Yamaha Motor Co., Ltd.

2004

XJR1300(S) 5EA3-SE3

SERVICE INFORMATION

Yamaha Motor Co., Ltd.

FOREWORD This service information has been prepared to introduce new service and data for the XJR1300(S) 2004. For complete service information procedures, it is necessary to use this Supplementary Service Information together with the following manual.

XJR1300(S) 2004 SERVICE MANUAL: 5EA3-ME3 XJR1300(L) '99 SERVICE INFORMATION: 5EA3-SE1

XJR1300(P) 2002 SERVICE INFORMATION: 5EA3-SE2

NOTE:

WARNING

CAUTION:

EAS00002

NOTICEThis manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealersand their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu-al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehiclesshould have a basic understanding of mechanics and the techniques to repair these types of vehicles.Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-hicle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi-cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers andwill appear in future editions of this manual where applicable.

Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT INFORMATIONParticularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death tothe motorcycle operator, a bystander or a person checking or repairing the mo-torcycle.

A CAUTION indicates special precautions that must be taken to avoid damageto the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

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GENINFO SPEC

ENG CARB

ELEC

CHASCHKADJ

TRBLSHTG

16

EAS00009

SYMBOLSThe following symbols are not relevant to everyvehicle.Symbols 1 to 8 indicate the subject of eachchapter.1 General information2 Specifications3 Periodic checks and adjustments4 Chassis5 Engine6 Carburetor(-s)7 Electrical system8 Troubleshooting

Symbols 9 to 16 indicate the following.9 Serviceable with engine mounted10 Filling fluid11 Lubricant12 Special tool13 Tightening torque14 Wear limit, clearance15 Engine speed16 Electrical data

Symbols 17 to 22 in the exploded diagrams indi-cate the types of lubricants and lubricationpoints.17 Engine oil18 Gear oil19 Molybdenum disulfide oil20 Wheel bearing grease21 Lithium soap base grease22 Molybdenum disulfide grease

Symbols 23 to 24 in the exploded diagrams indicatethe following:23 Apply locking agent (LOCTITE�)24 Replace the part

CONTENTS

SPECIFICATIONS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS . . . . . . . . 18 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

CHECKING THE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 20 XJR1300(S) 2004 WIRING DIAGRAM

–1–

SPECGENERAL SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Model XJR1300(S)

Model code: 5WM7 (EUR)/5WM8 (DEU)/5WM9 (AUS)

Fuel:Type Regular unleaded gasoline (EUR)

Unleaded gasoline (AUS)

Tire:Size front

rearManufacturer front

rearType front

rear

120/70ZR17 M/C (58W)180/55ZR17 M/C (73W)DUNLOPDUNLOPD252FJD252J

Wheel travel:Rear wheel travel 120 mm

Bulb wattage � quantity:Auxiliary lightMeter lightHigh beam indicator light

12 V 4 W � 1 (EUR)LED � 112 V 1.7 W � 1

–2–

SPECENGINE SPECIFICATIONS

ENGINE SPECIFICATIONS

Model Standard Limit

Clutch:Clutch spring heightQuantity

6.78 mm (0.27 in)1 pc

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Carburetor:I.D. markMain jet (M.J)Main air jet (M.A.J)Jet needle (J.N)Needle jet (N.J)Pilot jet (P.A.J.1)Pilot outlet (P.O)Pilot jet (P.J)Bypass 1 (B.P.1)Bypass 2 (B.P.2)Bypass 3 (B.P.3)Pilot screw (P.S)Valve seat size (V.S)Starter jet (G.S.1)Starter jet (G.S.2)Throttle valve size (Th.V)Float height (F.H)Fuel level (using special tool)Engine idle speedIntake vacuum

5WM7 00#107.5#805D139P-OM#140φ1.0#15φ0.9φ0.9φ0.82.02.3#52.50.8#11513.0 mm (0.51 in)3.0 � 4.0 mm (0.12 � 0.16 in)950 � 1150 r/min30.7 kPa (230 mmHg, 9.1 inHg)

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–3–

SPECCHASSIS SPECIFICATIONS

CHASSIS SPECIFICATIONS

Model Standard Limit

Front suspension:Fork spring free lengthFitting lengthCollar lengthSpring rate (K1)

(K2)Stroke (K1)

