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

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.
is expressly prohibited.

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.
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.

EAS00004

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

EAS00009

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

ELECTRICAL

MAINTENANCE SPECIFICATIONS

SPEC

Model

T.C.I.:

Pickup coil resistance/ color
T.C.I. unit model/ manufacturer

Charging system:

Type
Model/ manufacturer
Normal output
Rotor coil resistance
Stator coil resistance
Brush overall length
Spring force

Voltage regulator:

Type
Model/ manufacturer
No load regulated voltage

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

Starting circuit cut-off relay:

Model/ manufacturer
Coil winding resistance
Diode

Standard Limit

248 X 372 Ω/W/R-W/G
TNDF63/ DENSO (except for D)
TNDF64/ DENSO (for D)

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)

Semi-conductor, field control type
B3G/ DENSO

14.2 X 14.8 V

Constant mesh type

SM-13/ MITSUBA

0.65 kW
10 mm

8.82 N (899 kg)
28 mm

0.7 mm

MS5E-491/ JIDECO
180 A

4.2 X 4.6 Ω

G8R-30Y-P/OMRON
162 X 198 Ω
Yes

SSS
SSS
SSS

SSS
SSS
SSS
SSS
SSS

4.7 mm

SSS

SSS
SSS
SSS

SSS

SSS
SSS

5 mm

SSS

27 mm

SSS

SSS
SSS
SSS

SSS
SSS
SSS

Circuit breaker:

Type
Amperage for individual circuit Q’ty

MAIN
HEAD LIGHT
SIGNAL
IGNITION
TURN
Reserve

Fuse

40 A 1
15 A 1
15 A 1
15 A 1
15 A 1
40 A 1
15 A 1

8

SSS

SSS
SSS
SSS
SSS
SSS
SSS
SSS

CABLE ROUTING

CABLE ROUTING

SPEC

1 Starter motor cable
2 Battery negative (–) lead wire
3 Carburetor heater plug
4 A.C. generator coupler
5 Rear stop switch coupler
6 Neutral lead wire
7 Pickup lead wire
8 Side stand switch lead wire

9 T.P.S.
10 Tank fitting
11 #1 and #4 ignition coil lead wires
12 Horn lead wire

13 #3 high-tension cord
14 #4 high-tension cord
15 Engine frame ground lead wire
16 Rear stop switch
17 Relay assy
18 Guide wire
19 Fuel tank drain hose
20 Fuel tank breather hose

A Pass the starter motor cable and

the negative (–) lead wire of the
battery through the inside of the
seat rail.

9

CABLE ROUTING

SPEC

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.

C Clamp the throttle cables to the

fuel tank rail, on the tank fitting by
use of this band. The front end of
the band must be directed down­ward.

D Thread this clamp through the

upper hole in the gusset and se­cure the two throttle cables. The
front end of the clamp must be di­rected towards the inside of the
vehicle.

E Bundle the #3 and #4 high-ten-

sion cords, on the head cover
mounting bolt at the #3 cord, by
use of this band.

F Do not entangle the lead wires

and the hosing.
Pass the bundle of lead wires
and that of hosing orderly as
shown.

G Pass the air cleaner drain hose,

the fuel tank drain hose, and the
fuel tank breather hose (total 3
hoses) through the guide wire of
the engine.

10

CABLE ROUTING

SPEC

H Bundle the A.C. generator lead

wire, the pickup lead wire, the
side stand switch lead wire, the
starter motor cable, and the car­buretor heater lead wire (total 5
wires), by use of this clamp.

I Match the marks of the fuel tank

drain hose and fuel tank breather
hose, and arrange the two types
of hose properly.

J Match the paint mark of the air

cleaner drain hose to the lower
end of the guide wire.

K Clamp the wire harness to the

seat rail, at the front end of the
bracket.The front end of the
clamp must be directed down­ward.

L Clamp the wire harness.

M Pass the wire harness between

the handle standing lug member
and the rear fender.

