brake pads YAMAHA XJR 1300 2008 Owners Manual

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Immobilizer system .........................3-1
Main switch/steering lock ................3-2
Indicator and warning lights ............3-4
Speedometer ..................................3-5
Tachometer ....................................3-5
Multi-function display ......................3-6
Anti-theft alarm (optional) ...............3-9
Handlebar switches ........................3-9
Clutch lever ...................................3-10
Shift pedal .....................................3-11
Brake lever ...................................3-11
Brake pedal ..................................3-12
Fuel tank cap ................................3-12
Fuel ...............................................3-13
Fuel tank breather hose ................3-14
Catalytic converters ......................3-14
Seat ..............................................3-15
Helmet holder ...............................3-15
Storage compartment ...................3-16
Adjusting the front fork ..................3-16
Adjusting the shock absorber
assemblies ................................3-18Luggage strap holders ................. 3-20
EXUP system ............................... 3-21
Sidestand ..................................... 3-21
Ignition circuit cut-off system ........ 3-22
PRE-OPERATION CHECKS............. 4-1
Pre-operation check list .................. 4-2
OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting the engine ......................... 5-1
Shifting ........................................... 5-2
Tips for reducing fuel
consumption ............................... 5-3
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
Owner’s tool kit ............................... 6-1
Periodic maintenance and
lubrication chart .......................... 6-2
Removing and installing panels ..... 6-6
Checking the spark plugs ............... 6-7
Engine oil and oil filter element ...... 6-8
Replacing the air filter element
and cleaning the check hose .... 6-11
Checking the throttle cable
free play .................................... 6-12
Valve clearance ............................ 6-13
Tires ............................................. 6-13Cast wheels ................................. 6-16
Clutch lever .................................. 6-16
Adjusting the rear brake light
switch ....................................... 6-16
Checking the front and rear
brake pads ................................ 6-17
Checking the brake and clutch
fluid levels ................................. 6-18
Changing the brake and clutch
fluids ......................................... 6-19
Drive chain slack .......................... 6-19
Cleaning and lubricating the
drive chain ................................ 6-21
Checking and lubricating the
cables ....................................... 6-21
Checking and lubricating the
throttle grip and cable ............... 6-22
Checking and lubricating the
brake and shift pedals .............. 6-22
Checking and lubricating the
brake and clutch levers ............ 6-23
Checking and lubricating the
centerstand and sidestand ....... 6-23
Lubricating the swingarm
pivots ........................................ 6-24
Checking the front fork ................. 6-24
Checking the steering .................. 6-25
Checking the wheel bearings ....... 6-26
Battery ......................................... 6-26
Replacing the fuses ..................... 6-27
Replacing the headlight bulb ....... 6-28U5WME5E0.book Page 1 Wednesday, December 5, 2007 10:30 AM

PRE-OPERATION CHECKS
4-2
4
EAU15605
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-13
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-8
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-17, 6-18
Rear brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-17, 6-18
ClutchCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended fluid to specified level.
Check hydraulic system for leakage.6-16, 6-18
Throttle gripMake sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-12, 6-22
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU1770A
Periodic maintenance and lubrication chart NOTE:

The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.


From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technicalskills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
1*Fuel lineCheck fuel hoses for cracks or
damage.√√√√√
2 Spark plugsCheck condition.
Clean and regap.√√
Replace.√√
3*ValvesCheck valve clearance.
Adjust.Every 20000 km (12000 mi)
4 Air filter elementReplace.√
5*ClutchCheck operation, fluid level and
vehicle for fluid leakage.√√√√√
6*Front brakeCheck operation, fluid level and
vehicle for fluid leakage.√√√√√√
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation, fluid level and
vehicle for fluid leakage.√√√√√√
Replace brake pads. Whenever worn to the limit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6 3. Install the panel.
EAU22321
Checking the front and rear
brake pads Front brake
Rear brakeThe 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. 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 disappeared, have a Yamaha
dealer replace the brake pads as a set.1. Brake pad wear indicator groove
1. Brake pad wear indicator groove
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6
EAU22680
Checking the brake and clutch
fluid levels Front brake
Rear brakeClutch
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 fluid
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 locatedbehind panel A. (See page 6-6.)
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 quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking or clutch
performance.


