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Fuel Filler Neck

Servicing the fuel filler neck for the FJR1300 is an easy and quick task. Even with distractions the whole process probably won't take 20 minutes. Since the pressure relief valve can be affected if dirt and grime accumulate, it's important to do this service periodically. Yamaha doesn't include it in its table of periodic maintenance, but annually would appear to be a good schedule. Riding in dustier areas or on a lot of dirt of gravel roads might require a more frequent schedule. Adjust your maintenance schedule according to your comfort levels. In this example, this was the first time the fuel filler cap had been serviced in 2 and a half years and 25,000 miles. Some dirt/gravel roads had been ridden, but not many (maybe a total of 30 or 40 miles in all this time).

Use caution to avoid dropping anything inside the gas tank when working. Work in a well-ventilated area and avoid flames, smoking, or other ignition sources while working around fuel.

The detailed steps are:

1. Using a 4mm allen wrench, remove the filler neck bolts

A. The retaining bolts are not all the same length - keep track of which bolt goes where
B. Using the picture above and moving clockwise from the bolt with the socket in it (at the 9 o'clock position) the bolts lengths are: long, short, long, [filler cap hinge], long, short

2. Unlock the filler cap and place a rag in filler neck to prevent anything from falling inside the gas tank while you work

3. Remove the last retaining bolt located inside the filler cap assembly (it's another short bolt)

4. Clean the filler neck area

A. I used WD-40, a shop rag, and Q-Tips for the tight areas
B. Pay special attention to the threaded areas
C. Be careful with the vent and drain holes (indicated) so that nothing clogs them while cleaning

5. Clean the filler cap assembly

A. Remove the rubber gasket from the filler cap assembly
B. Using the cleaning supplies as used for the filler neck area, clean the cap assembly and the gasket
C. Pay special attention to the orange insert - this is the seal that fits between the pressure release valve inside the cap and the vent tube in the filler neck (shown in the previous photo).

6. Once clean reassemble in reverse order

A. Use care when installing the gasket to be sure that it interlocks with the cap assembly properly

7. Using a "star" pattern start each of the bolts in their proper locations (see #1A)

A Do not tighten any of the bolts until they are all started
B. Tighten the bolts in stages using a "star" pattern (ie: 9 o'clock, 2 o'clock, 7, 11, 4)
C. Final torque is 4 Nm (2.9 pound-feet) so tread lightly



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