(K2)Oil capacityOil level

357.3 mm (14.07 in)337.3 mm (13.28 in)195 mm (7.68 in)7.5 N/mm (0.76 kgf/mm, 42.83 lb/ in)13 N/mm (1.33 kgf/mm, 74.23 lb/ in)0 � 75 mm (0 � 2.95 in)75 � 130 mm (2.95 � 5.12 in)562 cm3 (0.5 Imp qt, 0.59 us qt)124 mm (4.88 in)

346.6 mm (13.65 in)���

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Rear suspension:Spring rate (K1)

(K2)(K3)

Stroke (K1)(K2)(K3)

21.3 N/mm (2.17 kgf/mm, 121.62 lb/in)27.8 N/mm (2.83 kgf/mm, 158.74 lb/in)33.7 N/mm (3.44 kgf/mm, 192.43 lb/in)0 � 37 mm (0 � 1.46 in)37 � 58 mm (1.46 � 2.28 in)58 � 93 mm (2.28 � 3.66 in)

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Front wheel:Rim size 17 M/C � MT3.50 ���

Rear wheel:Rim size 17 M/C � MT5.50 ���

Drive chain:Type/manufacturerNo. of links

50VA8/DAIDO112

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Front disc brake:Disc deflection limitMaster cylinder inside diameter

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15 mm (0.59 in)0.1 mm (0.0039 in)���

T.C.I.:T.C.I. unit model/manufacturer TNDF75/DENSO (except for DEU)

TNDF76/DENSO (DEU)���

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Oil level switch:Model/manufacturer 5UX/DENSO ���

Circuit breaker:TypeAmperage for individual circuit �

Q’tyMainHead LightSignalIgnitionParking LightBackupReserve

Fuse

40 A � 115 A � 110 A � 115 A � 110 A � 110 A � 140 A � 115 A � 110 A � 1

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–4–

SPECTIGHTENING TORQUES

TIGHTENING TORQUESENGINE TIGHTENING TORQUES

Part to be tightened Partname

Threadsize

Q’tyTightening

torque Remarksgname size

yNm m�kg ft�lb

Cylinder Nut M6 � 1.0 4 12 1.2 8.7Exhaust pipe and exhaust chamber Screw M8 � 1.25 2 20 2.0 14Exhaust chamber and muffler Bolt M8 � 1.25 4 20 2.0 14Muffler protector Screw M6 � 1.0 4 15 1.5 11Crankcase cover (right) Screw M6 � 1.0 2 10 1.0 7.2Drive sprocket cover Bolt M6 � 1.0 2 10 1.0 7.2Crankcase Bolt M12 � 1.25 5 35 3.5 25Stopper plate(Starter clutch idle gear shaft)

Bolt M6 � 1.0 1 10 1.0 7.2

Stopper lever Bolt M8 � 1.0 1 10 1.0 7.2Neutral switch Screw M5 � 0.8 3 3.5 0.35 2.5Speed sensor Bolt M6 � 1.0 1 10 1.0 7.2

CHASSIS TIGHTENING TORQUES

Part to be tightened Partname

Thread size Q’tyTightening

torque Remarksgname

yNm m�kg ft�lb

Rear fender cover and cover Screw M5 � 0.8 2 1.5 0.15 1.1Center stand Nut and

BoltM10 � 1.25 2 56 5.6 41

Front wheel axle – M18 � 1.5 1 72 7.2 52Front brake disk and hub Bolt M8 � 1.25 12 18 1.8 13Driven sprocket and hub Nut M8 � 1.25 6 69 6.9 4.3Rear wheel axle Nut M24 � 1.5 1 150 15.0 108Rear brake disc and hub Bolt M8 � 1.25 6 23 2.3 17

–5–

21 Rear brake light switch coupler22 Neutral switch lead23 Pickup coil lead24 Sidestand switch lead25 Throttle position sensor26 Fuel tank fitting27 Guide wire28 Fuel tank drain hose29 Fuel tank breather hose

11 Seat rail12 Thermo switch13 Standing handle14 Thermo switch coupler15 Rear brake fluid reservoir tank16 Speed sensor lead17 Starter motor lead18 Battery negative lead19 Carburetor heater coupler20 A.C.magneto

1 Throttle cables2 Ignition coil lead (#1, #4)3 Horn lead4 Spark plug lead (#3)5 Spark plug lead (#4)6 Ground lead7 Rear brake switch8 Intake air filter screw9 Air filter10 Relay assembly

SPECCABLE ROUTING

CABLE ROUTING

–6–

SPECCABLE ROUTING

A Clamp the #3 and #4 spark plugleads, on the head cover mount-ing bolt at the #3 spark plug lead,by use of clamp.

