Yamaha 2004 XJR1300 Service Information Download Page 2

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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

Summary of Contents for 2004 XJR1300

Page 1: ...Yamaha Motor Co Ltd 2004 XJR1300 S 5EA3 SE3 SERVICE INFORMATION ...

Page 2: ... 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 ...

Page 3: ... 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 S...

Page 4: ... Troubleshooting Symbols 9 to 16 indicate the following 9 Serviceable 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 Lith...

Page 5: ...S 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 ...

Page 6: ...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 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 ...

Page 7: ...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 9 φ0 8 2 0 2 3 52 5 0 8 115 13 0 mm 0 51 in 3 0 X 4 0 mm 0 12 X 0 16 in 950 X 1150 r min 30 7 kPa 230 mmHg 9 1 inHg SSS SSS SSS...

Page 8: ...58 74 lb in 33 7 N mm 3 44 kgf mm 192 43 lb in 0 X 37 mm 0 X 1 46 in 37 X 58 mm 1 46 X 2 28 in 58 X 93 mm 2 28 X 3 66 in SSS SSS SSS SSS SSS 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 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 ...

Page 9: ...lt 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 g name y Nm mSkg ftSlb Rear fender cover and cover Screw M5 0 8 2 1 5 0 15 1 1 Center...

Page 10: ...ail 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 1 Throttle cables 2 Ignition coil lead 1 4 3 Horn lead 4 Spark plug lead 3 5 Spark plug lead 4 6 Ground lead 7 Rear brake switch 8 Intake air filter screw 9 Air filter 10 Relay assembly SP...

Page 11: ...guide wire of the en gine D Clump the A C magneto lead pickup lead sidestand switch lead starter motor cable and carburetor heater lead total 5 wires by use of this clamp E Pass the wire harness between the handle standing lug member and the rear fender F Fasten the wire harness thermo switch lead to the seat rail at the front end of the seat rail bracket with a clamp Point the tip of the clamp to...

Page 12: ...through the upper hole in the gusset and se cure the two throttle cables The front end of the clamp must be di rected towards the inside of the vehicle L Match the marks of the fuel tank drain hose and fuel tank breather hose and arrange the two types of hose properly I Secure the carburetor heater lead starter motor cable battery negative lead A C magneto lead neutral switch lead side stand switc...

Page 13: ...LE ROUTING 1 Clutch cable 2 Gusset 3 Tension pipe 1 4 Air induction system assembly 5 Spark plug lead 2 6 Spark plug lead 1 7 Starter cable 8 Air filter 9 Carburetor air vent hose 10 Air filter drain hose 11 Frame ground 12 Turn signal relay coupler 13 Carburetor heater relay coupler 14 Fuse box for EUR 15 Igniter unit coupler 16 Starter motor 17 Speed sensor lead 18 A C magneto 19 Pickup coil rot...

Page 14: ... air vent hose and by the right side of the vehicle body To route to the right side of the body make sure to set between the starter motor and A C magneto H Route the speed sensor lead by the right side of the vehicle body along with the sidestand switch lead I Mount the square fixture of the clutch hose in parallel with the cover D Clamp the 1 and 2 spark plug leads using this clamp Clamp these c...

Page 15: ...the clutch hose and the frame then pull the lead wire out to the front and connect the lead wire to the horn N Connect the black coupler equipped lead wire to the 1 and 4 ignition coils O Pass this clamp through the low er hole of the gusset and secure the clutch cable The front end of the clamp must be directed towards the inside of the vehicle SPEC CABLE ROUTING ...

Page 16: ...er motor relay 17 Seat rail 18 Rear fender rib 19 Rear turn signal light right 20 Tail brake light bracket 21 Rear turn signal light left 22 Seat lock wire 23 Seat lock 24 Battery positive lead 25 Starter relay coupler 26 Fuse box 1 Throttle cables 2 Ignition coil 1 4 3 Ignition coil 2 3 4 Horn right 5 Throttle position sensor 6 Neutral switch coupler 7 Pickup coil coupler 8 Sidestand switch coupl...

Page 17: ...ss to the seat rail at the immediate rear of the side cover mounting bracket on the seat rail The front end of the clamp must face downward and be posi tioned inside the back stay E Fasten the starter motor cable battery negative lead and speed sensor lead to the seat rail be tween the air filter and tank at taching brackets with a clamp F Fasten two battery positive leads battery negative lead co...

