990141 – Transmission Second Gear Can Break – 2016-2020 Yamaha FJR13A & FJR13AE Motorcycles

SEOCONTENT-START

©2021 YAMAHA MOTOR CORPORATION, U.S.A.
MOTORCYCLE 1/20/21 M2021-002R
SAFETY
RECALL
This modification has top priority. This bulletin must be performed
immediately to ensure customer safety.
NOTE: Bulletins that announce a recall will have an “R” at the end of the bulletin number.
CERTAIN 2016~2020-MODEL FJR1300A, FJR1300AE, AND FJR1300PA
MOTORCYCLES
FACTORY MODIFICATION CAMPAIGN – Second Gear Failure
Yamaha Motor Corporation, U.S.A. has decided that a defect
that relates to motor vehicle safety exists in 2016~2020-model
FJR1300A, FJR1300AE, and FJR1300PA motorcycles.
In affected motorcycles, the side of second gear may not be
strong enough to handle high speed loads. As a result, cracks
may occur due to constant stress applied during repeated
gear shift operation and, eventually, the gear could break. If
this happens, the transmission and, in turn, the rear wheel,
could lock, increasing the risk of loss of control and a crash
with injury or death.
To correct this defect, Yamaha is initiating a Factory Modification Campaign. Affected units must have the
main axle and drive axle assemblies replaced with the stronger parts and the Engine Control Unit (ECU)
reprogrammed to prevent excessive rpm leading to second gear damage.
NOTE: This modification does not affect the emissions compliance of this product.
Yamaha is notifying all registered owners of affected motorcycles by mail. A copy of this letter is included in this
bulletin. The customer should take this letter along with the affected motorcycle to an authorized Yamaha dealer
for modification.
If your dealership was invoiced for one or more affected units, a computer report listing all affected motorcycles
invoiced to your dealership is included with a mailed copy of this bulletin. Use the list to help ensure all
motorcycles are modified. All sold motorcycles that have been registered with Yamaha will show the customer’s
name and address.
Your dealership must notify the owner of any affected motorcycle that was actually sold but listed as “unsold” in
the report. You must modify all affected motorcycles in your inventory as well as all customer-owned motorcycles
brought to you for this service. Any affected motorcycle that you purchase from Yamaha in the future may also
require modification. If you purchase a motorcycle from another dealer or Yamaha, check to see if the procedures
in this bulletin have already been performed before you sell the motorcycle.
Page 1 of 26
IN
I i I INTRODUCTION
Page 2 of 26
Motorcycles that are affected should not be operated until they are modified. It is a violation of Yamaha
policy for your dealership to deliver any affected motorcycle to customers until the procedures in this
bulletin are performed.
NOTE: Also check to see if the unit you are modifying is also affected by the Brake Switch Factory Modification
Campaign announced in Technical Bulletin M2021-001R. Perform both procedures at the same time for
customer convenience and shop efficiency.
When the modification on each motorcycle is performed, follow the Warranty Information section of this bulletin
to receive reimbursement. Be sure to use the Factory Modification Campaign procedures in Chapter 7 of the
Warranty and Y.E.S. Handbook (LIT-11760-00-16).
Unsold &
Sold:
Use YDS Unit Status to check to be sure the unit is affected and that it is not already
modified; confirm by checking the motorcycle according to the Identification Procedure
section of this bulletin. If the unit is affected, replace the main axle and drive axle assemblies,
and reprogram the ECU, as instructed in this bulletin.
IMPORTANT: Customers with unauthorized, aftermarket ECU modifications may experience
issues once the ECU reprograming required by this recall is performed. Yamaha cannot
participate in accommodating any unauthorized ECU changes. Therefore, damage resulting
to an ECU during recall reprogramming because of previous unauthorized modification is the
customer’s responsibility.
Parts
Required:
Yes. Order the appropriate Transmission Kit and Transmission Add Kit (two kits needed for
each model). See the Parts Information section of this bulletin for more information.
Warranty: Factory Modification Campaign. See the Warranty Information section of this bulletin. This
modification applies to all affected units regardless of ownership or warranty status.
Notify
Customers:
Yes, you must immediately contact any customer whose motorcycle shows as unregistered
on the enclosed report. Yamaha has sent letters to customers whose motorcycles were
registered with Yamaha as of 1/19/2021.
I .bi.t I DEALER ACTION SUMMARY
Page 3 of 26
Check Unit Status on YDS to make sure the Primary ID (PID) is in the Affected Range and is eligible for this repair.
The affected unit ranges for this issue are:
Year Model
Primary ID
Prefix From To
2016 ~ 2019 FJR1300A RP29E 0000002 0000822
2016 ~ 2019 FJR1300A RP29Y 0000002 0000151
2016 ~ 2020 FJR1300AE RP30E 0000001 0001009
2016 ~ 2020 FJR1300AE RP30Y 0000006 0000221
2018, 2020 FJR1300PA RP31Y 0000003 0000092
IMPORTANT: Affected Primary IDs may not be consecutive. Always check YDS Unit Status before starting
any repair.
Refer to the FJR1300 Service Manual (P/N: LIT-11616-29-61) as needed for these procedures. Also, for police
models, refer to the supplemental Service Manual (P/N: LIT-11616-31-59).
There is also a helpful video with tips and precautions available at: https://youtu.be/_GErePFGmhA
PREPARATION FOR TRANSMISSION REPLACEMENT
Refer to the Service Manual for the following procedures:
1. Drain the engine oil and remove the oil filter (Chapter 3).
2. Remove the passenger and rider seats (Chapter 4).
3. Remove the front fender and side body panels (cowlings), being sure to protect them from scratches or
other damage (Chapter 4).
4. Remove the fuel tank, protecting it from scratches or other damage (Chapter 7).
5. Remove the throttle body assembly with the air filter case (Chapter 7).
6. Drain the coolant (Chapter 3).
7. Remove the radiator (Chapter 6).
8. Remove the exhaust system (Chapter 3)
9. Remove the side stand and footrest (Chapter 4).
10. Remove the universal joint (Chapter 4).
11. Disconnect the lead wiring from the engine (Chapter 5).
12. Remove the engine (Chapter 5).
1~~1 AFFECTED RANGE
IQ. I SERVICE PROCEDURES
Page 4 of 26
DISASSEMBLE THE ENGINE
1. Set the engine on a flat surface using and engine
stand or wood block so that the engine is in the upright
position.
-1-
§12. Engine disassemble
1. Stand on a flat surface stand or something, head of the engine is 2. Remove the generator TIP
・Be careful not to lose (2 locations).
・Be aware of the generator’s force.
・When assembling, replace a new part in the countermeasure 3. Remove the starter clutch and the shaft ③.
4. Remove the middle gear TIP
・Be careful not to lose (2 locations)
・When assembling, replace a new part in the countermeasure 5. Remove the middle driven TIP
・Be careful not to drop (2 locations)
・When assembling, replace a new part in the countermeasure ①
③
②
④
⑤
Shim
2. Remove the generator cover ①.
TIP:
• Be careful not to lose the dowel pins (2 locations).
• Be aware of the generator’s magnetic force.
• When assembling, replace gasket with a new part in
the countermeasure parts.
-1-
§12. Engine disassemble
1. Stand on a flat surface stand or something, head of the engine is 2. Remove the generator TIP
・Be careful not to lose (2 locations).
・Be aware of the generator’s force.
・When assembling, replace a new part in the countermeasure 3. Remove the starter clutch and the shaft ③.
4. Remove the middle gear TIP
・Be careful not to lose (2 locations)
・When assembling, replace a new part in the countermeasure 5. Remove the middle driven TIP
・Be careful not to drop (2 locations)
・When assembling, replace a new part in the countermeasure ①
③
②
④
⑤
Shim
3. Remove the starter clutch idle gear ② and the shaft ③ .
-1-
§12. Engine disassemble
1. Stand on a flat surface using stand or something, so that head of the engine is on the 2. Remove the generator cover TIP
・Be careful not to lose the (2 locations).
・Be aware of the generator’s force.
・When assembling, replace a new part in the countermeasure 3. Remove the starter clutch and the shaft ③.
4. Remove the middle gear case TIP
・Be careful not to lose the (2 locations)
・When assembling, replace a new part in the countermeasure 5. Remove the middle driven TIP
・Be careful not to drop the (2 locations)
・When assembling, replace a new part in the countermeasure ①
③
②
④
⑤
Shim
4. Remove the middle gear case cover ④.
TIP:
• Be careful not to lose the dowel pins (2 locations).
