2001 YAMAHA XJR 1300 brake pads

6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-2
Removing and installing the panel ....................... 6-5
Checking the spark plugs .................................... 6-6
Engine oil and oil filter element ............................ 6-7
Cleaning the air filter element ............................ 6-11
Adjusting the carburetors ................................... 6-12
Adjusting the engine idling speed ...................... 6-13
Adjusting the throttle cable free play .................. 6-13
Adjusting the valve clearance ............................ 6-14
Tires ................................................................... 6-14
Wheels ............................................................... 6-17
Adjusting the brake pedal position ..................... 6-17
Rear brake light switch adjustment .................... 6-18
Checking the front and rear brake pads ............. 6-19
Checking the brake fluid level ............................ 6-19
Changing the brake fluid .................................... 6-20
Drive chain slack ................................................ 6-21
Lubricating the drive chain ................................. 6-22
Checking and lubricating the cables .................. 6-23Checking and lubricating the throttle
grip and cable ................................................. 6-23
Checking and lubricating the brake and
shift pedals ...................................................... 6-24
Checking and lubricating the brake and
clutch levers .................................................... 6-24
Checking and lubricating the centerstand and
sidestand ......................................................... 6-25
Checking the front fork ...................................... 6-25
Checking the steering ....................................... 6-26
Checking the wheel bearings ............................ 6-27
Battery ............................................................... 6-27
Replacing the fuses .......................................... 6-29
Replacing the headlight bulb ............................. 6-29
Replacing the tail/brake light bulb ..................... 6-31
Replacing a turn signal light bulb ...................... 6-31
Front wheel ....................................................... 6-32
Rear wheel ........................................................ 6-34
Troubleshooting ................................................. 6-36
Troubleshooting chart ........................................ 6-37
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_ l
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
l
From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
l
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_
CP-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line• Check fuel hoses and vacuum hose for cracks or damage.ÖÖÖÖ Ö
2*Fuel filter• Check condition.ÖÖ
3 Spark plugs• Check condition.
• Clean and regap.ÖÖ
• Replace.ÖÖ
4*Valves• Check valve clearance.
•Adjust.Every 20,000 km
5 Air filter element•Clean.ÖÖ
• Replace.ÖÖ
6*Clutch• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.) ÖÖÖÖÖ
7*Front brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
8*Rear brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6
EAU00715
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart. Each brake pad is
provided with a wear indicator, which
allows you to check the brake pad wear
without having to disassemble the
brake. To check the brake pad wear,
check the position of the wear indicator
while applying the brake. If a brake pad
has worn to the point that the wear indi-
cator almost touches the brake disc,
have a Yamaha dealer replace the
brake pads as a set.
EAU03742
Checking the brake fluid level Insufficient brake fluid may allow air to
enter the brake or clutch systems, possi-
bly causing them to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake flu-
id level may indicate worn brake pads
and/or brake system leakage. If the
brake level is low, be sure to check the
brake pads for wear and the brake sys-
tem for leakage.NOTE:_ The rear brake fluid reservoir is located
behind panel A. (See page 6-5 for panel
removal and installation procedures.) _
Observe these precautions:l
When checking the fluid level,
make sure that the top of the brake
or clutch fluid reservoir is level.
l
Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking or clutch
performance.
1. Brake pad wear indicator grooveFront
Rear
1. Minimum level markFront brake
1. Minimum level mark
Recommended brake fluid: DOT 4Rear brake
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
l
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking or clutch per-
formance.
l
Be careful that water does not en-
ter the brake or clutch fluid reser-
voir when refilling. Water will
significantly lower the boiling point
of the fluid and may result in vapor
lock.
l
Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.
l
As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU03792
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the oil seals
of the brake and clutch master cylin-
ders and caliper as well as the brake
and clutch hoses replaced at the inter-
vals listed below or whenever they are
damaged or leaking.l
Oil seals: Replace every two
years.
l
Brake and clutch hoses: Replace
every four years.
1. Minimum level markClutch
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6
EAU03598
Front wheel To remove the front wheel
EW000122
WARNING
_ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motor-
cycle so that there is no danger
of it falling over.
_1. Place the motorcycle on the cen-
terstand.
2. Disconnect the speedometer ca-
ble from the front wheel.3. Remove the brake hose holders
by removing the bolts.
4. Remove the brake calipers by re-
moving the bolts.
ECA00047
CAUTION:_ Do not pull the brake lever after the
brake caliper has been removed,
otherwise the brake pads will be
forced shut. _
5. Loosen the front wheel axle pinch
bolt, then the wheel axle.
6. Pull the wheel axle out, and then
remove the wheel.
1. Speedometer cable
1. Bolt (´ 3)
2. Brake hose holder
3. Front brake caliperLeft
Right
1. Front wheel axle pinch bolt
2. Wheel axle
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
6
EAU01758
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the pro-
jections mesh with the slots.2. Lift the wheel up between the fork
legs.