11

CABLE ROUTING

SPEC

1 Gusset

2 Tension pipe 1

3 #2 high-tension cord

4 #1 high-tension cord

5 Wire starter

6 A.C. generator

7 Oil filter cover

8 Side stand switch

9 Side stand switch lead wire
10 Horn lead wire
11 #2 and #3 ignition coil lead wires
12 Frame ground lead wire

13 Flasher relay coupler
14 Oil lamp relay coupler
15 Igniter unit coupler

A Pass the wire harness and the

starter cable through the holder
wire of the gusset.
Pass the starter cable under the
wire harness.

B Secure the lead wire branch of

the main harness to tension pipe
1, at the immediate rear of the

gusset, by use of this band.
The front end of the band must
be directed downward.

C Bundle the four high-tension

cords, the #1 and #2 cords up
and the #3 and #4 cords down,
by use of this band.
Position the leading ends of the
cords near, but not below, the
lower front end of the air induc­tion system assy.

12

CABLE ROUTING

SPEC

D Bundle the #1 and #2 high-ten-

sion cords using this clamp.
Clamp these cords above the #2
head cover mounting bolt.

E Route the air cleaner drain hose

through the right side of the ve­hicle with a clearance above the
starter motor.

F Mount the square fixture of the

clutch hose in parallel with the
cover.

G After securing the side stand

switch lead wire using this
clamp, first route the lead wire
between the pickup cover, the oil
filter cover, the A.C. generator,
and the starter motor. Next, as
with the engine lead wire, route
the lead wire through the right
side of the vehicle.

H Clamp the clutch hose.

I Secure the grommet of the

clutch hose by use of this holder
wire of the gusset.

J Pass the horn lead wire between

the clutch hose and the frame,
then pull the lead wire out to the
front, and connect the lead wire
to the horn.

K Connect the black-coupler-

equipped lead wire to the #1 and
#4 ignition coils.

13

CABLE ROUTING

SPEC

L Pass this clamp through the low-

er hole of the gusset and secure
the clutch hose.
The front end of the clamp must
be directed towards the inside of
the vehicle.

M Pass the main harness through

the inside of the clutch hose and
insert the harness into the left of
the headlight lower hole.

N Fasten the frame ground lead

wire together with the igniter unit
mounting screw.

O Clamp the seat lock wire to the

seat rail.
The front end of the clamp must
be directed downward.

14

CABLE ROUTING

SPEC

1 Throttle cable

2 #1 and #4 ignition coils

3 T.P.S.

4 Neutral switch coupler

5 Pickup coupler

6 Side stand switch coupler

7 Fuel sender coupler

8 Igniter unit

9 Starter cable
10 #2 and #3 ignition coils
11 Stoppers
12 Negative (–) lead wire of the bat-

tery

13 Relay assy

14 Starter motor cable
15 Thermoswitch
16 Starter relay
17 Rib of the rear fender
18 Seat lock wire
19 Positive (+) lead wire of the bat-

tery

20 Starter relay coupler
21 Fuse box
22 Negative (–) lead wire coupler of

the battery

23 Flasher relay
24 Oil lamp relay
25 Battery band

A Right horn.

Install the HI tone source (with H­marked label) at the right of the
vehicle.

B Connect the #1-#4 high-tension

cords in order of the cord num­ber.

C Pass the T.P.S. lead wire through

the clamp of the #4 carburetor.

D To fuel sender

15

CABLE ROUTING

SPEC

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 inser-

tion clamp onto the T-stud of the
frame.

H Pass the starter cable through

the front of the throttle cable.

I From left: #1, #2, #3, and #4

high-tension cords.

J Secure the wire harness and the

starter cable, on the harness
positioning tape, by use of this
band. The front end of the band
must be directed downward.
The harness must not deflect be­tween the T-stud and the clamp.

K Connect the starter cable to face

at right angles to the vehicle
body with contact with the stop­pers.

L Direct the crimping side of the

battery positive (+) lead wire
downward and connect the lead
wire.

M Connect the starter motor cable

to face outward at an angle of
about 45 degrees.