• When assembling, replace gasket with a new part in
the countermeasure parts.
-1-
§12. Engine disassemble
1. Stand on a flat surface stand or something, so head of the engine is on 2. Remove the generator TIP
・Be careful not to lose the (2 locations).
・Be aware of the generator’s force.
・When assembling, replace a new part in the countermeasure 3. Remove the starter clutch and the shaft ③.
4. Remove the middle gear TIP
・Be careful not to lose the (2 locations)
・When assembling, replace a new part in the countermeasure 5. Remove the middle driven TIP
・Be careful not to drop the (2 locations)
・When assembling, replace a new part in the countermeasure ①
③
②
④
⑤
5. Remove the middle driven shaft assembly ⑤. Shim
TIP:
• Be careful not to drop the two shims (2 locations).
• When assembling, replace O-ring with a new part in
the countermeasure parts.
-1-
§12. Engine 1. Stand stand head 2. Remove TIP
・Be careful (2 locations).
・Be aware force.
・When a new 3. Remove and the 4. Remove TIP
・Be careful (2 locations)
・When a new 5. Remove TIP
・Be careful (2 locations)
・When a new ①
③
②
④
⑤
Shim
Page 5 of 26
6. Remove the pick-up rotor cover ⑥.
TIP:
• Be careful not to lose the dowel pins (2 locations).
• Record the mounting positions of the guides
-2-
6. Remove the pick-up TIP
・Be careful not to lose (2 locations)
・Record the mounting the guides.
7. Remove the oil cooler Remove the following ・Water hose outlet ・Water jacket joint ・Oil cooler outlet hose TIP
When assembling, replace replace with a new part countermeasure parts.
8. Remove the water pump TIP
Remove tray 1 as 9. Remove the Middle Housing ⑨
TIP
・When assembling, replace new part in the countermeasure 10. Remove the clutch TIP
・Be careful not to lose (2 locations)
・When assembling, gasket new one.
⑥
1
2
3
⑦
⑧
1
⑨
⑩
7. Remove the oil cooler ⑦.
Remove the following parts:
• Water hose outlet hose 1
• Water jacket joint 2
• Oil cooler outlet hose 3
TIP:
When assembling, replace bolts and O-rings replace
with a new part in the countermeasure parts.
-2-
6. Remove the pick-TIP
・Be careful not to (2 locations)
・Record the mounting the guides.
7. Remove the oil Remove the following ・Water hose outlet ・Water jacket ・Oil cooler outlet TIP
When assembling, replace with a new countermeasure parts.
8. Remove the water TIP
Remove tray 9. Remove the Middle Housing ⑨
TIP
・When assembling, new part in the 10. Remove the clutch TIP
・Be careful not to (2 locations)
・When assembling, new one.
⑥
1
2
3
⑦
⑧
1
⑨
⑩
8. Remove the water pump.
TIP:
Remove tray 1 as well.
9. Remove the Middle Drive Shaft Bearing Housing ⑨.
TIP:
• When assembling, replace O-ring with a new part in
the countermeasure parts.
10. Remove the clutch cover ⑩.
TIP:
• Be careful not to lose the dowel pins (2 locations).
• When assembling, replace gasket with a new one.
-2-
6. Remove the pick-TIP
・Be careful not (2 locations)
・Record the mounting the guides.
7. Remove the oil Remove the following ・Water hose ・Water jacket ・Oil cooler outlet TIP
When assembling, replace with a new countermeasure 8. Remove the water TIP
Remove tray 9. Remove the Middle Housing ⑨
TIP
・When assembling, new part in the 10. Remove the TIP
・Be careful not (2 locations)
・When assembling, new one.
⑥
1
2
3
⑦
⑧
1
⑨
⑩
~
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~~
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Page 6 of 26
11. Mark the phase positions of the Balancer gear 1 and the
large reduction gear (primary driven gear) 2.
TIP:
• Turn the crankshaft clockwise.
• When piston #1 at the TDC on the compression
stroke, align the “T” mark “a” on the pickup rotor with
the crankcase mating surface “b” ⑪.
• Make sure and mark that the reduction gear 3 teeth
and the reduction gear 4 teeth mesh correctly ⑫.
• Make sure and mark that the reduction gear 2 that
meshes with balancer gear 1 mating mark ⑬.
-3-
11. Marking Balancer gear TIP
・Turn ・When compression “a” crankcase ・Make gear teeth ・Make gear mating 12. Remove ・Oil TIP
When new part ・Pressure ・Clutch TIP
Be careful sheet ・Pressure ・Short-・Ball ・Friction ・Clutch ・Clutch ・Friction ・Lock ・Clutch ・Clutch ・Clutch TIP
While clutch 11.
b a
⑬
⑪
⑫
1
5 4 3 2
7
6
9 8
17
9 9
15 9
14 12
10
7
9
16
9 9
11
13 7
10 10 10
10
7 10
11
14
18
A
10
1
2
4
3
12. Remove the Clutch Assembly.
• Oil guide plate 1
TIP:
When assembling, replace the bolts with new parts in
the countermeasure parts kit.
• Pressure plate (1) 2
• Clutch Spring 3
TIP:
Be careful not to drop off the plate sheet “a”.
• Pressure plate (2) 4
• Short-circuit clutch push rod 5
• Ball 6
• Friction plate (1) 7
• Clutch Plates (2) 8
• Clutch Plate (1) 9
• Friction plate (2) 10
• Lock washer/boss nut 11
• Clutch Damper Spring 12
• Clutch Damper Spring Seat 13
• Clutch boss 14
-3-
11. Marking the phase positions of the
Balancer gear 1 and the large reduction
gear (primary driven gear)2
TIP
・Turn the crankshaft clockwise
・When piston #1 at the T.D.C on the
compression stroke, align the “T” mark
“a” on the pickup rotor with the
crankcase mating surface “b”⑪.
・Make sure and mark that the reduction
gear 3 teeth and the reduction gear 4
teeth mesh correctly ⑫.
・Make sure and mark that the reduction
gear 2 that meshes with balancer gear 1
mating mark ⑬.
12. Remove the Clutch Assy
・Oil guide plate 1
TIP
When assembling, replace the bolt with a
new part in the countermeasure parts kit.
・Pressure plate (1) 2
・Clutch Spring 3
TIP
Be careful not to drop off the plate
sheet “a“.
・Pressure plate (2) 4
・Short-circuit clutch push rod 5
・Ball 6
・Friction plate (1) 7
・Clutch Plates (2) 8
・Clutch Plate (1) 9
・Friction plate (2) 10
・Lock washer/boss nut 11
・Clutch Damper Spring 12
・Clutch Damper Spring Seat 13
・Clutch boss 14
TIP
While holding the clutch boss”14” with the
clutch holder 18,loosen the clutch boss nut
11.
4 3 2
11
A
TIP:
While holding the clutch boss ‟14” with the clutch holder
18, loosen the clutch boss nut 11.
Universal clutch holder
90890-04018~ch holder
Universal c u
YM-91042
Page 7 of 26
• Thrust washer 15
• Spacer 16
TIP:
Insert two 5mm bolts into the spacer 16 And then
remove the spacer by pulling on the bolts.
• Clutch housing 17
-4-
When loosen impact wrench, plate by hand ・Thrust ・Spacer TIP
Insert two And then the bolts.
・Clutch 13. Remove TIP
・Remove ・When new part 14. Invert downward, by using 15. Remove ・Oil pan ・Oil delivery ・Oil delivery ・Oil Strainer ・Relief ・Dowel ・Oil Pump ・Oil pump 16
17
⑮ ⑭
⑯
7
5
4
3
2
1
6
8
-4-
・Thrust ・Spacer TIP
Insert And then the bolts.
・Clutch 13. Remove TIP
・Remove ・When new 14. Invert downward, by 15. Remove ・Oil ・Oil ・Oil ・Oil ・Relief ・Dowel ・Oil ・Oil 16
17
⑮ ⑭
⑯
7
5
4
3
2
1
6
8
13. Remove the oil pump drive sprocket ⑭.
TIP:
• Remove the oil pump drive chain guide ⑮.
• When assembling, replace the bolts with new parts in
the countermeasure parts kit.
14. Rotate the engine upside down and stand it on a flat
surface by using an engine stand or wood block.
