Yamaha 2003 FJR1300 Service manual

Yamaha 2003 FJR1300 Service manual
2004
FJR1300(S)
FJR1300A(S)
5JW1-AE5
SUPPLEMENTARY
SERVICE MANUAL
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
FJR1300(S)/FJR1300A(S) 2004. For complete service information procedures it is necessary to
use this Supplementary Service Manual together with the following manuals.
FJR1300(N) 2001 SERVICE MANUAL: 5JW1-AE1
FJR1300(P) 2002 SUPPLEMENTARY SERVICE MANUAL: 5JW1-AE2
FJR1300(R)/FJR1300A(R) 2003 SUPPLEMENTARY SERVICE MANUAL: 5JW1-AE4
FJR1300(S)/FJR1300A(S) 2004
SUPPLEMENTARY
SERVICE MANUAL
© 2003 by Yamaha Motor Co., Ltd.
First edition, September 2003
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS00002
NOTICE
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 manual. 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 vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
@
EAS00004
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person checking or repairing the
motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
EAS00007
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.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter.
Refer to “SYMBOLS”.
2 Each chapter is divided into sections. The current section title is shown at the top of each page,
except in chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s)
appears.
3 Sub-section titles appear in smaller print than the section title.
4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6 Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8 Jobs requiring more information (such as special tools and technical data) are described sequentially.
EAS00008
1
2
GEN
INFO
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1 to 9 indicate the subject of each
chapter.
SPEC
3
4
CHK
ADJ
1 General information
2 Specifications
3 Periodic checks and adjustments
4 Chassis
5 Engine
6 Cooling system
7 Fuel injection system
8 Electrical system
9 Troubleshooting
CHAS
5
6
ENG
COOL
7
8
FI
–
ELEC
9
Symbols 0 to G indicate the following.
0
0 Serviceable with engine mounted
A Filling fluid
B Lubricant
C Special tool
D Tightening torque
E Wear limit, clearance
F Engine speed
G Electrical data
TRBL
SHTG
A
B
C
D
+
T.
R.
E
F
G
H
I
J
G
E
K
M
L
B
M
M
LS
N
Symbols H to M in the exploded diagrams
indicate the types of lubricants and lubrication
points.
Symbols N to O in the exploded diagrams
indicate the following.
O
LT
H Engine oil
I Gear oil
J Molybdenum disulfide oil
K Wheel bearing grease
L Lithium soap base grease
M Molybdenum disulfide grease
New
N Apply locking agent (LOCTITE®)
O Replace the part
CONTENTS
GENERAL INFORMATION ..............................................................................1
FEATURES ...............................................................................................1
OUTLINE ...............................................................................................1
FI SYSTEM ...........................................................................................2
SPECIFICATIONS ............................................................................................3
GENERAL SPECIFICATIONS ..................................................................3
ENGINE SPECIFICATIONS ......................................................................3
ELECTRICAL SPECIFICATIONS .............................................................4
PERIODIC CHECKS AND ADJUSTMENTS ....................................................5
INTRODUCTION .......................................................................................5
PERIODIC MAINTENANCE AND LUBRICATION CHART .......................5
SEATS AND FUEL TANK .........................................................................7
FUEL TANK ..........................................................................................7
REMOVING THE FUEL TANK ..............................................................9
AIR FILTER CASE ..................................................................................10
FUEL INJECTION SYSTEM ...........................................................................12
FUEL INJECTION SYSTEM ...................................................................12
WIRING DIAGRAM (FJR1300) ...........................................................13
WIRING DIAGRAM (FJR1300A) .........................................................14
SUBSTITUTE CHARACTERISTICS OPERATION CONTROL
(FAIL-SAFE ACTION) .........................................................................16
THROTTLE BODIES ...........................................................................21
AIR INDUCTION SYSTEM ......................................................................25
INSTALLING THE REED VALVES .....................................................25
ELECTRICAL .................................................................................................26
ELECTRICAL COMPONENTS ...............................................................26
FUEL INJECTION SYSTEM ...................................................................28
CIRCUIT DIAGRAM (FJR1300) ..........................................................28
CIRCUIT DIAGRAM (FJR1300A) .......................................................29
CHECKING THE FUEL PUMP ...........................................................30
FJR1300 WIRING DIAGRAM
FJR1300A WIRING DIAGRAM
FEATURES
GEN
INFO
GENERAL INFORMATION
FEATURES
OUTLINE
The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature.
In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet that
is used in the respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating
conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that
meter the fuel through the use of jets have been provided with various auxiliary devices, so that an
optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases
increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accommodate this need, this model has adopted an electronically controlled fuel injection
(FI) system, in place of the conventional carburetor system. This system can achieve an optimum
air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel
injection volume according to the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine
response, better fuel economy, and reduced exhaust emissions. Furthermore, the air induction system (AI system) has been placed under computer control together with the FI system in order to
realize cleaner exhaust gases.
I
F
E
6 7
4
5
2
3G
JH
1
K C D B 9 8 0 A
1 Ignition coil
2 Air filter case
3 Intake air temperature sensor
4 Fuel delivery hose
5 Fuel tank
6 Fuel pump
7 Intake air pressure
sensor
8 Throttle position sensor
9 Fuel injector
0 O2 sensor
A Catalytic converter
B Crankshaft position
sensor
C Coolant temperature
sensor
D Spark plug
E Cylinder identification sensor
F Battery
G ECU
–1–
H Fuel injection system
relay
I Engine trouble warning light
J Lean angle cut-off
switch
K Air cut-off valve
FEATURES
GEN
INFO
FI SYSTEM
The fuel pump delivers fuel to the injector via the fuel filter. The fuel pump maintains the fuel pressure that is applied to the injector at only 324 kPa (3.24 kg/cm2, 46.08 psi). Accordingly, when the
energizing signal from the ECU energizes the injector, the fuel passage opens, causing the fuel to
be injected into the intake manifold only during the time the passage remains open. Therefore, the
longer the length of time the injector is energized (injection duration), the greater the volume of fuel
that is supplied. Conversely, the shorter the length of time the injector is energized (injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from
the throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake air temperature sensor, coolant temperature sensor, and O2 sensor enable the ECU to determine the
injection duration. The injection timing is determined through the signals from the crankshaft position sensor and the cylinder identification sensor. As a result, the volume of fuel that is required by
the engine can be supplied at all times in accordance with the driving conditions.
Illustration is for reference only.
È
1
#4 #3 #2 #1
0
2
4
3 6
9
5
7
8
1 Fuel pump
2 Fuel injector
3 Throttle body
4 Intake air temperature
sensor
5 Throttle position sensor
6 Intake air pressure
sensor
7 ECU
8 Coolant temperature
sensor
9 O2 sensor
É
A
0 Cylinder identification
sensor
A Crankshaft position
sensor
–2–
È Fuel system
É Control system
GENERAL SPECIFICATIONS/
ENGINE SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Model code
Standard
FJR1300: 5JWG (for Europe)
5JWH (for F)
5JWJ (for Oceania)
FJR1300A: 5VS7 (for Europe)
5VS8 (for F)
5VS9 (for Oceania)
Limit
-------------------
ENGINE SPECIFICATIONS
Item
Fuel pump
Pump type
Model (manufacturer)
Maximum consumption amperage
Output pressure
Throttle bodies
Model (manufacturer) × quantity
Intake vacuum pressure
Throttle cable free play (at the flange
of the throttle grip)
ID mark
Fuel injectors
Model
Manufacturer
Quantity
Standard
Limit
Electric
5JW 21 (DENSO)
6.0 A
324 kPa (3.24 kg/cm2, 46.08 psi)
-------------
42EHS (MIKUNI) × 4
33.3 kPa (250 mmHg, 9.8 inHg)
3 ~ 5 mm (0.12 ~ 0.20 in)
----------
5JW1 50
----
INP-151
NIPPON INJECTOR
4
----------
–3–
ELECTRICAL SPECIFICATIONS
SPEC
ELECTRICAL SPECIFICATIONS
Item
Ignition system
Ignition system type
Ignition timing
Advancer type
Pickup coil resistance/color
Transistorized coil ignition unit model
(manufacturer)
Starting circuit cut-off relay
Model (manufacturer)
Coil resistance
Fuel injection system relay
Model (manufacturer)
Standard
Limit
Transistorized coil ignition (digital)
5° BTDC at 1,050 r/min
Electric
420.8 ~ 569.3 Ω/Gy–B
F8T818 (MITSUBISHI)
F8T819 (MITSUBISHI) (for F)
-------------------
G8R-30Y-R (OMRON)
180 Ω
-------
G8R-30Y-R (OMRON)
----
–4–
INTRODUCTION/
PERIODIC MAINTENANCE AND LUBRICATION CHART
CHK
ADJ
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
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 technical skills.
No.
ITEM
CHECK OR MAINTENANCE JOB
ODOMETER READING (× 1,000 km)
1
10
20
30
40
ANNUAL
CHECK
√
√
√
√
1 * Fuel line
• Check fuel hoses for cracks or damage.
√
2 * Spark plugs
• Check condition.
• Clean and regap.
√
√
• Replace.
3 * Valves
4
Air filter element
√
• Check valve clearance.
• Adjust.
√
Every 40,000 km
√
• Clean.
√
√
• Replace.
√
• Check operation, fluid level and vehicle for fluid
leakage.
√
√
√
√
√
6 * Front brake
• Check operation, fluid level and vehicle for fluid
leakage.
√
√
√
√
√
7 * Rear brake
• Check operation, fluid level and vehicle for fluid
leakage.
5 * Clutch
• Replace brake pads.
Whenever worn to the limit
√
• Replace brake pads.
8 * Brake hoses
√
√
√
√
√
• Check for cracks or damage.
• Replace.
√
√
√
√
√
√
√
10 * Tires
•
•
•
•
√
√
√
√
11 * Wheel bearings
• Check bearing for looseness or damage.
√
√
√
√
• Check operation and for excessive play.
√
√
√
√
14 * Chassis fasteners
√
Every 4 years
• Check runout and for damage.
13 * Steering bearings
√
Whenever worn to the limit
9 * Wheels
12 * Swingarm
√
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
• Lubricate with lithium-soap-based grease.
• Check bearing play and steering for roughness.
Every 50,000 km
√
√
• Lubricate with lithium-soap-based grease.
• Make sure that all nuts, bolts and screws are
properly tightened.
–5–
√
√
√
√
Every 20,000 km
√
√
√
√
√
PERIODIC MAINTENANCE AND LUBRICATION CHART
No.
15
ITEM
CHECK OR MAINTENANCE JOB
CHK
ADJ
ODOMETER READING (× 1,000 km)
1
Sidestand, center- • Check operation.
• Lubricate.
stand
√
10
20
30
40
ANNUAL
CHECK
√
√
√
√
√
√
16 * Sidestand switch
• Check operation.
√
√
√
√
17 * Front fork
• Check operation and for oil leakage.
√
√
√
√
• Check operation and shock absorber for oil leakage.
√
√
√
√
√
√
√
√
18 *
Shock absorber
assembly
19 *
• Check operation.
Rear suspension
relay arm and connecting arm pivot- • Lubricate with lithium-soap-based grease.
ing points
20 *
Electronic fuel
injection
• Adjust engine idling speed and synchronization.
√
√
√
√
√
√
21
Engine oil
• Change.
• Check oil level and vehicle for oil leakage.
√
√
√
√
√
√
22
Engine oil filter
cartridge
• Replace.
√
23 * Cooling system
√
• Check coolant level and vehicle for coolant leakage.
√
√
√
• Change.
√
√
√
√
√
Every 3 years
24
Final gear oil
• Check oil level and vehicle for oil leakage.
