Yamaha 2004 XJR1300 Operating and installation instructions

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.

21
1
3
5
7
9
2
4
8
6
23 24
2220
18 1917
15
1413
11 12
10
GEN
INFO SPEC
ENG CARB
ELEC
CHAS
CHK
ADJ
TRBL
SHTG
16
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
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
ENGINE SPECIFICATIONS
Model Standard Limit
Clutch:
Clutch spring height
Quantity
6.78 mm (0.27 in)
1 pc
SSS
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
φ0.9
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
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS

–3–
SPEC
CHASSIS SPECIFICATIONS
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
SSS
SSS
SSS
SSS
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
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.C.I.:
T.C.I. unit model/manufacturer TNDF75/DENSO (except for DEU)
TNDF76/DENSO (DEU)
SSS
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
10 A 1
40 A 1
15 A 1
10 A 1
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS

–4–
SPEC
TIGHTENING TORQUES
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Part to be tightened Part
name
Thread
size
Q’ty
Tightening
torque Remarks
g
name
size
y
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
g
name
y
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
CABLE ROUTING

–6–
SPEC
CABLE ROUTING
A Clamp the #3 and #4 spark plug
leads, on the head cover mount-
ing bolt at the #3 spark plug lead,
by use of clamp.
B Do not entangle the lead wires
and the hosing.
Pass the clump of lead wires and
that of hosing orderly as shown.
C Pass the air filter drain hose, fuel
tank drain hose and fuel tank
breather hose (total 3 hoses)
through the 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 the downward.
G Clamp the wire harness.
H Pass the starter motor cable,
speed sensor lead and the bat-
tery negative lead through the in-
side of the seat rail.

–7–
M Match the paint mark of the air fil-
ter drain hose to the lower end of
the guide wire.
N Make sure to pull out the hose
sufficiently so that bending does
not occur and it can be set within
this range.
O Air filter drain hose can also be
routed at the rear side (The
middle position is prohibited).
J Clump the throttle cables to the
fuel tank rail, on the tank fitting by
use of this clamp. The front end
of the clamp must be directed
downward.
K Thread this clamp 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 switch lead, pickup lead
and rear brake switch lead,
speed sensor lead (total 9
wires), to the fuel tank rail, near
the air filter intake port mounting
screw, by use of this clamp.
The front end of the clamp must
be directed towards the front of
the vehicle.
SPEC
CABLE ROUTING

–8–
B Secure the lead wire branch of
the main harness to tension pipe
1, at the immediate rear of the
gusset, by use of this clamp.
The front end of the clamp must
be directed downward.
C Clamp the four spark plug leads,
the #1 and #2 spark plug leads
up and the #3 and #4 spark plug
leads down, by use of this clamp.
Position the leading ends of the
spark plug leads near, but not
below, the lower front end of the
air induction system assembly.
SPEC
CABLE ROUTING
1Clutch cable
2Gusset
3Tension pipe 1
4Air induction system assembly
5Spark plug lead (#2)
6Spark plug lead (#1)
7Starter cable
8Air filter
9Carburetor 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 rotor cover
20 Oil filter cover
21 Sidestand switch
22 Sidestand switch lead
23 Horn lead
24 Ignition coil lead (#2, #3)
A Pass the wire harness and the
starter cable through the holder
wire of the gusset.
Pass the starter cable under the
wire harness.

–9–
J After securing the side stand
switch lead wire using this
clamp, first route the lead wire
between the pickup cover, the oil
filter cover, the A.C. generator,
and the starter motor. Next, as
with the engine lead wire, route
the lead wire through the right
side of the vehicle.
K Clamp the clutch hose.
L Secure the grommet of the
clutch hose by use of this holder
wire of the gusset.
G Route the air filter drain hose by
the front side of the carburetor 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 cords above the #2
head cover mounting bolt.
E Make sure to tighten the frame
ground together with the igniter
unit attaching screw.
F Fasten the seat lock cable to the
seat rail with a clamp.
Point the tip of the clamp to the
downward.
SPEC
CABLE ROUTING

–10–
P Pass the main harness through
the inside of the clutch hose and
insert the harness into the left of
the headlight lower hole.
M Pass the horn lead wire between
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

–11–
27 Battery negative lead coupler
28 Turn signal relay
29 Carburetor heater relay coupler
30 Igniter unit
31 Starter cable
32 Horn (left)
33 Rear fender
34 Rear turn signal light lead (left)
35 Rear turn signal light lead (right)
36 Wire harness
37 Tail/ brake light lead
38 Stopper
14 Relay assembly
15 Starter motor cable
16 Starter 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
1Throttle cables
2Ignition coil (#1, #4)
3Ignition coil (#2, #3)
4Horn (right)
5Throttle position sensor
6Neutral switch coupler
7Pickup coil coupler
8Sidestand switch coupler
9Fuel sender coupler
10 Battery band
11 Battery
12 Rear brake fluid reservoir tank
13 Battery negative lead
SPEC
CABLE ROUTING

–12–
A Right horn.
Install the HI tone source (with H-
marked label) at the right of the
vehicle.
B Connect the #1-#4 spark plug
leads in order of the cord number.
C Pass the T.P.S. lead wire through
the clamp of the #4 carburetor.
D To the fuel sender.
G Clamp the wire harness 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 cou-
pler and wire harness with the
battery clamp.
SPEC
CABLE ROUTING

–13–
L Connect the fuel sender coupler,
neutral switch coupler, pickup
coupler, and side stand switch
coupler wires above the air
cleaner.
M Carburetors #1 to #4 in a left-to-
right way.
N Thread the wire harness inser-
tion clamp onto the T-stud of the
frame.
O Pass the starter cable through
the front of the throttle cable.
K Clamp the wire harness to 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 lock wire must not ex-
tend to the outside of the brack-
et.
J Pass the lead wire leading to the
fuse box under the wire harness.
SPEC
CABLE ROUTING

–14–
V Pass the left rear turn signal light
lead and right rear turn signal
light lead through the hole of the
rear fender respectively.
W Pass the wire harness between
the frame installation section
and storage space rib of the rear
fender.
X Connect the starter motor cable
to face outward at an angle of
about 45 degrees.
T Position of the wire harness, tail
brake light lead, 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
positioning tape, by use of this
clamp. The front end of the
clamp must be directed down-
ward.
The harness must not deflect be-
tween the T-stud and the clamp.
SPEC
CABLE ROUTING

–15–
Y Direct 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