15. Remove the oil pump ⑯.
• Oil pan 1, oil pan gasket 2
• Oil delivery pipe (2) 3
• Oil delivery pipe (3) 4
• Oil Strainer 5
• Relief valve 6
• Dowel pin 7
• Oil Pump Drive Chain 8
• Oil pump ⑯
TIP:
• When assembling, replace the gasket, O-ring and bolt
with the new parts in the countermeasure parts kit.
* It is necessary to use Loctite on the bolt.
• Remove the Oil Pump Drive Chain 8 by pulling out the
dowel pin 7 and shifting the oil pump ⑯.
• The oil pump drive chain “8” has a plate with a
different color. Remember which direction the different
color plate is facing (inside or outside of engine) and
have it noted. During reassembly the oil pump drive
chain 8 will need to face the same direction.
TIP
・When O-countermeasure * Necessary bolt.
・Remove by the ・The with Remember when outside disassemble.
When 16. Remove ・Middle ・Lock TIP
When with ・Middle 7
8
8
⑯
5
4
1 2 3
6
4
5 6
16. Remove the middle gear Comp.
• Middle drive pinion gear nut 1
• Lock washer 2
TIP:
When assembling, replace the lock washer with a new
part in the countermeasure parts.
• Middle drive pinion gear 3
• Middle Drive Shaft Assembly 4
• Spacer 5
• Middle driven gear 6
TIP:
Pull out the middle drive shaft assembly 4
*When pulling out, be careful not to drop 5 and 6.
-5-
by pulling the oil ・The oil with a Remember when outside disassemble.
When 16. Remove ・Middle ・Lock washer TIP
When assembling, with a new ・Middle ・Middle ・Spacer ・Middle TIP
Pull out the ※ When and 6.
17. Disassemble ・Remove (At Left TIP
・Loosen in stages ※ Loosen order ・The numbers indicate sequence.
8
5
4
1 2 3
6
4
5 6
17. Disassemble the crankcase as follows:
• Remove the crankcase bolts. (1 through 31 as shown).
TIP:
• Loosen each bolt ¼ of a turn a time, in stages and in a
crisscross pattern.
*Loosen the bolts in decreasing numerical order
(refer to the numbers in the figure.)
• The numbers embossed on the crankcase indicate the
crankcase tightening sequence.
18. Remove the lower crank case 1 from the upper crank
case 2.
TIP:
• Tap one side (thick part) of the crankcase with a plastic
hammer.
• Only hit the reinforced part of the crankcase.
• Work carefully and make sure the crankcase is
completely disassembled.
• Be careful not to lose the dowel pins (2 locations)
18. Remove upper Note
・Tap one with a ･Only hit crankcase.
・Work carefully crankcase
is completely ・Be careful (2 locations)
§13. Replacing 1. Remove ・Oil baffle ・Circlip TIP
When assembling, ①
3 2
4
1
2
REPLACE THE TRANSMISSION
1. Remove the shaft assembly ① as follows
• Oil baffle plate 1
• Circlip 2
TIP:
When assembling, replace the circlip with a new part in
the countermeasure parts kit.
• Stopper lever spring 3
TIP:
• Washer 4 may remain in place. Be sure to remove it.
• Don’t remove the oil seal 5 on the shaft
-6-
・Work crankcase
is ・Be (2 §13. 1. Remove ・Oil ・Circlip TIP
When new ・Stopper Note
・Washer to ・Don’t 2. Remove 3. Remove out And shift Note
Remove not ①
1
3 2
4
5
⑧
④
③
②
①
⑥
⑤
⑩
⑩
⑨
⑪
2. Remove the drive axle Assy ①.
3. Remove shift drum retainer ②, and pull out the long
shift fork guide bar ③.
Also remove the shift fork L ④ and the shift fork R ⑤.
TIP:
Remove the spring with the fork guide bar and ensure
that the spring ⑦ does not get lost.
4. Remove the shift cam ⑧ and pull out the short shift fork
guide bar ⑥.
TIP:
Remove the engagement between the fork and the shift
cam, and pull out the shift cam.
5. Remove shift fork C ⑨.
6. Remove the main axle assembly ⑩.
4. Remove the drill the short shift TIP
Remove the engagement and the shift cam, 5. Remove shift 6. Remove the main TIP
Remove the oil collar 2 and the axle.
※ The conical washer on the small diameter outside of the ・Remove three 1 2 3
⑩
⑧
⑨
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Page 10 of 26
TIP:
Remove the oil pump sprocket collar 1, the collar 2 and
the conical washer 3 from main axle.
*The conical washer “3” has a lip on the small-diameter
side that will face the outside of the engine during
reassembly.
• Remove the three Torx bolts.
There is a crimp on the bolt seat, so the Torx bolts will
need to be loosened carefully.
• Remove the main axle assembly with the slide
hammer bolts “4” and weight.
-7-
Remove the oil pump sprocket collar 1, the
collar 2 and the conical washer 3 from main
axle.
※ The conical washer 3 has a mountain
on the small diameter side, which is the
outside of the engine.
・Remove three torx bolts.
There is a crimp on the bolt seat, so
loosen the torx head carefully so as not
to damage it.
・Remove the main axle assembly with the
slide hammer bolts “4” and weight.
・In case without a slide hammer, using
M6 x 1.0 two 25 mm bolts.
・Tighten by about 1/4 turn after seating
and pull out the main axle while keeping
it tighten.
Note
・The main axle will fall into the
crankcase when the press fit is released.
・The 1st pinion gear ⑪ is not press
fit. therefore, it will fall when the main
axle is tilted.
• If a slide hammer is not available, using two 25mm M6
x 1.0 bolts will pull the main axle out ¼ turn at a time
after the bolts have been seated.
NOTE:
• The main axle will fall into the crankcase when the
press fit is released.
• The 1st pinion gear (11) is not a press-fit gear and will
fall when the main axle is tilted.
-7-
TIP
Remove collar 2 and axle.
※ The conical on the outside ・Remove There loosen to damage ・Remove slide hammer ・In case M6 x ・Tighten and pull it tighten.
Note
・The main crankcase ・The 1st fit. therefore, axle is 1 2 3
⑩
4
4
7. Clean the Crankcase
Clean thoroughly any residual gasket or oil on the
crankcase mating surface.
8. Install the transmission in the opposite order of removal.
8-1. Assembling the main axle assembly ⑩
*Replace with the countermeasure parts.
• Lubricate each gear, the shaft and bearing with
engine oil.
• Lubricate the entire outer surface of the main axle
bearing housing with engine oil and install it into
the crankcase.
• The 1st pinion gear ⑪ is not press-fitted, so, if it
falls off, the convex side is on the inside and the
plane side is on the outside.
• Install the conical washer 3, the collar 2, and the
oil pump sprocket collar 1.”
8-1. Assembling ※ Replace ・Lubricate the and the bearing.
・Lubricate the peripheral And insert ・The 1st pinion so if it falls the plane side ・Install the pump sprocket housing portion ・When installing “5” to align corresponding 7. Cleaning the Crankcase
Clean thoroughly any residual gasket or oil on the crankcase 8. Please install a transmission with the opposite procedure ⑪
3 2
Outside Inside
Outsid Inside
e
Plane
side
Convex side
Slide hammer bolt
90890·01083 bolt 6 mm
Slide hammer
YU–01083-1
Weight
90890·01084
Weight
YlJ–01083·3
• When installing the main axle assembly ⑩, use a
pin “5” to align the bearing housing hole with the
corresponding hole in the upper crankcase.
• To install the bearing housing (which is pressfit),
insert the three M6 25mm bolts or the old
retaining Torx bolts.
• Tighten each bolt 1/4 turn diagonally until the
bearing housing touches the crankcase surfaces.
Check that the main axle rotates smoothly.
• Next, remove the M6 25mm bolts or Torx used
to install the bearing housing. Apply Loctite to
the new bolts and tighten them to the specified
torque.
-8-
・When installing the main axle assembly⑩, use a pin
“5” to align the bearing housing hole with the
corresponding hole in the upper crankcase.
・For bearing housing press fit, insert the M6 x 25 mm
bolt 3pcs or the old retaining torx bolt.
・Tighten each bolt 1/4 turn diagonally until the
bearing housing touches the crankcase surfaces.
At this time, sometimes please check the main axle
rotates smoothly.
・Next, remove the press-fit bolt, and then prepare a
new parts and apply the LOCKTITE.
And tighten them to the specified torque.
