Yamaha 2004 XJR1300 Bedienungs- und Montageanleitung

Yamaha Motor Co., Ltd.

2004

XJR1300(S)

5EA3-SE3

SERVICE

INFORMATION

Yamaha Motor Co., Ltd.

FOREWORD

This service information has been prepared to introduce new service and data for the

XJR1300(S) 2004. For complete service information procedures, it is necessary to

use this Supplementary Service Information together with the following manual.

XJR1300(S) 2004 SERVICE MANUAL: 5EA3-ME3

XJR1300(L) '99 SERVICE INFORMATION: 5EA3-SE1

XJR1300(P) 2002 SERVICE INFORMATION: 5EA3-SE2

NOTE:

WARNING

CAUTION:

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 manu-

al. 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 ve-

hicle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi-

cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and

will appear in future editions of this manual where applicable.

Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

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 mo-

torcycle.

A CAUTION indicates special precautions that must be taken to avoid damage

to the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

23 24

2220

18 1917

1413

11 12

GEN

INFO SPEC

ENG CARB

ELEC

CHAS

CHK

ADJ

TRBL

SHTG

EAS00009

SYMBOLS

The following symbols are not relevant to every

vehicle.

Symbols 1to 8indicate the subject of each

chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Chassis

5Engine

6Carburetor(-s)

7Electrical system

8Troubleshooting

Symbols 9to 16 indicate the following.

9Serviceable with engine mounted

10 Filling fluid

11 Lubricant

12 Special tool

13 Tightening torque

14 Wear limit, clearance

15 Engine speed

16 Electrical data

Symbols 17 to 22 in the exploded diagrams indi-

cate the types of lubricants and lubrication

points.

17 Engine oil

18 Gear oil

19 Molybdenum disulfide oil

20 Wheel bearing grease

21 Lithium soap base grease

22 Molybdenum disulfide grease

Symbols 23 to 24 in the exploded diagrams indicate

the following:

23 Apply locking agent (LOCTITER)

24 Replace the part

CONTENTS

SPECIFICATIONS

GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS . . . . . . . . 18

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

CHECKING THE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 20

XJR1300(S) 2004 WIRING DIAGRAM

–1–

SPEC

GENERAL SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Model XJR1300(S)

Model code: 5WM7 (EUR)/5WM8 (DEU)/5WM9 (AUS)

Fuel:

Type Regular unleaded gasoline (EUR)

Unleaded gasoline (AUS)

Tire:

Size front

rear

Manufacturer front

rear

Type front

rear

120/70ZR17 M/C (58W)

180/55ZR17 M/C (73W)

DUNLOP

D252FJ

D252J

Wheel travel:

Rear wheel travel 120 mm

Bulb wattage quantity:

Auxiliary light

Meter light

High beam indicator light

12 V 4 W 1 (EUR)

LED 1

12 V 1.7 W 1

–2–

SPEC

ENGINE SPECIFICATIONS

Model Standard Limit

Clutch:

Clutch spring height

Quantity

6.78 mm (0.27 in)

1 pc

SSS

Carburetor:

I.D. mark

Main jet (M.J)

Main air jet (M.A.J)

Jet needle (J.N)

Needle jet (N.J)

Pilot jet (P.A.J.1)

Pilot outlet (P.O)

Pilot jet (P.J)

Bypass 1 (B.P.1)

Bypass 2 (B.P.2)

Bypass 3 (B.P.3)

Pilot screw (P.S)

Valve seat size (V.S)

Starter jet (G.S.1)

Starter jet (G.S.2)

Throttle valve size (Th.V)

Float height (F.H)

Fuel level (using special tool)

Engine idle speed

Intake vacuum

5WM7 00

#107.5

#80

5D139

P-OM

#140

φ1.0

#15

φ0.9

φ0.8

2.0

2.3

#52.5

0.8

#115

13.0 mm (0.51 in)

3.0 X4.0 mm (0.12 X0.16 in)

950 X1150 r/min

30.7 kPa (230 mmHg, 9.1 inHg)

SSS

–3–

SPEC

CHASSIS SPECIFICATIONS

Model Standard Limit

Front suspension:

Fork spring free length

Fitting length

Collar length

Spring rate (K1)

(K2)

Stroke (K1)

(K2)

Oil capacity

Oil level

357.3 mm (14.07 in)

337.3 mm (13.28 in)

195 mm (7.68 in)

