Yamaha XJR1300 1999 Service Information

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'99

XJR1300(L)

5EA3-SE1

SERVICE

INFORMATION

Yamaha Motor Co., Ltd.

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Summary of Contents for Yamaha XJR1300 1999

Page 1 XJR1300(L) 5EA3-SE1 SERVICE INFORMATION Yamaha Motor Co., Ltd.
Page 2 This service information has been prepared to introduce new service and data for the XJR1300(L) '99. For complete service information procedures, it is necessary to use this Service Information together with the following manual. XJR1300(L) '99 SERVICE MANUAL: 5EA3-ME1 Yamaha Motor Co., Ltd.
Page 3 EAS00002 NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motorcycle has a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology.
Page 4 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) CHAS CARB 6 Chassis 7 Electrical system 8 Troubleshooting TRBL...
Page 5 CONTENTS GENERAL INFORMATION ........1 MOTORCYCLE IDENTIFICATION ....... 1 VEHICLE IDENTIFICATION NUMBER .
Page 6 MOTORCYCLE IDENTIFICATION INFO EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER (For E) The vehicle identification number 1 is stamped into the right side of the steering head. EAS00018 MODEL CODE The model code label 1 is affixed to the frame. This information will be needed to order spare parts.
Page 7 SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model XJR1300(L) Model code: 5EA2/5EA3/5EA4 Dimensions: Overall length 2175 mm (GB) (D) (NL) (B) (F) (E) (P) (I) (GR) (SF) (AUS) 2250 mm (N) (SF) (G) (A) Overall width 775 mm Overall height 1115 mm Seat height 775 mm Wheelbase...
Page 8 SPEC GENERAL SPECIFICATIONS Model XJR1300(L) Carburetor: Type/quantity BS36/4 Manufacturer MIKUNI Spark plug: Type quantity DPR8EA-9/X24EPR-U9 Manufacturer NGK/DENSO 0.8 X 0.9 mm Spark plug gap Clutch type: Wet, multiple-disc Transmission: Primary reduction system Spur gear Primary reduction ratio 98/56 (1.750) Secondary reduction system Chain drive Secondary reduction ratio 38/17 (2.235)
Page 9 SPEC GENERAL SPECIFICATIONS Model XJR1300(L) Brake: Front brake type Dual disc brake operation Right hand operation Rear brake type Single disc brake operation Right foot operation Suspension: Front suspension Telescopic fork Rear suspension Swingarm Shock absorber: Front shock absorber Coil spring/Oil Damper Rear shock absorber Coil spring/Gas-oil damper Wheel travel:...
Page 10 SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model Standard Limit Cylinder head: Warp limit 0.1 mm Cylinder: Bore size 79.00 79.01 mm Taper limit 0.05 mm Out of round limit 0.05 mm Wear limit 79.1 mm Camshaft: Drive method Chain drive (Center) Cam cap inside diameter 25.000 25.021 mm...
Page 11 SPEC MAINTENANCE SPECIFICATIONS Model Standard Limit Cam chain: Cam chain type/No. of links 79RH2015/156 Cam chain adjustment method Automatic Valve, valve seat, valve guide: Valve clearance (cold) 0.11 0.15 mm 0.16 0.20 mm Valve dimensions: Head Dia. Face Width Seat Width Margin Thickness “A”...
Page 12 SPEC MAINTENANCE SPECIFICATIONS Model Standard Limit Valve spring: Inner spring Free length 39.65 mm 37.5 mm 39.65 mm 37.5 mm Set length (valve closed) 32.8 mm 32.8 mm Compressed pressure (installed) 61.7 72.5 N (6.29 7.39 kg) 61.7 72.5 N (6.29 7.39 kg) Tilt limit 2.5 /1.7 mm...
Page 13 SPEC MAINTENANCE SPECIFICATIONS Model Standard Limit Piston rings: Top ring: Type Barrel Dimensions (B 1.00 3.05 mm End gap (installed) 0.20 0.35 mm 0.6 mm Side clearance (installed) 0.045 0.080 mm 0.1 mm 2nd ring: Type Taper Dimensions (B 3.0 mm End gap (installed) 0.35 0.50 mm...
Page 14 SPEC MAINTENANCE SPECIFICATIONS Model Standard Limit Clutch: Friction plate thickness 3.1 mm 2.8 mm Quantity 8 pcs Clutch plate thickness 2.1 mm 0.1 mm <Warp limit> Quantity 7 pcs Clutch spring height 6 mm Quantity 1 pc Clutch housing thrust clearance 0.2 mm Clutch housing radial clearance 0.004...
Page 15 SPEC MAINTENANCE SPECIFICATIONS Model Standard Limit Lubrication system: Oil filter type Paper type Oil pump type Trochoid type Tip clearance 0.12 0.17 mm 0.2 mm Housing and rotor clearance 0.03 0.08 mm 0.15 mm Side clearance 0.03 0.08 mm 0.15 mm Bypass valve setting pressure 220 kPa (1.8...