・Check again the main axle rotates smoothly.
If it rotates not smooth, disassemble the main axle
Assy and press-fitting the bearing completely into
the crankcase.
• Check again to be sure the main axle rotates
smoothly. If it does not rotate smoothly, remove
the main axle and reinstall to ensure the bearing
housing is completely installed into the crankcase
assembly. When the main axle is installed
correctly, use a punch to recrimp (stake) the
Torx bolts into place. -8-
housing portion ・When installing “5” to align corresponding ・For bearing bolt 3pcs ・Tighten each bearing housing At this time, rotates smoothly.
・Next, remove new parts And tighten ・Check again If it rotates Assy and the crankcase.
3 5
⑩
8-2. Assembling the shift fork/shift cam
• Lubricate the shift dog clutch and shift fork fittings
using molybdenum oil while turning the main by hand.
• Lubricate the tip of the claw of shift fork C ⑨ using
molybdenum oil.
8-2. Assembling the shift fork/shift cam
・Lubricate molybdenum oil to the dog clutch and
shift fork fittings while turning the main axle
by
hand.
・Lubricate molybdenum oil to the tip claw of shift
fork C ⑨.
・Insert the shift fork C ⑨ and the shift cam fitting
part with the protrusion (red circle part) facing up
while fitting the fork tip claw part with the dog
clutch.
・Lubricate the engine oil to the shift cam, the
crankcase mating part, the shift fork and the
short-shift fork bar ⑥.
・Insert the shift cam ⑧ while using the gap which
move the shift fork C ⑨ to the dog clutch side.
・After that, assemble the Short Shift Fork Bar ⑥
・Lubricate the molybdenum oil on the tip claw of shift
fork R⑤/L④ and outer of the long shift fork bar ③.
・Align the projection of the shift fork with the groove
of the shift cam, and when the position is decided,
assemble the long shift fork bar ③.
8-3. Replace the Middle Drive Gear
・Remove the middle drive gear ⑫ and the washer
⑨ ⑥
⑨
④
“R” engrave
“L” engrave
③
⑫
⑫
• Install the shift fork C ⑨ onto the main axle with
the claw facing up.
• Lubricate the shift cam and its crankcase mating
surfaces as well as the short shift fork bar ⑥ with
engine oil.
8-2. Assembling the shift fork/shift cam
・Lubricate molybdenum oil to the dog clutch and
shift fork fittings while turning the main axle by
hand.
・Lubricate molybdenum oil to the tip claw of shift
fork C ⑨.
・Insert the shift fork C ⑨ and the shift cam fitting
part with the protrusion (red circle part) facing up
while fitting the fork tip claw part with the dog
clutch.
・Lubricate the engine oil to the shift cam, the
crankcase mating part, the shift fork and the
short-shift fork bar ⑥.
・Insert the shift cam ⑧ while using the gap which
move the shift fork C ⑨ to the dog clutch side.
・After that, assemble the Short Shift Fork Bar ⑥
・Lubricate the molybdenum oil on the tip claw of shift
fork R⑤/L④ and outer of the long shift fork bar ③.
・Align the projection of the shift fork with the groove
of the shift cam, and when the position is decided,
assemble the long shift fork bar ③.
8-3. Replace the Middle Drive Gear
・Remove the middle drive gear ⑫ and the washer
⑬
from original drive axle Assy ①.
⑨
engrave
⑫
• Install the shift cam ⑧ and align the shift fork C ⑨
with its appropriate groove on the shift cam. Install
the short shift fork bar ⑥. Make sure that the bar
has both springs installed and goes through the
shift fork C.
• Lubricate the tip of the claw on the shift fork R⑤/
L④ and the remaining long shift fork bar ③.
8-2. Assembling the shift fork/shift cam
・Lubricate molybdenum oil to the dog clutch and
shift fork fittings while turning the main axle by
hand.
・Lubricate molybdenum oil to the tip claw of shift
fork C ⑨.
・Insert the shift fork C ⑨ and the shift cam fitting
part with the protrusion (red circle part) facing up
while fitting the fork tip claw part with the dog
clutch.
・Lubricate the engine oil to the shift cam, the
crankcase mating part, the shift fork and the
short-shift fork bar ⑥.
⑨ ⑥
⑨
⑧
• Align the projection of the shift fork with the
groove of the shift cam, and when the position is
decided, assemble the long shift fork bar ③.
8-2. Assembling ・Lubricate molybdenum shift fork fittings hand.
・Lubricate molybdenum fork C ⑨.
・Insert the shift part with the while fitting the clutch.
・Lubricate the crankcase mating short-shift fork ・Insert the shift move the shift ・After that, assemble ・Lubricate the fork R⑤/L④ ・Align the projection of the shift cam, assemble the 8-3. Replace the ・Remove the ⑬
from original ⑨ ⑥
⑨
⑧
⑤ ④
③ “R” engrave
“L” engrave
⑤ ④
③
① ⑫
⑫
Page 11 of 26
!’5,l 12 Nm (1.2 m•kgf, 8.7 ft-lbf) !
1 m
1
Gl
Page 12 of 26
8-3. Replace the Middle Drive Gear
• Remove the middle drive gear ⑫ and the
washer ⑬ from original drive axle assembly
① and assemble the drive axle assembly of
countermeasure parts.
TIP:
• Install the middle drive gear ⑫ with its chamfered side
facing inward as shown in the figure on the right.
• Install the washer ⑬ with its chamfered side facing
towards the drive axle assembly as shown.
-9-
・Align the projection of the shift cam, assemble the long 8-3. Replace the ・Remove the middle ⑬
from original drive And assemble countermeasure TIP
・Install the middle side facing inward ・Install the washer towards the drive figure on the left.
⑤ ④
① ⑫
⑬
⑫
⑬
8-4. Assembling the Drive Axle Assembly
Lubricate the shift-dog clutch and shift fork fittings
using molybdenum oil.
8-2. Assembling the shift fork/shift cam
・Lubricate molybdenum oil to the dog clutch and
shift fork fittings while turning the main axle by
hand.
・Lubricate molybdenum oil to the tip claw of shift
fork C ⑨.
・Insert the shift fork C ⑨ and the shift cam fitting
part with the protrusion (red circle part) facing up
while fitting the fork tip claw part with the dog
clutch.
・Lubricate the engine oil to the shift cam, the
crankcase mating part, the shift fork and the
short-shift fork bar ⑥.
・Insert the shift cam ⑧ while using the gap which
move the shift fork C ⑨ to the dog clutch side.
・After that, assemble the Short Shift Fork Bar ⑥
・Lubricate the molybdenum oil on the tip claw of shift
fork R⑤/L④ and outer of the long shift fork bar ③.
・Align the projection of the shift fork with the groove
of the shift cam, and when the position is decided,
assemble the long shift fork bar ③.
8-3. Replace the Middle Drive Gear
・Remove the middle drive gear ⑫ and the washer
⑬
from original drive axle Assy ①.
And assemble the drive axle Assy of
countermeasure parts
TIP
・Install the middle drive gear ⑫ with its chamfered
side facing inward as shown in the figure on the left.
・Install the washer ⑬ with its chamfered side facing
towards the drive axle assembly as shown in the
figure on the left.
⑨ ⑥
⑨
④
“R” engrave
“L” engrave
③
⑫
⑬
⑫
⑬
• Install the shift fork R⑤/L④ on the drive axle
assembly and the shift cam in their appropriate
grooves.
• The right bearing has an alignment pin 1.
Align the pin 1 and the clip 2 of the bearing with
the positions as shown in the figure.
8-4. Assembling ・Lubricate fork fitting ・Place the while fitting ・The right Align the positions 8-5. Assemble Assemble the disassemble.
TIP
・Align the segment.
・Replace the new one ∗Apply the ・Hang the ・Assemble is sandwiched ・Assemble projection ⑤
1
④ 2
1
2
4
5
Note
Before assemble 3
8-5. Assemble the Shift Shaft Assembly
Assemble the shaft assembly (1) in the reverse
order of disassembly.
TIP:
• Align the stopper lever bearing 2 with the shift cam
segment.
• Replace the shift drum retainer fixing bolt 3 with a new
one in the countermeasure parts.
* Apply Loctite to the screws.
• Hang the stopper lever spring 4 on the hook.
• Assemble the torsion spring 5 so that the stopper is
sandwiched between them.
