FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the XJR1300 (P) 2002. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. XJR1300 (L) ’99 SERVICE MANUAL: 5EA3-AE1 EAS00000 XJR1300 (P) 2002 SUPPLEMENTARY SERVICE MANUAL 2001 by Yamaha Motor Co., Ltd. 1st Edition, August 2001 All rights reserved.
EAS00003 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”. 2 Each chapter is divided into sections.
EAS00009 1 2 GEN INFO SPEC 3 4 CHK ADJ ENG 5 6 CARB CHAS 7 8 SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 8 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetor(-s) 6 Chassis 7 Electrical system 8 Troubleshooting TRBL SHTG ELEC 10 Symbols 9 to 16 indicate the following.
CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CABLE ROUTING . .
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Model XJR1300 (P) Model code: 5EAT/5EAW (EUR) 5EAU/5EAX (for D) 5EAV/5EAY (for AUS) Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2,175 mm 775 mm 1,115 mm 790 mm 1,510 mm 120 mm 2,800 mm Basic weight: With oil and full fuel tank 247 kg Carburetor: Type/quantity Manufacturer BSR37/4 MIKUNI Transmission: Primary reduction system Primary reduction ratio S
GENERAL SPECIFICATIONS Model Tire: Type Size XJR1300 (P) Tubeless 120/70ZR17 (58W)/ 120/70ZR17 M/C (58W) 180/55ZR17 (73W)/ 180/55ZR17 M/C (73W) MICHELIN/DUNLOP MICHELIN/DUNLOP MACADAM90X E/D220F ST M MACADAM90X E/D220 ST M front rear Manufacturer Type SPEC front rear front rear Tire pressure (cold tire): Maximum load-except motorcycle Loading condition A * front rear Loading condition B * front rear High-speed riding front rear 203 kg 0 X 90 kg 250 kPa (2.5 kg/cm2, 2.5 bar) 250 kPa (2.5 kg/cm2, 2.
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Model Standard Limit Cylinder head: Warp limit SSS 0.2 mm Cylinder: Bore size Taper limit Out of round limit Wear limit 79.00 X 79.01 mm SSS SSS SSS SSS 0.05 mm 0.1 mm 79.1 mm Chain drive (Center) 25.000 X 25.021 mm 24.967 X 24.980 mm 0.020 X 0.054 mm SSS SSS SSS SSS 35.95 X 36.05 mm 28.058 X 28.158 mm 35.95 X 36.05 mm 28.045 X 28.145 mm SSS 35.85 mm 27.958 mm 35.85 mm 27.945 mm 0.
MAINTENANCE SPECIFICATIONS Model Piston: Piston to cylinder clearance Piston size “D” Measuring point “H” Piston off-set Piston off-set direction Piston pin bore inside diameter Piston pin outside diameter Carburetor: I.D. mark Main 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.
MAINTENANCE SPECIFICATIONS SPEC Tightening torques Part to be tightened g Carburetor joint and carburetor Carburetor and air filter joint Air induction system pipe joint Air induction system Part name Band Clamp – Bolt 5 Thread size M4 M4 0.7 0.7 – M6 1.0 Q’tyy 4 4 4 2 Tightening torque Nm mSkg 2.7 2.7 3.7 10 0.27 0.27 0.37 1.
MAINTENANCE SPECIFICATIONS SPEC CHASSIS Model Standard Limit Front suspension: Front fork travel Fork spring free length Fitting length Collar length Spring rate (K1) (K2) Stroke (K1) (K2) Optional spring Oil capacity Oil level Oil grade 130 mm 308.3 mm 287.3 mm 245 mm 6.4 N/mm (0.65 kg/mm) 10.8 N/mm (1.
MAINTENANCE SPECIFICATIONS SPEC Tightening torques Part to be tightened g Part name Thread size Q’tyy Tightening torque Nm mSkg Throttle cable and carburetor Ignition coil Nut Nut M6 M6 7 1.0 1.0 2 2 4 6.5 0.4 0.
MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Model Standard T.C.I.: Pickup coil resistance/color T.C.I. unit model/manufacturer Limit 248 X 372 Ω/W/R-W/G TNDF63/DENSO (except for D) TNDF64/DENSO (for D) SSS SSS SSS Charging system: Type Model/manufacturer Normal output Rotor coil resistance Stator coil resistance Brush overall length Spring force A.C. generator B3G/DENSO 13.5 V 28 A/5,000 r/min 2.8 X 3.0 Ω 0.19 X 0.21 Ω 13.7 mm 5.10 X 5.69 N (0.52 X 0.58 kg) SSS SSS SSS SSS SSS 4.
CABLE ROUTING SPEC CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 Starter motor cable Battery negative (–) lead wire Carburetor heater plug A.C. generator coupler Rear stop switch coupler Neutral lead wire Pickup lead wire Side stand switch lead wire T.P.S.
