Yamaha XJR1300 P 2002 User Manual [ru]

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

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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.
is expressly prohibited.

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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.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve­hicle unsafe and unfit for use.

This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools in necessary to ensure that the ve­hicle will operate as designed. 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 fed­eral environmental quality objectives.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi­cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.

NOTE:

S This Service Manual contains information regarding periodic maintenance to the emission control

system. Please read this material carefully.

S Designs and specifications are subject to change without notice.

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IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!

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

CAUTION:

NOTE: A NOTE provides key information to make procedures easier or clearer.

A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.

to

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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. The current section title is shown at the top of each page,
except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(-s) ap­pears.

3

Sub-section titles appear in smaller print than the section title.

4

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.

5

Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.

6

Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.

7

A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.

8

Jobs requiring more information (such as special tools and technical data) are described sequen­tially.

12

5

7

4

3

8

6

1

GEN

INFO

3

CHK

ADJ

5

CARB

7

2

SPEC

4

ENG

6

CHAS

8

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SYMBOLS

The following symbols are not relevant to every
vehicle.
Symbols
chapter.

General information

1

Specifications

2

Periodic checks and adjustments

3

Engine

4

Carburetor(-s)

5

Chassis

6

Electrical system

7

Troubleshooting

8

1

to 8 indicate the subject of each

ELEC

9

11 12

18 1917

21

10

1413

1615

TRBL

SHTG

2220

Symbols 9 to 16 indicate the following.

Serviceable with engine mounted

9

10

Filling fluid

11

Lubricant

12

Special tool

13

Tightening torque

14

Wear limit, clearance

15

Engine speed

16

Electrical data

Symbols 17 to 22 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

23 24

Symbols 23 to 24 in the exploded diagrams indi­cate the following:

23

Apply locking agent (LOCTITE)

24

Replace the part

CONTENTS

SPECIFICATIONS

GENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC INSPECTION AND ADJUSTMENT

INTRODUCTION 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC MAINTENANCE/LUBRICATION INTERVALS 20. . . . . . .

ENGINE 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE CLUTCH LEVER 22. . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE FRONT BRAKE 23. . . . . . . . . . . . . . . . . . . . . . . . .

CARBURETORS

AIR INDUCTION SYSTEM 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR INJECTION 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR CUTOFF VALVE 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR INDUCTION SYSTEM DIAGRAMS 25. . . . . . . . . . . . . . . . . . . . .

CHECKING THE AIR INDUCTION SYSTEM 26. . . . . . . . . . . . . . . .

CHASSIS

FRONT AND REAR BRAKES 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT BRAKE MASTER CYLINDER 27. . . . . . . . . . . . . . . . . . . . . .

ASSEMBLING AND INSTALLING THE

FRONT BRAKE MASTER CYLINDER 28. . . . . . . . . . . . . . . . . .

REAR BRAKE CALIPER 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL

CARBURETOR HEATING SYSTEM 32. . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

XJR1300 2002 WIRING DIAGRAM (for EUR)

XJR1300P 2002 WIRING DIAGRAM (for AUS)

GENERAL SPECIFICATIONS

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

Basic weight:

With oil and full fuel tank

Carburetor:

Type/ quantity

Manufacturer

2,175 mm
775 mm
1,115 mm
790 mm
1,510 mm
120 mm
2,800 mm

247 kg

BSR37/ 4
MIKUNI

SPEC

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
39/ 18 (2.167)
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)

1

Model XJR1300 (P)

Tire:

Type

Size front

rear

Manufacturer front

rear

Type 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

GENERAL SPECIFICATIONS

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

203 kg
0 X 90 kg
250 kPa (2.5 kg/ cm
250 kPa (2.5 kg/ cm
90 X 203 kg
250 kPa (2.5 kg/ cm
290 kPa (2.9 kg/ cm

250 kPa (2.5 kg/ cm
290 kPa (2.9 kg/ cm

2

, 2.5 bar)

2

, 2.5 bar)

2

, 2.5 bar)

2

, 2.9 bar)

2

, 2.5 bar)

2

, 2.9 bar)