• Assemble the pawl (1) so that it will grasp the
projection of the shift cam segment
NOTE:
Before assembling the crankcase, turn the shift drum
assembly over and check that the transmission gears
are shifting correctly.
8-4. Assembling the Drive Axle ・Lubricate the molybdenum fork fitting part.
・Place the the shift fork R⑤while fitting the dog clutch.
・The right bearing has alignment Align the pin 1 and the clip positions as shown in the 8-5. Assemble the Shift Shaft Assemble the shaft Assy1 in disassemble.
TIP
・Align the stopper lever bearing segment.
・Replace the shift drum retainer new one in the countermeasure ∗Apply the LOCKTITE to ・Hang the stopper lever spring ・Assemble the torsion spring is sandwiched between them.
・Assemble the pawl part so projection of the shift cam ⑤
1
④ 2
1
2
4
5
Note
Before assemble the crankcase, shifting drum Assy and check 3
Page 13 of 26
ASSEMBLE THE ENGINE
Assemble the crankcase parts by reversing the disassembly procedures.
1. Assemble the Crankcase
1-1. Lubricate the inside of the crankshaft journal
bearing using engine oil.
1-2. Apply sealant (Yamabond 4 Motorsports) to the
crankcase mating surface.
TIP:
• Do not apply sealant to the crankshaft journal bearing
or the oil passages.
• Do not apply sealant within the crankshaft journal
bearing or within a 2 to 3mm range of the bearing
journal.
1-3. Set the dowl pins (shown circled).
1-4. Move the shift drum assembly and the
transmission gear to the neutral position.
1-5. Install the lower crankcase 1 onto the upper
crankcase 2.
-11-
Assemble the Crankcase Parts reverse disassemble procedures.
1. Assemble the Crankcase
1-1. Lubricate the engine oil to the inside of the crankshaft 1-2. Lubricate the sealant (Three Bond 1215) to the crankcase Upper Crankcase
TIP
・Do not attach journal bearing ・Do not lubricate shaft journal 1-3. Set the Dowel pin
1-4. Move the shift drum Assy and the transmission gear 1-5. Assemble the lower crankcase 1 to the upper crankcase Lower Crankcase
§14. Engine Assemble
Assemble the Crankcase Parts reverse disassemble procedures.
1. Assemble the Crankcase
1-1. Lubricate the engine oil to the inside of the crankshaft journal bearing.
1-2. Lubricate the sealant (Three Bond 1215) to the crankcase mating surface.
Upper Crankcase
TIP
・Do not attach the sealant to the crank shaft
journal bearing and the oil gallery.
・Do not lubricate the sealant within the crank
shaft journal bearing and 2 to 3mm range.
1-3. Set the Dowel pin
1-4. Move the shift drum Assy and the transmission gear to the neutral position.
1-5. Assemble the lower crankcase 1 to the upper crankcase 2.
Lower Crankcase
-11-
§14. Engine Assemble
Assemble the Crankcase Parts reverse disassemble procedures.
1. Assemble the Crankcase
1-1. Lubricate the engine oil to the inside of the crankshaft 1-2. Lubricate the sealant (Three Bond 1215) to the crankcase Upper Crankcase
TIP
・Do not attach the journal bearing and ・Do not lubricate shaft journal bearing 1-3. Set the Dowel pin
1-4. Move the shift drum Assy and the transmission gear to 1-5. Assemble the lower crankcase 1 to the upper crankcase Lower Crankcase
Page 14 of 26
1-6. Replace the crankcase bolts with the new ones in
the countermeasure parts kit.
Tighten the bolts to the specified torque in the
order shown in the figure below.
(the number stamped on the crankcase).
TIP:
• Lubricate the bolts 1-10 thread and washers with
engine oil
• Replace the bolts with new parts in the
countermeasure parts kit.
• Lubricate the bolt 11-31 thread portion and mating
surface with the engine oil (except bolt 16).
• Apply Loctite to the threaded portion of the new bolt 16
in the countermeasure parts kit.
• Tighten the crankcase bolts with fingers.
1) Tighten the crankcase bolts in the proper
tightening sequence as shown.
2) Loosen and retighten the crankcase bolts in the
proper tightening sequence as shown.
Loosen one bolt and retighten individually
then repeat with the next bolt. Do not loosen all bolts at
the same time.
3) Tighten the crankcase bolts further to reach the
specified angle 115 – 125 ° in the proper tightening
sequence as shown.
If the bolt is tightened more than the specified
angle, do not loosen the bolt and then retighten it.
Instead, replace the bolt with a new one and perform
the procedure again.
TIP:
Do not use a torque wrench to tighten the bolt to the
specified angle.
On a hexagonal bolt, note that the angle angle from
one corner to another is 60°.
-12-
1-6. Assemble the crankcase bolts (31 pcs.).
Tighten the bolts to the specified torque in the order shown (the number stamped on the crankcase).
TIP
・Lubricate with ※Replace countermeasure ・Lubricate mating (except ・Apply of bolt ※ Replace countermeasure ・Tighten 1) Tighten tightening 2) Loosen the proper Note
It is not bolts. Loosen the next 3) Tighten reach proper Warning
If the bolt angle, it. Instead, Perform TIP
Do not to the specified On a hexagonal one corner 4) Tighten tightening ・Bolt 1-10
M9×115mm
⇒ Replace with new washer bolt
・Bolt 11
M8×65mm
・Bolt 12
M8×50mm
・Bolt 23、25
M6×80mm
・Bolt 13,14
M 6×65 mm shoulder bolt
・Bolt 19,22,24,26
M6×66mm
・Bolt 15-18,20,21,27-30
M6×55mm
⇒ 16: Replace with new bolts and Lubricate
thread locking agent
・Bolt 31
M6×45mm
4) Tighten the crankcase bolts in the proper tightening
sequence as shown (11 – 31).
NOTICE:
NOTICE:
Crankcase bolt ” 1″ – “10”
1st
20 Nm (2.0 m-kgf, 14 11-lbf)
Crankcase bolt ” 1″ – “10”
2nd
20 Nm (2.0 m-kgf, 14 ft-lbf)
Crankcase bolt “1” – ” 1 O”
Final
Specified angle 115-125°
Crankcase bolt ” 11 “, ” 12″
24 Nm (2.4 m-kgf, 17 11-lbf)
Crankcase bolt ” 13″ , “14”
12 Nm (1 .2 m-kgf, 8.711-lbf)
Crankcase bolt ” 15″ – ” 31 “
10 Nm (1 .0 m-kgf, 7.211-lbf)
Page 15 of 26
2. Assemble the Oil Pump
Assemble the following parts in reverse order of
disassembly.
• Relief valve
• Oil delivery pipe (2)
• Oil pump drive chain 1/oil pump
TIP:
• Set the oil pump drive chain to the main axle and pull it
up to the lower crank case side.
• Align the front and back of the chain with the direction
same as disassembly.
• Oil pump drive sprocket 2/collar 3
• Oil pump drive chain guide
• Dowel pin
• Oil delivery pipe (3)
• Oil strainer
-13-
2. Assemble disassemble.
・・・TIP
・・・・・・・3. TIP
・・・4. TIP
・・・5. 1
2
3
1 2
1
2
3. Assemble the Middle Gear
TIP:
• Assemble the middle driven gear 1 with the three
claws facing the inside of the engine
• Assemble the spacer 2 with the tapered flange side
facing the inside of the engine.
• Insert the middle driven gear 1 and spacer 2 onto the
middle drive shaft assembly.
4. Assemble the oil pan
TIP:
• Put the guides in the original position.
• Replace the oil pan gasket with the new one in the
countermeasure parts kit.
• There are no dowel pins.
5. Rotate the engine right side up and stand it on a flat
surface using an engine stand or a wood block.
Page 16 of 26
6. Assemble the Middle Driven Shaft Assembly
TIP:
The Shim 2 enters between the crankcase and the
middle driven shaft 1
*Pay attention to the direction
• Align hole position of the middle driven shaft end cover
3, and tighten the bolts to the specified torque.
• Replace the bolts with new ones from the
countermeasure parts kit.
*Apply Loctite to the bolt threads.
-14
6. Assemble TIP
・The Shim the middle *Pay attention ・Align shaft the specified ・Replace countermeasure *Apply 7. Assemble TIP
・Assemble positions.
・The dowel ・Replace thecountermeasure * Apply 8. Assembling TIP
・Assemble positions.
9. Assemble Assemble the balancer.
・When compression the pickup surface.
