2006~2008 and Certain 2009 FJR1300A/AE
Contents
1. cylinder assembly from the old main switch assembly is reused in the new main switch so the customer can use the same key as before 14 Remove the rubber screw covers from the lock cover on the old main switch Use a 3 8 drill bit to drill out the two tamper proof screw heads holding the lock cover to the main switch The lock cover which will not be reused acts as a guide for drilling the screws 15 Remove the lock cover from the new main switch by unscrewing the two tamper proof screws Re move the key cylinder assembly and spring from the new main switch Only the cover will be re used REMOVE REMAINDER OF BOLTS woe TAMPER PROOF RUBBER NS SCREW SCREW COVER DO NOT WORRY ABOUT DAMAGING THE OLD LOCK COVER IT IS NOT REUSED PAGE 5 of 10 16 17 18 19 20 21 Carefully remove the key cylinder assembly and spring from the old lock cover and install them in the new main switch cover in the same position as it was in the old switch Install the new lock assembly cover over the old key cylinder and spring on the new main switch Temporarily finger tighten the new tamper proof screws Check the new main switch for proper mechani cal operation using the original key from the old main switch Make sure the key operates smooth ly in all positions If not remove the spring and cylinder and reinstall correctly Tighten the tamper proof screws until they break off just above the screw heads T2. from the motorcycle Main Switch Removal The main switch is bolted to the bottom side of the upper triple clamp with two 8mm tamper proof bolts The bolt heads must be removed with a series of drill bits Follow these procedures closely and carefully for quick easy removal of the switch CAUTION Use extreme care to avoid damaging the top of the upper triple clamp while drilling the bolts You MUST use a drill press to ensure accurate drilling 8 Place a punch mark as accurately as possible in the center of each bolt An automatic type punch works best 9 Place the upper triple clamp upside down in a proper drill press vice using extreme caution not to damage it Use sturdy padding to avoid scratching 10 Starting with an 1 8 drill bit drill each bolt dead center slightly deeper than the switch base ap prox 1 2 to 3 4 deep 11 Repeat step 10 using a 1 4 drill bit 12 Repeat step 10 again using a 3 8 drill bit Only drill deep enough to pop the head off the bolt TIP If the bolt head does not come off the hole may not have been centered properly Repeat the drilling again with a one size larger drill bit which should re move the head PAGE 4 of 10 13 Remove the upper triple clamp from the drill press vise Using locking pliers Such as Vise Grips remove the remainder of the bolts from the holes Set the upper triple clamp aside Preparing the New Main Switch for Installation The key
3. MOTORCYCLE 1 29 2009 M2009 002R 2009 YAMAHA MOTOR CORPORATION U S A R C A This modification has top priority This bulletin must be performed immediately to ensure customer safety 2006 2008 and Certain 2009 FJR1300A AE FACTORY MODIFICATION CAMPAIGN Main Switch i INTRODUCTION Yamaha Motor Corporation U S A has decided that a defect which relates to motor vehicle safety exists in all 2006 through 2008 and certain 2009 FJR1300A and AE model motorcycles The main ignition switch s wire connection could overheat due to electrical resistance becoming hot enough to melt the solder connecting the wire to the main switch The wire could come off the switch if the solder melts preventing the electrical system from functioning If this occurs while the motorcycle is being ridden the engine would stall and be impos sible to restart which could result in an accident with injury or death MAIN SWITCH To correct this defect Yamaha is initiating a Factory Modification Campaign Affected motorcycles must have the main switch replaced with a new one designed to prevent overheating 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 the letter along with the affected motorcycle to an authorized Yamaha dealer for the modification A computer report listing all affected motorcycles invoiced to your dealership is included wi
