Yamaha XJR1300 1999, XJR1300L 1999 Manual

SYMBOLS

NOTE:
PARTICULARLY IMPORTANT INFORMATION
This materials distinguished by the following notation.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person checking or repairing the motorcycle.

A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
The following symbols are not relevant to every vehicle.
Symbols to 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

Symbols to indicate the following.

9. Serviceable with engine mounted
10. Filling fluid
11. Lubricant
12. Special tool
13. Tightening torque
14. Wear limit, clearance
15. Engine speed
16. Electrical data

Symbols to in the exploded diagrams indicate the types of lubricants and lubrication points.

17. Engine oil
18. Gear oil
19. Molybdenum disulfide oil
20. Wheel bearing grease
21. Lithium soap base grease
22. Molybdenum disulfide grease

Symbols to in the exploded diagrams indicate the following:

23. Apply locking agent (LOCTITE^®)
24. Replace the part

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER (For E)
The vehicle identification number is stamped into the right side of the steering head.

MODEL CODE
The model code label is affixed to the frame. This information will be needed to order spare parts.

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		1500 mm
Minimum ground clearance		120 mm
Minimum turning radius		2800 mm
Basic weight:
With oil and full fuel tank		253 kg
Engine:
Engine type Cylinder arrangement Displacement Bore x stroke Compression ratio Compression pressure (STD) Starting system Lubrication system:		Air-cooled 4-stroke, DOHC Forward-inclined parallel 4-cylinder 1250 cm3 79.0 x 63.8 mm 9.7: 1 1050 kPa (10.5 kg/cm2,10.5 bar) at 400 r/min Electric starter Wet sump
Oil type or grade:		SE or higher grade
Engine oil
	Periodic oil change With oil filter replacement Total amount	3. 3.0 L 3.35 L 4.2 L
Oil cooler capacity (including all routes)		0.2 L
Air filter:		Dry type element
Fuel:
Type Fuel tank capacity Fuel reserve amount		Regular unleaded gasoline 21 L 4.5 L
Carburetor:
Type/quantity Manufacturer		BS36/4 MIKUNI
Spark plug:
Type x quantity Manufacturer Spark plug gap		DPR8EA-9/X24EPR-U9 x 4 NGK/DENSO 0.8 ~ 0.9 mm
Clutch type:		Wet, multiple-disc
Transmission:
Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio 1st 2nd 3rd 4th 5th		Spur gear 98/56 (1.750) Chain drive 38/17 (2.235) Constant mesh 5-speed Left foot operation 40/14 (2.857) 36/18 (2.000) 33/21 (1.571) 31/24 (1.292) 29/26 (1.115)
Chassis:
Frame type Caster angle Trail		Double cradle 25.5 100 mm
Tire:
Type		Tubeless
Size	front rear	120/70ZR17 (58W) 180/55ZR17 (73W)
Manufacturer	front rear	MICHELIN/DUNLOP/BRIDGESTONE MICHELIN/DUNLOP/BRIDGESTONE
Type	front rear	MACADAM 90X/D207F/BT57F MACADAM 90X/D207/BT57R
Tire pressure (cold tire):
Maximum load-except motorcycle Loading condition A* front rear Loading condition B* front rear High-speed riding front rear		207 kg 0 ~ 90 kg 250 kPa (2.5 kg/cm2, 2.5 bar) 250 kPa (2.5 kg/cm2, 2.5 bar) 90 ~ 207 kg 250 kPa (2.5 kg/cm2, 2.5 bar) 290 kPa (2.9 kg/cm2, 2.9 bar) 250 kPa (2.5 kg/cm2, 2.5 bar) 290 kPa (2.9 kg/cm2, 2.9 bar)
Brake:
Front brake	type operation	Dual disc brake Right hand operation
Rear brake	type operation	Single disc brake Right foot operation
Suspension:
Front suspension Rear suspension		Telescopic fork Swingarm
Shock absorber:
Front shock absorber Rear shock absorber		Coil spring/Oil Damper Coil spring/Gas-oil damper
Wheel travel:
Front wheel travel Rear wheel travel		130 mm 110 mm
Electrical:
Ignition system Generator system Battery type Battery capacity		T.C.I. (Digital) A.C. generator GT14B-4 12 V 12AH
Headlight type:		Halogen bulb
Bulb wattage x quantity:
Headlight Auxiliary light Tail/brake light Flasher light Meter light Neutral indicator light High beam indicator light Oil level indicator light Turn indicator light		12 V 60 W/55 W x 1 12 V 4 W x 1 12 V 5 W/21 W x 2 12 V 21 W x 4 12 V 1.7 W x 4 12 V 1.7 W x 1 12 V 3.4 W x 1 12 V 1.7 W x 1 12 V 1.7 W x 2

*Load is the total weight of cargo, rider, passenger, and accessories.

