p Workshop Manual 2002

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for theXJR1300 (P) 2002. For complete service information procedures it is necessary to use this Supple-mentary Service Manual together with the following manual.

XJR1300 (L) ’99 SERVICE MANUAL: 5EA3-AE1

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XJR1300 (P) 2002SUPPLEMENTARYSERVICE MANUAL

2001 by Yamaha Motor Co., Ltd.1st Edition, August 2001

All rights reserved.Any reprinting or unauthorized usewithout the written permission of

Yamaha Motor Co., Ltd.is expressly prohibited.

NOTE:

CAUTION:

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NOTICEThis manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealersand their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu-al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehiclesshould 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 ve-hicle unsafe and unfit for use.

This model has been designed and manufactured to perform within certain specifications in regard toperformance and emissions. Proper service with the correct tools in necessary to ensure that the ve-hicle will operate as designed. If there is any question about a service procedure, it is imperative thatyou contact a Yamaha dealer for any service information changes that apply to this model. This policyis intended to provide the customer with the most satisfaction from his vehicle and to conform with fed-eral environmental quality objectives.

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

This Service Manual contains information regarding periodic maintenance to the emission controlsystem. Please read this material carefully.

Designs and specifications are subject to change without notice.

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IMPORTANT INFORMATIONParticularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

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

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

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

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HOW TO USE THIS MANUALThis manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensiveexplanations of all installation, removal, disassembly, assembly, repair and check procedures are laidout with the individual steps in sequential order.1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of eachpage 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) ap-pears.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 eachremoval and disassembly section.5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates adisassembly 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 ofparts, notes in jobs, etc.8 Jobs requiring more information (such as special tools and technical data) are described sequen-tially.

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9

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23 24

2220

18 1917

1615

1413

11 12

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GENINFO SPEC

ENG

CARB

ELEC

CHAS

CHKADJ

TRBLSHTG

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SYMBOLSThe following symbols are not relevant to everyvehicle.Symbols 1 to 8 indicate the subject of eachchapter.1 General information2 Specifications3 Periodic checks and adjustments4 Engine5 Carburetor(-s)6 Chassis7 Electrical system8 Troubleshooting

Symbols 9 to 16 indicate the following.9 Serviceable with engine mounted10 Filling fluid11 Lubricant12 Special tool13 Tightening torque14 Wear limit, clearance15 Engine speed16 Electrical data

Symbols 17 to 22 in the exploded diagrams indi-cate the types of lubricants and lubricationpoints.17 Engine oil18 Gear oil19 Molybdenum disulfide oil20 Wheel bearing grease21 Lithium soap base grease22 Molybdenum disulfide grease

Symbols 23 to 24 in the exploded diagrams indi-cate the following:23 Apply locking agent (LOCTITE)24 Replace the part

CONTENTSSPECIFICATIONS

GENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

PERIODIC INSPECTION AND ADJUSTMENTINTRODUCTION 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERIODIC MAINTENANCE/LUBRICATION INTERVALS 20. . . . . . . ENGINE 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE CLUTCH LEVER 22. . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

CARBURETORSAIR INDUCTION SYSTEM 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR INJECTION 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CUTOFF VALVE 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INDUCTION SYSTEM DIAGRAMS 25. . . . . . . . . . . . . . . . . . . . . CHECKING THE AIR INDUCTION SYSTEM 26. . . . . . . . . . . . . . . .

CHASSISFRONT AND REAR BRAKES 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT BRAKE MASTER CYLINDER 27. . . . . . . . . . . . . . . . . . . . . . ASSEMBLING AND INSTALLING THE

FRONT BRAKE MASTER CYLINDER 28. . . . . . . . . . . . . . . . . . REAR BRAKE CALIPER 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICALCARBURETOR HEATING SYSTEM 32. . . . . . . . . . . . . . . . . . . . . . . . . .