• Change.
25 *
Front and rear
brake switches
• Check operation.
26
Moving parts and
cables
• Lubricate.
27 *
• Check operation and free play.
Throttle grip hous• Adjust the throttle cable free play if necessary.
ing and cable
• Lubricate the throttle grip housing and cable.
28 *
Muffler and
exhaust pipe
29 *
Lights, signals and • Check operation.
• Adjust headlight beam.
switches
• Check the screw clamp for looseness.
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
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 the 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.
–6–
SEATS AND FUEL TANK
CHK
ADJ
SEATS AND FUEL TANK
EAS00040
FUEL TANK
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing the fuel tank
Rider seat
Fuel
Fuel tank side panel (left and right)
Bolt
Nut
Fuel sender coupler
Fuel pump coupler
Fuel tank overflow hose
Fuel tank breather hose
Hose holder
Fuel hose holder
Q’ty
1/1
2
1
1
1
1
1
1
1
–7–
Remarks
Remove the parts in the order listed.
Refer to “SEATS AND FUEL TANK” in
chapter 3. (Manual No.: 5JW1-AE1)
Drain.
SEATS AND FUEL TANK
Order
10
Fuel hose
Job/Part
11
12
Bolt
Fuel tank
CHK
ADJ
Q’ty
Remarks
1
Refer to “REMOVING THE FUEL TANK”.
Refer to “INSTALLING THE FUEL
HOSE” in chapter 3. (Manual No.: 5JW1AE1)
1
1
Refer to “REMOVING THE FUEL TANK”.
For installation, reverse the removal
procedure.
–8–
SEATS AND FUEL TANK
a
CHK
ADJ
REMOVING THE FUEL TANK
1. Remove the fuel in the fuel tank through the
fuel tank filler hole with a pump.
2. Remove:
• fuel hose
CAUTION:
Although the fuel has been removed from
the fuel tank, be careful when removing the
fuel hose since there may be fuel remaining
in it.
NOTE:
• To remove the fuel hose from the fuel injection pipe, slide the cover a on the end of the
hose in the direction of the arrow shown, and
then remove the hose.
• Before removing the hose, place a few rags
in the area under the hose.
3. Remove:
• fuel tank
NOTE:
Do not set the fuel tank down on the installation surface of the fuel pump. Be sure to lean
the fuel tank up against a wall, etc., in an
upright position.
–9–
AIR FILTER CASE
CHK
ADJ
EAS00043
AIR FILTER CASE
Order
Job/Part
Removing the air filter case
Seats
Q’ty
Fuel tank
Side covers (left and right)
1
2
3
4
5
6
7
8
9
Air shroud
Air filter case cover
Air filter element
Tray
Fuel tank bracket
Plastic locking tie
Intake air temperature sensor coupler
Bypass air unit inlet hose
Crankcase breather hose
1
1
1
1
1
1
1
1
1
– 10 –
Remarks
Remove the parts in the order listed.
Refer to “SEATS AND FUEL TANK” in
chapter 3. (Manual No.: 5JW1-AE1)
Refer to “SEATS AND FUEL TANK”.
Refer to “COWLINGS AND COVERS”.
(Manual No.: 5JW1-AE2)
Disconnect.
Disconnect.
AIR FILTER CASE
Order
10
11
12
13
Job/Part
Air induction system hose 5
Clamp screw
Air filter case
Air filter case breather hose
CHK
ADJ
Q’ty
Remarks
1
Disconnect.
4
Loosen.
1
1
For installation, reverse the removal
procedure.
– 11 –
FI
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
1 Ignition coil
2 Air filter case
3 Intake air temperature sensor
4 Fuel delivery hose
5 Fuel tank
6 Fuel pump
C Coolant temperature
sensor
D Spark plug
E Cylinder identification sensor
F Battery
G ECU
H Fuel injection system
relay
7 Intake air pressure
sensor
8 Throttle position sensor
9 Fuel injector
0 O2 sensor
A Catalytic converter
B Crankshaft position
sensor
I Engine trouble warning light
J Lean angle cut-off
switch
K Air cut-off valve
F
I
E
6
7
4
5
2
1
K
C
D B
9 8
0
– 12 –
A
3 G
J H
– 13 –
B
L
G/Y
G/Y
A
G/Y
L
A
L
B
å
L
G/Y
L
R/W
R/B
R
Br/L
ON
OFF
P
2
B
B
L/R
Br/R
Br/L
R
G/L BB
B
R/G R/W Y/L
1
R
Br/R
Br/L
Br/L
Br/L
R
Br/L
Br/R
¢
£
§
B
W
W
W
Br/G
Br/G
A
Br/G
Br/G
R/W
R/Y
Br
BB2
BB1
BB3
BB4
BB
B2
3
Br/W
Br/G
BB3 BB2
BB4 BB1
B
B
B
B
B2 B1
B2 BB
R
Br/L
Br/R
®
•
(BLACK)
B
R
W
4
Y
Br
Y
W
R
R
(GRAY)
W
L/R
W
W
W
R
R
R
B/R
R/B
B/R
R/B
Sb B Sb
Lg B Lg
Sb Br/Y R
B Lg Br/R
Sb
Lg
R/B
B/R
B
R Br Sb
Br/R Lg B
Br/Y Br/R
Br/Y
B/R
B/R
R/B
L/R
L/R B
Y
Dg Ch
B L
Y
Ch Dg
Br/W
A
Br/W
Br/W
B
Ch
(BROWN)
Dg
R
B
B
6
5
R
B
(BROWN)
B
Y
Br
B
B
Br
™
B/Y
B/Y
R/Y
R/Y
G/L
Y/B
R/Y A R/Y
R/Y
R/Y
R
B/Y
B/R
¥
R/W
L/W
s
(BLACK) (BLACK)
L/Y
L/Y
i
R
L/W R/W
B L/R
B L/R
L/R B L/R
(BLACK)
G/L
Y
G/B G B
B
L/R
Y
B
B
L/R
B
Y G
G/L
B
B
B
B
Y G
G
G/B
Y/B
G/L
Y/B A Y/B
Y
A
Y
G/B
A
j
R/W
R/B
Dg
Br/W
Ch
R/Y
B
Y
µ
B
Dg
Br/W
Ch
k
W/L
DOWN
UP
l
Lg
B
Dg
OFF
m
F
(BLACK)
Sb
B
Sb/W
Dg
B
Dg
B
E
B
B
Br
Br
(BLUE)
L/G
(BLUE)
Ch
B
Ch
B
n
Sb/W O/W
Dg Ch
Br/W
Br Br
L/Y
R/L
R
G
Sb/W
O/W
B
L/G
L/G
C
Sb/W
B/R
O/W C O/W
O/W
B
Sb
Sb
Sb
Lg
D
Sb
O/W B
B/Y
R/B
L/W
B
W/L
Br/W
Dg Ch
G/B
R/W
L/W
ON
OFF
A
Ch
B
B
R/L B
B
P
P
Y
Y
G/B
G
G
B
B
F
B
B
Dg
Dg
F
Dg
B
G
B
B
Ch
Ch
G
Ch
Br
P
Br
Br B Br
G/W B
(DARK GREEN)
H
SUB-WIRE
HARNESS 3
Br/G L B
Dg
g
W
W
C
W
R/G
C
R/G
G/W
B
G/W
L
Dg
Ch
Y
R/G
G/W
W
R/W
Br/R
[
Lg
A
Lg
F
Gy/G
(BLACK)
Y B/L
M
L
K
L
Y/G
B/L
L
B/L
P/W
B/L
Y
L
B/L
L W/B
L
W/B
B/L
(BLACK)
R/G B2
Br/R
W G/L
R/W G/W Y/L Lg Y Ch Dg L
c
d
e
f
b
a
^
]
\
L Y/G B/L
(BLACK)
P/W B/L L
(BLACK)
L
B/L
W L/Y
J
B/L E B/L
L D L
Y E Y
B2
Y/L
Lg
G/L
B/L
Br/W B/L
B/L
B2 A B2
Y/L C Y/L
G/W B/L
W/B E W/B
P/W E P/W
B/L
Gy/G E Gy/G
SUB-WIRE
HARNESS 2
(BLACK)
WIRE HARNESS
Gy/G Y W/B
B/L P/W
E
W/B Y Gy/G
P/W B/L
(DARK GRAY) (DARK GRAY)
W L
I
SUB-WIRE
HARNESS 3
Br/G L B
Gy/G B/L
SUB-WIRE
HARNESS 1
B
R/B W/L R/L
L/W L/Y R/W L/G B/R Sb B/Y Lg
G
R/L G/W
R L/W
SUB-WIRE
HARNESS 1
Ch
O Coolant temperature sensor
o
P Crankshaft position sensor
o
r
Q ECU (engine)
t
R Cylinder
#1 - injector
S Cylinder #2 - injector
T Cylinder #3 - injector
U Cylinder #4 - injector
V
u Air induction system solenoid
q p
v
w w
WvSpeed
sensor
£ Ignition fuse
¥ Engine stop switch
|
G/Y
8
9
Dg
Y R/Y
Lg L/Y Br/W
B
L/B P Sb B/Y Ch
h
(BLUE)
=
B
B
R
R
B
R
R
R
R/W L/W G/Y
Br B R/B
©
B
Dg
R/Y Y
Br/W B/R Lg
B
Ch B/Y Sb P G/B
R/W A R/W
(BLUE)
R
7
R/G
G/Y W/L R/W
R/B B Br
2 Main switch
†
}
6 Main fuse
7 Battery
8 Fuel injection system fuse
C Fuel
injection system relay
~
H Fuel pump
I O2 sensor
x
J Cylinder identification
sensor
z{
K Throttle position sensor
L Intake air pressure sensory
M Lean angle cut-off switch
N Intake air temperature sensor
Br/Y
B
B
L
Br/B
L
(BLACK) (BLACK)
R/W
Br/B
ç
¶
ß
R/G B2 B
R/W Lg Y/L
Br/B
Br/B
A
Br/B
Br/Y
B BB R/G
Y/L G/L R/W
B
D
Br/W
(BLACK)
O
G/W
(BLACK)
N
Gy
B
Gy
B/L
Gy
SUB-WIRE
HARNESS 2
G/B R/B R/L
L O/B L/B
B/L
P
WIRE HARNESS
R/L R/B G/B
L/B O/B L
C
Br/W
G/W
Y/G
W/Y
Gy/G
W/B
B/L
L
Y
P/W
Gy
R/L
L/Y
R/W
B/Y
B/R
L/W
SUB-WIRE
HARNESS 1
O/W Y/L W
G/L
R/G
WIRE HARNESS
Sb/W G/W Dg B Br/Y
Br L/R Ch Sb Lg
B
SUB-WIRE
HARNESS 1
Br/Y B Dg G/W Sb/W
Lg Sb Ch L/R Br
B/W
B3
Q
R/W
Y/L
Br/R
G/Y
Y/B
O/B
L/B
G/B
