engine YAMAHA XJR 1300 2000 Owner's Manual

6
PERIODIC MAINTENANCE AND MINOR REPAIR
Tool kit................................................................... 6-1
Periodic maintenance and lubrication ................... 6-2
Panel removal and installation .............................. 6-5
Panel A ................................................................. 6-5
Spark plugs........................................................... 6-6
Engine oil .............................................................. 6-7
Air filter ............................................................... 6-10
Carburetor adjustment ........................................ 6-11
Idle speed adjustment ........................................ 6-11
Throttle cable free play inspection ...................... 6-12
Valve clearance adjustment ................................ 6-12
Tires .................................................................... 6-13
Wheels ................................................................ 6-16
Rear brake pedal height adjustment ................... 6-16
Brake light switch adjustment ............................. 6-17
Checking the front and rear brake pads.............. 6-17
Inspecting the brake fluid level............................ 6-18
Brake fluid replacement ...................................... 6-19
Drive chain slack check ...................................... 6-19
Drive chain slack adjustment .............................. 6-19Drive chain lubrication........................................ 6-20
Cable inspection and lubrication ........................ 6-20
Throttle cable and grip lubrication ...................... 6-21
Brake and shift pedal lubrication ........................ 6-21
Brake and clutch lever lubrication ...................... 6-21
Center and sidestand lubrication ....................... 6-22
Front fork inspection ........................................... 6-22
Steering inspection ............................................ 6-23
Wheel bearings .................................................. 6-23
Battery................................................................ 6-23
Fuse replacement .............................................. 6-25
Headlight bulb replacement ............................... 6-25
Tail/brake light bulb replacement ........................ 6-27
Turn signal light bulb replacement...................... 6-27
Front wheel removal ........................................... 6-28
Front wheel installation ...................................... 6-29
Rear wheel removal ........................................... 6-30
Rear wheel installation ....................................... 6-31
Troubleshooting .................................................. 6-31
Troubleshooting chart ......................................... 6-32

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
EAU02971
NOTE:@ l
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
l
Hydraulic brake and clutch systems
• After disassembling the master cylinder, caliper or clutch release cylinder, always replace the brake fluid. Check the
brake fluid level of the master cylinder and clutch release cylinder regularly and fill as required.
• Replace the oil seals on the inner parts of the master cylinder, caliper and clutch release cylinder every two years.
• Replace the brake and clutch hoses every four years or if cracked or damaged.
@20
*Carburetors• Check engine idling speed, synchronization and starter operation.
• Adjust if necessary.ÖÖÖ
21 Engine oil• Check oil level and vehicle for oil leakage.
• Correct if necessary.
• Change. (Warm engine before draining.)ÖÖÖ
22 Engine oil filter element• Replace.ÖÖ NO. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
(1,000 km)EVERY
6,000 km
or
6 months
(whichever
comes first)12,000 km
or
12 months
(whichever
comes first)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6
EAU03053
Spark plugsRemoval
1. Remove the spark plug caps.2. Use the spark plug wrench in the
tool kit to remove the spark plugs
as shown.
Inspection
The spark plug is an important engine
component and is easy to inspect. The
condition of the spark plug can indicate
the condition of the engine.
Normally, all spark plugs from the
same engine should have the same
color on the white insulator around the
center electrode. The ideal color at this
point is a medium-to-light tan color for a
motorcycle that is being ridden normal-ly. If one spark plug shows a distinctly
different color, there could be some-
thing wrong with the engine.
Do not attempt to diagnose such prob-
lems yourself. Instead, take the motor-
cycle to a Yamaha dealer. You should
periodically remove and inspect the
spark plugs because heat and deposits
will cause any spark plug to slowly
break down and erode. If electrode ero-
sion becomes excessive, or if carbon
and other deposits are excessive, you
should replace the spark plug with the
specified plug.1. Spark plug cap
1. Spark plug wrench
Specified spark plug:
DPR8EA-9 (NGK) or
X24EPR-U9 (DENSO)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6Installation
1. Measure the electrode gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
2. Clean the gasket surface. Wipe off
any grime from the threads.
3. Install the spark plug and tighten it
to the specified torque.
NOTE:@ If a torque wrench is not available when
you are installing a spark plug, a good
estimate of the correct torque is 1/4 to
1/2 turn past finger tight. Have the
spark plug tightened to the specified
torque as soon as possible. @4. Install the spark plug caps.
EAU01784*
Engine oilOil level inspection
1. Place the motorcycle on the cen-
terstand. Warm up the engine for
several minutes.NOTE:@ Be sure the motorcycle is positioned
straight up when checking the oil level.
A slight tilt toward the side can result in
false readings. @
a. Spark plug gapSpark plug gap:
0.8 ~ 0.9 mm
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kg)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6 2. With the engine stopped, check
the oil level through the level win-
dow located at the lower part of
the right side crankcase cover.
NOTE:@ Wait a few minutes until the oil level
settles before checking. @3. The oil level should be between
the maximum and minimum level
marks. If the level is low, add suffi-
cient oil to raise it to the specified
level.Engine oil and oil filter element re-
placement
1. Warm up the engine for several
minutes.
2. Stop the engine. Place an oil pan
under the engine and remove the
oil filler cap.
3. Remove the drain bolt and drain
the oil.4. Remove the oil filter drain screw,
filter cover bolt, filter cover, oil filter
element and O-ring.
5. Reinstall the drain bolt and tighten
it to the specified torque.1. Oil level window
2. Maximum level mark
3. Minimum level mark
1. Engine oil drain bolt
1. Oil filter drain screw
2. Oil filter cover boltTightening torque:
Drain bolt:
43 Nm (4.3 m·kg)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
66. Install the new oil filter element
and O-ring.7. Align the projection on the filter
cover with the slot in housing and
install the filter cover.
8. Tighten the oil filter bolt and oil fil-
ter drain screw to the specified
torque.
NOTE:@ Make sure the O-rings are seated prop-
erly. @
9. Fill engine with oil. Install the oil fill-
er cap and tighten.
EC000066
CAUTION:@ l
Do not put in any chemical addi-
tives. Engine oil also lubricates
the clutch and additives could
cause clutch slippage.
l
Be sure no foreign material en-
ters the crankcase.
@
1. Oil filter element
2. O-ring (´ 2)
1. Projection
2. Slot
Tightening torque:
Oil filter bolt:
15 Nm (1.5 m·kg)
Oil filter drain screw:
7 Nm (0.7 m·kg)
Recommended oil:
See page 8-1.
Oil quantity:
Total amount:
4.2 L
Periodic oil change:
3.0 L
With oil filter replacement:
3.35 L