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

XJR1300 2002 WIRING DIAGRAM (for EUR)

XJR1300P 2002 WIRING DIAGRAM (for AUS)

1

SPECGENERAL SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Model XJR1300 (P)

Model code: 5EAT/5EAW (EUR)5EAU/5EAX (for D)5EAV/5EAY (for AUS)

Dimensions:Overall lengthOverall widthOverall heightSeat heightWheelbaseMinimum ground clearanceMinimum turning radius

2,175 mm775 mm1,115 mm790 mm1,510 mm120 mm2,800 mm

Basic weight:With oil and full fuel tank 247 kg

Carburetor:Type/quantityManufacturer

BSR37/4MIKUNI

Transmission:Primary reduction systemPrimary reduction ratioSecondary reduction systemSecondary reduction ratioTransmission typeOperationGear ratio 1st

2nd3rd4th5th

Spur gear98/56 (1.750)Chain drive39/18 (2.167)Constant mesh 5-speedLeft foot operation40/14 (2.857)36/18 (2.000)33/21 (1.571)31/24 (1.292)29/26 (1.115)

2

SPECGENERAL SPECIFICATIONS

Model XJR1300 (P)

Tire:TypeSize front

rear

Manufacturer frontrear

Type frontrear

Tubeless120/70ZR17 (58W)/120/70ZR17 M/C (58W)180/55ZR17 (73W)/180/55ZR17 M/C (73W)MICHELIN/DUNLOPMICHELIN/DUNLOPMACADAM90X E/D220F ST MMACADAM90X E/D220 ST M

Tire pressure (cold tire):Maximum load-except motorcycleLoading condition A *

frontrear

Loading condition B *frontrear

High-speed ridingfrontrear

203 kg0 90 kg250 kPa (2.5 kg/cm2, 2.5 bar)250 kPa (2.5 kg/cm2, 2.5 bar)90 203 kg250 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)

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

3

SPECMAINTENANCE SPECIFICATIONS

MAINTENANCE SPECIFICATIONSENGINE

Model Standard Limit

Cylinder head:Warp limit 0.2 mm

Cylinder:Bore sizeTaper limitOut of round limitWear limit

79.00 79.01 mm

0.05 mm0.1 mm79.1 mm

Camshaft:Drive methodCam cap inside diameterCamshaft outside diameterShaft-to-cap clearanceCam dimensions

Chain drive (Center)25.000 25.021 mm24.967 24.980 mm0.020 0.054 mm

Intake “A”“B”

Exhaust “A”“B”

Camshaft runout limit

35.95 36.05 mm28.058 28.158 mm35.95 36.05 mm28.045 28.145 mm

35.85 mm27.958 mm35.85 mm27.945 mm0.03 mm

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Piston:Piston to cylinder clearancePiston size “D”

0.015 0.040 mm78.970 78.985 mm

0.15 mm

Measuring point “H”Piston off-setPiston off-set directionPiston pin bore inside diameterPiston pin outside diameter

5 mm1 mmIN side18.004 18.015 mm17.991 18.000 mm

18.045 mm17.971 mm

Carburetor:I.D. markMain 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 speedIntake vacuum

5EAT 30#107.5#805D118-53-3P-0M#140ø1.0#150.90.90.822.3#52.50.8#11533 34 mm3 4 mm950 1,150 r/min31.3 kPa (235 mmHg)

5


Tightening torques

Part to be tightened Part name Threadsize

Q’tyTightening

torque Remarksgsize

yNm mkg

Carburetor joint and carburetorCarburetor and air filter jointAir induction system pipe jointAir induction system

BandClamp

–Bolt

M4 0.7M4 0.7

–M6 1.0

4442

2.72.73.710

0.270.270.371.0

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CHASSIS


Front suspension:Front fork travelFork spring free lengthFitting lengthCollar lengthSpring rate (K1)

(K2)Stroke (K1)