R/B
Gy/R
O
(BLACK)
O
R/B
Gy/R
R/B
B/L
W/Y
L
Y
X
W
L/W
Y W/Y
P/W R/W Br/W B/W W/B Gy/G L
R/B G/B L/B O/B
B3 O Gy/R
B/R G/YY/G B/Y R/W Y/L
B/L Y/B L/Y G/W Gy
R/L
Br/R
WIRE HARNESS
W Y/L O/W
R/G
G/L
B/L
W L/Y
Z
Z
B/L
L W/Y
O/B D O/B
L/B D L/B
G/B D G/B
R/B D R/B
WIRE HARNESS
Br/R
O/B
L/B
G/B
U
T
S
R
Br Br/R
Br/R R/W
R/W
(GRAY)
R/LO/B
R/L
(GRAY)
R/L L/B
R/L
(GRAY)
R/LG/B
R/L
(GRAY)
R/L R/B
R/L
SUB-WIRE
HARNESS 1
R/L
D
R/L
Lg Y R/Y
Br/B Y/B
L G/Y B2 R/W Br/G G/B Br/W
V
A
R/B
Y/B Br/B
R/Y Y Lg
Br/W G/B Br/G R/W B2 G/Y L
FUEL INJECTION SYSTEM
FI
WIRING DIAGRAM (FJR1300)
– 14 –
B
L
G/Y
G/Y
A
G/Y
L
A
L
B
©
L
G/Y
L
R/W
R/B
R
Br/L
ON
OFF
P
2
B
B
R
Br/R
Br/L
Br/L
Br/L
R
Br/L
Br/R
µ
º
æ
R
B
W
W
W
Br/W
Br/G
Br/G
A
Br/G
Br/G
R/W
R/Y
Br
BB2
BB1
BB3
BB4
BB
B2
3
Br/W
Br/G
BB3 BB2
BB4 BB1
B
B
B
B
B2 B1
B2 BB
R
Br/L
Br/R
…
ø
(BLACK)
B
¥
L/R
Br/R
Br/L
R
G/L BB
B
R/G R/W Y/L
1
W
4
W
R
R
Y
Br
(GRAY)
W
L/R
W
W
W
R
R
Br/L
Y
R
Sb Br/Y R
B Lg Br/R
B/R
R/B
Sb B Sb
Lg B Lg
B/R
R/B
Sb
Lg
R/B
B/R
B
R Br Sb
Br/R Lg B
Br/Y Br/R
Br/Y
B/R
B/R
R/B
L/R
L/R B
Y
Dg Ch
B L
Y
Ch Dg
Br/W
A
Br/W
B
Ch
(BROWN)
Dg
7
6
5
B
B
(BROWN)
Y
Br
B
G/Y
B
¶
Br
B/Y
B/Y
B/Y
B/R
L/R
Y/B
Y/B
G/L
Y/B A Y/B
}
Y
A
Y
G/B
A
t
R/W
R/B
Dg
Br/W
Ch
R/Y
B
Y
›
B
Dg
Br/W
Ch
u
W/L
DOWN
UP
v
Lg
B
Dg
OFF
w
H
(BLACK)
Sb
Sb/W
B
Dg
B
Dg
B
G
B
B
Br
Br
(BLUE)
L/G
(BLUE)
Ch
B
Ch
y
x
Sb/W O/W
Dg Ch
Br/W
Br Br
L/Y
R/L
R
I
Sb/W
O/W
B
L/G
L/G
E
Sb/W
B/R
O/W C O/W
O/W
B
Sb
Sb
Sb
Lg
F
Sb
O/W B
B/Y
R/B
L/W
D
W/L
Br/W
Dg Ch
G/B
R/W
ON
OFF
C
L/W
B
R/L B
B
B
Ch
Br
P
P
Br B Br
G/W B
B L/R
B L/R
L/R B L/R
(BLACK)
B
L/R
B
B
Y G
G/L
B
B
B
B
Y G
G
G/B
Y
Y
G/B
G
G
B
Dg
F
Dg
B
F
B
B
Dg
Ch
G
Ch
B
G
B
B
Ch
B
Br
P
q
W
W
C
W
R/G
C
R/G
G/W
B
G/W
Y
R/G
G/W
W
R/W
Br/R
f
Lg
L
Dg
Ch
W L
K
Y B/L
O
N
l
L
Y/G
B/L
L
B/L
P/W
B/L
Y
L
(BLACK)
R/G B2 G/R Br/R
W G/L
R/W G/W Y/L Lg Y Ch Dg L
m
n
o
p
B/L
L W/B
L
W/B
B/L
M
k
h
i
j
g
L Y/G B/L
(BLACK)
P/W B/L L
(BLACK)
L
B/L
W L/Y
L
B/L
B2
Y/L
G/R
Lg
G/L
P/W E P/W
B/L E B/L
L D L
Y E Y
(BLACK)
Y/L C Y/L
B2 A B2
Q
Gy
G/W
B/L
R
Br/W
(BLACK)
P
G/R C G/R
G/W B/L
B/L
Br/W B/L
B/L
Gy
B
Gy
B/L
WIRE HARNESS
R/B
Gy/R
R/B
O
WIRE HARNESS
SUB-WIRE
HARNESS 1
(BLACK)
O/W Y/L W
G/L G/R R/G
WIRE HARNESS
Sb/W G/W Dg B Br/Y
Br L/R Ch Sb Lg
B
d
c
W1 B1
Sb B
Lg W/R
Br/W
G/W
Y/G
W/Y
Gy/G
W/B
B/L
L
Y
P/W
Gy
R/L
L/Y
R/W
B/Y
B/R
L/W
Gy W
b
B
a
B/W
Sb
Lg
e
e
B1
W1
B/W
R/L
L/W Y Br/W
Y/L
Br/R
G/Y
Y/B
B2 W1 Sb
B1 G/R Lg
R/W
W/R
B3
S
O/B
L/B
G/B
R/B
Gy/R
O
(BLACK)
Sb
Lg
Z
B
R/L
Sb
Lg
Y
B1
W1
B2
R/L
B/W
G/R
Br/W
L/W
Sb W1 B2
Lg G/R B1
Br/W Y L/W
Y
B1
W1
B2
R/L
B/W
G/R
Br/W
L/W
B/L
W/Y
L
Y
B1
W1
B2
Br/W
L/W
Sb
Lg
W/R
Lg
Br/W
Y
Ch
B5
B4 Sb
[
R/W
Y
B2 W1
B1
B4
B5
W
G
P/W
R/W
W/B
B3
W2
B/L
L W/Y
W
V
U
T
W2
B3
P/W
B
Br/W
\
Gy W
W
Dg
R/W
(GRAY)
R/LO/B
R/L
(GRAY)
R/L L/B
R/L
(GRAY)
R/LG/B
R/L
(GRAY)
R/L R/B
R/L
SUB-WIRE
HARNESS 1
B
G
R R
R
B
^
R/W
R/W
W/B
R/L
Br/G L B
SUB-WIRE
HARNESS 3
R
W
W
B
R
R
B R/W
R R
G W
R B R/W W/B
P/W Br/W G/R R/L
]
R/L
D
R/L
F
SUB-WIRE
HARNESS 1
Lg Y R/Y
Br/B Y/B
L G/Y B2 R/W Br/G G/B Br/W
W2 B3
A
G/R
Br/R R/W
Br Br/R
X
O/B
L/B
G/B
Br/R
O/B D O/B
L/B D L/B
G/B D G/B
R/B
SUB-WIRE
HARNESS 3
Br/G L B
R/B D R/B
SUB-WIRE
HARNESS 1
B
G
WIRE HARNESS
Y/B Br/B
R/Y Y Lg
Br/W G/B Br/G R/W B2 G/Y L
L/W W/B P/W W/R
G
W
B/L
W L/Y
SUB-WIRE
HARNESS 1
Br/Y B Dg G/W Sb/W
Lg Sb Ch L/R Br
L/W
Y W/Y
P/W R/W Br/W B/W W/B Gy/G L
R/B G/B L/B O/B
B3 O Gy/R
B/R G/YY/G B/Y R/W Y/L
B/L Y/B L/Y G/W Gy
R/L
Br/R
SUB-WIRE
HARNESS 2
WIRE HARNESS
C
(BLACK)
W Y/L O/W
R/G G/R G/L
(BLACK)
G/B R/B R/L
L O/B L/B
SUB-WIRE
HARNESS 2
D
(BLACK)
R/L R/B G/B
L/B O/B L
Gy/G Y W/B
B/L P/W
E
W/B Y Gy/G
P/W B/L
W/B E W/B
Gy/G E Gy/G
(DARK GRAY) (DARK GRAY)
Lg
A
Gy/G
Gy/G B/L
R/B W/L R/L
L/W L/Y R/W L/G B/R Sb B/Y Lg
(DARK GREEN)
J
R/L G/W
R L/W
Q Coolant temperature sensor
y
R Crankshaft |position sensor
~
S ECU
(engine)
T Cylinder #1 - injector
U Cylinder #2 - injector
V Cylinder #3 - injector
Wå çCylinder
#4 - injector{ z
ç
† †
X Air induction system solenoid
Y Speed sensor
º Ignition fuse
‹ Engine stop switch
Y
B
R/Y
G/L
R/Y
R/Y
‹
R/W
(BLACK) (BLACK)
L/Y
s
R
L/W R/W
R
L/W
R
R/L
L/Y
R/Y A R/Y
R/Y
0
A
¤
R
R/L
Dg
Y R/Y
Lg L/Y Br/W
B
L/B P Sb B/Y Ch
r
(BLUE)
G/L
Y
G/B G B
Dg
R/Y Y
Br/W B/R Lg
B
Ch B/Y Sb P G/B
R/W A R/W
(BLUE)
B
B
B
R
B
R
R
R/L
R
8
R
R/W L/W G/Y
Br B R/B
Õ
B/W B
B
B/W
9
R
R/G
Br/W
G/Y W/L R/W
R/B B Br
B
B/W
ß
2 Main switch
7 Main fuse
9 Battery
®
0 Fuel
injection system fuse
E Fuel injection system relay
J Fuel pump
¢
K O2 sensor
§•
L Cylinder identification sensor
£
M Throttle position sensor
N Intake air pressure sensor
O Lean angle cut-off switch
P Intake air temperature sensor
Br/Y
B
B
L
Br/B
L
(BLACK) (BLACK)
R/W
Br/B
™
¡
¬
R/G B2 B
R/W Lg Y/L
Br/B
Br/B
A
Br/B
Br/Y
B BB R/G
Y/L G/L R/W
FUEL INJECTION SYSTEM
FI
WIRING DIAGRAM (FJR1300A)
FUEL INJECTION SYSTEM
FI
* Table of self-diagnostic fault code numbers displayed on meter
No.
11
12
13
Symptom
No normal signals are received
from the cylinder identification
sensor.
No normal signals are received
from the crankshaft position sensor.
Intake air pressure sensor - open
or short circuit detected.
Able/
unable to
start
Able/
unable to
drive
Unable
Unable
31
The amount of air-fuel ratio feedback compensation is maintained
continuously in the vicinity of the
upper limit (lean air-fuel ratio).
Able
Able
Able
Able
Able/
unable to
start
Able/
unable to
drive
No.
Able
Able
30
Symptom
The motorcycle has overturned.
Unable
Unable
Able
Able
32
The amount of air-fuel ratio feedback compensation is maintained
continuously in the vicinity of the
lower limit (rich air-fuel ratio).
14
Faulty intake air pressure sensor
pipe system; a hose is detached
or clogged.
Able
Able
33
Open circuit detected in the primary wire of the ignition coil
(#1,4).
Able
Able
15
Throttle position sensor - open or
short circuit detected.
Able
Able
34
Open circuit detected in the primary wire of the ignition coil (#2, 3).
Able
Able
16
A stuck throttle position sensor is
detected.
Able
Able
41
Lean angle cut-off switch - open
or short circuit detected.
Unable
Unable
Able
Able
19
A break or disconnection of the
black/red lead of the ECU is
detected.
Unable
Unable
42
No normal signals are received
from the speed sensor; or, an
open or short circuit is detected in
the neutral switch.
21
Coolant temperature sensor open or short circuit detected.
Able
Able
43
The ECU is unable to monitor the
battery voltage (an open circuit in
the line to the ECU).
Able
Able
22
Intake air temperature sensor open or short circuit detected.
Able
Able
44
An error is detected while reading
or writing on EEPROM (CO
adjustment value).
