2003 YAMAHA XJR 1300 brake light

DESCRIPTION
2-2
2
Right view10. Tail/brake light (page 6-31)
11. Luggage strap holders (page 3-16)
12. Shock absorber assembly spring
preload adjusting rings (page 3-15)
13. Owner’s tool kit (page 6-1)
14. Rear brake fluid reservoir (page 6-20)
15. Fuses, battery (page 6-28, 6-29)16. Air filter element (page 6-11)
17. Fuel tank (page 3-8)
18. Front brake fluid reservoir (page 6-20)
19. Front fork spring preload adjusting bolt (page 3-14)
20. Headlight (page 6-30)
21. Engine oil filler cap (page 6-8)
22. Engine oil level check window (page 6-8)
23. Brake pedal (page 3-7)
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3
INSTRUMENT AND CONTROL FUNCTIONS
Main switch/steering lock ..................................... 3-1
Indicator and warning lights ................................. 3-2
Speedometer unit ................................................ 3-3
Tachometer .......................................................... 3-3
Fuel gauge ........................................................... 3-3
Anti-theft alarm (optional) .................................... 3-4
Handlebar switches ............................................. 3-4
Clutch lever .......................................................... 3-5
Shift pedal ............................................................ 3-6
Brake lever ........................................................... 3-7
Brake pedal .......................................................... 3-7
Fuel tank cap ....................................................... 3-8
Fuel ...................................................................... 3-9Fuel tank breather hose .................................... 3-10
Fuel cock ........................................................... 3-10
Starter (choke) lever........................................... 3-11
Seat ................................................................... 3-11
Helmet holder .................................................... 3-12
Storage compartment ....................................... 3-13
Adjusting the front fork ...................................... 3-13
Adjusting the shock absorber assemblies ......... 3-15
Luggage strap holders ...................................... 3-16
Sidestand .......................................................... 3-17
Ignition circuit cut-off system ............................. 3-17
U5WME0.book Page 1 Monday, July 29, 2002 10:25 AM

PRE-OPERATION CHECKS
4-2
4
NOTE:_ Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved. _
EWA00033
WARNING
_ If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle. _Drive chainCheck chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.6-22–6-24
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-14–6-17
Brake and shift pedalsMake sure that operation is smooth.
Lubricate pedal pivoting points if necessary.6-25
Brake and clutch leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-25
Centerstand, sidestandMake sure that operation is smooth.
Lubricate pivots if necessary.6-25
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switchesCheck operation.
Correct if necessary.—
Sidestand switchCheck operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.3-17 ITEM CHECKS PAGE
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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
Cast wheels ....................................................... 6-17
Clutch lever free play ......................................... 6-17
Adjusting the brake pedal position ..................... 6-18
Rear brake light switch adjustment .................... 6-19
Checking the front and rear brake pads ............. 6-19
Checking the brake and clutch fluid levels ......... 6-20
Changing the brake and clutch fluids ................. 6-21
Drive chain slack ................................................ 6-22
Lubricating the drive chain ................................. 6-23
Checking and lubricating the cables .................. 6-24Checking and lubricating the throttle grip and
cable ............................................................... 6-24
Checking and lubricating the brake and
shift pedals ...................................................... 6-25
Checking and lubricating the brake and
clutch levers .................................................... 6-25
Checking and lubricating the centerstand and
sidestand ......................................................... 6-25
Checking the front fork ...................................... 6-26
Checking the steering ....................................... 6-27
Checking the wheel bearings ............................ 6-27
Battery ............................................................... 6-28
Replacing the fuses .......................................... 6-29
Replacing the headlight bulb ............................. 6-30
Replacing a 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
U5WME0.book Page 1 Monday, July 29, 2002 10:25 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU04408
NOTE:_

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.


Hydraulic brake and clutch service
Regularly check and, if necessary, correct the brake and clutch fluid levels.
Every two years replace the internal components of the brake master cylinders and calipers as well as clutch master
and release cylinders, and change the brake and clutch fluids.
Replace the brake and clutch hoses every four years and if cracked or damaged.
_22 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
23 Engine oil filter elementReplace.√√√
24
*Front and rear brake
switchesCheck operation.√√√√√ √
25 Moving parts and cablesLubricate.√√√√ √
26*Throttle grip housing
and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√√ √
27*Muffler and exhaust pipeCheck the screw clamp for looseness.√
28*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
U5WME0.book Page 4 Monday, July 29, 2002 10:25 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6
EAU01756
Rear brake light switch
adjustment The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
1. Remove panel A. (See page 6-5
for panel removal and installation
procedures.)2. Turn the adjusting nut while hold-
ing the rear brake light switch in
place. To make the brake light
come on earlier, turn the adjusting
nut in direction
a. To make the
brake light come on later, turn the
adjusting nut in direction
b.
3. Install the panel.
EAU01314
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 groove,
which allows you to check the brake
pad wear without having to disassem-
ble the brake.
1. Rear brake light switch
2. Rear brake light switch adjusting nut
1. Brake pad wear indicator grooveFront
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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
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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