B Do not entangle the lead wiresand the hosing.Pass the clump of lead wires andthat of hosing orderly as shown.

C Pass the air filter drain hose, fueltank drain hose and fuel tankbreather hose (total 3 hoses)through the guide wire of the en-gine.

D Clump the A.C.magneto lead,pickup lead, sidestand switchlead, starter motor cable andcarburetor heater lead (total 5wires), by use of this clamp.

E Pass the wire harness betweenthe handle standing lug memberand the rear fender.

F Fasten the wire harness, thermoswitch lead to the seat rail at thefront end of the seat rail bracketwith a clamp. Point the tip of theclamp to the downward.

G Clamp the wire harness.H Pass the starter motor cable,

speed sensor lead and the bat-tery negative lead through the in-side of the seat rail.

–7–

M Match the paint mark of the air fil-ter drain hose to the lower end ofthe guide wire.

N Make sure to pull out the hosesufficiently so that bending doesnot occur and it can be set withinthis range.

O Air filter drain hose can also berouted at the rear side (Themiddle position is prohibited).

J Clump the throttle cables to thefuel tank rail, on the tank fitting byuse of this clamp. The front endof the clamp must be directeddownward.

K Thread this clamp through theupper hole in the gusset and se-cure the two throttle cables. Thefront end of the clamp must be di-rected towards the inside of thevehicle.

L Match the marks of the fuel tankdrain hose and fuel tank breatherhose, and arrange the two typesof hose properly.

I Secure the carburetor heaterlead, starter motor cable, batterynegative lead, A.C. magnetolead, neutral switch lead, side-stand switch lead, pickup leadand rear brake switch lead,speed sensor lead (total 9wires), to the fuel tank rail, nearthe air filter intake port mountingscrew, by use of this clamp.The front end of the clamp mustbe directed towards the front ofthe vehicle.

SPECCABLE ROUTING

–8–

B Secure the lead wire branch ofthe main harness to tension pipe1, at the immediate rear of thegusset, by use of this clamp.The front end of the clamp mustbe directed downward.

C Clamp the four spark plug leads,the #1 and #2 spark plug leadsup and the #3 and #4 spark plugleads down, by use of this clamp.Position the leading ends of thespark plug leads near, but notbelow, the lower front end of theair induction system assembly.

SPECCABLE ROUTING

1 Clutch cable2 Gusset3 Tension pipe 14 Air induction system assembly5 Spark plug lead (#2)6 Spark plug lead (#1)7 Starter cable8 Air filter9 Carburetor air vent hose10 Air filter drain hose11 Frame ground12 Turn signal relay coupler13 Carburetor heater relay coupler14 Fuse box (for EUR)15 Igniter unit coupler16 Starter motor

17 Speed sensor lead18 A.C.magneto19 Pickup coil rotor cover20 Oil filter cover21 Sidestand switch22 Sidestand switch lead23 Horn lead24 Ignition coil lead (#2, #3)

A Pass the wire harness and thestarter cable through the holderwire of the gusset.Pass the starter cable under thewire harness.

–9–

J After securing the side standswitch lead wire using thisclamp, first route the lead wirebetween the pickup cover, the oilfilter cover, the A.C. generator,and the starter motor. Next, aswith the engine lead wire, routethe lead wire through the rightside of the vehicle.

K Clamp the clutch hose.L Secure the grommet of the

clutch hose by use of this holderwire of the gusset.

G Route the air filter drain hose bythe front side of the carburetor airvent hose and by the right side ofthe vehicle body. To route to theright side of the body, make sureto set between the starter motorand A.C.magneto.

H Route the speed sensor lead bythe right side of the vehicle bodyalong with the sidestand switchlead.

I Mount the square fixture of theclutch hose in parallel with thecover.

D Clamp the #1 and #2 spark plugleads using this clamp.Clamp these cords above the #2head cover mounting bolt.

E Make sure to tighten the frameground together with the igniterunit attaching screw.

F Fasten the seat lock cable to theseat rail with a clamp.Point the tip of the clamp to thedownward.

SPECCABLE ROUTING

–10–

P Pass the main harness throughthe inside of the clutch hose andinsert the harness into the left ofthe headlight lower hole.

M Pass the horn lead wire betweenthe clutch hose and the frame,then pull the lead wire out to thefront, and connect the lead wireto the horn.