Able
Able
50
Faulty ECU memory. When this
malfunction is detected, the code
number might not appear on the
meter.
Unable
Unable
24
No normal signals are received
from the O2 sensor.
Able
Able
• How to erase the self-diagnostic fault code from memory:
If the ECU detects a normal signal upon the completion of the repair of the malfunction, the selfdiagnostic fault code disappears from the meter and is replaced by the normal clock display. However, the self-diagnostic fault code of the previous malfunction remains in the ECU memory as
part of the malfunction history. To erase the self-diagnostic fault code from the malfunction history,
the operation for diagnostic code 62 must be performed in the diagnosis mode.
– 15 –
FUEL INJECTION SYSTEM
FI
SUBSTITUTE CHARACTERISTICS OPERATION CONTROL (FAIL-SAFE ACTION)
If the ECU detects an abnormal signal from a sensor while the motorcycle is being driven, the ECU
illuminates the engine trouble warning light and provides the engine with substitute characteristic
operation instructions that are appropriate for the type of the malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that
are programmed for every sensor, in order to provide the engine with substitute characteristics
operation instructions that enable the engine to continue to operate (or to stop its operation,
depending on circumstances).
The ECU takes fail-safe actions in two ways: one in which the sensor output is set to a prescribed
value, and the other in which the ECU directly operates an actuator. Details on the fail-safe actions
are given in the table below.
Table of substitute characteristic operation control by self-diagnostic fault code
Fail-safe action
Able/unable to
start
Able/unable to
drive
Cylinder identification
sensor
Continues to operate the engine based on the results
of the cylinder identification that existed up to that
point.
Able
Able
12
Crankshaft position sensor
• Stops the engine (by stopping the injection and
ignition).
Unable
Unable
13
14
Intake air pressure sensor
(open or short circuit)
(pipe system)
• Fixes the intake air pressure to 760 mmHg.
Able
Able
15
16
Throttle position sensor
(open or short circuit)
(stuck)
• Fixes the throttle position sensor to fully open.
Able
Able
19
Broken or disconnected
black/red lead of the ECU.
-- (No start)
Unable
Unable
21
Coolant temperature sensor
• Fixes the coolant temperature to 60 °C.
Able
Able
22
Intake air temperature
sensor
• Fixes the intake temperature to 20 °C.
Able
Able
--
24
31
32
O2 sensor
(inactive)
(compensation stuck to
upper limit)
(compensation stuck to
lower limit)
Able
Able
Faulty ignition
• Fuel is cut off only to the cylinder in which a malfunction is detected.
Able
(depending on
the number of
faulty cylinders)
Able
(depending on
the number of
faulty cylinders)
30
41
Lean angle cut-off switch
(latch up detected)
(open or short circuit)
• Turns OFF the fuel injection system relay of the fuel
system.
Unable
Unable
42
Speed sensor, neutral
switch
• Fixes the gear to the top gear.
Able
Able
43
Fuel system voltage
(monitor voltage)
• Fixes the battery voltage to 12 V.
Able
Able
Error in writing the
amount of CO adjustment on EEPROM
--
44
Able
Able
50
ECU internal malfunction
(memory check error)
--
Unable
Unable
Code No.
11
Item
33
34
– 16 –
FUEL INJECTION SYSTEM
FI
Self-diagnostic fault codes, symptoms, and probable causes
Diagnostic code indication
Code No.
Symptom
No normal signals are received from
the cylinder identification sensor.
Open or short circuit in wiring sub lead.
Open or short circuit in wiring harness.
Defective cylinder identification sensor.
Malfunction in ECU.
Improperly installed sensor.
—
•
•
•
•
•
Open or short circuit in wiring harness.
Defective crankshaft position sensor.
Malfunction in pickup rotor.
Malfunction in ECU.
Improperly installed sensor.
—
Intake air pressure sensor - open or
short circuit detected.
•
•
•
•
Open or short circuit in wiring sub lead.
Open or short circuit in wiring harness.
Defective intake air pressure sensor.
Malfunction in ECU.
03
Faulty intake air pressure sensor pipe
system; a hose is detached or
clogged.
• Intake air pressure sensor hose is detached, clogged,
kinked, or pinched.
• Malfunction of the intake air pressure sensor in the intermediate electrical potential.
• Malfunction in ECU.
03
Or, intake air pressure sensor - open
or short circuit detected.
•
•
•
•
03
Or, a stuck throttle position sensor is
detected.
• Open or short circuit in wiring sub lead.
• Open or short circuit in wiring harness.
• Defective sensor (stuck throttle position sensor).
01
Throttle position sensor - open or
short circuit detected.
•
•
•
•
•
01
No normal signals are received from
the crankshaft position sensor.
12
14
15
16
19
21
22
Diagnostic code
•
•
•
•
•
11
13
Probable cause of malfunction
Open or short circuit in wiring sub lead.
Open or short circuit in wiring harness.
Defective intake air pressure sensor.
Malfunction in ECU.
Open or short circuit in wiring sub lead.
Open or short circuit in wiring harness.
Defective throttle position sensor.
Malfunction in ECU.
Improperly installed throttle position sensor.
A stuck throttle position sensor is
detected.
Or,
Faulty intake air pressure sensor pipe
system; a hose is detached or
clogged.
•
•
•
•
Open or short circuit in wiring sub lead.
Open or short circuit in wiring harness.
Defective sensor (stuck throttle position sensor).
Intake air pressure sensor hose is detached, clogged,
kinked, or pinched.
• Malfunction of the intake air pressure sensor in the intermediate electrical potential.
• Malfunction in ECU.
01
03
A break or disconnection of the black/
red of the ECU is detected when the
start switch is pressed.
• Open circuit in wiring harness.
• Malfunction in ECU.
• Defective ECU coupler.
20
Coolant temperature sensor - open or
short circuit detected.
•
•
•
•
Open or short circuit in wiring harness.
Defective coolant temperature sensor.
Malfunction in ECU.
Improperly installed sensor.
06
Intake air temperature sensor - open
or short circuit detected.
•
•
•
•
Open or short circuit in wiring harness.
Defective intake air temperature sensor.
Malfunction in ECU.
Improperly installed sensor.
05
– 17 –
FUEL INJECTION SYSTEM
Code No.
Symptom
FI
Probable cause of malfunction
Diagnostic code
No normal signals are received from
the O2 sensor.
•
•
•
•
The motorcycle has overturned.
• Overturned.
• Malfunction in ECU.
08
The amount of air-fuel ratio feedback
compensation is maintained continuously in the vicinity of the upper limit
(lean air-fuel ratio).
•
•
•
•
•
•
Open or short circuit in wiring harness.
Fuel pressure too low.
Clogged injectors.
Defective O2 sensor (unable to output a rich signal).
Malfunction in ECU.
Malfunction in other areas of the fuel system.
—
The amount of air-fuel ratio feedback
compensation is maintained continuously in the vicinity of the lower limit
(rich air-fuel ratio).
•
•
•
•
•
•
Open or short circuit in wiring harness.
Fuel pressure too high.
Faulty injectors (excessive injection volume).
Defective O2 sensor (unable to output a lean signal).
Malfunction in ECU.
Malfunction in other areas of the fuel system.
—
Open circuit is detected in the primary
wire of the ignition coil (#1, 4).
•
•
•
•
Open or short circuit in wiring harness.
Malfunction in ignition coil.
Malfunction in ECU.
Malfunction in a component of ignition cutoff circuit system.
30
Open circuit is detected in the primary
wire of the ignition coil (#2, 3).
•
•
•
•
Open or short circuit in wiring harness.
Malfunction in ignition coil.
Malfunction in ECU.
Malfunction in a component of ignition cutoff circuit system.
31
Lean angle cut-off switch - open or
short circuit detected.
• Open or short circuit in wiring harness.
• Defective lean angle cut-off switch.
• Malfunction in ECU.
08
No normal signals are received from
the speed sensor; or, an open or
short circuit is detected in the neutral
switch.
•
•
•
•
•
•
07
21
43
The ECU is unable to monitor the battery voltage (an open circuit in the
monitor line to the ECU).
• Open circuit in wiring harness.
• Malfunction in ECU.
44
An error is detected while reading or
writing on EEPROM.
• Malfunction in ECU. (The CO adjustment value is not properly written on or read from the internal memory).
50
Faulty ECU memory. When this malfunction is detected, the code number
might not appear on the meter.
• Malfunction in ECU. (The program and data are not properly
written on or read from the internal memory.)
24
30
31
32
33
34
41
42
Open or short circuit in wiring harness.
Defective O2 sensor.
Malfunction in ECU.
Improperly installed sensor.
Open or short circuit in wiring harness.
Defective speed sensor.
Malfunction in vehicle speed sensor detected unit.
Defective neutral switch.
Malfunction in the engine side of the neutral switch.
Malfunction in ECU.
– 18 –
—
—
60
—
FI
FUEL INJECTION SYSTEM
Sensor operation data display verification table
NOTE:
• Check the intake air temperature and coolant temperature as close as possible to the area in
which the respective sensor is mounted.
• If it is not possible to check the intake temperature, use the ambient temperature as reference
(use the compared values for reference).
Diag code
Item
Description of action
Data displayed on meter
(reference value)
Throttle angle
Displays the throttle angle.
• Check with throttle fully closed.
• Check with throttle fully open.
0 ~ 125 degrees
• Fully closed position (15 ~ 17)
• Fully open position (97 ~ 100)
Pressure difference
(atmospheric pressure - intake air pressure)
Displays the pressure difference (atmospheric pressure intake air pressure).
Engine stop switch is on.
* Generate the pressure difference by cranking the engine
with the starter, without actually starting the engine.
Before cranking: Atmospheric
pressure (standard pressure is
760 mmHg)
After cranking: Value is lower
than the atmospheric pressure
Intake air temperature
Displays the intake air temperature.
* Check the temperature in the air cleaner case.
Compare it to the value displayed on the meter.
Coolant temperature
Displays the coolant temperature.
* Check the temperature of the coolant.
Compare it to the value displayed on the meter.
Vehicle speed pulse
Displays the accumulation of the vehicle pulses that are generated when the tire is spun.
(0 ~ 999; resets to 0 after 999)
OK if the numbers appear on
the meter.
08
Lean angle cut-off
switch
Displays the lean angle cut-off switch values.
Upright: 0.4 ~ 1.4 V
Overturned: 3.8 ~ 4.2 V
09
Fuel system voltage
(battery voltage)
Displays the fuel system voltage (battery voltage).
Engine stop switch is on.
0 ~ 18.7 V
Normally, approximately 12.0 V
Sidestand switch
Displays that the switch is ON or OFF. (When the gear is in a
position other than neutral.)
Stand retracted: ON
Stand extended: OFF
Neutral switch
Displays that the switch is ON or OFF.
Neutral: ON
In gear: OFF
E2PROM fault code
display
• Transmits the abnormal portion of the data in the E2PROM
that has been detected as a self-diagnostic fault code 44.
• If multiple malfunctions have been detected, different codes
are displayed at 2-second intervals, and this process is
repeated.
(01 ~ 04) Displays the cylinder
number.
(00) Displays when there is no
malfunction.
Malfunction history
code display
• Displays the codes of the history of the self-diagnosis malfunctions (i.e., a code of a malfunction that occurred once
and which has been corrected).
• If multiple malfunctions have been detected, different codes
are displayed at 2-second intervals, and this process is
repeated.
11 ~ 50
(00) Displays when there is no
malfunction.
Malfunction history
code erasure
• Displays the total number of codes that are being detected
through self diagnosis and the fault codes in the past history.
• Erases only the history codes when the engine stop switch
is turned from OFF to ON. If the engine stop switch is ON,
turn it OFF once, and then turn it back ON.