(K2)Optional springOil capacityOil levelOil grade

130 mm308.3 mm287.3 mm245 mm6.4 N/mm (0.65 kg/mm)10.8 N/mm (1.1 kg/mm)0 85 mm85 130 mmNo568 cm3

118 mmFork oil 10W or equivalent

300 mm

Rear suspension:Shock absorber travelSpring free lengthFitting lengthSpring rate (K1)

(K2)(K3)(K4)

Stroke (K1)(K2)(K3)(K4)

93 mm230 mm209 mm19.4 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 13 mm13 50 mm50 67.5 mm67.5 93.0 mm

225 mm

Front wheel:TypeRim size

Rim materialRim runout limit radial

lateral

Cast wheel17 MT3.50 or 17 M/C MT3.50Aluminum

1 mm0.5 mm

Rear wheel:TypeRim size

Rim materialRim runout limit radial

lateral

Cast wheel17 MT3.50 or17 M/C MT3.50Aluminum

1 mm0.5 mm

Drive chain:Type/manufacturerNo. of linksChain free play

50VA8/DAIDO11220 30 mm

Brake lever & brake pedal:Brake pedal position 40 mm

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Tightening torques

Part to be tightened Part name Thread size Q’tyTightening

torque Remarksg yNm mkg

Throttle cable and carburetorIgnition coil

NutNut

M6 1.0M6 1.0

22

46.5

0.40.65

8


ELECTRICAL


T.C.I.:Pickup coil resistance/colorT.C.I. unit model/manufacturer

248 372 Ω /W/R-W/GTNDF63/DENSO (except for D)TNDF64/DENSO (for D)

Charging system:TypeModel/manufacturerNormal outputRotor coil resistanceStator coil resistanceBrush overall lengthSpring force

A.C. generatorB3G/DENSO13.5 V 28 A/5,000 r/min2.8 3.0 Ω0.19 0.21 Ω13.7 mm5.10 5.69 N (0.52 0.58 kg)

4.7 mm

Voltage regulator:TypeModel/manufacturerNo load regulated voltage

Semi-conductor, field control typeB3G/DENSO14.2 14.8 V

Electric starter system:TypeStarter motor:Model/manufacturerOutputBrush overall lengthSpring forceCommutator diameterMica undercut

Starter relay:Model/manufacturerAmperage ratingCoil winding resistance

Constant mesh type

SM-13/MITSUBA0.65 kW10 mm8.82 N (899 kg)28 mm0.7 mm

MS5E-491/JIDECO180 A4.2 4.6 Ω

5 mm

27 mm

Starting circuit cut-off relay:Model/manufacturerCoil winding resistanceDiode

G8R-30Y-P/OMRON162 198 ΩYes

Circuit breaker:TypeAmperage for individual circuit Q’tyMAINHEAD LIGHTSIGNALIGNITIONTURNReserve

Fuse

40 A 115 A 115 A 115 A 115 A 140 A 115 A 1

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A Pass the starter motor cable andthe negative (–) lead wire of thebattery through the inside of theseat rail.

13 #3 high-tension cord14 #4 high-tension cord15 Engine frame ground lead wire16 Rear stop switch17 Relay assy18 Guide wire19 Fuel tank drain hose20 Fuel tank breather hose

1 Starter motor cable2 Battery negative (–) lead wire3 Carburetor heater plug4 A.C. generator coupler5 Rear stop switch coupler6 Neutral lead wire7 Pickup lead wire8 Side stand switch lead wire9 T.P.S.10 Tank fitting11 #1 and #4 ignition coil lead wires12 Horn lead wire

SPECCABLE ROUTING

CABLE ROUTING

10

C Clamp the throttle cables to thefuel tank rail, on the tank fitting byuse of this band. The front end ofthe band must be directed down-ward.

D Thread this clamp through theupper hole in the gusset and se-cure the two throttle cables. Thefront end of the clamp must be di-rected towards the inside of thevehicle.