MAINTENANCE SPECIFICATIONS

ENGINE

Model		Standard	Limit
Cylinder head:
Warp limit			0.1 mm
Cylinder:
Bore size Taper limit Out of round limit Wear limit		79.00 x 79.01 mm	0.05 mm 0.05 mm 79.1 mm
Camshaft:
Drive method Cam cap inside diameter Camshaft outside diameter Shaft-to-cap clearance		Chain drive (Center) 25.000 25.021 mm 24.967 24.980 mm 0.020 0.054 mm
Cam dimensions
Intake		35.95 x 36.05 mm 28.248 x 28.348 mm 7.95 x 8.05 mm	35.85 mm 28.15 mm
Exhaust		35.95 x 36.05 mm 28.248 x 28.348 mm 7.95 x 8.05 mm	35.85 mm 28.15 mm
Camshaft runout limit			0.03 mm
Cam chain:
Cam chain type/No. of links Cam chain adjustment method		79RH2015/156 Automatic
Valve, valve seat, valve guide:
Valve clearance (cold)	IN EX	0.11 0.15 mm 0.16 0.20 mm
Valve dimensions:
head diameter	IN EX	28.9 x 29.1 mm 24.9 x 25.1 mm
face width	IN EX	1.98 x 2.55 mm 1.98 x 2.55 mm
seat width	IN EX	0.9 x 1.1 mm 0.9 x 1.1 mm
margin thickness	IN EX	0.8 x 1.2 mm 0.8 x 1.2 mm
Stem outside diameter	IN EX	5.475 x 5.490 mm 5.460 x 5.475 mm	5.445 mm 5.43 mm
Guide inside diameter	IN EX	5.500 x 5.512 mm 5.500 x 5.512 mm	5.552 mm 5.552 mm
Stem-to-guide clearance	IN EX	0.010 x 0.037 mm 0.025 x 0.052 mm	0.08 mm 0.1 mm
Stem runout limit			0.01 mm
Valve seat width	IN EX	0.9 x 1.1 mm 0.9 x 1.1 mm	1.6 mm 1.6 mm
Valve spring:
Inner spring
Free length	IN EX	39.65 mm 39.65 mm	37.5 mm 37.5 mm
Set length (valve closed)	IN EX	32.8 mm 32.8 mm
Compressed pressure (installed)	IN EX	61.7 x 72.5 N (6.29 7.39 kg) 61.7 x 72.5 N (6.29 7.39 kg)
Tilt limit	IN EX		2.5/1.7 mm 2.5/1.7 mm
Direction of winding (top view) IN	IN EX	Clockwise Clockwise
Outer spring
Free length	IN EX	41.1 mm 41.1 mm	39 mm 39 mm
Set length (valve closed)	IN EX	34.8 mm 34.8 mm
Compressed pressure (installed)	IN EX	130.4 x 154.0 N (13.3 15.7 kg) 130.4 x 154.0 N (13.3 15.7 kg)
Tilt limit	IN EX		2.5/1.7 mm 2.5/1.7 mm
Direction of winding (top view)	IN EX	Counterclockwise Counterclockwise
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		0.015 x 0.040 mm 78.970 x 78.985 mm 2 mm 1 mm IN side 18.004 x 18.015 mm 17.991 x 18.000 mm	0.15 mm
Piston rings:
Top ring:
Type Dimensions (B x T) End gap (installed) Side clearance (installed)		Barrel 1.00 x 3.05 mm 0.20 0.35 mm 0.045 0.080 mm	0.6 mm 0.1 mm
2nd ring:
Type Dimensions (B x T) End gap (installed) Side clearance (installed)		Taper 1.2 x 3.0 mm 0.35 0.50 mm 0.03 0.07 mm	0.75 mm 0.1 mm
Oil ring:
Dimensions (B x T) End gap (installed) Side clearance		2.5 x 2.9 mm 0.2 0.5 mm 0.050 0.155 mm
Connecting rod:
Oil clearance		0.017 0.040 mm	0.08 mm
Crankshaft:
Crank width "A" Assembly width "B" Runout limit "C" Big end side clearance "D" Journal oil clearance		62.25 63.85 mm 382.0 383.2 mm 0.02 mm 0.160 0.262 mm 0.030 0.064 mm	0.5 mm 0.09 mm
Clutch:
Friction plate thickness Quantity Clutch plate thickness Quantity Clutch spring height Quantity Clutch housing thrust clearance Clutch housing radial clearance Clutch release method Push rod bending limit		2.9 3.1 mm 8 pcs 1.9 2.1 mm 7 pcs 6 mm 1 pc 0 x 0.2 mm 0.004 x 0.048 mm Hydraulic inner push	2.8 mm 0.1 mm <Warp limit> 0.1 mm 0.3 mm
Transmission:
Main axle deflection limit Drive axle deflection limit			0.06 mm 0.06 mm
Shifter:
Shifter type Guide bar bending limit		Guide bar	0.1 mm
Carburetor:
I.D. mark		5EA1 10
Main jet Main air jet Jet needle Needle jet Pilot jet Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Pilot screw Valve seat size Starter jet Starter jet Throttle valve size Float height	(M.J) (M.A.J) (J.N) (N.J) (P.A.J.1) (P.O) (P.J) (B.P.1) (B.P.2) (B.P.3) (P.S) (V.S) (G.S.1) (G.S.2) (Th. V) (F.H)	#95 #45 5D96-2 Y-2 #127.5 0.85 #40 0.9 1.0 0.8 1-1/2 2.3 #32.5 0.6 #125 21.3 x 23.3 mm
Fuel level (using special tool) Engine idle speed Intake vacuum		3.5 x 4.5 mm 1000 x 1100 r/min 31.3 kPa (235 mmHg)
Lubrication system:
Oil filter type Oil pump type Tip clearance Housing and rotor clearance Side clearance Bypass valve setting pressure Relief valve operating pressure Oil pressure (hot) Pressure check location		Paper type Trochoid type 0.12 x 0.17 mm 0.03 x 0.08 mm 0.03 x 0.08 mm 180 x 220 kPa (1.8 x 2.2 kg/cm2, 1.8 x 2.2 bar) 480 x 580 kPa (4.8 x 5.8 kg/cm2, 4.8 x 5.8 bar) 80 kPa (0.8 kg/cm2, 0.8 bar) at 1000 r/min MAIN GALLERY	0.2 mm 0.15 mm 0.15 mm