00 ~ 21
(00) Displays when there is no
malfunction.
Control number
• Displays the program control number.
00 ~ 255
01
03
05
06
07
20
21
60
61
62
70
– 19 –
FUEL INJECTION SYSTEM
FI
Troubleshooting details
Troubleshooting the self-diagnostic fault code
Code No.
19
Symptom A break or disconnection of the black/red lead of the ECU is detected.
Used diagnostic code No. 20 (sidestand switch)
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
Defective sidestand switch
Replace if defective.
If the transmission
Refer to “CHECKING THE SWITCHES” in
is in gear, it is reinchapter 8. (Manual No.: 5JW1-AE1)
stated by retracting
the sidestand.
Open circuit in wiring harness or sub lead.
Repair or replace if there is an open circuit.
If the transmission
(Between ECU and black/red lead)
Connected state of connector
If there is a malfunction, repair it and connect it is in neutral, it is
reinstated by
Inspect the coupler for any pins that may
securely.
reconnecting the
have pulled out.
Main wiring harness ECU coupler
wiring.
Check the locking condition of the coupler.
(black/red)
– 20 –
FUEL INJECTION SYSTEM
FI
THROTTLE BODIES
7
7
5
3
5
5
5
10
10
10
10
6
4
2
8
1
9
Order
Job/Part
Removing the throttle bodies
Seats/T-bar/rubber sheet
Q’ty
Fuel tank
Air filter case
Coolant
1
2
3
4
5
6
O2 sensor coupler
Cylinder identification sensor coupler
Sub-wire harness 2 coupler
Throttle stop screw
Throttle body joint clamp screw
Throttle bodies
1
1
2
1
8
1
– 21 –
Remarks
Remove the parts in the order listed.
Refer to “SEATS AND FUEL TANK” in
chapter 3. (Manual No.: 5JW1-AE1)
Refer to “SEATS AND FUEL TANK”.
Refer to “AIR FILTER CASE”.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3. (Manual No.: 5JW1-AE1)
Disconnect.
Disconnect.
Disconnect.
FUEL INJECTION SYSTEM
FI
7
7
5
3
5
5
5
10
10
10
10
6
4
2
8
1
9
Order
7
8
9
10
Job/Part
Throttle cable
Plunger control unit hose 1
Plunger control unit hose 2
Throttle body joint
Q’ty
Remarks
2
Disconnect.
1
Disconnect.
1
Disconnect.
4
For installation, reverse the removal
procedure.
– 22 –
FI
FUEL INJECTION SYSTEM
2
3
7
4
5
11
6
1
10
8
9
12
10
13
14
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the injectors
Throttle position sensor coupler
Intake air pressure sensor coupler
Cylinder #1-injector coupler
Cylinder #2-injector coupler
Cylinder #3-injector coupler
Cylinder #4-injector coupler
Sub-wire harness 2
Negative pressure hose
Bypass air unit
Bypass air unit outlet hose
Q’ty
1
1
1
1
1
1
1
1
1
4
– 23 –
10
Remarks
Remove the parts in the order listed.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
FI
FUEL INJECTION SYSTEM
2
3
7
4
5
11
6
1
10
8
9
12
10
13
14
Order
11
12
13
14
Job/Part
Intake air pressure sensor
Fuel injection pipe
Injector
Throttle position sensor
Q’ty
1
1
4
1
10
Remarks
For installation, reverse the removal
procedure.
– 24 –
AIR INDUCTION SYSTEM
FI
AIR INDUCTION SYSTEM
a
INSTALLING THE REED VALVES
1. Install:
• plate 1
b
1
NOTE:
Align the notch a in each plate with the projection b of each reed valve seat on the cylinder head cover.
– 25 –
ELECTRICAL COMPONENTS
ELEC
–
+
EAS00729
ELECTRICAL
ELECTRICAL COMPONENTS
1 Windshield drive unit
2 Battery
3 Starter relay
4 Fuel injection system fuse
5 Front brake light switch
6 Clutch switch
7 Fuse box
8 Radiator fan motor
9 Wire harness
0 Neutral switch
A Sidestand switch
B Oil level switch
C Rear brake light switch
D Horn
– 26 –
E Ignition coil
F Main fuse
G ABS motor fuse (FJR1300A)
ELECTRICAL COMPONENTS
1 Coolant temperature sensor
2 Intake air pressure sensor
3 Intake air temperature sensor
4 Relay unit
5 Lean angle cut-off switch
6 Hydraulic unit (FJR1300A)
7 Fail-safe relay (FJR1300A)
8 ECU (engine)
9 ECU (ABS) (FJR1300A)
0 Speed sensor
A Cylinder identification sensor
B O2 sensor
C Crankshaft position sensor
– 27 –
ELEC
–
D Accessory box solenoid
E Accessory box relay
F Headlight relay 1
G Radiator fan motor relay
H Turn signal relay
I Headlight relay 2
+
– 28 –
B
L
G/Y
G/Y
A
G/Y
L
A
L
B
å
L
G/Y
L
R/W
R/B
R
Br/L
ON
OFF
P
2
B
B
L/R
Br/R
Br/L
R
G/L BB
B
R/G R/W Y/L
1
R
Br/R
Br/L
Br/L
Br/L
R
Br/L
Br/R
¢
£
§
B
W
W
W
Br/G
Br/G
A
Br/G
Br/G
R/W
R/Y
Br
BB2
BB1
BB3
BB4
BB
B2
3
Br/W
Br/G
BB3 BB2
BB4 BB1
B
B
B
B
B2 B1
B2 BB
R
Br/L
Br/R
®
•
(BLACK)
B
R
W
4
Y
Br
Y
W
R
R
(GRAY)
W
L/R
W
W
W
R
R
R
B/R
R/B
B/R
R/B
Sb B Sb
Lg B Lg
Sb Br/Y R
B Lg Br/R
Sb
Lg
R/B
B/R
B
R Br Sb
Br/R Lg B
Br/Y Br/R
Br/Y
B/R
B/R
R/B
L/R
L/R B
Y
Dg Ch
B L
Y
Ch Dg
Br/W
A
Br/W
Br/W
B
Ch
(BROWN)
Dg
R
B
B
6
5
R
B
(BROWN)
B
Y
Br
B
B
G/Y
Br
™
B/Y
B/Y
R/Y A R/Y
R/Y
R/Y
R
B/Y
B/R
¥
R/W
L/W
(BLACK) (BLACK)
L/Y
L/Y
i
R
L/W R/W
Y
G/B
A
j
R/W
R/B
Dg
Br/W
Ch
R/Y
B
Y
µ
B
Dg
Br/W
Ch
k
W/L
DOWN
UP
l
Lg
B
Dg
OFF
m
F
(BLACK)
Sb
B
Sb/W
Dg
B
Dg
B
E
B
B
Br
Br
(BLUE)
L/G
(BLUE)
Ch
B
Ch
B
n
Sb/W O/W
Dg Ch
Br/W
Br Br
L/Y
R/L
R
G
Sb/W
O/W
B
L/G
L/G
C
Sb/W
B/R
O/W C O/W
O/W
B
Sb
Sb
Sb
Lg
D
Sb
O/W B
B/Y
R/B
L/W
B
W/L
Br/W
Dg Ch
G/B
R/W
L/W
ON
OFF
A
B L/R
B L/R
L/R B L/R
(BLACK)
R/Y
B
L/R
Y
B
R/Y
G/L
B
L/R
Y/B
B
Y G
G/L
B
B
B
B
Y G
G
G/B
Y/B
G/L
Y/B A Y/B
A
Y
Y
Y
G/B
G
G
B
B
F
B
B
Dg
Dg
F
Dg
B
G
B
B
Ch
Ch
G
Ch
Ch
Ch
B
B
R/L B
B
Br
P
Br
P
P
Br B Br
G/W B
(DARK GREEN)
H
SUB-WIRE
HARNESS 3
Br/G L B
Dg
g
W
W
C
W
R/G
C
R/G
G/W
B
G/W
L
Dg
Ch
Y
R/G
G/W
W
R/W
Br/R
[
Lg
A
Lg
F
Gy/G
(BLACK)
Y B/L
M
L
K
L
Y/G
B/L
L
B/L
P/W
B/L
Y
L
B/L
L W/B
L
W/B
B/L
(BLACK)
R/G B2
Br/R
W G/L
R/W G/W Y/L Lg Y Ch Dg L
c
d
e
f
b
a
^
]
\
L Y/G B/L
(BLACK)
P/W B/L L
(BLACK)
L
B/L
W L/Y
J
B/L E B/L
L D L
Y E Y
B2
Y/L
Lg
G/L
B/L
Br/W B/L
B/L
B2 A B2
Y/L C Y/L
G/W B/L
W/B E W/B
P/W E P/W
B/L
Gy/G E Gy/G
SUB-WIRE
HARNESS 2
(BLACK)
WIRE HARNESS
Gy/G Y W/B
B/L P/W
E
W/B Y Gy/G
P/W B/L
(DARK GRAY) (DARK GRAY)
W L
I
SUB-WIRE
HARNESS 3
Br/G L B
Gy/G B/L
SUB-WIRE
HARNESS 1
B
R/B W/L R/L
L/W L/Y R/W L/G B/R Sb B/Y Lg
G
R/L G/W
R L/W
SUB-WIRE
HARNESS 1
s
O
Coolant
temperature sensor
|
o
P Crankshaft position sensor
o
Q ECU (engine)r
t
R Cylinder
#1 - injector
S Cylinder #2 - injector
T Cylinder #3 - injector
U Cylinder #4 - injector
VuAir induction system solenoid
q p
vv
w w
W Speed
sensor
£ Ignition fuse
¥ Engine stop switch
G/L
Y
G/B G B
8
9
Dg
Y R/Y
Lg L/Y Br/W
B
L/B P Sb B/Y Ch
h
(BLUE)
=
B
B
R
R
B
R
R
R
R/W L/W G/Y
Br B R/B
©
B
Dg
R/Y Y
Br/W B/R Lg
B
Ch B/Y Sb P G/B
R/W A R/W
(BLUE)
R
7
R/G
G/Y W/L R/W
R/B B Br
2 Main switch
†
}
6 Main fuse
7 Battery
8 Fuel injection system fuse
C Fuel
injection system relay
~
H Fuel pump
I O2 sensor
x sensor
J Cylinder identification