CABLE ROUTING B Secure the carburetor heater lead wire, the starter motor cable, the negative (–) lead wire of the battery, the A.C. generator lead wire, the neutral lead wire, the side stand switch lead wire, the pickup lead wire, and the rear stop switch lead wire (total 8 wires), to the fuel tank rail, near the air cleaner intake port mounting screw, by use of this band. The front end of the band must be directed towards the front of the vehicle.
CABLE ROUTING H Bundle the A.C. generator lead K Clamp the wire harness to the wire, the pickup lead wire, the seat rail, at the front end of the side stand switch lead wire, the bracket.The front end of the starter motor cable, and the carclamp must be directed downburetor heater lead wire (total 5 ward. wires), by use of this clamp. L Clamp the wire harness.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 Gusset 13 Flasher relay coupler Tension pipe 1 14 Oil lamp relay coupler #2 high-tension cord 15 Igniter unit coupler #1 high-tension cord A Pass the wire harness and the Wire starter starter cable through the holder A.C. generator wire of the gusset. Oil filter cover Pass the starter cable under the Side stand switch wire harness.
CABLE ROUTING D Bundle the #1 and #2 high-ten- G After securing the side stand sion cords using this clamp. switch lead wire using this Clamp these cords above the #2 clamp, first route the lead wire head cover mounting bolt. between the pickup cover, the oil E Route the air cleaner drain hose filter cover, the A.C. generator, through the right side of the veand the starter motor. Next, as hicle with a clearance above the with the engine lead wire, route starter motor.
CABLE ROUTING L Pass this clamp through the low- N Fasten the frame ground lead er hole of the gusset and secure wire together with the igniter unit the clutch hose. mounting screw. The front end of the clamp must O Clamp the seat lock wire to the be directed towards the inside of seat rail. the vehicle. The front end of the clamp must M Pass the main harness through be directed downward. the inside of the clutch hose and insert the harness into the left of the headlight lower hole.
CABLE ROUTING Throttle cable #1 and #4 ignition coils T.P.S.
CABLE ROUTING E Clamp the starter motor cable and the negative (–) lead wire of the battery to the seat rail, between the air cleaner mounting bracket and the tank mounting bracket. F Connect the fuel sender coupler, neutral switch coupler, pickup coupler, and side stand switch coupler wires above the air cleaner. G Thread the wire harness insertion clamp onto the T-stud of the frame. SPEC H Pass the starter cable through K Connect the starter cable to face the front of the throttle cable.
CABLE ROUTING N Secure the two positive (+) lead P Store the wire harness, the tailwires of the battery, the negalight lead wire, and the rear left tive(–) lead wire coupler of the and right flasher lead wires, into battery, and the wire harness by the space between the taillight use of this battery band. bracket and the rib of the rear O Clamp the wire harness to the fender.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Meter lead wire Main switch lead wire Crown handle Starter cable Left handle switch lead wire Clutch hose Front left flasher lead wire Front right flasher lead wire Brake hose 2 Brake hose 1 Right handle switch lead wire Wire harness Taillight lead wires Taillight bracket Rib of the rear fender 16 17 18 19 Rear fender Rear left flasher lead wire Rear right flasher lead wire Wire harness A Pass the throttle cable through the guide wire of the stay headlig
CABLE ROUTING E Insert the left lead wire of the handle switch and the left lead wire of the front flasher into the left of the headlight lower hole. F Insert the right lead wire of the handle switch and the right lead wire of the front flasher into the right of the headlight lower hole. G Bundle the handle switch lead wire and brake hose 2, near the guide wire of the stay headlight by use of this band.
INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION INTERVALS CHK ADJ PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as new vehicles that are being prepared for sale.
CHK ADJ PERIODIC MAINTENANCE/LUBRICATION INTERVALS ODOMETER READING ( NO NO. 15 ITEM * g bearings g Steering CHECK OR MAINTENANCE JOB S Check bearing play and steering for roughness. 10 20 30 40 √ √ √ √ √ S Lubricate with lithium-soap-based grease. 16 * 17 1,000 km) 1 ANNUAL CHECK Every 20,000 km Chassis fasteners S Make sure that all nuts, bolts and screws are properly tightened. √ √ √ √ √ Sidestand, centeratand S Check operation. S Lubricate.
ADJUSTING THE CLUTCH LEVER CHK ADJ ENGINE EAS00082 ADJUSTING THE CLUTCH LEVER 1. Adjust: S clutch lever position (distance a from the handlebar grip to the clutch lever) a. While pushing the clutch lever forward, turn the adjusting dial 1 until the clutch lever is in the desired position. NOTE: Be sure to align the setting on the adjusting dial with the arrow mark 2 on the clutch lever holder.
ADJUSTING THE FRONT BRAKE CHK ADJ EAS00107 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: S brake lever position (distance a from the throttle grip to the brake lever) a. While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desired position. NOTE: Be sure to align the setting on the adjusting dial with the arrow mark 2 on the brake lever holder. Position #1 Position #5 23 Distance a is the largest. Distance a is the smallest.