Tightening torques

Part to be tightened	Part name	Thread size	Q'ty	Tightening torque		Remarks
				Nm	m/kg
Camshaft cap	Bolt	M6 x 1.0	18	12	1.2
Oil gallery bolt	Screw	M6 x 1.0	1	7	0.7
Spark plug	–	M12 x 1.25	4	18	1.8
Cylinder head	Cap nut	M10 x 1.25	12	35	3.5
Cylinder head cover	Bolt	M6 x 1.0	8	10	1.0
Cylinder	Stud bolt	M8 x 1.25	1	8	0.8
Cylinder	Nut	M8 x 1.25	3	20	2.0
Cylinder	Nut	M6 x 1.0	6	10	1.0
Connecting rod	Nut	M8 x 0.75	8	36	3.6
Cam sprocket	Bolt	M7 x 1.0	4	20	2.0
Timing chain tensioner	Bolt	M6 x 1.0	2	10	1.0
Timing chain tensioner cap bolt	Bolt	M11 x 1.0	1	20	2.0
Chain guide (upper)	Bolt	M6 x 1.0	4	10	1.0
Chain guide (intake)	Plug	M10 x 1.25	1	10	1.0
Oil pump	Screw	M6 x 1.0	2	10	1.0
Oil pump	Bolt	M6 x 1.0	3	10	1.0
Oil strainer housing	Bolt	M6 x 1.0	2	10	1.0
Oil filter case	Union bolt	M20 x 1.5	1	15	1.5
Oil pan	Bolt	M6 x 1.0	17	10	1.0
Drain bolt (engine oil)	Plug	M14 x 1.5	1	43	4.3
Oil gallery blind plug	Plug	M16 x 1.5	1	8	0.8
Drain filter	Screw	M5 x 0.8	1	7	0.7
Oil delivery pipe (oil pan)	Bolt	M6 x 1.0	4	10	1.0
Oil delivery pipe (oil cooler)	Bolt	M6 x 1.0	4	10	1.0
Oil cooler	Bolt	M6 x 1.0	2	10	1.0
Oil cooler cover	Bolt	M6 x 1.0	4	8	0.8
Oil delivery pipe (clamp)	Bolt	M6 x 1.0	1	10	1.0
Intake manifold	Bolt	M6 x 1.0	8	10	1.0
Air filter case cap	Bolt	M5 x 0.8	4	5	0.5
Air filter case	Bolt	M6 x 1.0	3	7	0.7
Exhaust pipe	Nut	M8 x 1.25	8	25	2.5
Muffler and stay	Bolt	M8 x 1.25	2	20	2.0
Exhaust chamber	Bolt	M10 x 1.25	1	25	2.5
Exhaust pipe and exhaust chamber	Screw	M8 x 1.25	4	20	2.0
Exhaust chamber and muffler	Bolt	M8 x 1.25	2	20	2.0
Exhaust pipe blind plug (CO test)	Bolt	M6 x 1.0	4	10	1.0
Bearing holder (main axle)	Screw	M6 x 1.0	3	12	1.2
Timing plate cover	Bolt	M6 x 1.0	4	7	0.7
Crankcase cover (right)	Screw	M5 x 0.8	2	4	0.4
Clutch cover	Bolt	M6 x 1.0	11	10	1.0
Drive sprocket cover	Bolt	M6 x 1.0	3	10	1.0
Clutch release cylinder	Bolt	M6 x 1.0	3	10	1.0
Crankcase	Bolt	M6 x 1.0	16	12	1.2
Crankcase	Bolt	M8 x 1.25	17	24	2.4
Crankcase	Bolt	M10 x 1.25	5	35	3.5
Main gallery	Plug	M20 x 1.5	3	12	1.2
Oil buffle plate	Bolt	M5 x 0.8	3	4	0.4
Stopper plate	Bolt	M6 x 1.0	1	10	1.0
Bearing housing	Screw	M6 x 1.0	3	10	1.0
HY-VO chain guide	Bolt	M6 x 1.0	2	10	1.0
Clutch boss	Nut	M20 x 1.5	1	70	7.0
Clutch pressure plate	Bolt	M6 x 1.0	6	8	0.8
Push lever comp.	Bolt	M6 x 1.0	2	10	1.0
Drive sprocket	Nut	M22 x 1.5	1	85	8.5
Shift shaft stopper	Screw	M8 x 1.25	1	22	2.2
Stopper plate (Starter clutch idle gear shaft)	Screw	M6 x 1.0	2	7	0.7
Stopper lever	Bolt	M6 x 1.0	1	10	1.0
Side plate	Screw	M5 x 0.8	1	4	0.4
Shift arm	Bolt	M6 x 1.0	1	10	1.0
Shift lod	Nut	M6 x 1.0	2	8	0.8
A.C. generator	Bolt	M8 x 1.25	2	25	2.5
Oil level sensor	Bolt	M6 x 1.0	2	10	1.0
Rotor	Bolt	M10 x 1.25	1	45	4.5

