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