NOTE:_ Make sure that the slot in the speedom-
eter gear unit fits over the retainer on
the fork leg. _3. Insert the wheel axle.
4. Lower the front wheel so that it is
on the ground.
5. Push down hard on the handlebar
several times to check for proper
fork operation.
6. Install the brake calipers by install-
ing the bolts.
NOTE:_ Make sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brake
discs. _7. Install the brake hose holders by
installing the bolts.
8. Install the front wheel axle pinch
bolt, and then tighten the wheel
axle, pinch bolt and brake caliper
bolts to the specified torques.
9. Connect the speedometer cable.
1. Speedometer gear unit retainer
Tightening torques:
Wheel axle:
73 Nm (7.3 m·kg)
Front wheel axle pinch bolt:
19 Nm (1.9 m·kg)
Brake caliper bolt:
40 Nm (4.0 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-35
67. While supporting the brake caliper
bracket, pull the wheel axle out.
8. Remove the wheel.
ECA00048
CAUTION:_ Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut. _
EAU03793
To install the rear wheel
1. Insert the wheel axle through the
brake caliper bracket and wheel
from the right-hand side.
2. Install the drive chain onto the rear
sprocket, and then adjust the drive
chain slack. (See page 6-21 for
drive chain slack adjustment pro-
cedures.)
3. Connect the brake torque rod to
the brake caliper bracket by in-
stalling the bolt and the nut.
4. Install the brake caliper by install-
ing the bolts.NOTE:_ Make sure that there is enough space
between the brake pads before install-
ing the brake caliper onto the brake
disc. _5. Take the motorcycle off the cen-
terstand so that the rear wheel is
on the ground.
6. Tighten the axle nut, brake caliper
bolts and brake torque rod nut to
the specified torques.Tightening torques:
Axle nut:
150 Nm (15.0 m·kg)
Brake caliper bolt:
40 Nm (4.0 m·kg)
Brake torque rod nut:
23 Nm (2.3 m·kg)
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INDEXAAir filter element, cleaning ...................... 6-11
Anti-theft alarm ........................................3-3BBattery ................................................... 6-27
Brake and clutch levers, checking and
lubricating ............................................ 6-24
Brake and shift pedals, checking and
lubricating ............................................ 6-24
Brake fluid, changing ............................. 6-20
Brake fluid level, checking...................... 6-19
Brake lever...............................................3-7
Brake light switch (rear), adjusting ......... 6-18
Brake pads, checking............................. 6-19
Brake pedal..............................................3-7
Brake pedal position, adjusting .............. 6-17CCables, checking and lubricating............ 6-23
Carburetors, adjusting............................ 6-12
Care.........................................................7-1
Centerstand and sidestand, checking
and lubricating ..................................... 6-25
Clutch lever ..............................................3-5
Conversion table ......................................8-5DDimmer switch .........................................3-4
Drive chain, lubricating ........................... 6-22
Drive chain slack .................................... 6-21
Adjusting .......................................... 6-21
Checking .......................................... 6-21
EEngine break-in ....................................... 5-4
Engine oil and oil filter element ................ 6-7
Engine stop switch................................... 3-5FFront fork, adjusting ............................... 3-12
Front fork, checking ............................... 6-25
Fuel ......................................................... 3-9
Fuel cock ................................................. 3-9
Fuel consumption, tips for reducing ......... 5-4
Fuel gauge .............................................. 3-4
Fuel tank cap ........................................... 3-8
Fuses, replacing .................................... 6-29HHandlebar switches ................................. 3-4
Headlight bulb, replacing ....................... 6-29
Helmet holder ........................................ 3-11
High beam indicator light ......................... 3-2
Horn switch ............................................. 3-4IIdentification numbers ............................. 9-1
Idling speed, adjusting ........................... 6-13
Ignition circuit cut-off system.................. 3-16
Indicator and warning lights ..................... 3-2KKey identification number ........................ 9-1LLight switch.............................................. 3-5
Luggage strap holders ........................... 3-15
MMain switch/steering lock .........................3-1
Model label ..............................................9-2NNeutral indicator light ...............................3-2OOil level warning light ...............................3-2PPanel, removing and installing..................6-5
Parking.....................................................5-5
Part locations ...........................................2-1
Pass switch ..............................................3-4
Periodic maintenance and lubrication
chart ......................................................6-2
Pre-operation check list ............................4-1SSafety information ....................................1-1
Seat .......................................................3-11
Shifting .....................................................5-3
Shift pedal ................................................3-6
Shift points (for Switzerland only) .............5-3
Shock absorber assemblies,
adjusting ............................................... 3-13
Sidestand ...............................................3-15
Spark plugs, checking ..............................6-6
Specifications ...........................................8-1
Speedometer unit.....................................3-3
Starter (choke) lever...............................3-10
Starting a cold engine ..............................5-1
Starting a warm engine ............................5-2
Start switch ..............................................3-5
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