Engine:
Complete disassembly, inspection, repair, and reassembly of the 1299cc inline-four engine.
Fuel System:
Fuel injection system (throttle body, injectors, ECU mapping), fuel pump, fuel tank, lines.
Ignition System:
Ignition coils, spark plugs, CDI unit, wiring.
Cooling System:
Radiator, coolant flow, water pump, thermostat, fan operation.
Transmission:
Six-speed gearbox, clutch operation (hydraulic actuation), gear shift mechanism, lubrication.
Drivetrain:
Shaft drive system, final drive housing, universal joints, lubrication.
Chassis Frame:
Frame construction, material specifications, alignment checks, welding points.
Suspension Front:
43mm telescopic forks, damping adjustments, spring preload, seal replacement, fork oil specifications.
Suspension Rear:
Monoshock suspension, linkage system, spring preload adjustment, damping adjustment, shock absorber overhaul.
Braking System:
Front and rear disc brakes, caliper specifications, master cylinder overhaul, brake fluid type, ABS system (if equipped).
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, rectifier/regulator), starter motor, lighting, fuses, relays.
Bodywork Fairings:
Removal and installation of fairings, body panels, seat, windscreen.
Instruments Controls:
Dashboard instrumentation, handlebar controls, throttle assembly, clutch lever.
Diagnostic Troubleshooting:
Fault finding procedures for all major systems, error codes, symptom-based troubleshooting.
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug inspection/replacement, chain adjustment (if applicable, but FJR is shaft drive), fluid level checks.
Component Overhaul:
Detailed instructions for disassembling, cleaning, inspecting, and reassembling major components (engine, transmission, forks, brake calipers).
Troubleshooting Diagnostics:
Systematic approach to identifying and resolving mechanical and electrical issues.
Specifications Tolerances:
Precise torque values, clearances, and dimensional specifications for all critical parts.
Wiring Diagrams:
Comprehensive, clear electrical schematics for all circuits.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
Engine Rebuild:
Detailed steps for engine internal repairs, including piston, ring, cylinder, valve, and crankshaft service.
Suspension Service:
Fork seal replacement, damper rod service, shock absorber rebuild.
Brake Bleeding:
Correct procedure for bleeding brake systems, including ABS-equipped models.
Fuel System Cleaning:
Injector cleaning and maintenance, throttle body synchronization.
Depth Level:
Comprehensive: Covers everything from basic maintenance to full engine and transmission rebuilds, including diagnostics and troubleshooting.
Diagnostic Capability:
Advanced diagnostics for electronic systems, fuel injection, and ignition.
Repair Scope:
Full repair capabilities, enabling technicians and skilled owners to perform any necessary service.
Engine Type:
Liquid-cooled, 4-stroke, DOHC, 5 valves per cylinder, inline-four
Displacement:
1299 cc (1.3 Liters)
Bore X Stroke:
81.0 mm x 63.0 mm
Compression Ratio:
10.8:1
Power Output:
Approx. 145 hp @ 8,500 rpm (manufacturer's claim, may vary)
Torque Output:
Approx. 123 Nm (91 lb-ft) @ 6,000 rpm (manufacturer's claim, may vary)
Top Speed:
Electronically limited to approx. 155 mph (250 km/h), though capable of higher speeds.
Fuel Induction:
Electronic Fuel Injection (EFI) with dual injectors per cylinder.
Fuel Type:
Unleaded gasoline, 91 octane (Octane Rating) or higher.
Fuel Capacity:
25.0 Liters (6.6 US gal)
Oil Change Interval:
Every 10,000 km (6,000 miles) or 1 year.
Air Filter Replacement:
Every 20,000 km (12,000 miles).
Spark Plug Inspection:
Every 20,000 km (12,000 miles).
Valve Clearance Check:
Every 40,000 km (24,000 miles).
Engine Oil:
Yamalube 4-stroke SAE 10W-40 API SG or higher.
Engine Oil Capacity:
4.20 Liters (4.43 US qt) without filter change; 4.50 Liters (4.76 US qt) with filter change.
Coolant:
Yamaha Coolant 50% or equivalent ethylene glycol-based coolant.
Common Wear Items:
Clutch plates, front fork seals, brake pads, fuel pump (over time).
Electrical Gremlins:
While generally reliable, potential issues can arise in charging systems or wiring harnesses with age and mileage, covered in troubleshooting section.
