2003 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
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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_

The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.


From 50,000 km, repeat the maintenance intervals starting from 10,000 km.


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 lineCheck fuel hoses and vacuum hose for cracks or damage.√√√√ √
2*Fuel filterCheck condition.√√
3 Spark plugsCheck condition.
Clean and regap.√√
Replace.√√
4*ValvesCheck valve clearance.
Adjust.Every 20,000 km
5 Air filter elementClean.√√
Replace.√√
6*ClutchCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.) √√ √ √ √
7*Front brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
8*Rear brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
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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
6-20
6 To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear
indicator groove has almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU04169
Checking the brake and clutch
fluid levels Insufficient brake fluid may allow air to
enter the brake or clutch systems, pos-
sibly causing them to become ineffec-
tive.
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:

When checking the fluid level,
make sure that the top of the brake
or clutch fluid reservoir is level.


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 grooveRear
1. Minimum level markFront brake
1. Minimum level markRecommended brake and clutch
fluid: DOT 4 brake fluidRear brake
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6


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.


The brake or clutch fluid reservoir
diaphragm will lose its shape from
the negative pressure if the fluid
level goes down too far. Be sure to
return the diaphragm to its original
shape before installing it into the
brake or clutch fluid reservoir.


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.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


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.
EAU03984
Changing the brake and
clutch fluids Have a Yamaha dealer change the
brake and clutch fluids at the intervals
specified in the NOTE after the periodic
maintenance and lubrication chart. In
addition, have the oil seals of the brake
and clutch master cylinders and cali-
pers as well as the brake and clutch
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.

Oil seals: Replace every two
years.


Brake and clutch hoses: Replace
every four years.
1. Minimum level markClutch
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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
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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
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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