16

CABLE ROUTING

SPEC

N Secure the two positive (+) lead

wires of the battery, the nega­tive(–) lead wire coupler of the
battery, and the wire harness by
use of this battery band.

O Clamp the wire harness to the

seat rail, on the wire harness
positioning tape and at the im­mediate rear of the side cover
mounting bracket on the seat
rail.
The front end of the clamp must
face downward and be posi­tioned inside the back stay.

P Store the wire harness, the tail-

light lead wire, and the rear left
and right flasher lead wires, into
the space between the taillight
bracket and the rib of the rear
fender.

Q The seat lock wire must not ex-

tend to the outside of the brack­et.

R Pass the lead wire leading to the

fuse box under the wire harness.

S After connecting the lead wire of

the thermoswitch, store the lead
wire into the space under the
wire harness.

T Clamp the wire harness to the

seat rail, on the wire harness
positioning tape and at the im­mediate rear of the side cover
mounting bracket on the seat
rail.
The front end of the clamp must
face downward and be posi­tioned inside the back stay.

17

CABLE ROUTING

SPEC

1 Meter lead wire

2 Main switch lead wire

3 Crown handle

4 Starter cable

5 Left handle switch lead wire

6 Clutch hose

7 Front left flasher lead wire

8 Front right flasher lead wire

9 Brake hose 2
10 Brake hose 1
11 Right handle switch lead wire
12 Wire harness
13 Taillight lead wires
14 Taillight bracket
15 Rib of the rear fender

16 Rear fender
17 Rear left flasher lead wire
18 Rear right flasher lead wire
19 Wire harness

A Pass the throttle cable through

the guide wire of the stay head­light.

B Insert the meter lead wire and

the main switch lead wire into the
upper hole of the headlight.

C Bundle the handle switch lead

wire, the clutch hose, and the
starter cable, under the crown
handle, by use of this band.
The handle switch lead wire
must be passed outside the
clutch hose.
The starter cable must be
passed inside the clutch hose.

D Pass the front left and right flash-

er lead wires through the front of
the stay headlight.
Securely mount the cap to face
upward.

18

CABLE ROUTING

SPEC

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.

H Match the wire harness, the

main switch lead wire, and the
meter lead wire, to the wire har­ness and main switch lead wire
positioning tapes, and bundle
the harness and the lead wires
by use of the band.

I The lead wires must be clamped

in this area.

J Bundle the front left and right

flasher lead wires by use of the
clamp.

K The wire harness, the taillight

lead wires, and the rear left and
right flasher lead wires must be
arranged below the rib of the rear
fender.

L Clamp the wire harness and the

rear left and right flasher lead
wires.
The front end of the clamp must
be directed forward.

M Pass the rear left and right flash-

er lead wires through the respec­tive holes in the rear fender.

19

INTRODUCTION/

NO.ITEM

CHECK OR MAINTENANCE JOB

ppg

5

Air filter element

9*Brake hoses

13*Swingarm

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

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

NOTE:

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 ( 1,000 km)

1 10 20 30 40

1 * Fuel line

2 * Fuel filter S Check condition. √ √

3 Spark plugs

4 * Valves

6 * Clutch

7 * Front brake

8 * Rear brake

*

10 * Wheels S Check runout and for damage. √ √ √ √

11 * Tires

12 * Wheel bearings S Check bearing for looseness or damage. √ √ √ √

*

14 Drive chain

S Check fuel hoses and vacuum hose for

cracks or damage.

S Check condition.
S Clean and regap.

S Replace. √ √

S Check valve clearance.
S Adjust

S Clean. √ √
S Replace. √ √

S Check operation, fluid level and vehicle for

fluid leakage. (See NOTE.)

S Check operation, fluid level and vehicle for

fluid leakage. (See NOTE.)

S Replace brake pads. Whenever worn to the limit

S Check operation, fluid level and vehicle for

fluid leakage. (See NOTE.)

S Replace brake pads. Whenever worn to the limit
S Check for cracks or damage. √ √ √ √ √

S Replace. (See NOTE.) Every 4 years

S Check tread depth and for damage.
S Replace if necessary.
S Check air pressure.
S Correct if necessary.