SPEC

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

2

MAINTENANCE SPECIFICATIONS

MAINTENANCE SPECIFICATIONS

ENGINE

SPEC

Model

Cylinder head:

Warp limit

Cylinder:

Bore size

Taper limit

Out of round limit

Wear limit

Camshaft:

Drive method

Cam cap inside diameter

Camshaft outside diameter

Shaft-to-cap clearance

Cam dimensions

Standard Limit

SSS 0.2 mm

79.00 X 79.01 mm

SSS
SSS
SSS

Chain drive (Center)

25.000 X 25.021 mm

24.967 X 24.980 mm

0.020 X 0.054 mm

SSS

0.05 mm

0.1 mm

79.1 mm

SSS
SSS
SSS
SSS

Intake “A”

“B”

Exhaust “A”

“B”

Camshaft runout limit

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

0.03 mm

3

Model Standard Limit

Piston:

Piston to cylinder clearance

Piston size “D”

MAINTENANCE SPECIFICATIONS

0.015 X 0.040 mm

78.970 X 78.985 mm

SPEC

0.15 mm

SSS

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.V)

Float height (F.H)

Fuel level (using special tool)

Engine idle speed

Intake vacuum

5 mm
1 mm
IN side

18.004 X 18.015 mm

17.991 X 18.000 mm

5EAT 30
#107.5
#80
5D118-53-3
P-0M
#140
ø1.0
#15

0.9

0.9

0.8
2

2.3
#52.5

0.8
#115
33 X 34 mm
3 X 4 mm
950 X 1,150 r/ min

31.3 kPa (235 mmHg)

SSS
SSS
SSS

18.045 mm

17.971 mm

SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS

4

Tightening torques

g

size

y

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened

Carburetor joint and carburetor
Carburetor and air filter joint
Air induction system pipe joint
Air induction system

Part name

Band

Clamp

–

Bolt

Thread

M4 0.7
M4 0.7

–

M6 1.0

Q’ty

4
4
4
2

Tightening

torque

Nm mSkg

2.7

2.7

3.7
10

0.27

0.27

0.37

1.0

Remarks

5

CHASSIS

MAINTENANCE SPECIFICATIONS

SPEC

Model

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

Rear suspension:

Shock absorber travel
Spring free length
Fitting length
Spring rate (K1)

(K2)

(K3)

(K4)
Stroke (K1)

(K2)

(K3)

(K4)

Standard Limit

130 mm

308.3 mm

287.3 mm
245 mm

6.4 N/ mm (0.65 kg/ mm)

10.8 N/ mm (1.1 kg/ mm)
0 X 85 mm
85 X 130 mm
No
568 cm
118 mm
Fork oil 10W or equivalent

93 mm
230 mm
209 mm

19.4 N/ mm (1.98 kg/ mm)

21.4 N/ mm (2.18 kg/ mm)

26.3 N/ mm (2.68 kg/ mm)

28.2 N/ mm (2.88 kg/ mm)
0 X 13 mm
13 X 50 mm
50 X 67.5 mm

67.5 X 93.0 mm

3

SSS

300 mm

SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS

SSS

225 mm

SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS

Front wheel:

Type
Rim size

Rim material
Rim runout limit radial

lateral

Rear wheel:

Type
Rim size

Rim material
Rim runout limit radial

lateral

Drive chain:

Type/ manufacturer
No. of links
Chain free play

Brake lever & brake pedal:

Brake pedal position

Cast wheel
17 MT3.50 or
17 M/ C MT3.50
Aluminum

SSS
SSS

Cast wheel
17 MT3.50 or
17 M/ C MT3.50
Aluminum

SSS
SSS

50VA8/ DAIDO
112
20 X 30 mm

40 mm SSS

SSS
SSS

SSS

1 mm

0.5 mm

SSS
SSS

SSS

1 mm

0.5 mm

SSS
SSS
SSS

6

Tightening torques

g

y

Part to be tightened

MAINTENANCE SPECIFICATIONS

Part name Thread size Q’ty

SPEC

Tightening

torque

Nm mSkg

Remarks

Throttle cable and carburetor
Ignition coil

Nut
Nut

M6 1.0
M6 1.0

2

246.5

0.4

0.65

7