Tightening sequence
Cylinder head

Crankcase

Lubrication chart:

CHASSIS

Model		Standard	Limit
Steering system:
Steering bearing type		Angular bearing
Front suspension:
Front fork travel Fork spring free length Fitting length Collar length		130 mm 407.3 mm 363.3 mm 150 mm	395 mm
Spring rate	(K1) (K2)	4.9 N/mm (0.5 kg/mm) 8.8 N/mm (0.9 kg/mm)
Stroke	(K1) (K2)	0 83 mm 83 130 mm
Optional spring Oil capacity Oil level Oil grade		No 538 cm3 137 mm Fork oil 10W or equivalent
Rear suspension:
Shock absorber travel Spring free length Fitting length		88 mm 210 mm 190 mm	206 mm
Spring rate	(K1) (K2)	20.6 N/mm (2.1 kg/mm) 31.4 N/mm (3.2 kg/mm)
Stroke	(K1) (K2)	0 50 mm 50 88 mm
Front wheel:
Type Rim size Rim material		Cast wheel 17 x MT3.50 Aluminum
Rim runout limit	radial lateral		1 mm 0.5 mm
Rear wheel:
Type Rim size Rim material		Cast wheel 17 x MT5.50 Aluminum
Rim runout limit	radial lateral		1 mm
Drive chain:
Type/manufacturer No. of links Chain free play		50ZVM/DAIDO 110 20 30 mm
Front disc brake:
Type Disc outside diameter x thickness Disc deflection limit Pad thickness Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type		Dual 298 x 5 mm 5.5 mm 14 mm 30.2 mm and 27 mm DOT #4	0.2 mm 0.5 mm
Rear disc brake:
Type Disc outside diameter thickness Disc deflection limit Pad thickness Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type		Single 267 5 mm 5.5 mm 12.7 mm 42.85 mm DOT #4	0.15 mm 0.5 mm
Brake lever & brake pedal:
Brake pedal position		45 mm
Throttle grip free play		3 5 mm