2
1
3
1 2
7. Assemble the Middle Gear Case Cover
TIP:
• Assemble the guides to their original positions.
• There are two dowel pins required.
• Replace the bolts 1 and 2 with new parts in the
countermeasure parts kit.
* Apply the LOCTITE to the thread bolt
8. Assemble the generator cover
TIP:
• Assemble the guides to their original positions.
/J ‘ -,,
~~
<‘)~~~
Page 17 of 26
9. Assemble the Clutch Assembly
Assemble the primary driven gear to align with the
balancer.
• When piston #1 is at the TDC on the compression
stroke, align the T mark on the pickup rotor with the
crankcase mating surface.
Insert a cross-headed screwdriver into one of the holes
of the clutch housing and primary driven gear, match
the phase of the scissors gear 1 and the primary drive
gear 2.
・Insert a cross-headed screwdriver into one
of the holes of the clutch housing and
primary driven gear, match the phase of the
scissors gear 1 and the primary drive gear 2.
・Temporary assemble the the primary driven
gear to match the position when marked in
disassemble process.
TIP
・There are three positions where is alignment
in the fitting.
1) The primary driven gear and the drive gear
2) The balancer gear and the primary driven gear
3) The Oil pump gear convex part and the primary
driven gear concave * This can be adjusted later
・If it is not marked during disassembly,
adjust the phase in the method described below.
① Piston #1 is at T.D.C on the compression
stroke,
align the “T” mark “a” on the pickup rotor with
the crankcase mating surface “b” .
② Align the punch mark “c” of the balancer gear
to the position “d” of the primary driven gear
as shown figure.
③ Make sure the punch mark “c” match the
punch mark “e” of the upper crankcase.
・Lubricate the engine oil to the outer of spacer 3
and assemble it.
TIP
Assemble the spacer 3 so that a screw hole is on
the outside of the engine.
・Remove the a cross-headed screwdriver in the
hole in the primary driven gear
・If the fitting part of the convex part of the oil
pump gear does not match, rotate the oil pump
to find the fitting position and fit it.
2)
1)
1
2
• Temporary assemble the primary driven gear to match
the position when marked in the disassembly process.
TIP:
• There are three positions where alignment is critical.
1) The primary driven gear and the drive gear
2) The balancer gear and the primary driven gear
3) The oil pump gear convex part and the primary
driven gear concave * This can be adjusted later
• If it is not marked during disassembly, adjust the phase
in the method described below.
① Piston #1 is at TDC on the compression stroke.
Align the “T” mark “a” on the pickup rotor with the
crankcase mating surface “b” .
② Align the punch mark “c” of the balancer gear to the
position “d” of the primary driven gear as shown in the
illustration.
③ Make sure the punch mark “c” matches the punch
mark “e” of the upper crankcase.
• Lubricate the outer surface of spacer 3 and install it
-14
9. Assemble the Clutch Assemble the primary the balancer.
・When piston #1 compression stroke, the pickup rotor surface.
-15-
・Insert of the primary scissors ・Temporary gear disassemble TIP
・There in the 1) The 2) The 3) The driven ・If it adjust ① Piston stroke,
align the ② Align to the as ③ Make punch ・Lubricate and TIP
Assemble the outside ・Remove hole ・If the pump to find 2)
1)
3)
3
1
2
-~ — \ ~
=-….–A–
)/~(7~~( , . I
Page 18 of 26
TIP:
Assemble the spacer 3 so that a screw hole is on the
outside of the engine.
• Remove the a cross-headed screwdriver in the hole in
the primary driven gear
• If the clutch assembly does not align with the convex
part of the oil pump gear, rotate the oil pump to find
the correct position and then push the clutch assembly
onto it.
• Install the clutch boss, lock washer 5 and the clutch
boss nut 6 onto the main axle. -15-
・Lubricate and assemble TIP
Assemble the outside ・Remove hole in ・If the fitting pump gear to find the 3
TIP:
• Tighten the clutch boss nut 6 to the specified torque.
• Fold the tab of the lock washer 5.
• Replace the lock washer 5 with a new one in the
countermeasure parts kit.
• Place ball 7 in the hole in the main axle.
• Install the short clutch push rod 8.
TIP:
Replace the O-ring with a new one from the
countermeasure parts kit.
• Install the clutch plates and friction plates in reverse
order of disassembly.
TIP:
• Lubricate the front and back of each plate with engine
oil.
• Assemble in the same direction and combination as
when disassembling.
• Put the friction plate which diameter is large on the
clutch housing side.
• Assemble the friction plate and the clutch plate one by
one on pressure plate 9.
• Align the pressure plate 9 and the cam shape on the
clutch boss side, and assemble the convex part of the
friction plate to the clutch housing.
• Assemble the clutch spring, the pressure plate and
bolts in reverse order of disassembly.
• Assemble the clutch cover in reverse order of
disassembly.
TIP:
• Tighten the clutch cover bolt in proper tightening
sequence as shown.
• Tighten the bolts to the specified torque.
-16-
・Assemble clutch and assemble the clutch TIP
・Tighten specified ・Fold ・Replace one in ・Place ・Assemble TIP
Replace countermeasure ・Assemble plate TIP
・Lubricate back ・Assemble combination ・Put the large ・Assemble plate ・Align shape assemble plate to ・Assemble pressure of disassemble.
・Assemble order TIP
・Tighten tightening ・Tighten 4
6
5
7 8
9
Page 19 of 26
10. Assemble the Middle Drive Shaft Bearing Housing 1
Assemble in reverse order of disassembly.
-17-
10. Assemble bearing housing Assemble in 11. Assemble Assemble in TIP
・Attach the crankcase.
・Align the impeller the protrusion sprocket.
・Replace the the countermeasure *Apply a thin grease B.
12. Assembe Assemble in 13. Assemble TIP
・Assemble positions.
・The dowel ・Replace the in the countermeasure 1
11. Assemble the Water Pump Assembly
Assemble in reverse order of disassembly.
TIP:
• Attach the water pump tray 1 to the crankcase.
• Align the impeller shaft groove “a” and the protrusion
“b” on the oil pump driven sprocket.
• Replace the O-ring 2 with a new part in the
countermeasure part kit.
*Apply a thin layer of the Yamaha grease B.
-17-
10. Assemble bearing Assemble 11. Assemble Assemble TIP
・Attach crankcase.
・Align the sprocket.
・Replace the *Apply grease 12. Assembe Assemble 13. Assemble TIP
・Assemble positions.
・The ・Replace in 1
12. Assemble the Oil Cooler Assembly
Assemble in reverse order of disassembly.
-17-
Assemble 11. Assemble TIP
・Attach crankcase.
・Align the sprocket.
・Replace the *12. Assemble 13. TIP
・positions.
・・1
13. Assemble the Pickup Rotor Cover 1
TIP:
• Assemble the guides to their original positions.
• There are two dowel pins 3 required.
• Replace the gasket 2 with a new part in the
countermeasure parts kit.
– ….. ‘I — ….. \ – \ (” \ \
\ )
\ —
~
\ …… ——- \ …….. —-
3 o o a _____✓,,,.._..,__1 ….
,~,~~,
~ L
12 N•m (1 .2 kgf•m, 8.7 lb•ft)
.v ~~3 (f;~
.·’,·
<(
3 ~
Page 20 of 26
REINSTALL THE ENGINE
1. Referring to the Service Manual, reinstall the engine, reversing the disassembly steps.
2. Replace the engine oil, referring to the Yamalube viscosity and grade specifications in the Service Manual
(Chapter 3) for the operating conditions.
3. Add the recommended coolant per the Service Manual (Chapter 3).
4. Start the engine, warm it up for a several minutes, and then stop it.
5. Check for oil and coolant leaks. Check oil and coolant levels and adjust as necessary.
6. Perform a test run and confirm that the shift up/down operation can be performed smoothly from 1st to 6th.
7. Reset the clock on the meter.
REPROGRAM THE ECU
Follow the standard procedures for reprogramming the ECU using the Yamaha Diagnostic Tool (YDT) 3.1 or
later. Use Technical Bulletin M2018-009 for reference.
• Make sure the battery is well-charged or connect a battery charger if necessary. Otherwise the
reprogramming process may be halted and not completed.
• An ECU, once reprogrammed, cannot be returned to the original programming.