AIR INDUCTION SYSTEM CARB CARBURETOR EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned exhaust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port. The required temperature for burning the unburned exhaust gases is approximately 600 to 700_C.
AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 2 3 4 A B C D E Reed valve Air cleaner Air cutoff valve Vacuum hose (cylinder #3) To the air cutoff valve To cylinder #1 To cylinder #2 To cylinder #3 To cylinder #4 25 CARB
AIR INDUCTION SYSTEM CARB EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: S hoses Loose connection ! Connect properly. Cracks/damage ! Replace. S pipes Cracks/damage ! Replace. 2. Check: S fibre reed 1 S fibre reed stopper S reed valve seat Cracks/damage ! Replace the reed valve. 3. Measure: S fibre reed bending limit a Out of specification ! Replace the reed valve. Fibre reed bending limit 0.2 mm 1 Surface plate 4. Check: S air cutoff valve Cracks/damage ! Replace.
FRONT AND REAR BRAKES CHAS CHASSIS FRONT AND REAR BRAKES EAS00586 FRONT BRAKE MASTER CYLINDER 10 Nm (1.0 mSkg) 30 Nm (3.0 mSkg) Order Job/Part Q’ty Removing the front brake master cylinder Brake fluid 1 2 3 4 5 6 7 Remarks Remove the parts in the order listed.
FRONT AND REAR BRAKES CHAS EAS00598 ASSEMBLING AND INSTALLING FRONT BRAKE MASTER CYLINDER THE WARNING S Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake components. Recommended brake fluid DOT 4 1. Install: S brake master cylinder 1 NOTE: S Install the brake master cylinder holder with the “UP” mark facing up.
FRONT AND REAR BRAKES CHAS 3. Fill: S brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. S Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
FRONT AND REAR BRAKES CHAS EAS00616 REAR BRAKE CALIPER 30 Nm (3.0 mSkg) 40 Nm (4.0 mSkg) Order 1 2 3 4 Job/Part Q’ty Remarks Remove the parts in the order listed. Drain. Removing the rear brake caliper Brake fluid Union bolt Copper washer Brake hose Brake caliper 1 2 1 1 For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EAS00617 6 Nm (0.6 mSkg) Order Job/Part Q’ty 1 2 3 4 5 6 7 Disassembling the rear brake caliper Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw Remarks Disassemble the parts in the order listed. 4 2 1 2 2 4 2 For assembly, reverse the disassembly procedure.
CARBURETOR HEATING SYSTEM ELEC ELECTRICAL CARBURETOR HEATING SYSTEM 2 3 5 6 14 51 52 53 32 Fuse (main) Battery Main switch Fuse (ignition) Neutral switch Carburetor heater relay Thermo switch Carburetor heater
ELEC CARBURETOR HEATING SYSTEM EAS00821 EAS00749 TROUBLESHOOTING 3. Main switch S Check the main switch for continuity. Refer to “CHECKING THE SWITCHES” in chapter 8. (Manual No.: 5EA3-AE1) The carburetor heating system fails to operate. Check: 1. Main and ignition fuses 2. Battery 3. Main switch 4. Neutral switch 5. Carburetor heater relay 6. Thermo switch 7. Carburetor heater 8. Wiring connections (of the entire carburetor heating system) S Is the main switch OK? YES NO Replace the main switch.
CARBURETOR HEATING SYSTEM ELEC EAS00825 6. Thermo switch The following procedure applies to all of the carburetor heating elements. S Remove the thermo switch from the thermo switch plate. S Connect the pocket tester to the (Ω 1) to the thermo switch as shown. 7. Carburetor heater S Remove the carburetor heating element from the carburetor. S Connect the pocket tester to the carburetor heating element as shown.
XJR1300 2002 WIRING DIAGRAM (for EUR) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 COLOR CODE B ..... Br . . . . Ch . . . Dg . . . G .... Gy . . . L ..... Lg . . . . Black Brown Chocolate Dark green Green Gray Blue Light green O .... Sb . . . . P ..... R..... Y ..... B/ L . . . B/ R . . B/ Y . . Orange Sky blue Pink Red Yellow Black/ Blue Black/ Red Black/ Yellow Br/ L . . Br/ W . G/Y . . L/B . . . L/R . . L/W . . L/Y . . . R/ B . .
XJR1300P 2002 WIRING DIAGRAM (for AUS) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 COLOR CODE B ..... Br . . . . Ch . . . Dg . . . G .... Gy . . . L ..... Lg . . . . Black Brown Chocolate Dark green Green Gray Blue Light green O .... Sb . . . . P ..... R..... Y ..... B/ L . . . B/ R . . B/ Y . . Orange Sky blue Pink Red Yellow Black/ Blue Black/ Red Black/ Yellow Br/ L . . Br/ W . G/Y . . L/B . . . L/R . . L/W . . L/Y . . . R/ B . .