S Check operation and for excessive play. √ √ √ √

S Lubricate with lithium-soap-based grease. Every 50,000 km

S Check chain slack.
S Make sure that the rear wheel is properly

aligned.

S Clean and lubricate.

√ √ √ √ √

√ √ √ √ √ √

√ √ √ √ √ √

√ √ √ √ √

√ √

Every 20,000 km

√ √ √ √ √

Every 1,000 km and after washing
the motorcycle or riding in the rain

ANNUAL

CHECK

20

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

NO.ITEM

CHECK OR MAINTENANCE JOB

gg

CHK

ADJ

ODOMETER READING ( 1,000 km)

1 10 20 30 40

S Check bearing play and steering for

15 * Steering bearings

16 * Chassis fasteners

17

18 * Sidestand switch S Check operation. √ √ √ √ √ √
19 * Front fork S Check operation and for oil leakage. √ √ √ √

20 *

21 * Carburetors

22 Engine oil

23

24 *

25

26 *

Sidestand,
centeratand

Shock absorber
assemblies

Engine oil filter
element

Front and rear
brake switches

Moving parts and
cables

Lights, signals
and switches

roughness.

S Lubricate with lithium-soap-based grease. Every 20,000 km

S Make sure that all nuts, bolts and

screws are properly tightened.

S Check operation.
S Lubricate.

S Check operation and shock absorbers for

oil leakage.

S Check starter (choke) operation.
S Adjust engine idling speed and

synchronization.

S Change.
S Check oil level and vehicle for oil leakage.

S Replace. √ √ √

S Check operation. √ √ √ √ √ √

S Lubricate. √ √ √ √ √

S Check operation.
S Adjust headlight beam.

√ √ √ √ √

√ √ √ √ √

√ √ √ √ √

√ √ √ √

√ √ √ √ √ √

√ √ √ √ √ √

√ √ √ √ √ √

ANNUAL

CHECK

NOTE:

D The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
D Hydraulic brake and clutch service.

S Regularly check and, if necessary, correct the brake and clutch fluid levels.
S Every two years replace the internal components of the brake master cylinders and calipers as

well as clutch master and release cylinders, and change the brake and clutch fluids.

S Replace the brake and clutch hoses every four years and if cracked or damaged.

21

ADJUSTING THE CLUTCH LEVER

ENGINE

EAS00082

ADJUSTING THE CLUTCH LEVER

1. Adjust:
S clutch lever position

(distance
clutch lever)

a. While pushing the clutch lever forward, turn

the adjusting dial
the desired position.

NOTE:

Be sure to align the setting on the adjusting dial
with the arrow mark
er.

a

from the handlebar grip to the

1

2

CHK

ADJ

until the clutch lever is in

on the clutch lever hold-

Position #1

Position #5

Distance is the larg­est

Distance is the small­est

a

a

22

ADJUSTING THE FRONT BRAKE

EAS00107

CHASSIS

ADJUSTING THE FRONT BRAKE

1. Adjust:
S brake lever position

a

(distance
lever)

a. While pushing the brake lever forward, turn

the adjusting dial
the desired position.

NOTE:

Be sure to align the setting on the adjusting dial
with the arrow mark
er.

from the throttle grip to the brake

1

2

CHK

ADJ

until the brake lever is in

on the brake lever hold-

Position #1

Position #5

Distance is the larg­est.

Distance is the small­est.

a

a

23

AIR INDUCTION SYSTEM

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.

CARB

VIEW 1. (NO FLOW)

EAS00508

AIR CUTOFF VALVE

The air cutoff valve is operated by the intake gas
pressure through the piston valve diaphragm.
Normally, the air cutoff valve is open to allow
fresh air to flow into the exhaust port. During
sudden deceleration (the throttle valve sudden­ly closes), negative pressure is generated and
the air cutoff valve is closed in order to prevent
after-burning.
Additionally, at high engine speeds and when
the pressure decreases, the air cutoff valve au­tomatically closes to guard against a loss of per­formance due to self-EGR.