z{
K Throttle position sensor
L Intake air pressure sensory
M Lean angle cut-off switch
N Intake air temperature sensor
Br/Y
B
B
L
Br/B
L
(BLACK) (BLACK)
R/W
Br/B
ç
¶
ß
R/G B2 B
R/W Lg Y/L
Br/B
Br/B
A
Br/B
Br/Y
B BB R/G
Y/L G/L R/W
B
D
Br/W
(BLACK)
O
G/W
(BLACK)
N
Gy
B
Gy
B/L
Gy
SUB-WIRE
HARNESS 2
G/B R/B R/L
L O/B L/B
B/L
P
WIRE HARNESS
R/L R/B G/B
L/B O/B L
C
Br/W
G/W
Y/G
W/Y
Gy/G
W/B
B/L
L
Y
P/W
Gy
R/L
L/Y
R/W
B/Y
B/R
L/W
SUB-WIRE
HARNESS 1
O/W Y/L W
G/L
R/G
WIRE HARNESS
Sb/W G/W Dg B Br/Y
Br L/R Ch Sb Lg
B
SUB-WIRE
HARNESS 1
Br/Y B Dg G/W Sb/W
Lg Sb Ch L/R Br
B/W
B3
Q
R/W
Y/L
Br/R
G/Y
Y/B
O/B
L/B
G/B
R/B
Gy/R
O
(BLACK)
O
R/B
Gy/R
R/B
B/L
W/Y
L
Y
X
W
L/W
Y W/Y
P/W R/W Br/W B/W W/B Gy/G L
R/B G/B L/B O/B
B3 O Gy/R
B/R G/YY/G B/Y R/W Y/L
B/L Y/B L/Y G/W Gy
R/L
Br/R
WIRE HARNESS
W Y/L O/W
R/G
G/L
B/L
W L/Y
Z
Z
B/L
L W/Y
O/B D O/B
L/B D L/B
G/B D G/B
R/B D R/B
WIRE HARNESS
Br/R
O/B
L/B
G/B
U
T
S
R
Br Br/R
Br/R R/W
R/W
(GRAY)
R/LO/B
R/L
(GRAY)
R/L L/B
R/L
(GRAY)
R/LG/B
R/L
(GRAY)
R/L R/B
R/L
SUB-WIRE
HARNESS 1
R/L
D
R/L
Lg Y R/Y
Br/B Y/B
L G/Y B2 R/W Br/G G/B Br/W
V
A
R/B
Y/B Br/B
R/Y Y Lg
Br/W G/B Br/G R/W B2 G/Y L
FUEL INJECTION SYSTEM
ELEC
–
+
FUEL INJECTION SYSTEM
CIRCUIT DIAGRAM (FJR1300)
– 29 –
B
L
G/Y
G/Y
A
G/Y
L
A
L
B
©
L
G/Y
L
R/W
R/B
R
Br/L
ON
OFF
P
2
B
B
R
Br/R
Br/L
Br/L
Br/L
R
Br/L
Br/R
µ
º
æ
R
B
W
W
W
Br/W
Br/G
Br/G
A
Br/G
Br/G
R/W
R/Y
Br
BB2
BB1
BB3
BB4
BB
B2
3
Br/W
Br/G
BB3 BB2
BB4 BB1
B
B
B
B
B2 B1
B2 BB
R
Br/L
Br/R
…
ø
(BLACK)
B
¥
L/R
Br/R
Br/L
R
G/L BB
B
R/G R/W Y/L
1
W
4
W
R
R
Y
Br
(GRAY)
W
L/R
W
W
W
R
R
Br/L
Y
R
Sb Br/Y R
B Lg Br/R
B/R
R/B
Sb B Sb
Lg B Lg
B/R
R/B
Sb
Lg
R/B
B/R
B
R Br Sb
Br/R Lg B
Br/Y Br/R
Br/Y
B/R
B/R
R/B
L/R
L/R B
Y
Dg Ch
B L
Y
Ch Dg
Br/W
A
Br/W
B
Ch
(BROWN)
Dg
7
6
5
B
B
(BROWN)
Y
G/Y
¶
Br
¤
B/Y
B/Y
B/Y
B/R
Y
B
R/Y
G/L
B L/R
B L/R
L/R B L/R
(BLACK)
G/L
Y
G/B G B
B
L/R
B
L/R
Y/B
}
Y/B
G/L
Y/B A Y/B
R/Y
R/Y
‹
R/W
(BLACK) (BLACK)
L/Y
s
R
Y
A
Y
G/B
A
t
R/W
R/B
L/W R/W
R
L/W
R
R/L
L/Y
R/Y A R/Y
R/Y
0
A
Dg
Y R/Y
Lg L/Y Br/W
B
L/B P Sb B/Y Ch
r
(BLUE)
B
B
R
R/L
Dg
Br/W
Ch
R/Y
B
Y
›
B
Dg
Br/W
Ch
u
W/L
DOWN
UP
v
Lg
B
Dg
OFF
w
H
(BLACK)
Sb
Sb/W
B
Dg
B
Dg
B
G
B
B
Br
Br
(BLUE)
L/G
(BLUE)
Ch
B
Ch
y
x
Sb/W O/W
Dg Ch
Br/W
Br Br
L/Y
R/L
R
I
Sb/W
O/W
B
L/G
L/G
E
Sb/W
B/R
O/W C O/W
O/W
B
Sb
Sb
Sb
Lg
F
Sb
O/W B
B/Y
R/B
L/W
D
W/L
Br/W
Dg Ch
G/B
R/W
ON
OFF
C
L/W
B
Y G
G/L
B
B
B
B
Y G
G
G/B
Y
Y
G/B
G
G
B
Dg
F
Dg
B
F
B
B
Dg
Ch
G
Ch
B
G
B
B
Ch
B
B
R/L B
B
B
Ch
Br
P
Br
P
P
Br B Br
G/W B
q
W
W
C
W
R/G
C
R/G
G/W
B
G/W
Y
R/G
G/W
W
R/W
Br/R
f
Lg
L
Dg
Ch
W L
K
Y B/L
O
N
l
L
Y/G
B/L
L
B/L
P/W
B/L
Y
L
(BLACK)
R/G B2 G/R Br/R
W G/L
R/W G/W Y/L Lg Y Ch Dg L
m
n
o
p
B/L
L W/B
L
W/B
B/L
M
k
h
i
j
g
L Y/G B/L
(BLACK)
P/W B/L L
(BLACK)
L
B/L
W L/Y
L
B/L
B2
Y/L
G/R
Lg
G/L
P/W E P/W
B/L E B/L
L D L
Y E Y
(BLACK)
Y/L C Y/L
B2 A B2
Q
Gy
G/W
B/L
R
Br/W
(BLACK)
P
G/R C G/R
G/W B/L
B/L
Br/W B/L
B/L
Gy
B
Gy
B/L
WIRE HARNESS
R/B
Gy/R
R/B
O
WIRE HARNESS
SUB-WIRE
HARNESS 1
(BLACK)
O/W Y/L W
G/L G/R R/G
WIRE HARNESS
Sb/W G/W Dg B Br/Y
Br L/R Ch Sb Lg
B
d
c
W1 B1
Sb B
Lg W/R
Br/W
G/W
Y/G
W/Y
Gy/G
W/B
B/L
L
Y
P/W
Gy
R/L
L/Y
R/W
B/Y
B/R
L/W
Gy W
b
B
a
B/W
Sb
Lg
e
e
B1
W1
B/W
R/L
L/W Y Br/W
Y/L
Br/R
G/Y
Y/B
B2 W1 Sb
B1 G/R Lg
R/W
W/R
B3
S
O/B
L/B
G/B
R/B
Gy/R
O
(BLACK)
Sb
Lg
Z
B
R/L
Sb
Lg
Y
B1
W1
B2
R/L
B/W
G/R
Br/W
L/W
Sb W1 B2
Lg G/R B1
Br/W Y L/W
Y
B1
W1
B2
R/L
B/W
G/R
Br/W
L/W
B/L
W/Y
L
Y
B1
W1
B2
Br/W
L/W
Sb
Lg
W/R
Lg
Br/W
Y
Ch
B5
B4 Sb
[
R/W
Y
B2 W1
B1
B4
B5
W
G
P/W
R/W
W/B
B3
W2
B/L
L W/Y
W
V
U
T
W2
B3
P/W
B
Br/W
\
Gy W
W
Dg
R/W
(GRAY)
R/LO/B
R/L
(GRAY)
R/L L/B
R/L
(GRAY)
R/LG/B
R/L
(GRAY)
R/L R/B
R/L
SUB-WIRE
HARNESS 1
B
G
R R
R
B
^
R/W
R/W
W/B
R/L
Br/G L B
SUB-WIRE
HARNESS 3
R
W
W
B
R
R
B R/W
R R
G W
R B R/W W/B
P/W Br/W G/R R/L
]
R/L
D
R/L
F
SUB-WIRE
HARNESS 1
Lg Y R/Y
Br/B Y/B
L G/Y B2 R/W Br/G G/B Br/W
W2 B3
A
G/R
Br/R R/W
Br Br/R
X
O/B
L/B
G/B
Br/R
O/B D O/B
L/B D L/B
G/B D G/B
R/B
SUB-WIRE
HARNESS 3
Br/G L B
R/B D R/B
SUB-WIRE
HARNESS 1
B
G
WIRE HARNESS
Y/B Br/B
R/Y Y Lg
Br/W G/B Br/G R/W B2 G/Y L
L/W W/B P/W W/R
G
W
B/L
W L/Y
SUB-WIRE
HARNESS 1
Br/Y B Dg G/W Sb/W
Lg Sb Ch L/R Br
L/W
Y W/Y
P/W R/W Br/W B/W W/B Gy/G L
R/B G/B L/B O/B
B3 O Gy/R
B/R G/YY/G B/Y R/W Y/L
B/L Y/B L/Y G/W Gy
R/L
Br/R
SUB-WIRE
HARNESS 2
WIRE HARNESS
C
(BLACK)
W Y/L O/W
R/G G/R G/L
(BLACK)
G/B R/B R/L
L O/B L/B
SUB-WIRE
HARNESS 2
D
(BLACK)
R/L R/B G/B
L/B O/B L
Gy/G Y W/B
B/L P/W
E
W/B Y Gy/G
P/W B/L
W/B E W/B
Gy/G E Gy/G
(DARK GRAY) (DARK GRAY)
Lg
A
Gy/G
Gy/G B/L
R/B W/L R/L
L/W L/Y R/W L/G B/R Sb B/Y Lg
(DARK GREEN)
J
R/L G/W
R L/W
Q Coolant temperature sensor
y
|
R Crankshaft position
sensor
S ECU~ (engine)
T Cylinder #1 - injector
U Cylinder #2 - injector
V Cylinder #3 - injector
WåCylinder
#4 - injector { z
çç
† †
X Air induction system solenoid
Y Speed sensor
º Ignition fuse
‹ Engine stop switch
Br
Dg
R/Y Y
Br/W B/R Lg
B
Ch B/Y Sb P G/B
R/W A R/W
(BLUE)
B
B
B
R
B
R
R
R/L
R
8
R
R/W L/W G/Y
Br B R/B
Õ
B/W B
B
B/W
9
R
R/G
Br/W
G/Y W/L R/W
R/B B Br
B
B/W
ß
2 Main switch
7 Main fuse
9 Battery
®
0 Fuel
injection system fuse
E Fuel injection system relay
J Fuel pump
¢
K O2 sensor
§•
L Cylinder identification sensor
£
M Throttle position sensor
N Intake air pressure sensor
O Lean angle cut-off switch
P Intake air temperature sensor
Br/Y
B
B
L
Br/B
L
(BLACK) (BLACK)
R/W
Br/B
™
¡
¬
R/G B2 B
R/W Lg Y/L
Br/B
Br/B
A
Br/B
Br/Y
B BB R/G
Y/L G/L R/W
FUEL INJECTION SYSTEM
ELEC
–
CIRCUIT DIAGRAM (FJR1300A)
+
FUEL INJECTION SYSTEM
ELEC
–
+
EAS00819
CHECKING THE FUEL PUMP
WARNING
@
Gasoline is extremely flammable and under
certain circumstances there can be a danger of an explosion or fire. Be extremely
careful and note the following points:
• Stop the engine before refueling.
• Do not smoke, and keep away from open
flames, sparks, or any other source of
fire.
• If you do accidentally spill gasoline, wipe
it up immediately with dry rags.
• If gasoline touches the engine when it is
hot, a fire may occur. Therefore, make
sure the engine is completely cool before
performing the following test.
1. Check:
• fuel pump operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the fuel tank.
b. Put the end of the fuel hose into an open
container.
c. Connect the battery (12 V) to the fuel pump
terminals as shown.
Battery positive lead → red/blue 1
Battery negative lead → black 2
G/W B
d. If fuel flows out of the fuel hose, the fuel
pump is OK. If fuel does not flow, replace
the fuel pump.
