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:
SThis Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully.
SDesigns and specifications are subject to change without notice.
EAS00004
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following.
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The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR |
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SAFETY IS INVOLVED! |
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Failure to follow WARNING instructions could result in severe injury or death to |
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the motorcycle operator, a bystander or |
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a person checking or repairing the mo- |
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torcycle. |
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A CAUTION indicates special precautions that must be taken to avoid damage |
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CAUTION: |
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to the motorcycle. |
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NOTE: |
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A NOTE provides key information to make procedures easier or clearer. |
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EAS00007
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order.
1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter.
Refer to “SYMBOLS”.
2Each 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.
3Sub-section titles appear in smaller print than the section title.
4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.
5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step.
6Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.
8Jobs requiring more information (such as special tools and technical data) are described sequentially.
2 1 4
3
5
8
6
7
1 |
2 |
GEN |
SPEC |
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INFO |
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3 |
4 |
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CHK |
ENG |
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ADJ |
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5 |
6 |
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CARB |
CHAS |
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7 |
8 |
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ELEC |
TRBL |
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SHTG |
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9 |
10 |
11 |
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12 |
13 |
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14 |
15 |
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16 |
17 |
18 |
19 |
20 |
21 |
22 |
23 |
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24 |
EAS00009
SYMBOLS
The following symbols are not relevant to every vehicle.
Symbols 1 to 8 indicate the subject of each chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Engine
5Carburetor(-s)
6Chassis
7Electrical system
8Troubleshooting
Symbols 9 to 16 indicate the following.
9 Serviceable with engine mounted
10Filling fluid
11Lubricant
12Special tool
13Tightening torque
14Wear limit, clearance
15Engine speed
16Electrical data
Symbols 17 to 22 in the exploded diagrams indicate the types of lubricants and lubrication points.
17Engine oil
18Gear oil
19Molybdenum disulfide oil
20Wheel bearing grease
21Lithium soap base grease
22Molybdenum disulfide grease
Symbols 23 to 24 in the exploded diagrams indicate the following:
23Apply locking agent (LOCTITE )
24Replace 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)
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GENERAL SPECIFICATIONS |
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SPEC |
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SPECIFICATIONS |
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GENERAL SPECIFICATIONS |
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Model |
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XJR1300 (P) |
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Model code: |
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5EAT/5EAW (EUR) |
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5EAU/5EAX (for D) |
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5EAV/5EAY (for AUS) |
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Dimensions: |
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Overall length |
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2,175 mm |
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Overall width |
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775 mm |
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Overall height |
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1,115 mm |
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Seat height |
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790 mm |
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Wheelbase |
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1,510 mm |
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Minimum ground clearance |
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120 mm |
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Minimum turning radius |
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2,800 mm |
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Basic weight: |
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With oil and full fuel tank |
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247 kg |
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Carburetor: |
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Type/quantity |
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BSR37/4 |
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Manufacturer |
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MIKUNI |
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Transmission: |
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Primary reduction system |
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Spur gear |
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Primary reduction ratio |
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98/56 (1.750) |
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Secondary reduction system |
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Chain drive |
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Secondary reduction ratio |
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39/18 (2.167) |
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Transmission type |
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Constant mesh 5-speed |
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Operation |
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Left foot operation |
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Gear ratio 1st |
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40/14 (2.857) |
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2nd |
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36/18 (2.000) |
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3rd |
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33/21 (1.571) |
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4th |
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31/24 (1.292) |
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5th |
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29/26 (1.115) |
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1
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GENERAL SPECIFICATIONS |
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SPEC |
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Model |
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XJR1300 (P) |
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Tire: |
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Type |
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Tubeless |
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Size |
front |
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120/70ZR17 (58W)/ |
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120/70ZR17 M/C (58W) |
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rear |
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180/55ZR17 (73W)/ |
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180/55ZR17 M/C (73W) |
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Manufacturer |
front |
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MICHELIN/DUNLOP |
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rear |
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MICHELIN/DUNLOP |
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Type |
front |
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MACADAM90X E/D220F ST M |
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rear |
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MACADAM90X E/D220 ST M |
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Tire pressure (cold tire): |
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Maximum load-except motorcycle |
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203 kg |
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Loading condition A * |
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0 X 90 kg |
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front |
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250 kPa (2.5 kg/cm2, 2.5 bar) |
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rear |
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250 kPa (2.5 kg/cm2, 2.5 bar) |
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Loading condition B * |
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90 X 203 kg |
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front |
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250 kPa (2.5 kg/cm2, 2.5 bar) |
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rear |
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290 kPa (2.9 kg/cm2, 2.9 bar) |
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High-speed riding |
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250 kPa (2.5 kg/cm2, 2.5 bar) |
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front |
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rear |
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290 kPa (2.9 kg/cm2, 2.9 bar) |
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*Load is the total weight of cargo, rider, passenger, and accessories.