VIEW 1. (NO FLOW)
When decelerating (the throttle closes), the valve will
close.
VIEW 2. (FLOW)
During normal operation the valve is open.

From the air cleaner

A

To the cylinder

B

To the carburetor joint

C

VIEW 2. (FLOW)

24

EAS00509

AIR INDUCTION SYSTEM DIAGRAMS

AIR INDUCTION SYSTEM

CARB

Reed valve

1

Air cleaner

2

Air cutoff valve

3

Vacuum hose (cylinder #3)

4

To the air cutoff valve

A

To cylinder #1

B

To cylinder #2

C

To cylinder #3

D

To cylinder #4

E

25

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
S fibre reed stopper
S reed valve seat

Cracks/ damage ! Replace the reed valve.

1

CARB

3. Measure:
S fibre reed bending limit

Out of specification ! Replace the reed
valve.

Fibre reed bending limit

0.2 mm

Surface plate

1

4. Check:
S air cutoff valve

Cracks/ damage ! Replace.

a

26

FRONT AND REAR BRAKES

EAS00586

FRONT BRAKE MASTER CYLINDER

FRONT AND REAR BRAKES

CHASSIS

CHAS

10 Nm (1.0 mSkg)

30 Nm (3.0 mSkg)

Order Job/ Part Q’ty Remarks

Removing the front brake master
cylinder

Brake fluid

Brake lever

1

Brake switch lead

2

Front brake switch

3

Union bolt

4

Copper washers/ Brake hose

5

Master cylinder bracket

6

Master cylinder

7

Remove the parts in the order listed.

Drain
1
2
1

Refer to “DISASSEMBLING/ ASSEM-

1

3/2

BLING AND INSTALLING THE REAR
BRAKE MASTER CYLINDER” in

1

chapter 6. (Manual No.: 5EA3-AE1)

1

For installation, reverse the removal

procedure.

27

FRONT AND REAR BRAKES

EAS00598

ASSEMBLING AND INSTALLING THE
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.

Recommended brake fluid

DOT 4

1. Install:
S brake master cylinder

NOTE:

S Install the brake master cylinder holder with

the “UP” mark facing up.

S Align the end of the brake master cylinder hold-

er with the punch mark

S First, tighten the upper bolt, then the lower bolt.

CHAS

1

a

on the handlebar.

Brake master cylinder bolt

10 Nm (1.0 mSkg)

2. Install:

S copper washers (New)
S brake hose 1
S brake hose 2
S union bolt

Union bolt

2
3

4

30 Nm (3.0 mSkg)

1

WARNING

Proper brake hose routing is essential to in­sure safe motorcycle operation. Refer to
“CABLE ROUTING”.

CAUTION:

S When installing the brake hose 1

the brake master cylinder, make sure that
the brake pipe touches the projection
shown. And install the paint mark
ward the brake master cylinder side.

S Install the brake hose 2

angle as the brake hose 1

3

at the same

2

.

2

onto

b

a

to-

as

NOTE:

Turn the handlebar to the left and to the right to
make sure that the brake hose does not touch
other parts (e.g., wire harness, cables, leads).
Correct if necessary.

28

FRONT AND REAR BRAKES

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.

S When refilling, be careful that water does

not enter the reservoir. Water will signifi­cantly lower the boiling point of the brake
fluid and could cause vapor lock.

CHAS

CAUTION:

Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.

4. Bleed:
S brake system

Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3. (Manual No.:
5EA3-AE1)

5. Check:
S brake fluid level

Below the minimum level mark
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3. (Manual No.:
5EA3-AE1)

6. Check:
S brake lever operation

Soft or spongy feeling ! Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3. (Manual No.:
5EA3-AE1)

a

! Add the

29

EAS00616

REAR BRAKE CALIPER

FRONT AND REAR BRAKES

CHAS

30 Nm (3.0 mSkg)

40 Nm (4.0 mSkg)

Order Job/ Part Q’ty Remarks

Removing the rear brake caliper

Brake fluid
Union bolt

1

Copper washer

2

Brake hose

3

Brake caliper

4

Remove the parts in the order listed.