Page 18: ...the seat rail on the wire harness positioning tape and at the im mediate rear of the side cover mounting bracket on the seat rail The front end of the clamp must face downward and be posi tioned inside the back stay H Store the wire harness the tail light lead wire and the rear left and right flasher lead wires into the space between the taillight bracket and the rib of the rear fender I The seat ...

Page 19: ...d left rear turn sig nal light lead right rear turn sig nal lead should be not higher than the rib height of the rear fender U Clamp the wire harness left rear turn signal light lead and right rear turn signal light lead Point the tip of the clamp to the front side P From left 1 2 3 and 4 spark plug leads Q Point inward R Point outward S Secure the wire harness and the starter cable on the harness...

Page 20: ...ct the crimping side of the battery positive lead wire downward and connect the lead wire Z Connect the starter cable to face at right angles to the vehicle body with contact with the stop pers SPEC CABLE ROUTING ...

Page 21: ... Bind the left handlebar switch lead clutch cable and starter cable under the crown handle with a clamp Pass the left handlebar switch lead through the inside of the clutch cable Pass the starter cable through the frame side then the inside of the clutch cable and the front side of the left handlebar switch lead C Route the turn signal light lead by the front side of the headlight stay left and ri...

Page 22: ...rn signal light left and meter lead SPEC CABLE ROUTING G Bind the right handlebar switch lead and brake hose 2 by the side of the wire guide of the headlight stay with a clamp H Pass the throttle cables through the wire guide of the headlight stay I To the upper hole J To the left side of the lower hole K To the right side of the lower hole L Clamp the right front turn signal light lead and wire h...

Page 23: ...ent S Clean Ǹ Ǹ 5 Air filter element S Replace Ǹ Ǹ 6 Clutch S Check operation fluid level and vehicle for fluid leakage Ǹ Ǹ Ǹ Ǹ Ǹ 7 Front brake S Check operation fluid level and vehicle for fluid leakage Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ 7 Front brake S Replace brake pads Whenever worn to the limit 8 Rear brake S Check operation fluid level and vehicle for fluid leakage Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ 8 Rear brake S Replace brake pads Whe...

Page 24: ...Ǹ Ǹ 26 Throttle grip housing and cable S Check operation and free play S Adjust the throttle cable free play if necessary S Lubricate the throttle grip housing and cable Ǹ Ǹ Ǹ Ǹ Ǹ 27 Muffler and exhaust pipe S Check the screw clamp for looseness Ǹ Ǹ Ǹ Ǹ Ǹ 28 Lights signals and switches S Check operation S Adjust headlight beam Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ D The air filter needs more frequent service if you are rid...

Page 25: ...ce Sgasket 4 5 6 Exhaust gas leaks Replace 2 Check Stightening torque Exhaust pipe nut 7 25 Nm 2 5 mSkg 18 1 ftSlb Exhaust pipe and exhaust chamber screw 8 20 Nm 2 0 mSkg 14 5 ftSlb Muffler bracket bolt 9 20 Nm 2 0 mSkg 14 5 ftSlb Exhaust chamber bolt 10 25 Nm 2 5 mSkg 18 1 ftSlb Exhaust chamber and muffler bolt 11 20 Nm 2 0 mSkg 14 5 ftSlb Muffler and stay bolt 12 20 Nm 2 0 mSkg 14 5 ftSlb Muffle...

Page 26: ...24 Meter lights 25 Oil level warning light 26 Neutral indicator light 27 Immobilizer indicator light 28 High beam indicator light 29 Turn signal indicator light left 30 Turn signal indicator light right 31 Oil level switch 32 Rear brake light switch 33 Auxiliary light 34 Tail brake light 35 Right handlebar switch 36 Front brake switch 37 Engine stop switch 38 Start switch 39 Fuse park 40 Fuse igni...

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Page 28: ... Black Red Black Yellow Brown Blue Brown Red COLOR CODE Br W G W G Y L B L R L W L Y R B R G R W R Y Sb W W B W G W R Y B Y G Y L Brown White Green White Green Yellow Blue Black Blue Red Blue White Blue Yellow Red Black Red Green Red White Red Yellow Sky blue White White Black White Green White Red Yellow Black Yellow Green Yellow Blue XJR1300 S 2004 WIRING DIAGRAM ...

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