2
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MAINTENANCE SPECIFICATIONS |
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SPEC |
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MAINTENANCE SPECIFICATIONS |
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ENGINE |
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Model |
Standard |
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Limit |
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Cylinder head: |
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Warp limit |
SSS |
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0.2 mm |
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Cylinder: |
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Bore size |
79.00 X 79.01 mm |
SSS |
Taper limit |
SSS |
0.05 mm |
Out of round limit |
SSS |
0.1 mm |
Wear limit |
SSS |
79.1 mm |
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Camshaft: |
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Drive method |
Chain drive (Center) |
SSS |
Cam cap inside diameter |
25.000 X 25.021 mm |
SSS |
Camshaft outside diameter |
24.967 X 24.980 mm |
SSS |
Shaft-to-cap clearance |
0.020 X 0.054 mm |
SSS |
Cam dimensions |
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Intake |
“A” |
35.95 X 36.05 mm |
35.85 mm |
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“B” |
28.058 X 28.158 mm |
27.958 mm |
Exhaust |
“A” |
35.95 X 36.05 mm |
35.85 mm |
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“B” |
28.045 X 28.145 mm |
27.945 mm |
Camshaft runout limit |
SSS |
0.03 mm |
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3
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MAINTENANCE SPECIFICATIONS |
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SPEC |
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Model |
Standard |
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Limit |
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Piston: |
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Piston to cylinder clearance |
0.015 X 0.040 mm |
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0.15 mm |
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Piston size “D” |
78.970 X 78.985 mm |
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SSS |
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Measuring point “H” |
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5 mm |
SSS |
Piston off-set |
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1 mm |
SSS |
Piston off-set direction |
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IN side |
SSS |
Piston pin bore inside diameter |
18.004 X 18.015 mm |
18.045 mm |
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Piston pin outside diameter |
17.991 X 18.000 mm |
17.971 mm |
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Carburetor: |
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I.D. mark |
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5EAT 30 |
SSS |
Main jet |
(M.J) |
#107.5 |
SSS |
Main air jet |
(M.A.J) |
#80 |
SSS |
Jet needle |
(J.N) |
5D118-53-3 |
SSS |
Needle jet |
(N.J) |
P-0M |
SSS |
Pilot jet |
(P.A.J.1) |
#140 |
SSS |
Pilot outlet |
(P.O) |
ø1.0 |
SSS |
Pilot jet |
(P.J) |
#15 |
SSS |
Bypass 1 |
(B.P.1) |
0.9 |
SSS |
Bypass 2 |
(B.P.2) |
0.9 |
SSS |
Bypass 3 |
(B.P.3) |
0.8 |
SSS |
Pilot screw |
(P.S) |
2 |
SSS |
Valve seat size |
(V.S) |
2.3 |
SSS |
Starter jet |
(G.S.1) |
#52.5 |
SSS |
Starter jet |
(G.S.2) |
0.8 |
SSS |
Throttle valve size |
(Th.V) |
#115 |
SSS |
Float height |
(F.H) |
33 X 34 mm |
SSS |
Fuel level (using special tool) |
3 X 4 mm |
SSS |
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Engine idle speed |
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950 X 1,150 r/min |
SSS |
Intake vacuum |
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31.3 kPa (235 mmHg) |
SSS |
4
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MAINTENANCE SPECIFICATIONS |
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SPEC |
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Tightening torques |
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Thread |
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Tightening |
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Part to be tightened |
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Part name |
Q’ty |
torque |
Remarks |
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size |
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Nm |
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mSkg |
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Carburetor joint and carburetor |
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Band |
M4 |
0.7 |
4 |
2.7 |
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0.27 |
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Carburetor and air filter joint |
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Clamp |
M4 |
0.7 |
4 |
2.7 |
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0.27 |
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Air induction system pipe joint |
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– |
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– |
4 |
3.7 |
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0.37 |
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Air induction system |
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Bolt |
M6 |
1.0 |
2 |
10 |
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1.0 |
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5
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MAINTENANCE SPECIFICATIONS |
SPEC |
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CHASSIS |
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Model |
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Standard |
Limit |
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Front suspension: |
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130 mm |
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Front fork travel |
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SSS |
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Fork spring free length |
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308.3 mm |
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300 mm |
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Fitting length |
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287.3 mm |
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SSS |
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Collar length |
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245 mm |
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SSS |
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Spring rate |
(K1) |