Tightening torques

Part to be tightened		Part name	Thread size	Q'ty	Tightening torque		Remarks
					Nm	m/kg
Handle crown and inner tube		Bolt	M8 x 1.25	2	30	3.0
Handle crown and steering stem		Nut	M22 x 1.0	1	110	11.0
Handle crown and handlebar holder (lower)		Nut	M10 x 1.25	2	40	4.0
Upper handlebar holder		Bolt	M8 x 1.25	4	23	2.3
Lower bracket and inner tube		Bolt	M8 x 1.25	4	23	2.3
Steering stem and ring nut		Nut	M25 x 1.0	1	18	1.8	See "NOTE"
Front master cylinder and holder		Bolt	M6 x 1.0	2	10	1.0
Front brake hose union bolt		Bolt	M10 x 1.25	1	30	3.0
Meter		Nut	M6 x 1.0	2	7	0.7
Headlight stay (lower)		Bolt	M6 x 1.0	2	10	1.0
Grip end		–	M16 x 1.5	2	26	2.6
Front turn signal lights		Nut	M12 x 1.25	2	7	0.7
Front fender and front fork		Bolt	M6 x 1.0	4	7	0.7
Headlight stay and upper cover		Cap nut	M6 x 1.0	4	7	0.7
Engine stay (front) and frame		Bolt	M8 x 1.25	4	30	3.0
Engine mount	(front) (rear-upper)	Nut Nut	M10 x 1.25 M10 x 1.25	2 1	64 55	6.4 5.5
Engine stay (rear-upper) and frame		Bolt	M10 x 1.25	2	48	4.8
Engine stay (rear-upper) and frame		Bolt	M12 x 1.25	2	88	8.8
Engine stay (rear-lower)		Nut	M10 x 1.25	2	64	6.4
Frame and down tube		Nut and Bolt	M8 x 1.25	4	26	2.6
Pivot shaft		Nut	M18 x 1.5	1	125	12.5
Rear shock absorber and frame		Bolt	M8 x 1.25	1	23	2.3
Rear shock absorber and swing arm		Bolt	M10 1.25	1	30	3.0
Drive chain guide and swing arm		Bolt	M6 x 1.0	1	7	0.7
Chain case and swing arm		Screw	M6 x 1.0	2	7	0.7
Fuel tank		Bolt	M8 x 1.25	1	19	1.9
Fuel tank cap		Screw	M5 x 0.8	4	6	0.6
Fuel cock		Screw	M6 x 1.0	2	7	0.7
Seat lock		Nut	M6 x 1.0	2	7	0.7
Fuel sender		Bolt	M5 x 0.8	4	4	0.4
Side cover and frame		Screw	M6 x 1.0	2	7	0.7
Tail light		Nut	M6 x 1.0	3	7	0.7
Rear fender and frame		Bolt	M6 x 1.0	4	7	0.7
Rear fender cover and cover		Screw	M5 x 0.8	2	4	0.4
Rear fender cover and frame		Screw	M6 x 1.0	2	7	0.7
Grab bar		Bolt	M8 x 1.25	4	30	3.0
Ignitor		Screw	M6 x 1.0	2	7	0.7
Rear turn signal light and rear fender		Nut	M12 x 1.25	2	4	0.4
Hook		Screw	M6 x 1.0	2	7	0.7
Helmet holder		Bolt	M6 x 1.0	2	13	1.3
Tail light bracket		Bolt	M8 x 1.25	4	30	3.0
Side stand		Bolt	M10 x 1.25	1	40	4.0
Side stand		Nut	M10 x 1.25	1	40	4.0
Side stand switch		Screw	M5 x 0.8	2	4	0.4
Footrest bracket		Bolt	M8 x 1.25	4	28	2.8
Rear footrest bracket		Bolt	M8 x 1.25	4	28	2.8
Footrest and footrest bracket		Bolt	M10 x 1.25	2	55	5.5
Rear brake reservoir tank		Screw	M6 x 1.0	1	5	0.5
Rear master cylinder and bracket		Bolt	M8 x 1.25	2	23	2.3
Center stand		Nut and Bolt	M10 x 1.25	2	41	4.1
Front wheel axle		–	M16 x 1.5	1	73	7.3
Front wheel axle pinch bolt		Bolt	M8 x 1.0	1	19	1.9
Front brake caliper and front fork		Bolt	M10 x 1.25	4	40	4.0
Front brake disk and hub		Bolt	M8 x 1.25	12	20	2.0
Front brake caliper and bleed screw		–	M8 x 1.25	2	6	0.6
Front brake hose		Union bolt	M10 x 1.25	2	30	3.0
Tensionbar and swingarm		Nut and bolt	M8 x 1.25	2	23	2.3
Driven sprocket and hub		Nut	M8 x 1.25	6	60	6.0
Chain puller		Nut	M8 x 1.25	2	16	1.6
Rear brake caliper and caliper bracket		Bolt	M10 x 1.25	2	40	4.0
Rear wheel axle		Nut	M18 x 1.5	1	150	15.0
Rear brake hose		Union bolt	M10 x 1.25	2	30	3.0
Rear brake caliper and bleed screw		–	M8 x 1.25	1	6	0.6
Rear brake disc and hub		Bolt	M8 x 1.25	6	20	2.0

NOTE:

1. First, tighten the ring nut approximately 52 Nm (5.2 mfkg) by using the torque wrench, then loosen the ring nut one turn.
2. Retighten the ring nut to specification.