Page 16 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening Thread torque Part to be tightened Part name Q’ty Remarks size size mfkg Camshaft cap Bolt Oil gallery bolt Screw Spark plug – 1.25 Cylinder head Cap nut 1.25 Cylinder head cover Bolt Cylinder Stud bolt 1.25 Cylinder...
Page 17 SPEC MAINTENANCE SPECIFICATIONS Tightening Thread torque Part to be tightened Part name Q’ty Remarks size size mfkg Crankcase Bolt 1.25 Crankcase Bolt 1.25 Main gallery Plug Oil buffle plate Bolt Stopper plate Bolt Bearing housing Screw HY-VO chain guide Bolt Clutch boss Clutch pressure plate Bolt...
Page 18 SPEC MAINTENANCE SPECIFICATIONS Tightening sequence Cylinder head Crankcase 2-12...
Page 19 SPEC MAINTENANCE SPECIFICATIONS Model XJR1300(L) Lubrication chart: Pressure feed Splashed Ex. camshaft Lifter Timing chain area Generator IN. camshaft Lifter shaft Piston, Cylinder Clutch Transmission Connecting rod bearing Crankshaft bearings Main gallery Oil filter Oil cooler Relief valve Oil pump Oil pan / Oil strainer 2-13...
Page 20 SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model Standard Limit Steering system: Steering bearing type Angular bearing Front suspension: Front fork travel 130 mm Fork spring free length 407.3 mm 395 mm Fitting length 363.3 mm Collar length 150 mm Spring rate (K1) 4.9 N/mm (0.5 kg/mm) (K2) 8.8 N/mm (0.9 kg/mm)
Page 21 SPEC MAINTENANCE SPECIFICATIONS Model Standard Limit Front disc brake: Type Dual Disc outside diameter thickness 5 mm Disc deflection limit 0.2 mm Pad thickness 5.5 mm 0.5 mm Master cylinder inside diameter 14 mm Caliper cylinder inside diameter 30.2 mm and 27 mm Brake fluid type DOT #4 Rear disc brake:...
Page 22 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Part to be tightened Part name Thread size Q’ty Remarks Nm mfkg Handle crown and inner tube Bolt 1.25 Handle crown and steering stem 11.0 Handle crown and handlebar holder 1.25 (lower) Upper handlebar holder Bolt 1.25 Lower bracket and inner tube...
Page 23 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Part name Thread size Q’ty Remarks Nm mfkg Hook Screw Helmet holder Bolt Tail light bracket Bolt 1.25 Side stand Bolt 1.25 Side stand 1.25 Side stand switch Screw Footrest bracket Bolt 1.25 Rear footrest bracket...
Page 24 5 /1050 r/min Advanced timing (B.T.D.C.) 50 /5000 r/min Advancer type TPS & Electrical type T.C.I.: 372 Ω/W/R-W/G Pickup coil resistance/color T.C.I. unit model/manufacturer 5EA20/YAMAHA Ignition coil: Model/manufacturer 83R/YAMAHA Minimum spark gap 6 mm 2.9 Ω Primary winding resistance Secondary winding resistance 14.3 kΩ...
Page 25 SPEC MAINTENANCE SPECIFICATIONS Model Standard Limit Mica undercut 0.7 mm Starter relay: Model/manufacturer MS5E-491/JIDECO Amperage rating 100 A 4.6 Ω Coil winding resistance Horn: Type Plane type Quantity 2 pcs Model/manufacturer YF12/NIKKO Maximum amperage Flasher relay: Type Full transistor type Model/manufacturer FE246BH/DENSO Self cancelling device...
Page 26 CONVERSION TABLE/ SPEC GENERAL TORQUE SPECIFICATIONS EAS00028 EAS00029 CONVERSION TABLE GENERAL TIGHTENING TORQUES All specification data in this manual are listed in This chart specifies tightening torques for stan- SI and METRIC UNITS. dard fasteners with a standard ISO thread pitch. Use this table to convert METRIC unit data to Tightening torque specifications for special IMPERIAL unit data.
Page 27 Starter clutch (outer/roller) Crankcase cover (push rod hole) Primary drive gear/damper Transmission gear (wheel/pinion) Shift cam Shift fork/guide bar Shift shaft assembly Crankcase mating surfaces Yamaha bond No. 1215 Blind plug and oil seal (crankcase main gallery) Yamaha bond No. 1215 2-21...
Page 28 SPEC LUBRICATION POINT AND GRADE OF LUBRICANT CHASSIS Lubrication Point Symbol Steering bearing (upper/lower) and bearing cover lip Front wheel oil seal (left/right) Rear wheel oil seal (left/right) Clutch hub fitting area Rear brake pedal shaft Shift pedal Centerstand sliding surface Sidestand sliding surface Tube guide (throttle grip) inner surface Brake lever bolt, sliding surface...