B R/L
1 2
+
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
– 30 –
FJR1300 WIRING DIAGRAM
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
[
\
]
_
a
b
c
d
e
f
g
h
i
j
k
l
m
n
o
p
q
r
s
t
u
v
w
x
y
z
{
|
}
~
å
ç
†
¢
£
Immobilizer unit
Main switch
Rectifier/regulator
Generator
Backup fuse (odometer, clock and windshield)
Main fuse
Battery
Fuel injection system fuse
Starter relay
Starter motor
Relay unit
Starting circuit cut-off relay
Fuel injection system relay
Neutral switch
Sidestand switch
Accessory box solenoid
Accessory box relay
Fuel pump
O2 sensor
Cylinder identification sensor
Throttle position sensor
Intake air pressure sensor
Lean angle cut-off switch
Intake air temperature sensor
Coolant temperature sensor
Crankshaft position sensor
ECU (engine)
Cylinder #1 - injector
Cylinder #2 - injector
Cylinder #3 - injector
Cylinder #4 - injector
Air induction system solenoid
Speed sensor
Cylinders #1, #4 - ignition coil
Cylinders #2, #3 - ignition coil
Spark plug
Meter assembly
Immobilizer system indicator light
Oil level warning light
Neutral indicator light
Multifunction meter
Engine trouble warning light
High beam indicator light
Left turn signal indicator light
Right turn signal indicator light
Meter light
Oil level switch
Left handlebar switch
Clutch switch
Pass switch
Dimmer switch
Windshield position switch
Turn signal switch
Horn switch
Horn
Front turn signal light (left)
Front turn signal light (right)
Hazard switch
Headlight relay 1
Headlight relay 2
Headlight assembly
Auxiliary light
Headlight
Taillight assembly
Tail/brake light
Rear turn signal light (left)
Rear turn signal light (right)
Rear brake light switch
Turn signal relay
Windshield drive unit
Radiator fan motor
Radiator fan motor relay
Parking lighting fuse
Hazard lighting fuse
Ignition fuse
§
•
¶
ß
®
©
™
¥
µ
Headlight fuse
Signaling system fuse
Radiator fan motor fuse
Windshield motor fuse
CYCLELOCK
Right handlebar switch
Front brake light switch
Engine stop switch
Start switch
COLOR CODE
B .............Black
Br............Brown
Ch...........Chocolate
Dg...........Dark green
G.............Green
Gy...........Gray
L .............Blue
Lg ...........Light green
O.............Orange
P .............Pink
R.............Red
Sb ...........Sky blue
W ............White
Y .............Yellow
B/L ..........Black/Blue
B/R .........Black/Red
B/W.........Black/White
B/Y..........Black/Yellow
Br/B ........Brown/Black
Br/G ........Brown/Green
Br/L.........Brown/Blue
Br/R ........Brown/Red
Br/W .......Brown/White
Br/Y ........Brown/Yellow
G/B .........Green/Black
G/L..........Green/Blue
G/W ........Green/White
G/Y .........Green/Yellow
Gy/G .......Gray/Green
Gy/R .......Gray/Red
L/B ..........Blue/Black
L/G..........Blue/Green
L/R..........Blue/Red
L/W .........Blue/White
L/Y ..........Blue/Yellow
O/B .........Orange/Black
P/W.........Pink/White
R/B .........Red/Black
R/G .........Red/Green
R/L..........Red/Blue
R/W ........Red/White
R/Y .........Red/Yellow
W/B.........White/Black
W/Y.........White/Yellow
Y/B..........Yellow/Black
Y/G .........Yellow/Green
Y/L ..........Yellow/Blue
FJR1300A WIRING DIAGRAM
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
[
\
]
_
a
b
c
d
e
f
g
h
i
j
k
l
m
n
o
p
q
r
s
t
u
v
w
x
y
z
{
|
}
~
å
ç
†
¢
£
Immobilizer unit
Main switch
Rectifier/regulator
Generator
ABS fuse
Backup fuse (odometer, clock and windshield)
Main fuse
ABS motor fuse
Battery
Fuel injection system fuse
Starter relay
Starter motor
Relay unit
Starting circuit cut-off relay
Fuel injection system relay
Neutral switch
Sidestand switch
Accessory box solenoid
Accessory box relay
Fuel pump
O2 sensor
Cylinder identification sensor
Throttle position sensor
Intake air pressure sensor
Lean angle cut-off switch
Intake air temperature sensor
Coolant temperature sensor
Crankshaft position sensor
ECU (engine)
Cylinder #1 - injector
Cylinder #2 - injector
Cylinder #3 - injector
Cylinder #4 - injector
Air induction system solenoid
Speed sensor
Sub-wire harness (ABS)
ECU (ABS)
Rear wheel sensor
Fail-safe relay
Hydraulic unit
ABS test coupler
Front wheel sensor
Cylinders #1, #4 - ignition coil
Cylinders #2, #3 - ignition coil
Spark plug
Meter assembly
Immobilizer system indicator light
Oil level warning light
Neutral indicator light
ABS warning light
Multifunction meter
Engine trouble warning light
High beam indicator light
Left turn signal indicator light
Right turn signal indicator light
Meter light
Oil level switch
Left handlebar switch
Clutch switch
Pass switch
Dimmer switch
Windshield position switch
Turn signal switch
Horn switch
Horn
Front turn signal light (left)
Front turn signal light (right)
Hazard switch
Headlight relay 1
Headlight relay 2
Headlight assembly
Auxiliary light
Headlight
Taillight assembly
Tail/brake light
§
•
¶
ß
®
©
™
¥
µ
º
æ
ø
¡
¬
…
Õ
¤
‹
›
Rear turn signal light (left)
Rear turn signal light (right)
Rear brake light switch
Turn signal relay
Windshield drive unit
Radiator fan motor
Radiator fan motor relay
Parking lighting fuse
Hazard lighting fuse
Ignition fuse
Headlight fuse
Signaling system fuse
Radiator fan motor fuse
Windshield motor fuse
CYCLELOCK
Right handlebar switch
Front brake light switch
Engine stop switch
Start switch
COLOR CODE
B .............Black
Br............Brown
Ch...........Chocolate
Dg...........Dark green
G.............Green
Gy...........Gray
L .............Blue
Lg ...........Light green
O.............Orange
P .............Pink
R.............Red
Sb ...........Sky blue
W ............White
Y .............Yellow
B/L ..........Black/Blue
B/R .........Black/Red
B/W.........Black/White
B/Y..........Black/Yellow
Br/B ........Brown/Black
Br/G ........Brown/Green
Br/L.........Brown/Blue
Br/R ........Brown/Red
Br/W .......Brown/White
Br/Y ........Brown/Yellow
G/B .........Green/Black
G/L..........Green/Blue
G/W ........Green/White
G/Y .........Green/Yellow
Gy/G .......Gray/Green
Gy/R .......Gray/Red
L/B ..........Blue/Black
L/G..........Blue/Green
L/R..........Blue/Red
L/W .........Blue/White
L/Y ..........Blue/Yellow
O/B .........Orange/Black
P/W.........Pink/White
R/B .........Red/Black
R/G .........Red/Green
R/L..........Red/Blue
R/W ........Red/White
R/Y .........Red/Yellow
W/B.........White/Black
W/Y.........White/Yellow
Y/B..........Yellow/Black
Y/G .........Yellow/Green
Y/L ..........Yellow/Blue
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
FJR1300 WIRING DIAGRAM
G
Ch
B
B BB R/G
Y/L G/L R/W
1
R/G B2 B
R/W Lg Y/L
B
Br/G L B
SUB-WIRE
HARNESS 1
E
F
SUB-WIRE
HARNESS 3
Dg
W/B Y Gy/G
P/W B/L
Gy/G Y W/B
B/L P/W
(BLACK)
(BLACK)