ELECTRICAL

Model	Standard	Limit
Voltage:	12 V
Ignition system:
Ignition timing (B.T.D.C.) Advanced timing (B.T.D.C.) Advancer type	5/1050 r/min 50/5000 r/min TPS & Electrical type
T.C.I.:
Pickup coil resistance/color T.C.I. unit model/manufacturer	248 x 372 Ω/W/R-W/G 5EA20/YAMAHA
Ignition coil:
Model/manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance	83R/YAMAHA 6 mm 1.9 x 2.9 Ω 9.5 x 14.3 kΩ
Spark plug cap:
Type Resistance	Resin type 10 kΩ
Charging system:
Type Model/manufacturer Normal output Rotor coil resistance Stator coil resistance Brush overall length Spring force	A.C. generator B3G-B/DENSO 13.5 V 28 A/3000 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)	4.7 mm
Voltage regulator:
Type Model/manufacturer No load regulated voltage	Semi-conductor, field control type B3G-B/DENSO 14.2 x 14.8 V
Electric starter system:
Type Starter motor: Model/manufacturer Output Brush overall length Spring force Commutator diameter Mica undercut Starter relay: Model/manufacturer Amperage rating Coil winding resistance	Constant mesh type SM-13/MITSUBA 0.65 kW 10 mm 7.65 x 10.01 N (0.780 x 1.021 kg) 28 mm 0.7 mm MS5E-491/JIDECO 100 A 4.2 4.6 Ω	5 mm 27 mm

Horn:
Type Quantity Model/manufacturer Maximum amperage	Plane type 2 pcs YF12/NIKKO 3 A
Flasher relay:
Type Model/manufacturer Self cancelling device Flasher frequency	Full transistor type FE246BH/DENSO No 75 95 cyl/min
Oil level switch:
Model/manufacturer	5G2/DENSO
Fuel gauge:
Model/manufacturer Sender unit resistance full empty	4 KG/NIPPON SEIKI 4 10 Ω 90 100 Ω
Starting circuit cut-off relay:
Model/manufacturer Coil winding resistance Diode	G8R-30Y-J/OMRON 162 198 Ω Yes
Oil level switch relay:
Model/manufacturer	G8D-117Y-2/OMRON
Circuit breaker:
Type Amperage for individual circuit x Q'ty MAIN HEAD LIGHT SIGNAL IGNITION Reserve	Fuse 30 A x 1 15 A x 1 15 A x 1 7.5 A x 1 30 A x 1 15 A x 1 7.5 A x 1

CONVERSION TABLE

All specification data in this manual are listed in SI and METRIC UNITS.
Use this table to convert METRIC unit data to IMPERIAL unit data.
Ex.

CONVERSION TABLE

GENERAL TIGHTENING TORQUES

This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached. Unless otherwise specified, tightening torque specifications require clean, dry threads. Components should be at room temperature.

1. Distance across flats
2. Outside thread diameter

LUBRICATION POINT AND GRADE OF LUBRICANT

ENGINE

Lubrication Point	Symbol
Oil seal lips
O-ring
Bearing
Piston surface
Piston pin
Crankshaft pin
Crankshaft journal/big end
Connecting rod bolt/nut
Camshaft cam lobe/journal
Valve stem (IN, EX)
Valve stem end (IN, EX)
Valve lifter
Oil pump rotor (inner/outer), housing
Oil strainer assembly
Starter idle gear inner surface
Starter wheel gear inner surface
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

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
Clutch lever bolt, sliding surface
Rear footrest pivot
Swingarm pivot bearing
Swingarm pivot shaft outer surface
Swingarm thrust cover lip

CABLE ROUTING

1. Starter motor cable
2. Battery negative (–) lead
3. Battery negative (–) lead connector
4. AC generator connector
5. Rear brake switch lead connector
6. Neutral lead
7. Pickup lead
8. Sidestand switch lead
9. Throttle position sensor
10. Ignition coil lead (#2, 3)
11. Throttle cable
12. Engine ground lead
13. Air ventilation hose
14. Rear brake switch
15. Starting circuit cutoff relay