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
1. Minimum level mark
1. Minimum level mark
1
1. Minimum level mark
1
Recommended brake and clutch flu-
id:
DOT 4 brake fluid
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6 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 grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU22750
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.
EAU22760
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22793
To check the drive chain slack
1. Place the motorcycle on the cen-
terstand.
2. Shift the transmission into the neu-
tral position.
3. Spin the rear wheel several times
to locate the tightest portion of the
drive chain.
4. Measure the drive chain slack as
shown.1. Drive chain slack
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
63. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
4. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
5. Install the socket (together with the
bulb) by pushing it in.
6. Install the headlight unit by install-
ing the screws.
EAU24360
Front wheel
EAU38890
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 bolt.
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.
1. Auxiliary light bulb socket
1. Wheel axle
2. Front wheel axle pinch bolt
1. Brake caliper bolt
2. Brake hose holder
3. Brake caliper
4. Bolt
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
6
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.7. Push down hard on the handlebar
several times to check for proper
fork operation.
EAU25080
Rear wheel
EAU25161
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.
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)
1. Axle nut
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
6
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.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 6-19.)
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.
1. Brake caliper bolt
2. Brake torque rod
3. Bolt
4. Brake caliper bracket
5. Brake caliper
6. Nut
1. Wheel axle
2. Drive chain slack adjusting bolt
3. Locknut
U5WME5E0.book Page 34 Wednesday, December 5, 2007 10:30 AM

INDEXAAir filter element and check hose,
replacing and cleaning........................ 6-11
Anti-theft alarm (optional)........................ 3-9
Auxiliary light bulb, replacing ................ 6-31BBattery................................................... 6-26
Brake and clutch fluid levels,
checking ............................................. 6-18
Brake and clutch fluids, changing ......... 6-19
Brake and clutch levers, checking and
lubricating ........................................... 6-23
Brake and shift pedals, checking and
lubricating ........................................... 6-22
Brake lever ............................................ 3-11
Brake pedal ........................................... 3-12CCables, checking and lubricating .......... 6-21
Care ........................................................ 7-1
Catalytic converters .............................. 3-14
Centerstand and sidestand, checking
and lubricating .................................... 6-23
Clutch lever .................................. 3-10, 6-16DDimmer switch ........................................ 3-9
Drive chain, cleaning and lubricating .... 6-21
Drive chain slack ................................... 6-19EEngine break-in ....................................... 5-3
Engine oil and oil filter element ............... 6-8
Engine stop switch ................................ 3-10
Engine trouble warning light.................... 3-4
EXUP system ........................................ 3-21
FFront and rear brake pads, checking .... 6-17
Front fork, adjusting .............................. 3-16
Front fork, checking .............................. 6-24
Fuel....................................................... 3-13
Fuel consumption, tips for reducing........ 5-3
Fuel tank breather hose........................ 3-14
Fuel tank cap ........................................ 3-12
Fuses, replacing ................................... 6-27HHandlebar switches ................................ 3-9
Hazard switch ....................................... 3-10
Headlight bulb, replacing ...................... 6-28
Helmet holder ....................................... 3-15
High beam indicator light ........................ 3-4
Horn switch ........................................... 3-10IIdentification numbers ............................ 9-1
Ignition circuit cut-off system ................ 3-22
Immobilizer system ................................. 3-1
Immobilizer system indicator light........... 3-4
Indicator and warning lights .................... 3-4KKey identification number ....................... 9-1LLicense plate light bulb, replacing ........ 6-31
Luggage strap holders .......................... 3-20MMain switch/steering lock........................ 3-2
Matte color, caution ................................ 7-1
Model label ............................................. 9-2
Multi-function display .............................. 3-6NNeutral indicator light .............................. 3-4
OOil level warning light .............................. 3-4PPanels, removing and installing .............. 6-6
Parking .................................................... 5-4
Part locations .......................................... 2-1
Pass switch ............................................. 3-9
Periodic maintenance and lubrication
chart ...................................................... 6-2
Pre-operation check list........................... 4-2RRear brake light switch, adjusting ......... 6-16SSafety information ................................... 1-1
Seat ....................................................... 3-15
Shifting .................................................... 5-2
Shift pedal ............................................. 3-11
Shock absorber assemblies,
adjusting ............................................. 3-18
Sidestand .............................................. 3-21
Spark plugs, checking ............................. 6-7
Specifications .......................................... 8-1
Speedometer........................................... 3-5
Starting the engine .................................. 5-1
Start switch............................................ 3-10
Steering, checking................................. 6-25
Storage.................................................... 7-3
Storage compartment............................ 3-16
Swingarm pivots, lubricating ................. 6-24TTachometer ............................................. 3-5
Tail/brake light ....................................... 6-30
Throttle cable free play, checking ......... 6-12
U5WME5E0.book Page 1 Wednesday, December 5, 2007 10:30 AM