Yamaha 2002 XJR1300 Service Manual
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Yamaha 2002 XJR1300 Service Manual

Yamaha 2002 XJR1300 Service Manual

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  • Page 3 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. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

  • Page 4: Important Information

    If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform with fed- eral environmental quality objectives.

  • Page 5: How To Use This Manual

    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.
  • Page 6 EAS00009 SYMBOLS SPEC The following symbols are not relevant to every INFO 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 CHAS CARB 7 Electrical system 8 Troubleshooting...

  • Page 7: Table Of Contents

    CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS ....... . MAINTENANCE SPECIFICATIONS ......ENGINE .

  • Page 8: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model XJR1300 (P) Model code: 5EAT/5EAW (EUR) 5EAU/5EAX (for D) 5EAV/5EAY (for AUS) Dimensions: Overall length 2,175 mm Overall width 775 mm Overall height 1,115 mm Seat height 790 mm Wheelbase 1,510 mm Minimum ground clearance 120 mm Minimum turning radius 2,800 mm...
  • Page 9 SPEC GENERAL SPECIFICATIONS Model XJR1300 (P) Tire: Type Tubeless Size front 120/70ZR17 (58W)/ 120/70ZR17 M/C (58W) rear 180/55ZR17 (73W)/ 180/55ZR17 M/C (73W) Manufacturer front MICHELIN/DUNLOP rear MICHELIN/DUNLOP Type front MACADAM90X E/D220F ST M rear MACADAM90X E/D220 ST M Tire pressure (cold tire): Maximum load-except motorcycle 203 kg Loading condition A *...

  • Page 10: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model Standard Limit Cylinder head: Warp limit 0.2 mm Cylinder: Bore size 79.00 X 79.01 mm Taper limit 0.05 mm Out of round limit 0.1 mm Wear limit 79.1 mm Camshaft: Drive method Chain drive (Center) Cam cap inside diameter 25.000 X 25.021 mm Camshaft outside diameter...
  • Page 11 SPEC MAINTENANCE SPECIFICATIONS Model Standard Limit Piston: Piston to cylinder clearance 0.015 X 0.040 mm 0.15 mm Piston size “D” 78.970 X 78.985 mm Measuring point “H” 5 mm Piston off-set 1 mm Piston off-set direction IN side Piston pin bore inside diameter 18.004 X 18.015 mm 18.045 mm Piston pin outside diameter...
  • Page 12 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening Thread torque Part to be tightened Part name Q’ty Remarks size size mSkg Carburetor joint and carburetor Band 0.27 Carburetor and air filter joint Clamp 0.27 Air induction system pipe joint – – 0.37 Air induction system Bolt...

  • Page 13: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model Standard Limit Front suspension: Front fork travel 130 mm Fork spring free length 308.3 mm 300 mm Fitting length 287.3 mm Collar length 245 mm Spring rate (K1) 6.4 N/mm (0.65 kg/mm) (K2) 10.8 N/mm (1.1 kg/mm) Stroke (K1) 0 X 85 mm...
  • Page 14 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Part to be tightened Part name Thread size Q’ty Remarks Nm mSkg Throttle cable and carburetor Ignition coil 0.65...

  • Page 15: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model Standard Limit T.C.I.: 248 X 372 Ω/W/R-W/G Pickup coil resistance/color T.C.I. unit model/manufacturer TNDF63/DENSO (except for D) TNDF64/DENSO (for D) Charging system: Type A.C. generator Model/manufacturer B3G/DENSO Normal output 13.5 V 28 A/5,000 r/min 2.8 X 3.0 Ω Rotor coil resistance 0.19 X 0.21 Ω...

  • Page 16: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING Starter motor cable #3 high-tension cord A Pass the starter motor cable and Battery negative (–) lead wire #4 high-tension cord the negative (–) lead wire of the Carburetor heater plug Engine frame ground lead wire battery through the inside of the A.C.
  • Page 17 SPEC CABLE ROUTING B Secure the carburetor heater C Clamp the throttle cables to the E Bundle the #3 and #4 high-ten- lead wire, the starter motor fuel tank rail, on the tank fitting by sion cords, on the head cover cable, the negative (–) lead wire use of this band.
  • Page 18 SPEC 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 car- clamp must be directed down- buretor heater lead wire (total 5...
  • Page 19 SPEC CABLE ROUTING Gusset Flasher relay coupler gusset, by use of this band. Tension pipe 1 Oil lamp relay coupler The front end of the band must #2 high-tension cord Igniter unit coupler be directed downward. #1 high-tension cord C Bundle the four high-tension Wire starter A Pass the wire harness and the cords, the #1 and #2 cords up...
  • Page 20 SPEC CABLE ROUTING D Bundle the #1 and #2 high-ten- G After securing the side stand I Secure the grommet of the sion cords using this clamp. switch lead wire using this clutch hose by use of this holder Clamp these cords above the #2 clamp, first route the lead wire wire of the gusset.
  • Page 21 SPEC 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.
  • Page 22 SPEC CABLE ROUTING Throttle cable Starter motor cable A Right horn. #1 and #4 ignition coils Thermoswitch Install the HI tone source (with H- T.P.S. Starter relay marked label) at the right of the Neutral switch coupler Rib of the rear fender vehicle.
  • Page 23 SPEC CABLE ROUTING E Clamp the starter motor cable H Pass the starter cable through K Connect the starter cable to face and the negative (–) lead wire of the front of the throttle cable. at right angles to the vehicle the battery to the seat rail, be- I From left: #1, #2, #3, and #4 body with contact with the stop-...
  • Page 24 SPEC CABLE ROUTING N Secure the two positive (+) lead P Store the wire harness, the tail- S After connecting the lead wire of wires of the battery, the nega- light lead wire, and the rear left the thermoswitch, store the lead tive(–) lead wire coupler of the and right flasher lead wires, into wire into the space under the...
  • Page 25 SPEC CABLE ROUTING Meter lead wire Rear fender C Bundle the handle switch lead Main switch lead wire Rear left flasher lead wire wire, the clutch hose, and the Crown handle Rear right flasher lead wire starter cable, under the crown Starter cable Wire harness handle, by use of this band.
  • Page 26 SPEC CABLE ROUTING E Insert the left lead wire of the H Match the wire harness, the K The wire harness, the taillight handle switch and the left lead main switch lead wire, and the lead wires, and the rear left and wire of the front flasher into the meter lead wire, to the wire har- right flasher lead wires must be...