B Secure the carburetor heaterlead wire, the starter motorcable, the negative (–) lead wireof the battery, the A.C. generatorlead wire, the neutral lead wire,the side stand switch lead wire,the pickup lead wire, and the rearstop switch lead wire (total 8wires), to the fuel tank rail, nearthe air cleaner intake port mount-ing screw, by use of this band.The front end of the band mustbe directed towards the front ofthe vehicle.

SPECCABLE ROUTING

E Bundle the #3 and #4 high-ten-sion cords, on the head covermounting bolt at the #3 cord, byuse of this band.

F Do not entangle the lead wiresand the hosing.Pass the bundle of lead wiresand that of hosing orderly asshown.

G Pass the air cleaner drain hose,the fuel tank drain hose, and thefuel tank breather hose (total 3hoses) through the guide wire ofthe engine.

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H Bundle the A.C. generator leadwire, the pickup lead wire, theside stand switch lead wire, thestarter motor cable, and the car-buretor heater lead wire (total 5wires), by use of this clamp.

I Match the marks of the fuel tankdrain hose and fuel tank breatherhose, and arrange the two typesof hose properly.

J Match the paint mark of the aircleaner drain hose to the lowerend of the guide wire.

SPECCABLE ROUTING

K Clamp the wire harness to theseat rail, at the front end of thebracket.The front end of theclamp must be directed down-ward.

L Clamp the wire harness.M Pass the wire harness between

the handle standing lug memberand the rear fender.

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13 Flasher relay coupler14 Oil lamp relay coupler15 Igniter unit coupler

A Pass the wire harness and thestarter cable through the holderwire of the gusset.Pass the starter cable under thewire harness.

B Secure the lead wire branch ofthe main harness to tension pipe1, at the immediate rear of the

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

C Bundle the four high-tensioncords, the #1 and #2 cords upand the #3 and #4 cords down,by use of this band.Position the leading ends of thecords near, but not below, thelower front end of the air induc-tion system assy.

1 Gusset2 Tension pipe 13 #2 high-tension cord4 #1 high-tension cord5 Wire starter6 A.C. generator7 Oil filter cover8 Side stand switch9 Side stand switch lead wire10 Horn lead wire11 #2 and #3 ignition coil lead wires12 Frame ground lead wire

SPECCABLE ROUTING

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D Bundle the #1 and #2 high-ten-sion cords using this clamp.Clamp these cords above the #2head cover mounting bolt.

E Route the air cleaner drain hosethrough the right side of the ve-hicle with a clearance above thestarter motor.

F Mount the square fixture of theclutch hose in parallel with thecover.

SPECCABLE ROUTING

G After securing the side standswitch lead wire using thisclamp, first route the lead wirebetween the pickup cover, the oilfilter cover, the A.C. generator,and the starter motor. Next, aswith the engine lead wire, routethe lead wire through the rightside of the vehicle.

H Clamp the clutch hose.

I Secure the grommet of theclutch hose by use of this holderwire of the gusset.

J Pass the horn lead wire betweenthe clutch hose and the frame,then pull the lead wire out to thefront, and connect the lead wireto the horn.

K Connect the black-coupler-equipped lead wire to the #1 and#4 ignition coils.

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SPECCABLE ROUTING

L Pass this clamp through the low-er hole of the gusset and securethe clutch hose.The front end of the clamp mustbe directed towards the inside ofthe vehicle.

M Pass the main harness throughthe inside of the clutch hose andinsert the harness into the left ofthe headlight lower hole.

N Fasten the frame ground leadwire together with the igniter unitmounting screw.

O Clamp the seat lock wire to theseat rail.The front end of the clamp mustbe directed downward.

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14 Starter motor cable15 Thermoswitch16 Starter relay17 Rib of the rear fender18 Seat lock wire19 Positive (+) lead wire of the bat-

tery20 Starter relay coupler21 Fuse box22 Negative (–) lead wire coupler of

the battery23 Flasher relay24 Oil lamp relay25 Battery band

A Right horn.Install the HI tone source (with H-marked label) at the right of thevehicle.

