Yamaha XJR1300W 2007 Manuals

Manuals and User Guides for Yamaha XJR1300W 2007. We have 1 Yamaha XJR1300W 2007 manual available for free PDF download: Service Manual

Yamaha XJR1300W 2007 Service Manual

Yamaha XJR1300W 2007 Service Manual (386 pages)

Brand: Yamaha | Category: Motorcycle | Size: 31 MB

Table of Contents

Table of Contents

7
- Symbols
  6
- General Information
  9
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    Outline of the Fi System
    11
    
    Fi System
    12
    
    Immobilizer System
    13
    
    Instrument Function
    14
  - Important Information
    17
    
    Preparation for Removal and Disassembly
    17
    
    Replacement Parts
    17
    
    Gaskets, Oil Seals and O-Rings
    17
    
    Lock Washers/Plates and Cotter Pins
    17
    
    Bearings and Oil Seals
    17
    
    Circlips
    18
  - Checking the Connections
    19
  - Special Tools
    20
Specifications

23
- General Specifications
  24
- Engine Specifications
  25
- Chassis Specifications
  32
- Electrical Specifications
  35
- Tightening Torque
  38
  - General Tightening Torque Specifications
    38
  - Engine
    38
  - Chassis
    41
- Lubrication Points and Lubricant Types
  44
  - Engine
    44
  - Chassis
    45
- Lubrication Diagrams
  48
- Cable Routing
  54
Periodic Checks and Adjustments

71
- Periodic Maintenance
  
  73
  - General Maintenance and Lubrication Chart
    73
  - Introduction
    73
- Engine
  
  76
  - Adjusting the Valve Clearance
    76
    
    Synchronizing the Throttle Bodies
    78
    
    Adjusting the Exhaust Gas Volume
    80
    
    Checking the Engine Idling Speed
    81
    
    Adjusting the Throttle Cable Free Play
    81
    
    Checking the Spark Plugs
    82
    
    Checking the Ignition Timing
    83
    
    Measuring the Compression Pressure
    83
    
    Checking the Engine Oil Level
    84
    
    Changing the Engine Oil
    85
    
    Measuring the Engine Oil Pressure
    86
    
    Adjusting the Clutch Lever
    87
    
    Checking the Clutch Fluid Level
    87
    
    Bleeding the Hydraulic Clutch System
    88
    
    Replacing the Air Filter Element
    89
    
    Checking the Throttle Body Joint
    89
    
    Checking the Fuel Line
    89
    
    Checking the Crankcase Breather Hose
    90
    
    Checking the Exhaust System
    90
    
    Adjusting the Exup Cables
    91
- Chassis
  
  92
  - Adjusting the Front Brake
    92
  - Adjusting the Rear Brake
    92
  - Checking the Brake Fluid Level
    93
  - Checking the Front Brake Pad
    93
  - Checking the Rear Brake Pads
    93
  - Checking the Front Brake Hoses
    94
  - Checking the Rear Brake Hose
    94
  - Adjusting the Rear Brake Light Switch
    94
  - Bleeding the Hydraulic Brake System
    95
  - Adjusting the Shift Pedal
    96
  - Adjusting the Drive Chain Slack
    96
  - Lubricating the Drive Chain
    97
  - Checking and Adjusting the Steering Head
    97
  - Checking the Front Fork
    98
  - Adjusting the Front Forks
    99
  - Adjusting the Rear Shock Absorber Assembly
    100
  - Checking the Tires
    102
  - Checking the Wheels
    104
  - Checking and Lubricating the Cables
    104
  - Lubricating the Levers
    104
  - Lubricating the Pedal
    104
  - Lubricating the Sidestand
    104
  - Lubricating the Center Stand
    104
  - Electrical System
    105
Chassis

107
- Front Wheel
  
  112
  - Removing the Front Wheel
    112
  - Disassembling the Front Wheel
    112
  - Checking the Front Wheel
    112
  - Assembling the Front Wheel
    113
  - Adjusting the Front Wheel Static Balance
    113
  - Installing the Front Wheel (Disc)
    114
- Rear Wheel
  
  116
  - Removing the Rear Wheel (Disc)
    119
  - Disassembling the Rear Wheel
    119
  - Checking the Rear Wheel
    119
  - Checking the Rear Wheel Drive Hub
    119
  - Checking the Rear Wheel Sprocket
    119
  - Assembling the Rear Wheel
    120
  - Adjusting the Rear Wheel Static Balance
    120
  - Installing the Rear Wheel
    120
- Front Brake
  
