2003 YAMAHA XJR 1300 spark plugs

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
6-2
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
U5WME0.book Page 2 Monday, July 29, 2002 10:25 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6
EAU03329
Checking the spark plugs The spark plugs are important engine
components, which are easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plugs should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
To remove a spark plug
1. Remove the spark plug cap.2. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.
To check the spark plugs
1. Check that the porcelain insulator
around the center electrode on
each spark plug is a medi-
um-to-light tan (the ideal color
when the motorcycle is ridden nor-
mally).
2. Check that all spark plugs installed
in the engine have the same color.
NOTE:_ If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle. _3. Check each spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and replace
it if necessary.
1. Spark plug cap (× 4)
1. Spark plug wrench
Specified spark plug:
DPR8EA-9 (NGK) or
X24EPR-U9 (DENSO)
U5WME0.book Page 6 Monday, July 29, 2002 10:25 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-37
6
EAU01297
Troubleshooting chart
EW000125
WARNING
_ Keep away open flames and do not smoke while checking or working on the fuel system. _
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plugs
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
DryWet
Open the throttle halfway and operate
the electric starter.
U5WME0.book Page 37 Monday, July 29, 2002 10:25 AM

MOTORCYCLE CARE AND STORAGE
7-4
7
Storage Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA00014
CAUTION:_

Storing the motorcycle in a
poorly ventilated room or cover-
ing it with a tarp, while it is still
wet, will allow water and humid-
ity to seep in and cause rust.


To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
_
Long-term
Before storing your motorcycle for
several months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. Turn the fuel cock lever to “ON”.
3. Drain the carburetor float cham-
bers by loosening the drain bolts;
this will prevent fuel deposits from
building up. Pour the drained fuel
into the fuel tank.
4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
5. Perform the following steps to pro-
tect the cylinders, piston rings, etc.
from corrosion.a. Remove the spark plug caps
and spark plugs.
b. Pour a teaspoonful of engine
oil into each spark plug bore.
c. Install the spark plug caps onto
the spark plugs, and then place
the spark plugs on the cylinder
head so that the electrodes are
grounded. (This will limit spark-
ing during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder walls with oil.)
e. Remove the spark plug caps
from the spark plugs, and then
install the spark plugs and the
spark plug caps.
EWA00003
WARNING
_ To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over. _
U5WME0.book Page 4 Monday, July 29, 2002 10:25 AM

INDEXAAir filter element, cleaning ...................... 6-11
Anti-theft alarm ........................................3-4BBattery ................................................... 6-28
Brake and clutch fluid levels, checking ... 6-20
Brake and clutch fluids, changing........... 6-21
Brake and clutch levers, checking and
lubricating ............................................ 6-25
Brake and shift pedals, checking and
lubricating ............................................ 6-25
Brake lever...............................................3-7
Brake light switch (rear), adjusting ......... 6-19
Brake pads, checking............................. 6-19
Brake pedal..............................................3-7
Brake pedal position, adjusting .............. 6-18CCables, checking and lubricating............ 6-24
Carburetors, adjusting............................ 6-12
Care.........................................................7-1
Centerstand and sidestand,
checking and lubricating ...................... 6-25
Clutch lever ..............................................3-5
Clutch lever free play ............................. 6-17
Conversion table ......................................8-5DDimmer switch .........................................3-4
Drive chain, lubricating ........................... 6-23
Drive chain slack .................................... 6-22
Adjusting .......................................... 6-23
Checking .......................................... 6-22
EEngine break-in ....................................... 5-4
Engine idling speed ............................... 6-13
Engine oil and oil filter element ................ 6-7
Engine stop switch................................... 3-5FFront fork, adjusting ............................... 3-13
Front fork, checking ............................... 6-26
Fuel ......................................................... 3-9
Fuel cock ............................................... 3-10
Fuel consumption, tips for reducing ......... 5-4
Fuel gauge .............................................. 3-3
Fuel tank breather hose ......................... 3-10
Fuel tank cap ........................................... 3-8
Fuses, replacing .................................... 6-29HHandlebar switches ................................. 3-4
Hazard switch .......................................... 3-4
Headlight bulb, replacing ....................... 6-30
Helmet holder ........................................ 3-12
High beam indicator light ......................... 3-2
Horn switch ............................................. 3-4IIdentification numbers ............................. 9-1
Ignition circuit cut-off system.................. 3-17
Indicator and warning lights ..................... 3-2KKey identification number ........................ 9-1
LLight switch ..............................................3-5
Luggage strap holders ...........................3-16MMain 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 ...3-15
Sidestand ...............................................3-17
Spark plugs, checking ..............................6-6
Specifications ...........................................8-1
Speedometer unit.....................................3-3
U5WME0.book Page 1 Monday, July 29, 2002 10:25 AM