N Connect the black-coupler-equipped lead wire to the #1 and#4 ignition coils.

O Pass this clamp through the low-er hole of the gusset and securethe clutch cable.The front end of the clamp mustbe directed towards the inside ofthe vehicle.

SPECCABLE ROUTING

–11–

27 Battery negative lead coupler28 Turn signal relay29 Carburetor heater relay coupler30 Igniter unit31 Starter cable32 Horn (left)33 Rear fender34 Rear turn signal light lead (left)35 Rear turn signal light lead (right)36 Wire harness37 Tail /brake light lead38 Stopper

14 Relay assembly15 Starter motor cable16 Starter motor relay17 Seat rail18 Rear fender rib19 Rear turn signal light (right)20 Tail /brake light bracket21 Rear turn signal light (left)22 Seat lock wire23 Seat lock24 Battery positive lead25 Starter relay coupler26 Fuse box

1 Throttle cables2 Ignition coil (#1, #4)3 Ignition coil (#2, #3)4 Horn (right)5 Throttle position sensor6 Neutral switch coupler7 Pickup coil coupler8 Sidestand switch coupler9 Fuel sender coupler10 Battery band11 Battery12 Rear brake fluid reservoir tank13 Battery negative lead

SPECCABLE ROUTING

–12–

A Right horn.Install the HI tone source (with H-marked label) at the right of thevehicle.

B Connect the #1-#4 spark plugleads in order of the cord number.

C Pass the T.P.S. lead wire throughthe clamp of the #4 carburetor.

D To the fuel sender.

G Clamp the wire harness to theseat rail at the immediate rear ofthe side cover mounting bracketon the seat rail.The front end of the clamp mustface downward and be posi-tioned inside the back stay.

E Fasten the starter motor cable,battery negative lead and speedsensor lead to the seat rail be-tween the air filter and tank at-taching brackets with a clamp.

F Fasten two battery positiveleads, battery negative lead cou-pler and wire harness with thebattery clamp.

SPECCABLE ROUTING

–13–

L Connect the fuel sender coupler,neutral switch coupler, pickupcoupler, and side stand switchcoupler wires above the aircleaner.

M Carburetors #1 to #4 in a left-to-right way.

N Thread the wire harness inser-tion clamp onto the T-stud of theframe.

O Pass the starter cable throughthe front of the throttle cable.

K Clamp the wire harness to theseat rail, on the wire harnesspositioning tape and at the im-mediate rear of the side covermounting bracket on the seatrail.The front end of the clamp mustface downward and be posi-tioned inside the back stay.

H Store the wire harness, the tail-light lead wire, and the rear leftand right flasher lead wires, intothe space between the taillightbracket and the rib of the rearfender.

I The seat lock wire must not ex-tend to the outside of the brack-et.

J Pass the lead wire leading to thefuse box under the wire harness.

SPECCABLE ROUTING

–14–

V Pass the left rear turn signal lightlead and right rear turn signallight lead through the hole of therear fender respectively.

W Pass the wire harness betweenthe frame installation sectionand storage space rib of the rearfender.

X Connect the starter motor cableto face outward at an angle ofabout 45 degrees.

T Position of the wire harness, tailbrake light lead, left rear turn sig-nal light lead, right rear turn sig-nal lead should be not higherthan the rib height of the rearfender.

U Clamp the wire harness, left rearturn signal light lead and rightrear turn signal light lead.Point the tip of the clamp to thefront side.

P From left: #1, #2, #3, and #4spark plug leads.

Q Point inward.R Point outward.S Secure the wire harness and the

starter cable, on the harnesspositioning tape, by use of thisclamp. The front end of theclamp must be directed down-ward.The harness must not deflect be-tween the T-stud and the clamp.

SPECCABLE ROUTING

–15–

Y Direct the crimping side of thebattery positive (+) lead wiredownward and connect the leadwire.

Z Connect the starter cable to faceat right angles to the vehiclebody with contact with the stop-pers.

SPECCABLE ROUTING

–16–

SPECCABLE ROUTING

1 Speedometer lead2 Crown handle3 Left handlebar switch lead4 Starter cable5 Clutch cable6 Front turn signal light lead (left)7 Immobilizer unit lead8 Main switch lead9 Wire harness10 Front turn signal light lead (right)11 Brake hose 212 Brake hose 113 Right handlebar switch lead14 Immobilizer unit coupler15 Housing connector16 Housing connector 2

A Pass the meter lead, left handlebar switch lead and right handle-bar switch lead through the up-per hole of the headlight.