  122
- Rear Brake
  
  135
  - Introduction
    140
  - Checking the Rear Brake Disc
    140
  - Replacing the Rear Brake Pads
    140
  - Removing the Rear Brake Caliper
    141
  - Disassembling the Rear Brake Caliper
    141
  - Checking the Rear Brake Caliper
    142
  - Assembling the Rear Brake Caliper
    142
  - Installing the Rear Brake Caliper
    142
  - Removing the Rear Brake Master Cylinder
    143
  - Checking the Rear Brake Master Cylinder
    144
  - Assembling the Rear Brake Master Cylinder
    144
  - Installing the Rear Brake Master Cylinder
    144
- Handlebar
  
  146
  - Removing the Handlebar
    147
  - Checking the Handlebar
    147
  - Installing the Handlebar
    147
- Front Fork
  
  149
  - Removing the Front Fork Legs
    152
  - Disassembling the Front Fork Legs
    152
  - Checking the Front Fork Legs
    153
  - Assembling the Front Fork Legs
    154
  - Installing the Front Fork Legs
    157
- Steering Head
  
  158
  - Removing the Lower Bracket
    160
  - Checking the Steering Head
    160
  - Installing the Steering Head
    160
- Rear Shock Absorber Assembly
  
  162
- Swingarm
  
  165
  - Removing the Swingarm
    166
  - Checking the Swingarm
    166
  - Installing the Swingarm
    166
- Chain Drive
  
  168
  - Removing the Drive Chain
    169
  - Checking the Drive Chain
    169
  - Checking the Drive Sprocket
    170
  - Checking the Rear Wheel Sprocket
    170
  - Checking the Rear Wheel Drive Hub
    170
Engine

171
- Engine Removal
  
  174
  - Installing the Engine
    177
- Camshafts
  
  179
  - Removing the Camshafts
    180
  - Checking the Camshafts
    180
  - Checking the Timing Chain and Camshaft Sprocket
    182
  - Checking the Timing Chain Guides
    182
  - Checking the Timing Chain Tensioner
    182
  - Installing the Camshafts
    182
- Cylinder Head
  
  186
  - Removing the Cylinder Head
    187
  - Checking the Cylinder Head
    187
  - Installing the Cylinder Head
    187
- Valves and Valve Springs
  
  189
  - Removing the Valves
    190
  - Checking the Valves and Valve Guides
    191
  - Checking the Valve Seats
    192
  - Checking the Valve Springs
    194
  - Checking the Valve Lifters
    195
  - Installing the Valves
    195
- Cylinder and Piston
  
  197
  - Removing the Piston
    198
  - Checking the Cylinder and Piston
    198
  - Checking the Piston Rings
    199
  - Checking the Piston Pin
    200
  - Installing the Piston and Cylinder
    200
- Generator
  
  203
  - Checking the Generator
    204
- Timing Plate
  
  206
- Electric Starter
  
  207
  - Checking the Starter Motor
    208
  - Electric Starter
    208
  - Assembling the Starter Motor
    209
  - Installing the Starter Motor
    209
- Clutch
  
  210
  - Removing the Clutch
    217
  - Checking the Friction Plates
    217
  - Checking the Clutch Plates
    218
  - Checking the Clutch Spring Plate
    218
  - Checking the Clutch Housing
    218
  - Checking the Clutch Boss
    219
  - Checking the Pressure Plate
    219
  - Checking the Clutch Push Rods
    219
  - Installing the Clutch
    219
  - Disassembling the Clutch Master Cylinder
    221
  - Checking the Clutch Master Cylinder
    221
  - Assembling the Clutch Master Cylinder
    221
  - Installing the Clutch Master Cylinder
    222
  - Disassembling the Clutch Release Cylinder
    223
  - Checking the Clutch Release Cylinder
    223
  - Assembling the Clutch Release Cylinder
    224
  - Installing the Clutch Release Cylinder
    224
- Oil Pump
  
  226
  - Disassembling the Oil Pump
    228
  - Checking the Oil Pump
    228
  - Assembling the Oil Pump
    228
  - Installing the Oil Pump
    229
- Shift Shaft
  