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 10. Start the engine and warm it up for
several minutes. While warming
up, check for oil leakage. If oil
leakage is found, stop the engine
immediately and check for the
cause.
NOTE:@ After the engine is started, the oil level
indicator light should go off if oil is filled
to the specified level. @
EC000067
CAUTION:@ If the indicator light flickers or re-
mains on, immediately stop the en-
gine and consult with a Yamaha
dealer. @
EAU01755
Air filterThe air filter should be cleaned at the
specified intervals. It should be cleaned
more frequently if you are riding in un-
usually wet or dusty areas.
1. Remove the seat. (See page 3-11
for seat removal and installation
procedures.)
2. Remove panel A. (See page 6-5
for panel removal and installation
procedures.)
3. Remove the air filter case cover by
lifting up the wires as shown and
removing the screws.4. Pull out the air filter.1. Air filter case cover
2. Screw (´ 4)
1. Air filter

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
65. Tap the air filter lightly to remove
most of the dust and dirt and blow
out the remaining dirt with com-
pressed air as shown. If the air fil-
ter is damaged, replace it.
6. Reassemble by reversing the re-
moval procedure.
EC000082
CAUTION:@ l
Make sure the air filter is prop-
erly seated in the air filter case.
l
The engine should never be run
without the air filter installed.
Excessive piston and/or cylin-
der wear may result.
@
EAU00630
Carburetor adjustmentThe carburetors are important parts of
the engine and require very sophisti-
cated adjustment. Most adjustments
should be left to a Yamaha dealer who
has the professional knowledge and
experience to do so. However, the idle
speed may be adjusted by the owner
as part of routine maintenance.
EC000095
CAUTION:@ The carburetors were set at the
Yamaha factory after many tests. If
they are changed, poor engine per-
formance and damage may result. @
EAU00632
Idle speed adjustment1. Start the engine and warm it up for
a few minutes at approximately
1,000 to 2,000 r/min. Occasionally
rev the engine to 4,000 to
5,000 r/min. The engine is warm
when it quickly responds to the
throttle.

PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6 2. Set the idle to the specified engine
speed by adjusting the throttle
stop screw. Turn the screw in di-
rection
a to increase engine
speed and in direction
b to de-
crease engine speed.
NOTE:@ If the specified idle speed cannot be
obtained by performing the above ad-
justment, consult a Yamaha dealer. @
EAU00635
Throttle cable free play
inspectionThere should be a free play of 3 ~
5 mm at the throttle grip. If the free play
is incorrect, ask a Yamaha dealer to
make this adjustment.
EAU00637
Valve clearance adjustmentThe correct valve clearance changes
with use, resulting in improper fuel/air
supply or engine noise. To prevent this,
the valve clearance must be adjusted
regularly. This adjustment however,
should be left to a professional
Yamaha service technician.
1. Throttle stop screw
Standard idle speed:
1,000 ~ 1,100 r/min
a. Free play

PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
EC000096
CAUTION:@ Too little chain slack will overload
the engine and other vital parts.
Keep the slack within the specified
limits. @3. After adjusting, tighten the lock-
nuts. Then tighten the axle nut to
the specified torque.
EAU03006
Drive chain lubricationThe chain consists of many parts which
work with each other. If the chain is not
maintained properly, it will wear out
quickly. Therefore, the chain must be
serviced regularly. This service is es-
pecially necessary when riding in dusty
areas. This motorcycle is equipped
with a sealed type chain. Steam clean-
ing, high-pressure washers, and sol-
vents can damage the drive chain, so
do not use these for cleaning it. Use
only kerosene to clean the drive chain.
Wipe it dry, and thoroughly lubricate it
with SAE 30 ~ 50W motor oil. Do not
use any other lubricants on the drive
chain. They may contain solvents that
could damage the sealed chain.
EC000097
CAUTION:@ Be sure to oil the chain after wash-
ing the motorcycle or riding in the
rain. @
EAU02962
Cable inspection and
lubrication
EW000112
WARNING
@ Damage to the outer housing of ca-
bles may lead to internal rusting and
interfere with the cable movement.
Replace damaged cables as soon as
possible to prevent unsafe condi-
tions. @Lubricate the cables and cable ends. If
a cable does not operate smoothly, ask
a Yamaha dealer to replace it. Tightening torque:
Axle nut:
150 Nm (15.0 m·kg)Recommended lubricant:
Engine oil