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6.4 N/mm (0.65 kg/mm) |
SSS |
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(K2) |
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10.8 N/mm (1.1 kg/mm) |
SSS |
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Stroke |
(K1) |
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0 X 85 mm |
SSS |
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(K2) |
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85 X 130 mm |
SSS |
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Optional spring |
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No |
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SSS |
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Oil capacity |
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568 cm3 |
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SSS |
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Oil level |
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118 mm |
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SSS |
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Oil grade |
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Fork oil 10W or equivalent |
SSS |
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Rear suspension: |
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93 mm |
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Shock absorber travel |
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SSS |
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Spring free length |
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230 mm |
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225 mm |
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Fitting length |
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209 mm |
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SSS |
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Spring rate |
(K1) |
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19.4 N/mm (1.98 kg/mm) |
SSS |
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(K2) |
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21.4 N/mm (2.18 kg/mm) |
SSS |
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(K3) |
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26.3 N/mm (2.68 kg/mm) |
SSS |
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(K4) |
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28.2 N/mm (2.88 kg/mm) |
SSS |
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Stroke |
(K1) |
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0 X 13 mm |
SSS |
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(K2) |
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13 X 50 mm |
SSS |
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(K3) |
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50 X 67.5 mm |
SSS |
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(K4) |
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67.5 X 93.0 mm |
SSS |
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Front wheel: |
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Cast wheel |
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Type |
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SSS |
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Rim size |
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17 |
MT3.50 or |
SSS |
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Rim material |
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17 M/C |
MT3.50 |
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Aluminum |
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SSS |
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Rim runout limit |
radial |
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SSS |
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1 mm |
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lateral |
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SSS |
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0.5 mm |
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Rear wheel: |
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Cast wheel |
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Type |
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SSS |
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Rim size |
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17 |
MT3.50 or |
SSS |
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Rim material |
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17 M/C |
MT3.50 |
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Aluminum |
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SSS |
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Rim runout limit |
radial |
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SSS |
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1 mm |
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lateral |
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SSS |
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0.5 mm |
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Drive chain: |
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50VA8/DAIDO |
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Type/manufacturer |
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SSS |
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No. of links |
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112 |
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SSS |
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Chain free play |
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20 X 30 mm |
SSS |
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Brake lever & brake pedal: |
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40 mm |
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Brake pedal position |
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SSS |
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6
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MAINTENANCE SPECIFICATIONS |
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SPEC |
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Tightening torques |
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Tightening |
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Part to be tightened |
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Part name |
Thread size |
Q’ty |
torque |
Remarks |
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Nm |
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mSkg |
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Throttle cable and carburetor |
|
Nut |
M6 |
1.0 |
2 |
4 |
|
|
0.4 |
|
|
Ignition coil |
|
Nut |
M6 |
1.0 |
2 |
6.5 |
|
0.65 |
|
|
|
7
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