IMPORTANT: Customers with unauthorized, aftermarket ECU modifications may experience
issues after the ECU reprograming required by this recall is performed. Yamaha cannot participate
in accommodating any unauthorized ECU changes. Therefore, damage resulting to an ECU
during recall reprogramming because of previous unauthorized modification is the customer’s
responsibility.
Once the “reprogramming completed” message displays, confirm the reprogram date changed from “00…” to
the actual date (formatted YYYYMMDD) on the before/after reprograming chart.
Once the “reprogramming completed” message displays, confirm the Reprogram date changed from
“00…” to the actual date (formatted YYYYMMDD) on the before/after reprogramming chart as shown
below.
4. Turn the key off, then on again. Re-establish the connection to the vehicle using YDT. From the Select
Function menu, enter “Diagnosis of malfunction,” and erase any fault/event codes that are present.
TIP: If the key is not switched off / on again before attempting the clear the trouble codes, the codes will
not be able to be erased.
BN67
B883
Page 5 of 6
NOTE:
After finishing the reprogramming, error code P0606 will remain in the ECU malfunction history. There is no
trouble on the unit; therefore, please erase the malfunction code using YDT.
NOTICE:
• . r•
—
.• -I 0 ltH .. N72t’-‘llf
-‘”‘””- -“””” ‘”””‘ “””‘.’, — – E,
‘ ” …………. _…. 0 .=. =-=—- 1-D
Page 21 of 26
After completing the procedure, make sure to properly record and submit the warranty claim for this campaign to
ensure correct reimbursement and to update the unit’s repair history in Yamaha’s database.
KITS
Order one Transmission Kit and one Transmission Add Kit per affected unit
PART NUMBER DESCRIPTION
AFFECTED MODEL
DEALER COST
FJR1300A FJR1300P
TRANSMISSION KIT
90891-
10304-00
TRANSMISSION KIT,
FJR1300 O – $432.67
90891-
10309-00
TRANSMISSION KIT,
FJR1300P – O $433.69
TRANSMISSION ADD
KIT
90891-
10314-00
TRANSMISSION
ADD KIT, FJR1300 O – $0.69
TRANSMISSION
ADD KIT, FJR1300P – O $0.96
KIT CONTENTS
FJR1300A, FJR1300AE
KIT PART NAME PART NUMBER APPLICABLE MODELS
TRANSMISSION KIT, FJR1300 90891-10304-00
• FJR1300A
• FJR1300AE
KIT PART CONTENTS
No. PART NUMBER PART NUMBER PART NAME QTY
1 93210-33133 O-RING 1
2 93210-47675 O-RING 1
3 95022-06020 BOLT, FLG. 2
4 90110-06166 BOLT, HEX. SOCKET 2
5 91312-06025 BOLT, HEX. SOCKET 1
6 91312-06020 BOLT, HEX. SOCKET 2
7 5JW-13473-00 O-RING 1
8 90110-06163 BOLT, HEX. SOCKET 4
~~ IDENTIFICATION PROCEDURE
I ~~ I PARTS INFORMATION
Page 22 of 26
9 5GH-13440-61 OIL CLEANER ASSY. 1
10 93210-15566 O-RING 1
11 5JW-13414-01 GASKET, STRAINER 1
12 21411-19801 GASKET 1
13 91312-06012 BOLT, HEX. SOCKET 8
14 93210-14003 O-RING 2
15 91312-06016 BOLT, HEX. SOCKET 2
16 4FM-14613-00 GSKT., EXT. 1 4
17 3XW-14714-00 GSKT., MUFF. JT. 2
18 90119-09001 BOLT, HEX. 10
19 95812-06055 BOLT, FLG. 1
20 5JW-15451-11 GSKT., CRANKCASE COVER 1 1
21 5JW-15461-11 GSKT., CRANKCASE COVER 2 1
22 93210-27194 O-RING 1
23 5JW-15462-11 GSKT., CRANKCASE COVER 3 1
24 90149-06149 SCREW 2
25 5JW-15456-11 GSKT.,1 1
26 90215-25218 WASHER, TONGUED 1
27 93210-06632 O-RING 1
28 B88-17410-09 MAIN AXLE ASSY.,1 1
29 90149-06085 SCREW 3
No. PART NUMBER PART NUMBER PART NAME QTY
Page 23 of 26
30 B88-17420-09 DRIVE AXLE ASSY. 1
31 90215-27003 WASHER, TONGUED 1
32 93210-84724 O-RING 1
33 93210-76546 O-RING 1
34 95822-08035 BOLT, FLG. 3
35 99002-10600 CIRCLIP (E) 1
36 90119-05059 BOLT, HEX. W/WASHER 2
37 5PW-2411J-01 DAMPER, SIDE COVER 2
38 91312-05012 BOLT, HEX. SOCKET 2
39 90465-10098 CLAMP 2
40 90109-10058 BOLT 2
41 90149-10001 SCREW 1
42 1UA-82591-00 BAND 1
43 90464-30011 CLAMP 2
44 90110-08097 BOLT, HEX. SOCKET 2
No. PART NUMBER PART NUMBER PART NAME QTY
Page 24 of 26
KIT PART NAME PART NUMBER APPLICABLE MODELS
TRANSMISSION ADD KIT, FJR1300 90891-10314-00
• FJR1300A
• FJR1300AE
KIT PART CONTENTS
No. PART NUMBER PART NUMBER PART NAME QTY
51 90430-06014 GASKET 1
52 93210-18417 O-RING 2
53 5JW-14452-00 SEAL 1
54 91312-06012 BOLT, HEX. SOCKET 2
FJR1300P
KIT PART NAME PART NUMBER APPLICABLE MODELS
TRANSMISSION KIT, FJR1300P 90891-10309 • FJR1300P
KIT PART CONTENTS
No. PART NUMBER PART NUMBER PART NAME QTY
1~43 Same as
90891-10304-00 1
46 90269-05005 RIVET 6
47 95604-06200 NUT, S/L FLG. 2
48 92014-06040 BOLT, BUTTON HEAD 2
49 90464-16061 CLAMP 4
50 90464-65001 CLAMP 1
Page 25 of 26
FJR1300P
KIT PART NAME PART NUMBER APPLICABLE MODELS
TRANSMISSION ADD KIT, FJR1300P 90891-10313 • FJR1300P
KIT PART CONTENTS
No. PART NUMBER PART NUMBER PART NAME QTY
51 90430-06014 GASKET 1
52 93210-18417 O-RING 2
53 5JW-14452-00 SEAL 1
54 91312-06012 BOLT, HEX. SOCKET 2
55 90110-08097 BOLT, HEX. SOCKET 2
The owner of each registered motorcycle will receive a letter announcing this campaign. The customer’s letter
includes the Vehicle Identification Number and Recall Number.
The modification is authorized for all affected motorcycles, both sold and unsold, regardless of ownership or
warranty status. You do not need the customer’s letter to perform the modification or to file for reimbursement.
Submit a Recall Claim as described below using Campaign Number 990141. The labor allowance for FJR13A/E
is 14.0 hours. The labor allowance for FJR13P is 14.6 hours. Your claim will also be credited for 5 quarts of
engine oil and 3 quarts of coolant.
To submit your Recall Claim on YDS, go to Service > Warranty Claims/Authorization > Claims/Authorization >
New. Then, from the menu, select Recall / Service per Bulletin Claim (90 code).
WARRANTY INFORMATION
The owner of each registered motorcycle will receive a letter announcing this campaign. The
customer’s letter includes the Vehicle Identification Number and Recall Number.
The modification is authorized for all affected motorcycles, both sold and unsold, regardless of
ownership or warranty status. You do not need the customer’s letter to perform the modification
or to file for reimbursement.
Submit a Recall Claim as described below using Campaign Number 990141. The labor
allowance for FJR13A/E is 14.0 hours. The labor allowance for FJR13P is 14.6 hours
To submit your Recall Claim on YDS, go to Service > Warranty Claims/Authorization >
Claims/Authorization > New. Then, from the menu, select Recall / Service per Bulletin Claim (90
code).
If you have any questions about proper procedures for Factory Modification Campaigns, see
Chapter 7 in your Warranty and Y.E.S. Handbook (LIT-11760-00-16).