4. ORATION U S A 6555 KATELLA AVENUE CYPRESS CALIFORNIA 90630 5101 800 962 7926 January 29 2009 SAFETY RECALL NOTICE Dear Yamaha Owner This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act Yamaha Motor Corporation U S A has decided that a defect which relates to motor vehicle safety exists in all 2006 through 2008 and certain 2009 FJR1300A and AE model motorcycles Our records show that you own the affected motorcycle shown above The reason for In affected motorcycles the main ignition switch s wire connection could overheat due to electrical resis this recall tance becoming hot enough to melt the solder connecting the wire to the main switch The wire could come off the switch if the solder melts preventing the electrical system from functioning If this occurs while the motorcycle is being ridden the engine would stall and be impossible to restart which could result in an accident with injury or death What Yamaha To correct this defect affected motorcycles must have the main switch replaced with a new one designed and your dealer to prevent overheating Your current key will still work in the new main switch There will be no charge will do to you for this procedure Replacing the main switch takes about 1 hour but your dealer may need to keep your motorcycle longer depending upon their schedule What you should Please call your Yamaha dealer to make a service ap
5. ace the motorcycle on the centerstand on a level surface Remove the seats PAGE 2 of 10 Remove the fuel tank panel Remove the two bolts holding the front of the tank Loosen do not remove the long bolt holding the rear of the tank Lift and support the front of the tank as it pivots on the rear mount Ma 10 Nm 1 0 m kg 7 2 ft 1b a 16 Nm 1 6 m kg 11 ft Ib j gt Z Via oo KS HEE a gt is j sl 1 a aga 3 i i af i gt AV i p Wa YY ex S YY f F si Remove the center support T bar and pull back REMOVING THE T BAR the heat protector to access the connectors Dis connect the red and white connectors LTN Pig 37 Mn 3 7 m kig 27 ft Ib Set the fuel tank temporarily back into position Carefully cover the tank and both sides of the cowling near the handlebars to prevent damage DISCONNECT THE RED AND WHITE CONNECTORS Remove the upper triple clamp nut and loosen the two fork clamp bolts See adjacent photo The handlebar has three adjustment positions Mark handlebar position on the upper triple clamp with erasable marker so the handlebars can be returned to their same position for the customer Remove the handlebars and hang them carefully along side the cowling supported by the cables and hoses with padding to avoid damage PAGE 3 of 10 7 Cut the zip tie holding the main switch harness then remove the upper triple clamp and main switch assembly
6. aha and address of the new owner along with the serial number shown above your name on the address label above 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 Customer Support Group Yamaha Motor Corporation U S A PAGE 10 of 10 ROUTE TO SERVICE KA PARTS V WARRANTY v SALES
7. ecall Number The modification is authorized for all 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 Request for the parts and labor for the main switch exchange as described below using Recall Number 990051 Choose the status M You will be reimbursed for the Main Switch Steering Lock plus labor The labor allowance is 1 0 hour which includes an allowance for the small amount of Loctite used YDS When signed on to YDS click on the Service Tab and then Recall Request Add This function will allow you to enter multiple Primary IDs for the same recall Remember that YDS requires a 7 digit serial number so use a 0 as the first digit The system will check your submission instantly to make sure the Primary ID numbers you ve entered are valid for the recall You can check back the next day for your claim numbers to track your credit MAIL Complete a recall Reimbursement Request LIT 11790 00 03 as shown below Dealer Number DEREDE Dealer Name Recall Number Primary I D Date Completed SO Be RE See A EE eee LETTE TTY EEE TT EPP ETT Ty EE Pettey ty tty EET TT ery Ty yy EEE If you have any questions about proper procedures for Factory Modification Campaigns see Chapter 8 in your Warranty and Y E S Handbook LIT 11760 00 05 PAGE 9 of 10 YAMAHA YAMAHA MOTOR CORP
8. he screws are designed to break when the proper tightening torque is reached Install the new rubber covers over the tamper proof screws Remove the red circled protective cover from the top of the main switch The new main switch is now ready to be installed on the upper triple clamp Installing the New Main Switch 22 Be sure the plastic main switch cover is still installed properly in the upper triple clamp PAGE 6 of 10 NEW SWITCH LOCK COVER KEY CYLINDER SPRING INSTALL OLD OLD SWITCH KEY CYLINDER INTO NEW MAIN SWITCH DISCARD NEWge KEY CYLINDER SWITCH COVER 23 Apply blue Loctite 242 to the new tamper proof bolts and install main switch in the upper triple clamp Tighten the bolts until the heads break off indicating proper torque has been reached CAUTION Be sure to hold the upper triple clamp secure ly and with proper padding so it will not be scratched during the tightening procedure Reassembly 24 Reinstall the upper triple clamp and handlebars in the reverse order of removal Install the new zip tie supplied in the kit in the same location as the one that was cut off Be sure to tighten all hardware to the proper torque Steering stem nut 115 Nm 11 5m kg 85 ft lb Upper bracket pinch bolt 26 Nm 2 6m kg 19 ft lb Handlebar bolt 23 Nm 2 3m kg 17 ft lb Handlebar nut 65 Nm 6 5m kg 47 ft lb 25 Connect the red and white connectors from the ma
