbers ............................ 9-1
Ignition circuit cut-off system ................ 3-20
Immobilizer system ................................. 3-1
Immobilizer system indicator light........... 3-4
Indicator and warning lights .................... 3-3KKey identification number ....................... 9-1LLocks for optional side cases and
travel trunk ......................................... 3-19MMain switch/steering lock........................ 3-2
Model label ............................................. 9-2
Multi-function display .............................. 3-6
NNeutral indicator light .............................. 3-4OOil level warning light .............................. 3-4PPanels, removing and installing .............. 6-5
Parking .................................................... 5-4
Part locations .......................................... 2-1
Pass switch ............................................. 3-8
Periodic maintenance and
lubrication chart .................................... 6-2
Pre-operation check list........................... 4-2RRear brake light switch, adjusting ......... 6-19
Rear suspension, lubricating ................. 6-25SSafety information ................................... 1-1
Seats ..................................................... 3-14
Shifting .................................................... 5-2
Shift pedal ............................................. 3-10
Shock absorber assembly, adjusting .... 3-18
Sidestand .............................................. 3-19
Spark plugs, checking ............................. 6-7
Specifications .......................................... 8-1
Speedometer........................................... 3-5
Starting the engine .................................. 5-1
Start switch.............................................. 3-9
Steering, checking................................. 6-26
Storage.................................................... 7-3
Storage compartment............................ 3-15
Swingarm pivots, lubricating ................. 6-24TTachometer ............................................. 3-5
Throttle cable free play, adjusting ......... 6-15
5JWE3.book Page 1 Friday, September 5, 2003 3:08 PM