Page 29 SPEC CABLE ROUTING CABLE ROUTING Starter motor cable Throttle position sensor A Fasten the wireharness to the Battery negative (–) lead Ignition coil lead (#2, 3) seat rail with a plastic band. Make Battery negative (–) lead con- Throttle cable sure that the end of band down nector Engine ground lead...
Page 30 SPEC CABLE ROUTING D Route the wireharness and start- F Fasten the wireharness to the I Fasten the high tension cables er motor cable in front of the res- frame with a plastic band. Make and throttle cables with a plastic ervoir tank bracket and the bat- sure that the end of band down clamp.
Page 31 SPEC CABLE ROUTING L Route the wireharness and start- er motor cable behind the side cover bracket and fasten them with a plastic band at front of the bracket. M Align the white paint marks of the fuel tank drain hose, fuel tank breather hose and air filter case drain hose.
Page 32 SPEC CABLE ROUTING Clutch hose A Insert the plastic band through E Fasten the high tension cables Starter cable the hole of plastic panel and then (#1, 2) with a plastic clamp. Posi- Air filter case drain hose fasten the clutch hose with it. tion the clamp at 50 –...
Page 33 SPEC CABLE ROUTING H Fasten the seat lock cable to the K Fasten the sidestand switch lead N Route the speedometer cable seat real with a plastic band. with steel clamp on the frame through the guide. Make sure that the end of band and then route it between the O Touch the brake pipe to the bra- down ward.
Page 34 SPEC CABLE ROUTING Throttle cables Starter relay Taillight lead Ignition coil (#2, 3) Seat lock cable Starter cable Throttle position sensor Seat lock Neutral switch connector Battery positive (+) lead A Position the horn (high) to right Pickup coil connector Fuse box side.
Page 35 SPEC CABLE ROUTING E Connect the fuel sender connec- G Fasten the battery positive (+) J Position the seat lock cable in- tor, neutral switch connector, lead and battery positive (+) lead side under the seat lock bracket. pickup coil connector and side- connector on the groove of the K Fasten the wireharness to the stand switch connector above...
Page 36 SPEC CABLE ROUTING N Fasten the wireharness, taillight lead and rear turn signal light leads (left and right) with steel clamp on the frame make sure that the end of clamp forward. O Route the rear turn signal light leads (left and right) through the each holes of the rear fender.
Page 37 SPEC CABLE ROUTING Meter leads A Route the throttle cables through D Route the handlebar switch lead Main switch lead the guide on the headlight stay. (left) and front turn signal light Starter cable B Route the meter leads, main lead (left) into the left under hole Handlebar switch lead (left) switch lead into the upper hole of...
Page 38 SPEC CABLE ROUTING H Touch the brake pipe to the stop- per. I Route the handlebar switch lead (right) and front turn signal light lead (right) into the right under hole of the headlight stay. J Fasten the handlebar switch lead (right) and front brake hose with a plastic band.
Page 39 INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION INTERVALS PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera- tion and a longer service life. The need for costly overhaul work will be greatly reduced. This informa- tion applies to vehicles already in service as well as new vehicles that are being prepared for sale.
Page 40 PERIODIC MAINTENANCE/LUBRICATION INTERVALS It is recommended that these items be serviced by a Yamaha dealer. **: Molybdenum disulfide grease. ***: Lithium soap base grease. NOTE: Brake fluid replacement: 1. When disassembling the master cylinder, caliper cylinder or clutch release cylinder, replace the brake fluid.
Page 41 XJR1300’99 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 Oil level relay Start switch Engine stop switch Front brake switch...

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Xjr1300l 1999