B Connect the #1-#4 high-tensioncords in order of the cord num-ber.

C Pass the T.P.S. lead wire throughthe clamp of the #4 carburetor.

D To fuel sender

1 Throttle cable2 #1 and #4 ignition coils3 T.P.S.4 Neutral switch coupler5 Pickup coupler6 Side stand switch coupler7 Fuel sender coupler8 Igniter unit9 Starter cable10 #2 and #3 ignition coils11 Stoppers12 Negative (–) lead wire of the bat-

tery13 Relay assy

SPECCABLE ROUTING

16

H Pass the starter cable throughthe front of the throttle cable.

I From left: #1, #2, #3, and #4high-tension cords.

J Secure the wire harness and thestarter cable, on the harnesspositioning tape, by use of thisband. The front end of the bandmust be directed downward.The harness must not deflect be-tween the T-stud and the clamp.

K Connect the starter cable to faceat right angles to the vehiclebody with contact with the stop-pers.

L Direct the crimping side of thebattery positive (+) lead wiredownward and connect the leadwire.

M Connect the starter motor cableto face outward at an angle ofabout 45 degrees.

E Clamp the starter motor cableand the negative (–) lead wire ofthe battery to the seat rail, be-tween the air cleaner mountingbracket and the tank mountingbracket.

F Connect the fuel sender coupler,neutral switch coupler, pickupcoupler, and side stand switchcoupler wires above the aircleaner.

G Thread the wire harness inser-tion clamp onto the T-stud of theframe.

SPECCABLE ROUTING

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P Store the wire harness, the tail-light lead wire, and the rear leftand right flasher lead wires, intothe space between the taillightbracket and the rib of the rearfender.

Q The seat lock wire must not ex-tend to the outside of the brack-et.

R Pass the lead wire leading to thefuse box under the wire harness.

S After connecting the lead wire ofthe thermoswitch, store the leadwire into the space under thewire harness.

T Clamp the wire harness to theseat rail, on the wire harnesspositioning tape and at the im-mediate rear of the side covermounting bracket on the seatrail.The front end of the clamp mustface downward and be posi-tioned inside the back stay.

N Secure the two positive (+) leadwires of the battery, the nega-tive(–) lead wire coupler of thebattery, and the wire harness byuse of this battery band.

O Clamp the wire harness to theseat rail, on the wire harnesspositioning tape and at the im-mediate rear of the side covermounting bracket on the seatrail.The front end of the clamp mustface downward and be posi-tioned inside the back stay.

SPECCABLE ROUTING

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16 Rear fender17 Rear left flasher lead wire18 Rear right flasher lead wire19 Wire harness

A Pass the throttle cable throughthe guide wire of the stay head-light.

B Insert the meter lead wire andthe main switch lead wire into theupper hole of the headlight.

1 Meter lead wire2 Main switch lead wire3 Crown handle4 Starter cable5 Left handle switch lead wire6 Clutch hose7 Front left flasher lead wire8 Front right flasher lead wire9 Brake hose 210 Brake hose 111 Right handle switch lead wire12 Wire harness13 Taillight lead wires14 Taillight bracket15 Rib of the rear fender

SPECCABLE ROUTING

C Bundle the handle switch leadwire, the clutch hose, and thestarter cable, under the crownhandle, by use of this band.The handle switch lead wiremust be passed outside theclutch hose.The starter cable must bepassed inside the clutch hose.

D Pass the front left and right flash-er lead wires through the front ofthe stay headlight.Securely mount the cap to faceupward.

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K The wire harness, the taillightlead wires, and the rear left andright flasher lead wires must bearranged below the rib of the rearfender.

L Clamp the wire harness and therear left and right flasher leadwires.The front end of the clamp mustbe directed forward.