B Bind the left handlebar switchlead, clutch cable and startercable under the crown handlewith a clamp.Pass the left handlebar switchlead through the inside of theclutch cable.Pass the starter cable throughthe frame side, then the inside ofthe clutch cable and the frontside of the left handlebar switchlead.

C Route the turn signal light leadby the front side of the headlightstay (left and right).Make sure to install the cap up-ward.

D Pass the left front turn signal lightlead, main switch lead, immobi-lizer unit lead and wire harnessthrough the lower left hole of thehead light.

E To the front brake caliperF Pass the right front turn signal

light lead through the lower righthole of the head light.

–17–

N Tighten the clamp pointing thetip to the inward.

O Install the coupler locking sec-tion facing the housing connec-tor 2.

P Place the cover onto the couplerfor the immobilizer lead and wireharness.

Q Clamp the main switch lead, im-mobilizer lead, left handlebarswitch lead, right handlebarswitch lead, front turn signal light(left) and meter lead.

SPECCABLE ROUTING

G Bind the right handlebar switchlead and brake hose 2 by theside of the wire guide of theheadlight stay with a clamp.

H Pass the throttle cables throughthe wire guide of the headlightstay.

I To the upper holeJ To the left side of the lower holeK To the right side of the lower holeL Clamp the right front turn signal

light lead and wire harness.Clamp the wire harness aligningwith the positioning tape.

M Tighten the clamp pointing thetip to the upward.

–18–

INTRODUCTION/PERIODIC MAINTENANCE ANDLUBRICATION INTERVALS

CHKADJ

NOTE:

EAS00036

PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended checks and adjustments. Iffollowed, these preventive maintenance procedures will ensure more reliable vehicle operation, alonger service life and reduce the need for costly overhaul work. This information applies to vehiclesalready in service as well as to new vehicles that are being prepared for sale. All service techniciansshould be familiar with this entire chapter.

EAS00037

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

�The annual checks must be performed every year, except if a kilometer-based maintenance is per-formed 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 technical skills.

NO. ITEM CHECK OR MAINTENANCE JOB

ODOMETER READING(� 1,000 km) ANNUAL

CHECK1 10 20 30 40

CHECK

1 * Fuel line � Check fuel and vacuum hoses for cracks or damage. � � � � �

2 * Fuel filter � Check condition. � �

3 Spark plugs

� Check condition.� Clean and regap.

� �

p p g

� Replace. � �

4 * Valves� Check valve clearance.� Adjust.

Every 20000 km

5 Air filter element� Clean. � �

5 Air filter element� Replace. � �

6 * Clutch � Check operation, fluid level and vehicle for fluid leakage. � � � � �

7 * Front brake� Check operation, fluid level and vehicle for fluid leakage. � � � � � �

7 * Front brake� Replace brake pads. Whenever worn to the limit

8 * Rear brake� Check operation, fluid level and vehicle for fluid leakage. � � � � � �

8 * Rear brake� Replace brake pads. Whenever worn to the limit

9 * Brake hoses� Check for cracks or damage. � � � � �

9 * Brake hoses� Replace. Every 4 years

10 * Wheels � Check runout and for damage. � � � �

11 * Tires

� Check tread depth and for damage.� Replace if necessary.� Check air pressure.� Correct if necessary.

� � � � �

12 * Wheel bearings � Check bearing for looseness or damage. � � � �

13 * Swingarm� Check operation and for excessive play. � � � �

13 * Swingarm� Lubricate with lithium-soap-based grease. Every 50000 km

14 Drive chain� Check chain slack.� Make sure that the rear wheel is properly aligned.� Clean and lubricate.

Every 1000 km and after washing the motorcycleor riding in the rain

15 * Steering bearings� Check bearing play and steering for roughness. � � � � �

15 * Steering bearings� Lubricate with lithium-soap-based grease. Every 20000 km

16 * Chassis fasteners� Make sure that all nuts, bolts and screws are properly

tightened.� � � � �

17 Sidestand, centerstand� Check operation.� Lubricate.

� � � � �

18 * Sidestand switch � Check operation. � � � � � �

19 * Front fork � Check operation and for oil leakage. � � � �

–19–

INTRODUCTION/PERIODIC MAINTENANCE ANDLUBRICATION INTERVALS

CHKADJ

NOTE:

NO. ITEM CHECK OR MAINTENANCE JOB

ODOMETER READING(� 1,000 km) ANNUAL

CHECK1 10 20 30 40

CHECK

20 *Shock absorber assem-blies

� Check operation and shock absorbers for oil leakage. � � � �

21 * Carburetors� Check starter (choke) operation.� Adjust engine idling speed and synchronization.

