2004 YAMAHA XJR 1300 torque

PERIODIC MAINTENANCE AND MINOR REPAIR
6-1
6
EAU17240
Safety is an obligation of the owner. Pe-
riodic inspection, adjustment and lubri-
cation will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
WARNING
EWA10320
If you are not familiar with mainte-
nance work, have a Yamaha dealerdo it for you.
EAU17380
Owner’s tool kit The owner’s tool kit is located under the
seat. (See page 3-14.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.NOTE:If you do not have the tools or experi-
ence required for a particular job, havea Yamaha dealer perform it for you.
WARNING
EWA10350
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-es.
1. Owner’s tool kit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6 2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-fied torque as soon as possible.
4. Install the spark plug cap.
EAU19691
Engine oil and oil filter
element The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level
1. Place the vehicle on the center-
stand.NOTE:
Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in afalse reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles, and then check the oil level
through the check window located
at the bottom-right side of the
crankcase.
NOTE:The engine oil should be between theminimum and maximum level marks.
4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
To change the engine oil (with or
without oil filter element replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf, 13 ft·lbf)
1. Engine oil filler cap
2. Engine oil level check window
3. Maximum level mark
4. Minimum level mark
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
62. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
NOTE:
Skip steps 4–10 if the oil filter elementis not being replaced.
4. Remove panel C. (See page 6-5.)
5. Remove the oil filter element drain
screw to drain the oil from the oil fil-
ter element.
6. Remove the oil filter element cover
by removing the bolt.7. Remove and replace the oil filter
element and O-ring.8. Install the oil filter element cover by
aligning the projection on the cover
with the slot in the crankcase, in-
stalling the bolt, then tightening it
to the specified torque.
NOTE:Make sure that the O-ring is properlyseated.
9. Install the oil filter element drain
screw, and then tighten it to the
specified torque.
1. Engine oil drain bolt
1. Oil filter element drain screw
2. Bolt
3. Oil filter element cover
1. Oil filter element
2. O-ring
1. Projection
2. SlotTightening torque:
Oil filter element cover bolt:
15 Nm (1.5 m·kgf, 11 ft·lbf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 10. Install the panel.
11. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
12. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler cap.
CAUTION:
ECA11620


In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do notmix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.


Make sure that no foreign mate-rial enters the crankcase.
13. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
NOTE:After the engine is started, the engine
oil level warning light should go off if theoil level is sufficient.CAUTION:
ECA10400
If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha dealercheck the vehicle.
14. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU20610
Cleaning the air filter element The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
1. Remove the seat. (See page
3-14.)
2. Remove panel A. (See page 6-5.)
3. Remove the air filter case cover by
removing the screws.
4. Pull the air filter element out.
Tightening torque:
Oil filter element drain screw:
7 Nm (0.7 m·kgf, 5 ft·lbf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element replace-
ment:
3.00 L (3.17 US qt) (2.64 Imp.qt)
With oil filter element replacement:
3.35 L (3.54 US qt) (2.95 Imp.qt)
1. Air filter case cover
2. Screw
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
CAUTION:
ECA10570
Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within thespecified limits.
3. Tighten the locknuts, and then
tighten the axle nut to the specified
torque.
EAU23020
Lubricating the drive chain The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.CAUTION:
ECA10580
The drive chain must be lubricated
after washing the motorcycle orriding in the rain.
1. Clean the drive chain with kero-
sene and a small soft brush.CAUTION:
ECA11120
To prevent damaging the O-rings, do
not clean the drive chain with steam
cleaners, high-pressure washers orinappropriate solvents.
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
1. Locknut
2. Drive chain slack adjusting bolt
3. Axle nut
4. Alignment marks
Tightening torque:
Axle nut:
150 Nm (15.0 m·kgf, 108 ft·lbf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6
EAU24360
Front wheel
EAU24470
To remove the front wheel
WARNING
EWA10820


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


Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Place the motorcycle on the cen-
terstand.
2. Loosen the front wheel axle pinch
bolt, then the wheel axle and the
brake caliper bolts.3. Remove the brake hose holder on
each side by removing the bolts.
4. Remove the brake caliper on each
side by removing the bolts.
CAUTION:
ECA11050
Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will beforced shut.
5. Pull the wheel axle out, and then
remove the wheel.
EAU33660
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle.
3. 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 brakediscs.
4. Install the brake hose holders by
installing the bolts.
5. Take the motorcycle off the center-
stand so that the front wheel is on
the ground.
6. Tighten the wheel axle, the front
wheel axle pinch bolt and the
brake caliper bolts to the specified
torques.
1. Wheel axle
2. Front wheel axle pinch bolt
1. Bolt
2. Brake hose holder
3. Brake caliper
Tightening torques:
Wheel axle:
72 Nm (7.2 m·kgf, 52 ft·lbf)
Front wheel axle pinch bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
Brake caliper bolt:
40 Nm (4.0 m·kgf, 29 ft·lbf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
67. Push down hard on the handlebar
several times to check for proper
fork operation.
EAU25080
Rear wheel
EAU25160
To remove the rear wheel
WARNING
EWA10820


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


Securely support the motor-
cycle so that there is no dangerof 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.
4. Remove the axle nut and the brake
caliper by removing the bolts.
CAUTION:
ECA11300
Do not apply the brake after the
brake caliper has been removed,
otherwise the brake pads will beforced shut.
1. Locknut
2. Drive chain slack adjusting bolt
3. Axle nut
1. Bolt
2. Brake torque rod
3. Nut
4. Brake caliper bracket
5. Brake caliper
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
6 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 andinstall 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.
EAU25841
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 6-20.)
4. Connect the brake torque rod to
the brake caliper bracket by install-
ing 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 brakedisc.
6. Take the motorcycle off the center-
stand so that the rear wheel is on
the ground.7. Tighten the axle nut, brake caliper
bolts and brake torque rod nut to
the specified torques.
1. Wheel axle
2. Drive chain slack adjusting bolt
3. Locknut
Tightening torques:
Axle nut:
150 Nm (15.0 m·kgf, 108 ft·lbf)
Brake caliper bolt:
40 Nm (4.0 m·kgf, 29 ft·lbf)
Brake torque rod nut:
23 Nm (2.3 m·kgf, 17 ft·lbf)
U5WME1E0.book Page 34 Thursday, September 11, 2003 11:10 AM