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Table of Contents
Related Manuals for Yamaha 2004 XJR1300
Summary of Contents for Yamaha 2004 XJR1300
- Page 1 2004 XJR1300(S) 5EA3-SE3 SERVICE INFORMATION Yamaha Motor Co., Ltd.
- Page 2 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 Yamaha Motor Co., Ltd.
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Page 3: Important Information
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. - Page 4 EAS00009 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 8 indicate the subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Carburetor(-s) 7 Electrical system CARB 8 Troubleshooting...
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Page 5: Table Of Contents
CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS ........1 ENGINE SPECIFICATIONS ........2 CHASSIS SPECIFICATIONS . -
Page 6: Specifications
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 120/70ZR17 M/C (58W) rear 180/55ZR17 M/C (73W) Manufacturer front DUNLOP rear DUNLOP Type front D252FJ rear D252J... -
Page 7: Engine Specifications
SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Model Standard Limit Clutch: Clutch spring height 6.78 mm (0.27 in) Quantity 1 pc Carburetor: I.D. mark 5WM7 00 Main jet (M.J) #107.5 Main air jet (M.A.J) Jet needle (J.N) 5D139 Needle jet (N.J) P-OM Pilot jet (P.A.J.1) #140... -
Page 8: Chassis Specifications
SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Model Standard Limit Front suspension: Fork spring free length 357.3 mm (14.07 in) 346.6 mm (13.65 in) Fitting length 337.3 mm (13.28 in) Collar length 195 mm (7.68 in) Spring rate (K1) 7.5 N/mm (0.76 kgf/mm, 42.83 lb/in) (K2) 13 N/mm (1.33 kgf/mm, 74.23 lb/in) 0 X 75 mm (0 X 2.95 in) -
Page 9: Tightening Torques
SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening Part Thread torque Part to be tightened Q’ty Remarks name name size size mSkg ftSlb Cylinder Exhaust pipe and exhaust chamber Screw 1.25 Exhaust chamber and muffler Bolt 1.25 Muffler protector Screw Crankcase cover (right) Screw... -
Page 10: Cable Routing
SPEC CABLE ROUTING CABLE ROUTING Throttle cables Seat rail Rear brake light switch coupler Ignition coil lead (#1, #4) Thermo switch Neutral switch lead Horn lead Standing handle Pickup coil lead Spark plug lead (#3) Thermo switch coupler Sidestand switch lead Spark plug lead (#4) Rear brake fluid reservoir tank Throttle position sensor... - Page 11 SPEC CABLE ROUTING A Clamp the #3 and #4 spark plug D Clump the A.C.magneto lead, G Clamp the wire harness. leads, on the head cover mount- pickup lead, sidestand switch H Pass the starter motor cable, ing bolt at the #3 spark plug lead, lead, starter motor cable and speed sensor lead and the bat- by use of clamp.
- Page 12 SPEC CABLE ROUTING I Secure the carburetor heater J Clump the throttle cables to the M Match the paint mark of the air fil- lead, starter motor cable, battery fuel tank rail, on the tank fitting by ter drain hose to the lower end of negative lead, A.C.
- Page 13 SPEC CABLE ROUTING Clutch cable Speed sensor lead B Secure the lead wire branch of Gusset A.C.magneto the main harness to tension pipe Tension pipe 1 Pickup coil rotor cover 1, at the immediate rear of the Air induction system assembly Oil filter cover gusset, by use of this clamp.
- Page 14 SPEC CABLE ROUTING D Clamp the #1 and #2 spark plug G Route the air filter drain hose by J After securing the side stand leads using this clamp. the front side of the carburetor air switch lead wire using this Clamp these cords above the #2 vent hose and by the right side of clamp, first route the lead wire...
- Page 15 SPEC CABLE ROUTING M Pass the horn lead wire between P Pass the main harness through the clutch hose and the frame, the inside of the clutch hose and then pull the lead wire out to the insert the harness into the left of front, and connect the lead wire the headlight lower hole.
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Page 16: Throttle Cables
SPEC CABLE ROUTING Throttle cables Relay assembly Battery negative lead coupler Ignition coil (#1, #4) Starter motor cable Turn signal relay Ignition coil (#2, #3) Starter motor relay Carburetor heater relay coupler Horn (right) Seat rail Igniter unit Throttle position sensor Rear fender rib Starter cable Neutral switch coupler... -
Page 17: Air Filter
SPEC CABLE ROUTING A Right horn. E Fasten the starter motor cable, G Clamp the wire harness to the Install the HI tone source (with H- battery negative lead and speed seat rail at the immediate rear of marked label) at the right of the sensor lead to the seat rail be- the side cover mounting bracket vehicle. -
Page 18: Seat Rail
SPEC CABLE ROUTING H Store the wire harness, the tail- K Clamp the wire harness to the L Connect the fuel sender coupler, light lead wire, and the rear left seat rail, on the wire harness neutral switch coupler, pickup and right flasher lead wires, into positioning tape and at the im- coupler, and side stand switch... - Page 19 SPEC CABLE ROUTING P From left: #1, #2, #3, and #4 T Position of the wire harness, tail V Pass the left rear turn signal light spark plug leads. brake light lead, left rear turn sig- lead and right rear turn signal Q Point inward.
- Page 20 SPEC CABLE ROUTING 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.
- Page 21 SPEC CABLE ROUTING Speedometer lead A Pass the meter lead, left handle C Route the turn signal light lead Crown handle bar switch lead and right handle- by the front side of the headlight Left handlebar switch lead bar switch lead through the up- stay (left and right).
- Page 22 SPEC CABLE ROUTING G Bind the right handlebar switch N Tighten the clamp pointing the lead and brake hose 2 by the tip to the inward. side of the wire guide of the O Install the coupler locking sec- headlight stay with a clamp. tion facing the housing connec- H Pass the throttle cables through tor 2.
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Page 23: Periodic Checks And Adjustments
S The annual checks must be performed every year, except if a kilometer-based maintenance is per- formed instead. S From 50,000 km, repeat the maintenance intervals starting from 10,000 km. S Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING... - Page 24 INTRODUCTION/PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ODOMETER READING ANNUAL 1,000 km) ITEM CHECK OR MAINTENANCE JOB CHECK CHECK Shock absorber assem- S Check operation and shock absorbers for oil leakage. blies S Check starter (choke) operation. Carburetors S Adjust engine idling speed and synchronization. S Change.
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Page 25: Engine
CHECKING THE EXHAUST SYSTEM EAS00099 ENGINE CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex- haust pipes, mufflers and gaskets. 1. Check: S exhaust pipe 1 S muffler 2 S muffler protector 3 Cracks/damage ! Replace. S gasket 4 , 5 , 6 Exhaust gas leaks ! Replace. -
Page 26: Xjr1300(S) 2004 Wiring Diagram
XJR1300(S) 2004 WIRING DIAGRAM Main switch Front turn signal light (left) A.C. magneto Front turn signal light (right) Fuse (back up) Carburetor heater relay Fuse (main) Thermo switch Battery Carburetor heater Starter relay Ground Starter motor Immobilizer unit Alarm Starting circuit cut-off relay Neutral switch Sidestand switch Ignitor unit... - Page 28 XJR1300(S) 2004 WIRING DIAGRAM COLOR CODE Black Br/W Brown/White Brown Green/White Chocolate Green/Yellow Dark green Blue/Black Green Blue/Red Gray Blue/White Blue Blue/Yellow Light green Red/Black Orange Red/Green Pink Red/White Red/Yellow Sky blue Sb/W Sky blue/White White White/Black Yellow White/Green Black/Blue White/Red Black/Red Yellow/Black...