1. Fasten the wireharness to the seat rail with a plastic band. Make sure that the end of band down ward.
2. Align the white tape on the wireharness with a plastic band and fasten them to the seat real. Make sure that the end of band down ward.
3. Fasten the wireharness with the steel clamp on the frame.
4. Route the wireharness and starter motor cable in front of the reservoir tank bracket and the battery negative (–) lead behind the reservoir tank bracket. And fasten them with a plastic band.
5. Fasten the wireharness, neutral lead, sidestand switch lead, pickup coil lead, AC generator lead and rear brake switch lead to the frame with a plastic band. Make sure that the end of band forward of motorcycle.
6. Fasten the wireharness to the frame with a plastic band. Make sure that the end of band down ward.
7. Insert the plastic band through the hole of plastic panel and then fasten the throttle cables with it. Make sure that the end of band inside of motorcycle.
8. Fasten the wireharness to the frame with a plastic band. Make sure that the end of band down ward.
9. Fasten the high tension cables and throttle cables with a plastic clamp.
10. Route the air ventilation hoses, air filter case drain hose, fuel tank drain hose and fuel tank breather hose through the engine guide.
11. Fasten the AC generator lead, pick-up coil lead, sidestand switch lead and starter motor cable with a plastic band.
12. Route the wireharness and starter motor cable behind the side cover bracket and fasten them with a plastic band at front of the bracket.
13. Align the white paint marks of the fuel tank drain hose, fuel tank breather hose and air filter case drain hose.
14. Touch the brake pipe to the brake caliper stopper.

1. Clutch hose
2. Starter cable
3. Air filter case drain hose
4. Frame ground
5. Flasher relay connector
6. Oil light relay connector
7. Igniter unit connectors
8. Starter motor
9. AC generator
10. Sidestand switch
11. Sidestand switch lead
12. Ignition coil lead (#1, 4)

1. Insert the plastic band through the hole of plastic panel and then fasten the clutch hose with it. Make sure that the end of band inside of motorcycle.
2. To headlight lower hole.
3. Route the wireharness and starter cable through the guide.
4. Connect the ignition lead with white marking tape to the ignition coil (#1, 4).
5. Fasten the high tension cables (#1, 2) with a plastic clamp. Position the clamp at 50 – 80 mm above the high tension cable number.
6. Fasten the horn lead to the frame with a plastic band. Make sure that the end of band down ward.
7. Install the frame ground and igniter unit together with screw.
8. Fasten the seat lock cable to the seat real with a plastic band. Make sure that the end of band down ward.
9. Route the air filter case drain hose over the starter motor to right side of motorcycle.
10. Position the clutch pipe parallel with the oil filter cover.
11. Fasten the sidestand switch lead with steel clamp on the frame and then route it between the pickup cover, oil filter cover, AC generator and starter motor to the right side of motorcycle.
12. Fasten the clutch hose with steel clamp on the frame.
13. Clamp the gromet on the clutch hose with wire holder on the frame.
14. Route the speedometer cable through the guide.
15. Touch the brake pipe to the brake caliper stopper.
16. Touch the brake pipe to the brake hose joint.

1. Throttle cables
2. Ignition coil (#2, 3)
3. Throttle position sensor
4. Neutral switch connector
5. Pickup coil connector
6. Sidestand switch connector
7. Battery
8. Reservoir tank
9. Battery negative (–) lead
10. Starting circuit cutoff relay
11. Battery positive (+) lead connector
12. Starter relay
13. Seat lock cable
14. Seat lock
15. Battery positive (+) lead
16. Fuse box
17. Starter relay connector
18. Flasher relay
19. Oil light relay
20. Igniter unit
21. Fuel sender connector
22. Starter cable
23. Ignition coil (#1, 4)
24. Taillight lead
25. Starter cable

1. Position the horn (high) to right side.
2. Fasten the throttle cable (front side) to the frame with a plastic clamp.
3. Fasten the throttle position sensor with steel clamp on the carburetor (#4).
4. To fuel sender.
5. Connect the fuel sender connector, neutral switch connector, pickup coil connector and sidestand switch connector above the air filter case.
6. Route the battery negative (–) lead inside of the reservoir tank bracket and under the reservoir tank and then connect it.
7. Fasten the battery positive (+) lead and battery positive (+) lead connector on the groove of the battery with the battery rubber band.
8. Position the starter motor cable at 45 degree out side of the motorcycle.
9. Position the wireharness, taillight lead and rear turn signal light leads (left and right) between the taillight bracket and rear fender rib.
10. Position the seat lock cable inside under the seat lock bracket.
11. Fasten the wireharness to the frame with a plastic band. Make sure that the end of band down ward.
12. Route the starter cable between the throttle cables.
13. Fasten the wireharness, starter cable to the frame with a plastic band. Make sure that end of band down ward.
14. 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.
15. Route the rear turn signal light leads (left and right) through the each holes of the rear fender.
16. Touch the starter cable to the stopper and position it vertical of the motorcyle.