� � � � � �

22 Engine oil� Change.� Check oil level and vehicle for oil leakage.

� � � � � �

23 Engine oil filter element � Replace. � � �

24 *Front and rear brakeswitches

� Check operation. � � � � � �

25 Moving parts and cables � Lubricate. � � � � �

26 *Throttle grip housingand cable

� Check operation and free play.� Adjust the throttle cable free play if necessary.� Lubricate the throttle grip housing and cable.

� � � � �

27 *Muffler and exhaustpipe

� Check the screw clamp for looseness. � � � � �

28 *Lights, signals andswitches

� Check operation.� Adjust headlight beam.

� � � � � �

� 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 wellas 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.

–20––20–

CHKADJCHECKING THE EXHAUST SYSTEM

EAS00099

ENGINECHECKING THE EXHAUST SYSTEMThe following procedure applies to all of the ex-haust pipes, mufflers and gaskets.1. Check:�exhaust pipe 1�muffler 2�muffler protector 3Cracks/damage � Replace.

�gasket 4 , 5 , 6Exhaust gas leaks � Replace.

2. Check:� tightening torque

Exhaust pipe nut 725 Nm (2.5 m�kg, 18.1 ft�lb)

Exhaust pipe and exhaustchamber screw 820 Nm (2.0 m�kg, 14.5 ft�lb)

Muffler bracket bolt 920 Nm (2.0 m�kg, 14.5 ft�lb)

Exhaust chamber bolt 10

25 Nm (2.5 m�kg, 18.1 ft�lb)Exhaust chamber and muffler bolt11

20 Nm (2.0 m�kg, 14.5 ft�lb)Muffler and stay bolt 12

20 Nm (2.0 m�kg, 14.5 ft�lb)Muffler protector screw 13

15 Nm (1.5 m�kg, 10.9 ft�lb)

56 Front turn signal light (left)57 Front turn signal light (right)58 Carburetor heater relay59 Thermo switch60 Carburetor heater61 Ground

1 Main switch2 A.C. magneto3 Fuse (back up)4 Fuse (main)5 Battery6 Starter relay7 Starter motor8 Immobilizer unit9 Alarm10 Starting circuit cut-off relay11 Neutral switch12 Sidestand switch13 Ignitor unit14 Ignition coil15 Spark plug16 Pickup coil17 Throttle position sensor18 Speed sensor19 Fuel sender20 Meter assembly21 Speedometer22 Tachometer23 Fuel gauge24 Meter lights25 Oil level warning light26 Neutral indicator light27 Immobilizer indicator light28 High beam indicator light29 Turn signal indicator light (left)30 Turn signal indicator light (right)31 Oil level switch32 Rear brake light switch33 Auxiliary light34 Tail brake light35 Right handlebar switch36 Front brake switch37 Engine stop switch38 Start switch39 Fuse (park)40 Fuse (ignition)41 Fuse (signal)42 Fuse (headlight)43 Turn signal relay44 Horn45 Headlight relay46 Left handlebar switch47 Pass switch48 Dimmer switch49 Horn switch50 Turn signal switch51 Hazard switch52 Clutch switch53 Headlight54 Rear turn signal light (left)55 Rear turn signal light (right)

XJR1300(S) 2004 WIRING DIAGRAM

BBrChDgGGyLLgOPRSbWYB/LB/RB/YBr/LBr/R

BlackBrownChocolateDark greenGreenGrayBlueLight greenOrangePinkRedSky blueWhiteYellowBlack/BlueBlack/RedBlack/YellowBrown/BlueBrown/Red

COLOR CODEBr/WG/WG/YL/BL/RL/WL/YR/BR/GR/WR/YSb/WW/BW/GW/RY/BY/GY/L

Brown/WhiteGreen/WhiteGreen/YellowBlue/BlackBlue/RedBlue/WhiteBlue/YellowRed/BlackRed/GreenRed/WhiteRed/YellowSky blue/WhiteWhite/BlackWhite/GreenWhite/RedYellow/BlackYellow/GreenYellow/Blue

XJR1300(S) 2004 WIRING DIAGRAM