2003 YAMAHA XJR 1300 maintenance

PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6
EC000102
CAUTION:_

Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.


To charge a sealed-type (MF)
battery, a special (con-
stant-voltage) battery charger is
required. Using a conventional
battery charger will damage the
battery. If you do not have ac-
cess to a sealed-type (MF) bat-
tery charger, have a Yamaha
dealer charge your battery.
_
EAU04410*
Replacing the fuses The fuse box is located under the seat.
(See page 3-11 for seat removal and
installation procedures.)
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
EC000103
CAUTION:_ Do not use a fuse of a higher amper-
age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire. _3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
1. Main fuse
2. Signaling system fuse
3. Headlight fuse
4. Ignition fuse
5. Turn signal light fuse
6. Spare fuse (× 2)
Specified fuses:
Main fuse: 40 A
Ignition fuse: 15 A
Signaling system fuse: 15 A
Headlight fuse: 15 A
Turn signal light fuse: 15 A
U5WME0.book Page 29 Monday, July 29, 2002 10:25 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6
EAU04189
Replacing the headlight bulb This motorcycle is equipped with a
quartz bulb headlight. If the headlight
bulb burns out, replace it as follows.
1. Remove the headlight unit by re-
moving the screws.2. Disconnect the headlight coupler,
and then remove the bulb cover.3. Unhook the headlight bulb holder,
and then remove the defective
bulb.
EW000119
WARNING
_ Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down. _4. Place a new headlight bulb into
position, and then secure it with
the bulb holder.
1. Screw (× 2)
1. Headlight coupler
2. Bulb cover
1. Headlight bulb holder
U5WME0.book Page 30 Monday, July 29, 2002 10:25 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6
EC000105
CAUTION:_ Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely af-
fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with
alcohol or thinner. _5. Install the headlight bulb cover,
and then connect the coupler.
6. Install the headlight unit by install-
ing the screws.
7. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAU04411
Replacing a tail/brake light
bulb 1. Remove the seat. (See page 3-11 for
seat removal and installation proce-
dures.)
2. Remove the socket (together with the
bulb) by turning it counterclockwise.
3. Remove the defective bulb by push-
ing it in and turning it counterclock-
wise.
4. Insert a new bulb into the socket,
push it in, and then turn it clockwise
until it stops.
5. Install the socket (together with the
bulb) by turning it clockwise.
6. Install the seat.
EAU03497
Replacing a turn signal light
bulb 1. Remove the turn signal light lens
by removing the screw.
1. Do not touch the glass part of the bulb.
1. Tail/brake light bulb socket
1. Screw
U5WME0.book Page 31 Monday, July 29, 2002 10:25 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6 2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw.
ECA00065
CAUTION:_ Do not overtighten the screw, other-
wise the lens may break. _
EAU04412
Front wheel To remove the front wheel
EW000122
WARNING
_

It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no danger
of it falling over.
_1. Disconnect the speedometer ca-
ble from the front wheel.2. Remove the brake hose holders
by removing the bolts.
3. 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. _
1. Turn signal light bulb
1. Speedometer cable
1. Bolt (× 3)
2. Brake hose holder
3. Front brake caliperLeft
Right
U5WME0.book Page 32 Monday, July 29, 2002 10:25 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
64. Loosen the front wheel axle pinch
bolt, then the wheel axle.
5. Place the motorcycle on the cen-
terstand.
6. Pull the wheel axle out, and then
remove the wheel.
EAU04360
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. 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. _
1. Front wheel axle pinch bolt
2. Wheel axle
1. Speedometer gear unit retainer
U5WME0.book Page 33 Monday, July 29, 2002 10:25 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
6 5. Install the brake hose holders by
installing the bolts.
6. Take the motorcycle off the cen-
terstand so that the front wheel is
on the ground.
7. Tighten the wheel axle, then the
front wheel axle pinch bolt and the
brake caliper bolts to the specified
torques.
8. Connect the speedometer cable.
9. Push down hard on the handlebar
several times to check for proper
fork operation.
EAU04413
Rear wheel To remove the rear wheel
EW000122
WARNING
_

It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no danger
of it falling over.
_1. Loosen the axle nut and the brake
caliper bolts.2. Disconnect the brake torque rod
from the brake caliper bracket by
removing the nut and the bolt.
3. Place the motorcycle on the cen-
terstand. Tightening torques:
Wheel axle:
72 Nm (7.2 m·kgf)
Front wheel axle pinch bolt:
20 Nm (2.0 m·kgf)
Brake caliper bolt:
40 Nm (4.0 m·kgf)1. Locknut
2. Drive chain slack adjusting bolt
3. Axle nut
1. Bolt
2. Brake torque rod
3. Nut/bolt
4. Brake caliper bracket
5. Brake caliper
6. Bolt (× 2)
U5WME0.book Page 34 Monday, July 29, 2002 10:25 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-35
64. Remove the axle nut and the
brake caliper by removing the
bolts.
ECA00082
CAUTION:_ Do not apply the brake after the
brake caliper has been removed,
otherwise the brake pads will be
forced shut. _5. Loosen the locknuts, and then turn
the drive chain slack adjusting bolt
on each side of the swingarm fully
in direction
a.6. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:_ The drive chain does not need to be
disassembled in order to remove and
install the rear wheel. _7. While supporting the wheel and
the brake caliper bracket, pull the
wheel axle out.
8. Remove the brake caliper bracket
and the wheel.
EAU03895
To install the rear wheel
1. Place the wheel and the brake cal-
iper bracket in the original position.
2. Insert the wheel axle through the
brake caliper bracket and wheel
from the right-hand side, and then
install the axle nut.
3. Install the drive chain onto the rear
sprocket, and then adjust the drive
chain slack. (See page 6-23 for
drive chain slack adjustment pro-
cedures.)
4. Connect the brake torque rod to
the brake caliper bracket by in-
stalling the bolt and the nut.
5. 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. _6. Take the motorcycle off the cen-
terstand so that the rear wheel is
on the ground.
1. Wheel axle
2. Drive chain slack adjusting bolt
3. LocknutU5WME0.book Page 35 Monday, July 29, 2002 10:25 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
6 7. Tighten the axle nut, brake caliper
bolts and brake torque rod nut to
the specified torques.
EAU01008
Troubleshooting Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills. Tightening torques:
Axle nut:
150 Nm (15.0 m·kgf)
Brake caliper bolt:
40 Nm (4.0 m·kgf)
Brake torque rod nut:
23 Nm (2.3 m·kgf)
U5WME0.book Page 36 Monday, July 29, 2002 10:25 AM