1. Meter leads
2. Main switch lead
3. Starter cable
4. Handlebar switch lead (left)
5. Clutch hose
6. Brake hose
7. Handlebar switch lead (right)

1. Route the throttle cables through the guide on the headlight stay.
2. Route the meter leads, main switch lead into the upper hole of the headlight body.
3. Route the handlebar switch lead (left) inside of the clutch hose. Fasten the handlebar switch lead (left), clutch hose and starter cable with a plastic band.
4. Route the handlebar switch lead (left) and front turn signal light lead (left) into the left under hole of the headlight body.
5. Route the front turn signal light leads (left and right) in front of the headlight stay.
6. Route the speedometer cable through the guide on the headlight stay.
7. To front brake master cylinder.
8. Touch the brake pipe to the stopper.
9. Route the handlebar switch lead (right) and front turn signal light lead (right) into the right under hole of the headlight stay.
10. Fasten the handlebar switch lead (right) and front brake hose with a plastic band.

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. All service technicians should be familiar with this entire chapter.

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

ITEM	REMARKS	BREAK-IN 1,000 km	EVERY
			6,000 km or 6 months	12,000 km or 12 months
Valves*	Check valve clearance. Adjust if necessary.	EVERY 24,000 km or 24 months
Spark plugs	Check condition. Clean or replace of necessary.
Air filter	Clean. Replace if necessary.
Carburetor*	Check idle speed/synchronization/starter operation. Adjust if necessary.
Fuel line*	Check fuel hose for cracks or damage. Replace if necessary.
Fuel filter*	Check condition. Replace if necessary.
Engine oil	Replace (Warm engine before draining).
Engine oil filter*	Replace.
Brake*	Check operation/fluid leakage/See NOTE. Correct if necessary.
Clutch*	Check operation/fluid leakage/See NOTE. Correct if necessary.
Swingarm pivot*	Check swingarm assembly for looseness. Correct if necessary. Moderately repack every 24,000 km or 24 months.**
Rear suspension link pivots*	Check operation. Apply grease lightly every 24,000 km or 24 months.**
Wheels*	Check balance/damage/runout. Replace if necessary.
Wheel bearings*	Check bearing assembly for looseness/damage. Replace if damaged.
Steering bearings*	Check bearing assembly for looseness. Correct if necessary. Moderately repack every 24,000 km or 24 months.
Front forks*	Check operation/oil leakage. Repair if necessary.
Rear shock absorber*	Check operation/oil leakage. Repair if necessary.
Drive chain	Check chain free play/alignment. Adjust if necessary. Clean and lube.	EVERY 500 km
Fittings/Fasteners*	Check all chassis fittings and fasteners. Correct if necessary.
Center and sidestand*	Check operation. Repair if necessary.
Sidestand switch*	Check operation. Clean or replace if necessary.
A.C. Generator*	Replace generator brushes every 100,000 km.

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. Normally check the brake fluid level and add the fluid as required.
2. On the inner parts of the master cylinder, caliper cylinder and clutch release cylinder, replace the oil seals every two years.
3. Replace the brake and clutch hoses every four years, or if cracked or damaged.

XJR1300'99 WIRING DIAGRAM for EUR

1. AC generator
2. Fuse (main)
3. Battery
4. Starter relay
5. Main switch
6. Fuse (ignition)
7. Starter motor
8. Starting circuit cut-off relay
9. Ignitor unit
10. Ignition coil
11. Spark plug
12. Pickup coil
13. TPS (throttle position sensor)
14. Neutral switch
15. Sidestand switch
16. Oil level relay
17. Start switch
18. Engine stop switch
19. Front brake switch
20. Handlebar switches (right)
21. Lights switch
22. Fuse (signal)
23. Rear brake switch
24. Horn
25. Flasher relay
26. Oil level switch
27. Connector
28. Meter assembly
29. Tachometer
30. Fuel gauge
31. Fuel sender
32. Meter lights
33. Neutral indicator light
34. Turn signal indicator light (left)
35. Turn signal indicator light (right)
36. Oil warning light
37. High beam indicator light
38. Clutch switch
39. Turn signal switch
40. Horn switch
41. Pass switch
42. Dimmer switch
43. Handlebar switch (left)
44. Fuse (headlight)
45. Auxiliary light
46. Tail / brake light
47. Headlight
48. Front turn signal lights
49. Rear turn signal lights

COLOR CODE