M Pass the rear left and right flash-er lead wires through the respec-tive holes in the rear fender.

H Match the wire harness, themain switch lead wire, and themeter lead wire, to the wire har-ness and main switch lead wirepositioning tapes, and bundlethe harness and the lead wiresby use of the band.

I The lead wires must be clampedin this area.

J Bundle the front left and rightflasher lead wires by use of theclamp.

E Insert the left lead wire of thehandle switch and the left leadwire of the front flasher into theleft of the headlight lower hole.

F Insert the right lead wire of thehandle switch and the right leadwire of the front flasher into theright of the headlight lower hole.

G Bundle the handle switch leadwire and brake hose 2, near theguide wire of the stay headlightby use of this band.

SPECCABLE ROUTING

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CHKADJ

INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS

NOTE:

PERIODIC INSPECTION AND ADJUSTMENT

INTRODUCTIONThis chapter includes all information necessary to perform recommended inspections and adjust-ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera-tion and a longer service life. The need for costly overhaul work will be greatly reduced. This informa-tion applies to vehicles already in service as well as new vehicles that are being prepared for sale. Allservice technicians should be familiar with this entire chapter.

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

The annual checks must be performed every year, except if a kilometer-based maintenance is per-formed instead.

From 50,000 km, repeat the maintenance intervals starting from 10,000 km. Items marked with an asterisk should be performed by Yamaha dealer as they require special tools,

data and technical skills.

NO ITEM CHECK OR MAINTENANCE JOBODOMETER READING ( 1,000 km) ANNUAL

NO. ITEM CHECK OR MAINTENANCE JOB1 10 20 30 40 CHECK

1 * Fuel line Check fuel hoses and vacuum hose for

cracks or damage.√ √ √ √ √

2 * Fuel filter Check condition. √ √

3 Spark plugs

Check condition. Clean and regap.

√ √p p g

Replace. √ √

4 * Valves Check valve clearance. Adjust

Every 20,000 km

5 Air filter element Clean. √ √

5 Air filter element Replace. √ √

6 * Clutch Check operation, fluid level and vehicle for

fluid leakage. (See NOTE.)√ √ √ √ √

7 * Front brake

Check operation, fluid level and vehicle forfluid leakage. (See NOTE.)

√ √ √ √ √ √

Replace brake pads. Whenever worn to the limit

8 * Rear brake

Check operation, fluid level and vehicle forfluid leakage. (See NOTE.)

√ √ √ √ √ √

Replace brake pads. Whenever worn to the limit

9 * Brake hoses Check for cracks or damage. √ √ √ √ √

9 * Brake hoses Replace. (See NOTE.) Every 4 years

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

11 * Tires

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

√ √ √ √ √

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

13 * Swingarm Check operation and for excessive play. √ √ √ √

13 * Swingarm Lubricate with lithium-soap-based grease. Every 50,000 km

14 Drive chain

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

aligned. Clean and lubricate.

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

21

NOTE:

CHKADJPERIODIC MAINTENANCE/LUBRICATION INTERVALS

NO ITEM CHECK OR MAINTENANCE JOBODOMETER READING ( 1,000 km) ANNUAL

NO. ITEM CHECK OR MAINTENANCE JOB1 10 20 30 40 CHECK

15 * Steering bearings

Check bearing play and steering forroughness.

√ √ √ √ √g g

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

16 * Chassis fasteners Make sure that all nuts, bolts and

screws are properly tightened.√ √ √ √ √

17Sidestand, centeratand

Check operation. Lubricate.

√ √ √ √ √

18 * Sidestand switch Check operation. √ √ √ √ √ √

19 * Front fork Check operation and for oil leakage. √ √ √ √

20 *Shock absorberassemblies

Check operation and shock absorbers foroil leakage.