Drain.
1
2
1
1

For installation, reverse the removal

procedure.

30

EAS00617

6 Nm (0.6 mSkg)

FRONT AND REAR BRAKES

CHAS

Order Job/ Part Q’ty Remarks

Disassembling the rear brake caliper

1

Brake pad clip
Brake pad pin

2

Brake pad spring

3

Brake pad

4

Brake caliper piston

5

Brake caliper piston seal

6

Bleed screw

7

Disassemble the parts in the order listed.
4
2
1
2
2
4
2

For assembly, reverse the disassembly

procedure.

31

CARBURETOR HEATING SYSTEM

ELECTRICAL

CARBURETOR HEATING SYSTEM

ELEC

32

2 Fuse (main)
3 Battery
5 Main switch

6 Fuse (ignition)
14 Neutral switch
51 Carburetor heater relay
52 Thermo switch
53 Carburetor heater

CARBURETOR HEATING SYSTEM

ELEC

EAS00821

TROUBLESHOOTING

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)

NOTE:

Before troubleshooting, remove the following
part(-s):

1) Rider and passenger seats

Troubleshoot with the following special tool(-s).

Pocket tester

90890-03112

EAS00738

1. Main, and ignition fuses

EAS00749

3. Main switch

S Check the main switch for continuity.

Refer to “CHECKING THE SWITCHES” in
chapter 8. (Manual No.: 5EA3-AE1)

S Is the main switch OK?

YES NO

Replace the main
switch.

EAS00751

4. Neutral switch

S Check the neutral switch for continuity.

Refer to “CHECKING THE SWITCHES” in
chapter 8. (Manual No.: 5EA3-AE1)

S Is the neutral switch OK?

YES NO

Replace the neutral
switch.

S Check the main and ignition fuses for conti-

nuity.
Refer to “CHECKING THE FUSES” in chap-
ter 3. (Manual No.: 5EA3-AE1)

S Are the main and ignition fuses OK?

YES

NO

Replace the fuse(-s).

EAS00739

2. Battery

S Check the condition of the battery.

Refer to “CHECKING THE BATTERY” in
chapter 3. (Manual No.: 5EA3-AE1)

Open-circuit voltage

12.8 V or more at 20_C

S Is the battery OK?

YES

NO

EAS00822

5. Carburetor heater relay

S Disconnect the carburetor heater relay cou-

pler from the wire harness.

S Connect the pocket tester (Ω 1) to the car-

buretor heater relay coupler as shown.

Tester positive probe ! red/ white
Tester negative probe ! black

1

2

S Check the carburetor heater relay for no

continuity.

S Is the carburetor heater relay OK?

YES

NO

S Clean the battery

terminals.

S Recharge or re-

place the battery.

Replace the carbure­tor heater relay.

33

CARBURETOR HEATING SYSTEM

6. Thermo switch

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.

Tester positive probe ! black
Tester negative probe ! black/ red

S Check the thermo switch for continuity at the

temperatures indicated below.

1

2

ELEC

EAS00825

The following procedure applies to all of the
carburetor heating elements.

7. Carburetor heater

S Remove the carburetor heating element

from the carburetor.

S Connect the pocket tester to the carburetor

heating element as shown.

Tester positive probe !

heating element

Tester negative probe !

heating element body

1

2

ON

11_C

COOL DOWN

A

HEAT UP

B

16_C

OFF

S Does the thermo switch operated properly?

YES

NO

Replace the thermo
switch.

S Measure the carburetor heater resistance.

Carburetor heating element
resistance

12 V 15 W: 4 X 11 Ω at 20_C
12 V 20 W: 4 X 11 Ω at 20_C

S Is the carburetor heating element OK?

YES

NO

Replace the carbure­tor heating element.

EAS00826

8. Wiring

S Check the entire carburetor heating sys-

tem’s wiring.
Refer to “CIRCUIT DIAGRAM”.

S Is the carburetor heating system’s wiring

properly connected and without defects?