  • Page 27: Periodic Inspection And Adjustment

    D The annual checks must be performed every year, except if a kilometer-based maintenance is per- formed instead. D From 50,000 km, repeat the maintenance intervals starting from 10,000 km. D Items marked with an asterisk should be performed by Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (...
  • Page 28 PERIODIC MAINTENANCE/LUBRICATION INTERVALS ODOMETER READING ( 1,000 km) ANNUAL ITEM ITEM CHECK OR MAINTENANCE JOB CHECK OR MAINTENANCE JOB CHECK S Check bearing play and steering for √ √ √ √ √ roughness. Steering bearings S Lubricate with lithium-soap-based grease. Every 20,000 km S Make sure that all nuts, bolts and √...

  • Page 29: Engine

    ADJUSTING THE CLUTCH LEVER 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.

  • Page 30: Chassis

    ADJUSTING THE FRONT BRAKE 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.

  • Page 31: Carburetors

    CARB AIR INDUCTION SYSTEM CARBURETOR EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned ex- haust 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.

  • Page 32: Air Induction System Diagrams

    CARB AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Reed valve 2 Air cleaner 3 Air cutoff valve 4 Vacuum hose (cylinder #3) A To the air cutoff valve B To cylinder #1 C To cylinder #2 D To cylinder #3 E To cylinder #4...

  • Page 33: Checking The Air Induction System

    CARB AIR INDUCTION SYSTEM 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.

  • Page 34: Chassis

    CHAS FRONT AND REAR BRAKES 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 Remarks Removing the front brake master cylinder Brake fluid Remove the parts in the order listed. Drain Brake lever Brake switch lead...

  • Page 35: Assembling And Installing The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00598 ASSEMBLING INSTALLING FRONT BRAKE MASTER CYLINDER WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents.
  • Page 36 CHAS FRONT AND REAR BRAKES 3. Fill: S brake master cylinder reservoir (with the specified amount of the recom- mended 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.

  • Page 37: Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER 30 Nm (3.0 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain. Union bolt Copper washer Brake hose Brake caliper For installation, reverse the removal...
  • Page 38 CHAS FRONT AND REAR BRAKES EAS00617 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Disassembling the rear brake caliper Disassemble the parts in the order listed. Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly...

  • Page 39: Electrical

    ELEC CARBURETOR HEATING SYSTEM ELECTRICAL CARBURETOR HEATING SYSTEM Fuse (main) Battery Main switch Fuse (ignition) Neutral switch Carburetor heater relay Thermo switch Carburetor heater...

  • Page 40: Troubleshooting

    ELEC CARBURETOR HEATING SYSTEM EAS00821 EAS00749 TROUBLESHOOTING 3. Main switch The carburetor heating system fails to op- S Check the main switch for continuity. erate. Refer to “CHECKING THE SWITCHES” in chapter 8. (Manual No.: 5EA3-AE1) Check: S Is the main switch OK? 1.
  • Page 41 ELEC CARBURETOR HEATING SYSTEM 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. 7. Carburetor heater S Connect the pocket tester to the (Ω 1) to S Remove the carburetor heating element the thermo switch as shown.

  • Page 43: Xjr1300 2002 Wiring Diagram (For Eur)

    XJR1300 2002 WIRING DIAGRAM (for EUR) AC generator Fuse (main) Battery Starter relay Main switch Fuse (ignition) Starter motor Starting circuit cut-off relay Ignitor unit Ignition coil Spark plug Pickup coil TPS (throttle position sensor) Neutral switch Sidestand switch Start switch Engine stop switch Lights switch Front brake switch...

  • Page 44: Xjr1300P 2002 Wiring Diagram (For Aus)

    XJR1300P 2002 WIRING DIAGRAM (for AUS) AC generator Fuse (main) Battery Starter relay Main switch Fuse (ignition) Starter motor Starting circuit cut-off relay Ignitor unit Ignition coil Spark plug Pickup coil TPS (throttle position sensor) Neutral switch Sidestand switch Start switch Engine stop switch Front brake switch Handlebar switches (right)

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2002 xjr1300p

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