  230
  - Checking the Shift Shaft
    231
  - Checking the Stopper Lever
    231
  - Installing the Shift Shaft
    231
- Oil Pan
  
  232
  - Removing the Oil Pan
    233
  - Checking the Relief Valve
    233
  - Checking the Oil Strainer
    233
  - Installing the Oil Strainer
    233
  - Installing the Oil Pan
    233
- Crankcase
  
  234
  - Disassembling the Crankcase
    235
  - Checking the Crankcase
    235
  - Assembling the Crankcase
    235
- Starter Clutch
  
  238
- Crankshaft Assembly
  
  241
  - Removing the Crankshaft Assembly
    243
  - Removing the Connecting Rods
    243
  - Checking the Crankshaft and Connecting Rods
    243
  - Checking the Hy-Vo Chain
    247
  - Installing the Connecting Rods
    247
  - Installing the Crankshaft Journal Bearing
    248
  - Installing the Crankshaft
    249
- Transmission
  
  250
  - Checking the Shift Forks
    254
  - Checking the Transmission
    254
  - Installing the Shift Forks and Shift Drum
    255
  - Installing the Transmission
    255
Fuel System

257
- Fuel Tank
  
  258
  - Removing the Fuel Tank
    259
  - Removing the Fuel Pump
    259
  - Checking the Fuel Pump Body
    259
  - Installing the Fuel Pump
    259
  - Installing the Fuel Tank
    259
- Throttle Bodies
  
  261
- Air Induction System
  
  270
  - Checking the Air Induction System
    273
  - Installing the Air Induction System
    273
Electrical System

275
- Ignition System
  
  278
  - Circuit Diagram
    278
  - Trouble Shooting
    280
- Electric Starting System
  
  282
  - Circuit Diagram
    282
  - Starting Circuit Cut-Off System Operation
    284
  - Trouble Shooting
    286
- Charging System
  
  288
  - Circuit Diagram
    288
  - Trouble Shooting
    290
- Lighting System
  
  292
  - Circuit Diagram
    292
  - Trouble Shooting
    294
- Signaling System
  
  296
  - Circuit Diagram
    296
  - Trouble Shooting
    298
- Fuel Injection System
  
  302
  - Circuit Diagram
    302
  - Ecu Self-Diagnostic Function
    304
  - Fail-Safe Actions (Substitute Characteristics Operation Control)
    305
  - Troubleshooting Method
    309
  - Diagnostic Monitoring Mode
    309
  - Troubleshooting Details
    318
- Fuel Pump System
  
  342
  - Circuit Diagram
    342
  - Trouble Shooting
    344
- Immobilizer System
  
  346
  - Circuit Diagram
    346
  - General Information
    348
  - Part Replacement and Key Code Registration Requirements
    348
  - Trouble Shooting
    352
  - Self-Diagnosis Fault Code Indication
    353
- Electrical Components
  
  356
  - Checking the Switches
    358
  - Checking the Fuses
    363
  - Checking and Charging the Battery
    364
  - Checking the Relays
    367
  - Checking the Turn Signal Relay
    367
  - Checking the Diode
    368
  - Checking the Ignition Spark Gap
    369
  - Checking the Spark Plug Caps
    370
  - Checking the Ignition Coil
    370
  - Checking the Crankshaft Position Sensor
    371
  - Checking the Lean Angle Sensor
    371
  - Checking the Horn
    372
  - Checking the Engine Oil Level Gauge
    372
  - Checking the Engine Temperature Sensor
    373
  - Checking the Speed Sensor
    373
  - Checking the Throttle Position Sensor
    374
  - Checking the Fuel Sender
    374
  - Checking the Ai System Solenoid
    375
  - Checking Intake Air Pressure Sensors 1 and 2
    375
  - Checking the Intake Air Temperature Sensor
    376
Troubleshooting

377
- General Information
  378
- Incorrect Engine Idling Speed
  378
- Starting Failures
  378
- Troubleshooting
  378
- Faulty Clutch
  379
- Faulty Gear Shifting
  379
- Jumps out of Gear
  379
- Overheating
  379
- Poor Medium-And-High-Speed Performance
  379
- Shift Pedal Does Not Move
  379
- Faulty Front Fork Legs
  380
- Faulty Lighting or Signaling System
  380
- Poor Braking Performance
  380

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