7.5 N/mm (0.76 kgf/mm, 42.83 lb/in)

13 N/mm (1.33 kgf/mm, 74.23 lb/in)

0 X75 mm (0 X2.95 in)

75 X130 mm (2.95 X5.12 in)

562 cm3(0.5 Imp qt, 0.59 us qt)

124 mm (4.88 in)

346.6 mm (13.65 in)

SSS

Rear suspension:

Spring rate (K1)

(K2)

(K3)

Stroke (K1)

(K2)

(K3)

21.3 N/mm (2.17 kgf/mm, 121.62 lb/in)

27.8 N/mm (2.83 kgf/mm, 158.74 lb/in)

33.7 N/mm (3.44 kgf/mm, 192.43 lb/in)

0 X37 mm (0 X1.46 in)

37 X58 mm (1.46 X2.28 in)

58 X93 mm (2.28 X3.66 in)

SSS

Front wheel:

Rim size 17 M/C MT3.50 SSS

Rear wheel:

Rim size 17 M/C MT5.50 SSS

Drive chain:

Type/manufacturer

No. of links

50VA8/DAIDO

112

SSS

Front disc brake:

Disc deflection limit

Master cylinder inside diameter

SSS

15 mm (0.59 in)

0.1 mm (0.0039 in)

SSS

T.C.I.:

T.C.I. unit model/manufacturer TNDF75/DENSO (except for DEU)

TNDF76/DENSO (DEU)

SSS

Oil level switch:

Model/manufacturer 5UX/DENSO SSS

Circuit breaker:

Type

Amperage for individual circuit

Q’ty

Main

Head Light

Signal

Ignition

Parking Light

Backup

Reserve

Fuse

40 A 1

15 A 1

10 A 1

15 A 1

10 A 1

40 A 1

15 A 1

10 A 1

SSS

–4–

SPEC

TIGHTENING TORQUES

ENGINE TIGHTENING TORQUES

Part to be tightened Part

name

Thread

size

Q’ty

Tightening

torque Remarks

name

size

Nm mSkg ftSlb

Cylinder Nut M6 1.0 4 12 1.2 8.7

Exhaust pipe and exhaust chamber Screw M8 1.25 2 20 2.0 14

Exhaust chamber and muffler Bolt M8 1.25 4 20 2.0 14

Muffler protector Screw M6 1.0 4 15 1.5 11

Crankcase cover (right) Screw M6 1.0 2 10 1.0 7.2

Drive sprocket cover Bolt M6 1.0 2 10 1.0 7.2

Crankcase Bolt M12 1.25 5 35 3.5 25

Stopper plate

(Starter clutch idle gear shaft)

Bolt M6 1.0 1 10 1.0 7.2

Stopper lever Bolt M8 1.0 1 10 1.0 7.2

Neutral switch Screw M5 0.8 3 3.5 0.35 2.5

Speed sensor Bolt M6 1.0 1 10 1.0 7.2

CHASSIS TIGHTENING TORQUES

Part to be tightened Part

name

Thread size Q’ty

Tightening

torque Remarks

name

Nm mSkg ftSlb

Rear fender cover and cover Screw M5 0.8 2 1.5 0.15 1.1

Center stand Nut and

Bolt

M10 1.25 2 56 5.6 41

Front wheel axle – M18 1.5 1 72 7.2 52

Front brake disk and hub Bolt M8 1.25 12 18 1.8 13

Driven sprocket and hub Nut M8 1.25 6 69 6.9 4.3

Rear wheel axle Nut M24 1.5 1 150 15.0 108

Rear brake disc and hub Bolt M8 1.25 6 23 2.3 17

–5–

21 Rear brake light switch coupler

22 Neutral switch lead

23 Pickup coil lead

24 Sidestand switch lead

25 Throttle position sensor

26 Fuel tank fitting

27 Guide wire

28 Fuel tank drain hose

29 Fuel tank breather hose

11 Seat rail

12 Thermo switch

13 Standing handle

14 Thermo switch coupler

15 Rear brake fluid reservoir tank

16 Speed sensor lead

17 Starter motor lead

18 Battery negative lead

19 Carburetor heater coupler

20 A.C.magneto

1Throttle cables

2Ignition coil lead (#1, #4)

3Horn lead

4Spark plug lead (#3)

5Spark plug lead (#4)

6Ground lead

7Rear brake switch

8Intake air filter screw

9Air filter

10 Relay assembly

SPEC

CABLE ROUTING

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