WIRE HARNESS
SUB-WIRE
HARNESS 2
Br/G L B
SUB-WIRE
HARNESS 1
SUB-WIRE
HARNESS 3
D
C
A
B
R/L R/B G/B
L/B O/B L
G/B R/B R/L
L O/B L/B
W Y/L O/W
R/G
G/L
O/W Y/L W
G/L
R/G
Sb/W G/W Dg B Br/Y
Br L/R Ch Sb Lg
Br/Y B Dg G/W Sb/W
Lg Sb Ch L/R Br
Y/B Br/B
R/Y Y Lg
Br/W G/B Br/G R/W B2 G/Y L
Lg Y R/Y
Br/B Y/B
L G/Y B2 R/W Br/G G/B Br/W
WIRE HARNESS
SUB-WIRE
HARNESS 2
WIRE HARNESS
SUB-WIRE
HARNESS 1
WIRE HARNESS
SUB-WIRE
HARNESS 1
WIRE HARNESS
SUB-WIRE
HARNESS 1
G/L BB
B
R/G R/W Y/L
5
R/G
R
R/B
L/W
L/W
R
R
A
6
R
Lg
R
B
R
C
R L/W
R
R
R/W
B/Y
W/L
Sb
B/R
L/G
R/B W/L R/L
L/W L/Y R/W L/G B/R Sb B/Y Lg
L/Y
R/L
B
W
W
W
3
R
(BLACK)
W
W
W
4
W
B
W
R
R
R
W
R
R
L/W R/W
R
R
R
R
B
2
ON
OFF
P
Br/R
Br/R
R
Br/L
R
Br/L
B
Sb
L/G
8
7
(GRAY)
B
D
B
Sb
Gy/G B/L
B
D
=
L/G
R/L
I
Gy/G
(BLUE)
R/W
B
B
R/L
Sb
B
B
B
Gy/G E Gy/G
E
L/W
9
B/L
R
W L
B
R/B D R/B
(DARK GRAY) (DARK GRAY)
(BLUE)
R/B
R/L
B
Br/L
R/L R/B
Br/R
(GRAY)
S
J
Sb/W
Gy
B/L
L
W/B
B/L
W/B E W/B
Gy
B
B
B2 BB
W L/Y
L W/B
B/L
B/L
Sb/W
O/W C O/W
ß
L
B
(BLUE)
Br/L
R
•
L
G/Y
L
A
L
G/Y
A
G/Y
Br
B
£
Dg
R/Y Y
Br/W B/R Lg
B
Ch B/Y Sb P G/B
R/W
O/W B
l
i
Br/G
A
Br/G
L/Y
L/Y
B/Y
B/Y
m
n
DOWN
P
R/Y
R/Y
Br
|
}
Br
B
Y
G/B
Lg
Sb
Dg Ch
Br/W
Y/B
G/L
Y/B A Y/B
Br/Y Br/R
Br/W
A
Br/W
o
Br/W
Dg Ch
R/W
P
R/G
G/W
W
Br
Dg
Br/W
Ch
t
Dg
Br/W
Ch
ON
OFF
Dg
B
Dg
Ch
B
Ch
Ch
Dg
Y
Ch
Dg
B L/R
L/R
L/R
Y G
z{
Ch
G
Ch
Dg
Ch
W
Y
B
B
w w
B
B
Y
B
Dg
B
q
G
B
p
B
B
B
F
B
B
G
B
B
y
B
B
B
B
a
c
d
e
f
G/W B/L
(BLACK)
B/L
W/Y
L
W
W L/Y
L W/Y
B/L
B/L
Y/L
Y/L C Y/L
B2
B2 A B2
Ch
g
R/B
X
Z
Y
Z
Gy/R
R/B
R/G B2
Br/R
W G/L
R/W G/W Y/L Lg Y Ch Dg L
(BLACK)
G
vv
B L/R
Dg
F
Dg
Y G
u
B L
Y
Ch Dg
L
Br B Br
B/R
R/B
L/R
G/L
Lg
b
Y
(BLACK)
x
G/W
O
W
C
W
Sb B Sb
Lg B Lg
L/R B
Y
Dg Ch
Br
r
L/R B L/R
R
(BLACK)
G/B
G
G/B
Y
B
R/W
P
o
G/L
G/L
Y
G/B G B
B3
O
Br/R
G/B
A
Y
Br/W
B/R
Br/R R/W
Y/L
B/W
R/W
Br Br/R
^
Y
B
Br/Y
B/R
R/B
Br/R
]
Y
Y/B
R/Y
L/R
B
B
V
Br/R
G/Y
Y/B
B
A
(BROWN)
(BROWN)
s
R/Y
G/L
Br/W
B/L
Lg
\
R/L
R/LO/B
L
Y/G
B/L
A
O/B
(GRAY)
Lg
[
R/Y A R/Y
Br/G
Br/W
Br/G
B/R
R/B
R/G
C
R/G
G/W
B
G/W
OFF
Y
†
R/B
U
O/B D O/B
Q
Br/W
G/W
Y/G
W/Y
Gy/G
(BLACK) (BLACK)
å
Sb Br/Y R
B Lg Br/R
P/W E P/W
G/W B
UP
Br/G
L/R
R Br Sb
Br/R Lg B
R/L L/B
N
k
R/L
(GRAY)
O/B
L/B
G/B
R/B
R/Y
j
L/B
Gy/R
O
W/B
B/L
L
Y
P/W
B/L E B/L
L D L
Br/W B/L
Dg
Y R/Y
Lg L/Y Br/W
B
L/B P Sb B/Y Ch
¢
Br/R
Br/Y
B
T
L/B D L/B
Gy
B/L
B/Y
B/R
(BLACK) (BLACK)
~
(BLACK)
R/L B
L
B/L
P/W
R/Y
h
B
(GRAY)
R/W A R/W
L
Sb
Lg
R/B
B/R
B
Br
M
R/W
Br/L
B
L
L
P/W B/L L
Br
G/Y
B
L
Br
Y E Y
B
L Y/G B/L
ç
R/W
B
B/L
Y
L
(BLACK)
§
Br/B
L
L/W
Y W/Y
P/W R/W Br/W B/W W/B Gy/G L
R/B G/B L/B O/B
B3 O Gy/R
B/R G/YY/G B/Y R/W Y/L
B/L Y/B L/Y G/W Gy
R/L
Br/R
(DARK GREEN)
Br/L
Br/B
K
Y B/L
(BLACK)
Sb/W O/W
BB3 BB2
BB4 BB1
¶
Br Br
B
B
G/Y
Br/B
Br/B
A
Br/B
G
F
R/W L/W G/Y
Br B R/B
G/Y W/L R/W
R/B B Br
Sb/W
O/W
O/W
µ
¥
(BLUE)
B
B
Br/L
H
W/L
™
BB3
BB4
BB2
BB1
Br/Y
R/LG/B
P
R/L
L/Y
R/W
B/Y
B/R
L/W
R/L G/W
R/W
R/B
©
R/L
Gy
B/L
BB
B2
G/B
(BLACK)
B2 B1
®
G/B D G/B
FJR1300A WIRING DIAGRAM
B BB R/G
Y/L G/L R/W
1
R/G B2 B
R/W Lg Y/L
E
D
C
B
A
5
Br/L
Br/W
G/L BB
B
R/G R/W Y/L
6
R
R/G
L/W
R
R
C
7
R
W
W
W
3
(BLACK)
W
W
W
R
R/L
4
R
W
W
ON
OFF
P
R
Br/L
WIRE HARNESS
O/W Y/L W
G/L G/R R/G
(BLACK)
(BLACK)
SUB-WIRE
HARNESS 2
WIRE HARNESS
SUB-WIRE
HARNESS 1
Sb/W G/W Dg B Br/Y
Br L/R Ch Sb Lg
Br/Y B Dg G/W Sb/W
Lg Sb Ch L/R Br
Y/B Br/B
R/Y Y Lg
Br/W G/B Br/G R/W B2 G/Y L
Lg Y R/Y
Br/B Y/B
L G/Y B2 R/W Br/G G/B Br/W
WIRE HARNESS
SUB-WIRE
HARNESS 1
WIRE HARNESS
SUB-WIRE
HARNESS 1
R L/W
B/R
L/G
R/B W/L R/L
L/W L/Y R/W L/G B/R Sb B/Y Lg
Ch
B
L/Y
F
SUB-WIRE
HARNESS 1
Dg
B
Br/G L B
SUB-WIRE
HARNESS 3
Br/G L B
SUB-WIRE
HARNESS 1
SUB-WIRE
HARNESS 3
R
R
Sb
L/G
0
9
B
B/W
R
Br/L
Sb
R
B
Br/R
SUB-WIRE
HARNESS 2
W Y/L O/W
R/G G/R G/L
G/B R/B R/L
L O/B L/B
R/L
R
R
W
(GRAY)
R
Br/R
WIRE HARNESS
R/L R/B G/B
L/B O/B L
G
E
B/Y
W/L
(BLACK)
L/W R/W
B
2
R/W
R
R/L
Gy/G Y W/B
B/L P/W
(BLACK)
R
R/L
8
R
Lg
D
R
R
R
B
R/B
L/W
W/B Y Gy/G
P/W B/L
B
B/W
A
B
Sb
L/G
R/L
K
Gy/G
Gy/G B/L
B
F
B
B/W B
D
B
(BLUE)
R/W
B
Br/L
R/L
Sb
B
B
Gy/G E Gy/G
G
L/W
B/L
T
W L
B
R/B D R/B
(DARK GRAY) (DARK GRAY)
(BLUE)
R/B
R/L
B
R/L R/B
Br/R
(GRAY)
U
L
W/B
B/L
L
Sb/W
Sb/W
Gy
B
W L/Y
L W/B
B/L
B/L
R
¬
B
B
Br/L
W/L
¤
G/Y W/L R/W
R/B B Br
R/W L/W G/Y
Br B R/B
(BLUE)
(BLUE)
L
Br/L
R
Br/L
G/Y
L
A
L
G/Y
A
G/Y
Br/R
B
æ
º
Dg
Y R/Y
Lg L/Y Br/W
B
L/B P Sb B/Y Ch
Br/G
A
Br/G
t
w
v
u
x
OFF
DOWN
L/Y
Br/R
Br/R R/W
Y/L
B3
R/W
Br/W
P
(BLACK)
Br/W B/L
Lg
A
B/L
Lg
f
B/L
W/Y
L
G/W
Q
g
G/L
G/W B/L
Y
W L/Y
L W/Y
B/L
B/L
(BLACK)
Gy W
}
R/Y
R/Y
Br/G
G/B
Lg
Sb
Dg Ch
Br/W
¶
ß
Br
B
Y
Y
Y
Br/Y
G/L
Y
G/B G B
Br/W
A
Br/W
y
Br/W
Dg Ch
Dg
Br/W
Ch
~
Dg
Br/W
Ch
R/G
G/W
W
(BLACK)
Ch
B
Ch
Ch
Dg
Ch
Dg
¢
B L/R
L/R
L/R
Y G
L
Y
Ch Dg
§•
Y/L
Y/L C Y/L
Ch
G
Ch
Dg
Ch
k
B2
B2 A B2
B
B
† †
B
B
G
Y
B
B
Dg
z
B
£
B
F
B
B
G
B
B
B
B
Br/W
L/W
R/L
B/W
R/L
B/W
R/W
W/B
Br/W
]
R B R/W W/B
P/W Br/W G/R R/L
[
P/W
b
W1 B1
B1
W1
Gy W
B1
W1
B2
B1
W1
B2
B1
W1
B2
Y
Y
Y
W
W
G
B4
B5
R/G B2 G/R Br/R
W G/L
R/W G/W Y/L Lg Y Ch Dg L
B2 W1 Sb
B1 G/R Lg
R/B
(BLACK)
Ch
R/W
R
B
^
Br/W Y L/W
O
W
W/B
R/L
G/R
R R
c
e
d
e
q
B
B
Sb
Lg
R/W
m
n
o
p
Gy/R
B
Sb
Lg
G/R
Br/W
L/W
W2 B3
\
P/W
L/W Y Br/W
B
{
Sb
Lg
G/R
Br/W
L/W
Z
G
Y
çç
B L/R
B
G/R C G/R
B3
W2
W/R
W/R
Lg
G/R
Y G
å
B
L
Br B Br
Dg
F
Dg
Y
L/R
Sb
Lg
a
l
Y
B/R
R/B
L/R B
Y
Dg Ch
P
W
C
W
L/R B L/R
B
B
R/W
ON
OFF
Dg
B
Dg
B/R
Br
Br
|
Sb B Sb
Lg B Lg
R/B
Sb B
Lg W/R
G/B
G
G/B
Y
B
h
i
j
P
y
G/L
L/R
Br/Y Br/R
G/B
A
Y/B
G/L
Y/B A Y/B
B
(BROWN)
Br/W
Br/R
Y
Y/B
R/Y
B
A
R/Y
G/L
Br
R/W
Br Br/R
L
Y/G
B/L
B/Y
Y
¥
Br/Y
B
R
R/G
C
R/G
G/W
B
G/W
UP
R/Y A R/Y
(BROWN)
B/R
R/B
X
Br/R
G/Y
Y/B
Br/W
G/W
Y/G
W/Y
Gy/G
(BLACK) (BLACK)
Br/W
Br/G
B/R
R/B
(GRAY)
R/Y
Br/G
B/Y
R/L
S
B/W
Dg
R/Y Y
Br/W B/R Lg
B
Ch B/Y Sb P G/B
O/B
P
B/Y
B/R
s
µ
L/R
Sb Br/Y R
B Lg Br/R
P/W E P/W
G/W B
B/L
R/W
W
O/B D O/B
R/LO/B
W/B
B/L
L
Y
P/W
B/L E B/L
L D L
R/W A R/W
©
R Br Sb
Br/R Lg B
L
B/L
P/W
R/Y
L/Y
B
®
(BLACK)
R/L B
O/W B
O
(BLACK) (BLACK)
Sb
Lg
R/B
B/R
B
N
P/W B/L L
R/L L/B
Gy
B
Br
Br
L
B
L
Y E Y
(BLACK)
ø
G/Y
L
B/L
Y
L
R/L
(GRAY)
O/B
L/B
G/B
R/B
(DARK GREEN)
Br
r
™
B
L
B
Br
Sb/W O/W
R/W
Br/B
L
R/W
M
Y B/L
(BLACK)
L Y/G B/L
Br/L
Br/B
Br Br
B
B
BB3 BB2
BB4 BB1
Br/B
Br/B
A
Br/B
I
H
B
G/Y
¡
Sb/W
O/W
O/W
›
‹
J
L/B
Gy/R
O
R/L
L/Y
R/W
B/Y
B/R
L/W
R/L G/W
R/W
R/B
BB3
BB4
BB2
BB1
Br/Y
V
L/B D L/B
O/W C O/W
…
(GRAY)
B/L
Õ
R/L
L/W
Y W/Y
P/W R/W Br/W B/W W/B Gy/G L
R/B G/B L/B O/B
B3 O Gy/R
B/R G/YY/G B/Y R/W Y/L
B/L Y/B L/Y G/W Gy
R/L
Br/R
(BLACK)
B2 B1
BB
B2
G/B
Gy
R/LG/B
W/B E W/B
B
B2 BB
G/B D G/B
Gy
B/L
R/B
B/W
R/L
B
R/L
G
W
Sb W1 B2
Lg G/R B1
Lg
Br/W
B5
B4 Sb
Y
R/W
B2 W1
B1
L/W W/B P/W W/R
W2
B3
G
B
W
W
R
R
R R
G W
R
B
B R/W
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