9. in switch harness to the main harness 26 Reposition the heat protector and then reinstall the center support T bar Center support mounting bolts 37 Nm 3 7m kg 27 ft lb 27 Reinstall the fuel tank and tighten the mounting bolts Front fuel tank mounting bolts 10 Nm 1 0m kg 7 2 ft lb Rear fuel tank mounting bolt 16 Nm 1 6m kg 11 ft lb 28 Confirm that the main switch works properly in each position 29 Move the handlebars from lock to lock while checking for proper clearance and routing of all cables and hoses 30 Tag and hold the old main switch for 90 days from the date you submit your Recall Reimbursement Request Put a punch mark on the frame number as described in dentification Procedure in this bulletin NEW BOLT PROPERLY TORQUED PAGE 7 of 10 7J IDENTIFICATION PROCEDURE When the modification is complete put a punch mark next to the Primary ID as shown Check for this punch mark if you encounter an unfamiliar unit You can also check unit status on YDS or by contacting your Regional Technical Advisor PREVIOUS NEW PARTS INFORMATION 90891 30058 00 FJR1300 Key Set Kit Kit Includes e Main Switch Assembly e Anti theft bolts 8mm x 2 e 100mm Clamp zip tie e Rubber Screw Covers x 2 PAGE 8 of 10 C WARRANTY INFORMATION The owner of each warranty registered unit will receive a letter announcing this campaign The customer s letter includes the Primary ID and R
10. pointment to have this procedure performed Re do now member to take this letter with you when you take in your motorcycle You should not ride your motorcycle until this modification is performed 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 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 you need help 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 lf 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 Wash ington DC 20590 or call the toll free Vehicle Safety Hotline at 1 888 327 4236 TTY 1 800 424 9153 or go to http www safercar gov If you no longer If you have sold your motorcycle to another party please call us toll free at 1 800 962 7926 with the name own this Yam
11. r and key according to this bulletin on all affected units Check first to be sure the modification has not already been performed see Identification Procedure in this bulletin Yes order a new main switch kit for each affected unit See the Parts Information section for details Factory Modification Campaign See the Warranty Information section of this bulletin This modi fication applies to all affected units regardless of ownership or warranty status 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 for warranty as of 1 28 09 AFFECTED RANGE All 2006 FJR1300A All 2008 FJR1300A All 2006 FJR1300AC All 2008 FJR1300AC All 2006 FJR1300AE All 2008 FJR1300AE All 2006 FJR1300AEC All 2008 FJR1300AEC All 2007 FJR1300A 2009 FIR1300A RP15E 006050 006392 All 2007 FJR1300AC 2009 FJR1300AC RP15Y 001047 001108 All 2007 FJR1300AE 2009 FIR1300AE RP16E 001560 001736 All 2007 FIR1300AEC 2009 FJR1300AEC RP16Y 000275 000306 Q SERVICE PROCEDURES Refer to the service manual as needed when performing these procedures 2006 and 2007 models LIT 11616 19 83 2008 models LIT 11616 21 63 2009 models LIT 11616 22 73 IMPORTANT You will need to have a drill press for this procedure Triple Clamp Main Switch Assembly Removal The front of the fuel tank must be raised to access the main switch wire connectors 1 Pl
12. th 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 is 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 will also require modification If you purchase a motorcycle from another dealer check to see if the procedures in this bulletin have already been performed before you sell the motorcycle 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 motorcycles to customers until the procedures in this bulletin are performed When the modification on each motorcycle is performed follow the Warranty Information section of this bul letin 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 08 PAGE 1 of 10 ost DEALER ACTION SUMMARY Unsold Units Sold Units Parts Warranty Notify Customers Replace the main switch during PDI service reusing the original key cylinder and key Replace the main switch reusing the original key cylinde
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