ENTER CAMPAIGN CODE 990141 HERE
If you have any questions about proper procedures for Factory Modification Campaigns, see Chapter 7 in your
Warranty and Y.E.S. Handbook (LIT-11760-00-16).
l~I WARRANTY INFORMATION
.. WarrantyOalm
J WarT.Vlty / Y. E.S. ~m If reQuest Is und« S7S0
Recall / 59rvlce P9° Bulletin Oilm (90 C.odes) I
V Parts and NX Qualitv Assurance Claim
… W.arranty Authoru1hon
Warranty/ Y. E.S. Authorization – If rt’Quest: is S750 or over
Ort of Warranty Authonzaoon
Un-ReQ1stered / un-sold UM AUthortzatlon
• SJilpplng DanW1ge
VISible Damage AUthortz..tiOn Pictures ReQulred
Conc..aled Damagt! Oaim S349 and und.ir
Concealed Damage Authonz.a on S350 and owr • Pictures R,;quired
MiSSino Parts Claim S349 and und8′
) M1ssino Parts Authoozaoon $350 ¥ld over
Unit R~I/SuYice Campaign
This screen allows you to enter Recall Request Information for sinole or multiple Primary IDs.
NOTE: The same recall information will be used for all of the primary IDs provided . . • campai9n Nbr:
* Primary ID:
*Rnish Date:
• Miles or Hours:
STEP 1 : Get Repair Options>>
Primary ID fi nish Date Miles Or 1-t”s
Page 26 of 26
IMPORTANT SAFETY RECALL NOTICE
This notice applies to your motorcycle, VIN xxxxxxxxxxxxxxxxx Model:
January 20, 2021
990141
Dear Yamaha Owner:
Yamaha Motor Corporation, U.S.A. has decided that a defect that relates to motor vehicle safety exists in 2016~2020-Model
FJR1300A, FJR1300AE, and FJR1300PA motorcycles. Our records show that you own the affected motorcycle shown above.
The reason
for this
recall:
What
Yamaha and
your dealer
will do:
What you
should do
now:
If you need
help:
In affected motorcycles, the side of second gear may not be strong enough to handle high speed loads. As
a result, cracks may occur due to constant stress applied during repeated gear shift operation and,
eventually, the gear could break. If this happens, the transmission and, in turn, the rear wheel, could lock,
increasing the risk of loss of control and a crash with injury or death.
Your authorized Yamaha dealer will inspect your motorcycle’s second gear and replace the main axle and
drive axle assembly and reprogram the Engine Control Unit (ECU) to change the performance
characteristics for second gear operation. The procedure takes about 14 hours to perform, so your dealer
will need to keep your motorcycle for several days. There will be no charge to you for this procedure.
Please call your Yamaha dealer to make a service appointment to have this procedure performed. At that
same time, you can find out how long they expect to keep your motorcycle for this service. Remember to
take this letter with you when you take in your motorcycle.
You may also get a notice regarding a Brake Switch Recall. When you take in your motorcycle for this
procedure, also ask your dealer to confirm if the modification of the brake switch needs to be performed as
well.
You should not operate your affected motorcycle shown above until modification is performed.
IMPORTANT NOTE: Some customers with unauthorized, aftermarket ECU modifications may experience
issues once the ECU reprograming required by this recall is performed. Yamaha cannot participate in
accommodating any unauthorized ECU changes. Therefore, damage resulting to an ECU during recall
reprogramming because of previous unauthorized modification is the customer’s responsibility.
If you are unable to return to the Yamaha dealer who sold you the motorcycle, this service will be
performed by any authorized Yamaha Motorcycle dealer. For the name of a dealer near you, call 1-800-88-
YAMAHA or visit the Yamaha web site at www.yamaha-motor.com.
If you have had this repair performed before you received this letter, you may be entitled to receive
reimbursement for the cost of obtaining a pre-notification remedy of the problem associated with this repair.
For more information, contact Yamaha Customer Relations at 1-800-962-7926.
Federal regulations require that any vehicle lessor receiving this recall notice must forward a copy of this
notice to the lessee within 10 days.
If, after contacting your dealership, you have questions or concerns which the dealership is unable to
answer, please write to:
Yamaha Motor Corporation, U.S.A.
Customer Relations Department
P.O. Box 6555 Cypress, CA 90630
Or call: 1-800-962-7926
If, after contacting Yamaha Customer Relations, you are still not satisfied that we have done our best to
remedy the situation without charge and within a reasonable time, you may submit a written complaint to
the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE.,
Washington, DC 20590; or call the Auto Safety Hotline at 1-888-327-4236 (TTY: 1-800- 424-9153); or go to
https://www.safercar.gov. Refer to NHTSA recall number 20V813.
If you no
longer own
this
Yamaha:
If you have sold your motorcycle to another party, please call us toll-free at 1-800-962-7926 with the name
and address of the new owner, along with Vehicle Identification Number shown above your name on this
letter.
We’re sorry to cause you any inconvenience, but we are sincerely concerned about your safety and continued satisfaction
with our products. Thank you for giving your attention to this important matter.
Sincerely,
Motorsports Service Support
Yamaha Motor Corporation, U.S.A
9 VAMAHA
YAMAHA MOTOR CORPORATION, U.S.A. 6555 Katella Avenue, Cypress, CA 90630-5101 800-962-7926

******************************************************************************************************

Page 26 of 26
IMPORTANT SAFETY RECALL NOTICE This notice applies to your motorcycle, VIN xxxxxxxxxxxxxxxxx Model: January 20, 2021 990141 Dear Yamaha Owner: Yamaha Motor Corporation, U.S.A. has decided that a defect that relates to motor vehicle safety exists in 2016~2020-Model FJR1300A, FJR1300AE, and FJR1300PA motorcycles. Our records show that you own the affected motorcycle shown above. The reason for this recall: What Yamaha and your dealer will do: What you should do now: If you need help: In affected motorcycles, the side of second gear may not be strong enough to handle high speed loads. As a result, cracks may occur due to constant stress applied during repeated gear shift operation and, eventually, the gear could break. If this happens, the transmission and, in turn, the rear wheel, could lock, increasing the risk of loss of control and a crash with injury or death. Your authorized Yamaha dealer will inspect your motorcycle’s second gear and replace the main axle and drive axle assembly and reprogram the Engine Control Unit (ECU) to change the performance characteristics for second gear operation. The procedure takes about 14 hours to perform, so your dealer will need to keep your motorcycle for several days. There will be no charge to you for this procedure. Please call your Yamaha dealer to make a service appointment to have this procedure performed. At that same time, you can find out how long they expect to keep your motorcycle for this service. Remember to take this letter with you when you take in your motorcycle. You may also get a notice regarding a Brake Switch Recall. When you take in your motorcycle for this procedure, also ask your dealer to confirm if the modification of the brake switch needs to be performed as well. You should not operate your affected motorcycle shown above until modification is performed. IMPORTANT NOTE: Some customers with unauthorized, aftermarket ECU modifications may experience issues once the ECU reprograming required by this recall is performed. Yamaha cannot participate in accommodating any unauthorized ECU changes. Therefore, damage resulting to an ECU during recall reprogramming because of previous unauthorized modification is the customer’s responsibility. If you are unable to return to the Yamaha dealer who sold you the motorcycle, this service will be performed by any authorized Yamaha Motorcycle dealer. For the name of a dealer near you, call 1-800-88-YAMAHA or visit the Yamaha web site at www.yamaha-motor.com. If you have had this repair performed before you received this letter, you may be entitled to receive reimbursement for the cost of obtaining a pre-notification remedy of the problem associated with this repair. For more information, contact Yamaha Customer Relations at 1-800-962-7926. Federal regulations require that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within 10 days. If, after contacting your dealership, you have questions or concerns which the dealership is unable to answer, please write to: Yamaha Motor Corporation, U.S.A. Customer Relations Department P.O. Box 6555 Cypress, CA 90630 Or call: 1-800-962-7926 If, after contacting Yamaha Customer Relations, you are still not satisfied that we have done our best to remedy the situation without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590; or call the Auto Safety Hotline at 1-888-327-4236 (TTY: 1-800- 424-9153); or go to https://www.safercar.gov. Refer to NHTSA recall number 20V813. If you no longer own this Yamaha: If you have sold your motorcycle to another party, please call us toll-free at 1-800-962-7926 with the name and address of the new owner, along with Vehicle Identification Number shown above your name on this letter. We’re sorry to cause you any inconvenience, but we are sincerely concerned about your safety and continued satisfaction with our products. Thank you for giving your attention to this important matter.
Sincerely,
Motorsports Service Support
Yamaha Motor Corporation, U.S.A

SEOCONTENT-END