34

NO

Properly connect or
repair the carburetor
heating system’s wir-
ing.

XJR1300 2002 WIRING DIAGRAM (for EUR)

COLOR CODE

B Black. . . . .

Br Brown. . . .

Ch Chocolate. . .
Dg Dark green. . .

G Green. . . .

Gy Gray. . .

L Blue. . . . .

Lg Light green. . . .

O Orange. . . .

Sb Sky blue. . . .

P Pink. . . . .

R Red. . . . .

Y Yellow. . . . .

B/ L Black/ Blue. . .
B/ R Black/ Red. .
B/ Y Black /Yellow. .

Br/ L Brown / Blue. .
Br/ W Brown/ White.
G/ Y Green / Yellow. .
L/ B Blue/ Black. . .
L/ R Blue/ Red. .
L/ W Blue/White. .
L/ Y Blue/ Yellow. . .
R/ B Red/ Black. .

R/ L Red/ Blue. .
R/ W Red/ White. .
R/ Y Red/ Yellow. .
W/ G White/ Green. .
W/ R White/ Red. .
Y/ B Yellow/ Black. .

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 Start switch
17 Engine stop switch
18 Lights switch
19 Front brake switch
20 Handlebar switches (right)
21 Alarm
22 Fuse (turn)
23 Fuse (signal)
24 Fuse (headlight)
25 Horn
26 Flasher relay
27 Rear brake switch
28 Oil level relay
29 Oil level switch
30 Meter assembly
31 Speedometer
32 Neutral indicator light
33 Tachometer
34 Fuel gauge
35 Meter lights
36 Turn signal indicator light (left)
37 Turn signal indicator light (right)
38 Oil warning light
39 High beam indicator light
40 Fuel sender
41 Auxiliary light
42 Tail/brake light
43 Clutch switch
44 Hazard switch
45 Turn signal switch
46 Horn switch
47 Dimmer switch
48 Pass switch
49 Handlebar switch (left)
50 Headlight
51 Carburetor heater relay
52 Thermo switch
53 Carburetor heater
54 Rear turn signal lights
55 Front turn signal lights

XJR1300P 2002 WIRING DIAGRAM (for AUS)

COLOR CODE

B Black. . . . .

Br Brown. . . .

Ch Chocolate. . .
Dg Dark green. . .

G Green. . . .

Gy Gray. . .

L Blue. . . . .

Lg Light green. . . .

O Orange. . . .

Sb Sky blue. . . .

P Pink. . . . .

R Red. . . . .

Y Yellow. . . . .

B/ L Black/ Blue. . .
B/ R Black/ Red. .
B/ Y Black /Yellow. .

Br/ L Brown / Blue. .
Br/ W Brown/ White.
G/ Y Green / Yellow. .
L/ B Blue/ Black. . .
L/ R Blue/ Red. .
L/ W Blue/White. .
L/ Y Blue/ Yellow. . .
R/ B Red/ Black. .

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 Start switch
17 Engine stop switch
18 Front brake switch
19 Handlebar switches (right)
20 Carburetor heater relay
21 Thermo switch
22 Carburetor heater
23 Fuse (signal)
24 Fuse (headlight)
25 Meter assembly
26 Speedometer
27 Neutral indicator light
28 Tachometer
29 Fuel gauge
30 Meter lights
31 Turn signal indicator light (left)
32 Turn signal indicator light (right)
33 Oil warning light
34 High beam indicator light
35 Fuel sender
36 Oil level relay
37 Oil level switch
38 Rear brake switch
39 Tail/brake light
40 Flasher relay
41 Horn
42 Handlebar switch (left)
43 Pass switch
44 Dimmer switch
45 Horn switch
46 Turn signal switch
47 Clutch switch
48 Headlight
49 Rear turn signal lights
50 Front turn signal lights

R/ L Red/ Blue. .
R/ W Red/ White. .
R/ Y Red/ Yellow. .
W/ G White/ Green. .
W/ R White/ Red. .
Y/ B Yellow/ Black. .