√ √ √ √

21 * Carburetors Check starter (choke) operation. Adjust engine idling speed and

synchronization.√ √ √ √ √ √

22 Engine oil Change. Check oil level and vehicle for oil leakage.

√ √ √ √ √ √

23Engine oil filter element Replace. √ √ √

24 *Front and rearbrake switches Check operation. √ √ √ √ √ √

25Moving parts andcables Lubricate. √ √ √ √ √

26 *Lights, signalsand switches

Check operation. Adjust headlight beam.

√ √ √ √ √ √

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

Regularly check and, if necessary, correct the brake and clutch fluid levels. 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. Replace the brake and clutch hoses every four years and if cracked or damaged.

22

ADJUSTING THE CLUTCH LEVERCHKADJ

NOTE:

a

a

ENGINEEAS00082

ADJUSTING THE CLUTCH LEVER1. Adjust:clutch lever position(distance a from the handlebar grip to theclutch lever)

a. While pushing the clutch lever forward, turnthe adjusting dial 1 until the clutch lever is inthe desired position.

Be sure to align the setting on the adjusting dialwith the arrow mark 2 on the clutch lever hold-er.

Position #1 Distance is the larg-est

Position #5 Distance is the small-est

23

ADJUSTING THE FRONT BRAKECHKADJ

NOTE:

a

a

EAS00107

CHASSISADJUSTING THE FRONT BRAKE1. Adjust:brake lever position(distance a from the throttle grip to the brakelever)

a. While pushing the brake lever forward, turnthe adjusting dial 1 until the brake lever is inthe desired position.

Be sure to align the setting on the adjusting dialwith the arrow mark 2 on the brake lever hold-er.

Position #1 Distance is the larg-est.

Position #5 Distance is the small-est.

24

VIEW 1. (NO FLOW)

VIEW 2. (FLOW)

AIR INDUCTION SYSTEM CARB

CARBURETOREAS00507

AIR INDUCTION SYSTEMAIR INJECTIONThe air induction system burns unburned ex-haust gases by injecting fresh air (secondaryair) into the exhaust port, reducing the emissionof hydrocarbons.When there is negative pressure at the exhaustport, the reed valve opens, allowing secondaryair to flow into the exhaust port. The requiredtemperature for burning the unburned exhaustgases is approximately 600 to 700C.

EAS00508

AIR CUTOFF VALVEThe air cutoff valve is operated by the intake gaspressure through the piston valve diaphragm.Normally, the air cutoff valve is open to allowfresh air to flow into the exhaust port. Duringsudden deceleration (the throttle valve sudden-ly closes), negative pressure is generated andthe air cutoff valve is closed in order to preventafter-burning.Additionally, at high engine speeds and whenthe pressure decreases, the air cutoff valve au-tomatically closes to guard against a loss of per-formance due to self-EGR.

VIEW 1. (NO FLOW)When decelerating (the throttle closes), the valve willclose.VIEW 2. (FLOW)During normal operation the valve is open.A From the air cleanerB To the cylinderC To the carburetor joint

25


EAS00509

AIR INDUCTION SYSTEM DIAGRAMS

1 Reed valve2 Air cleaner3 Air cutoff valve4 Vacuum hose (cylinder #3)A To the air cutoff valveB To cylinder #1C To cylinder #2D To cylinder #3E To cylinder #4

26


EAS00510

CHECKING THE AIR INDUCTION SYSTEM1. Check:hosesLoose connection Connect properly.Cracks/damage Replace.

pipesCracks/damage Replace.

2. Check: fibre reed 1 fibre reed stopper reed valve seatCracks/damage Replace the reed valve.

3. Measure: fibre reed bending limit aOut of specification Replace the reedvalve.

Fibre reed bending limit0.2 mm

1 Surface plate

4. Check:air cutoff valveCracks/damage Replace.

27

CHASFRONT AND REAR BRAKES

Order Job/Part Q’ty Remarks

1234567

Removing the front brake mastercylinderBrake fluid

Brake leverBrake switch leadFront brake switchUnion boltCopper washers/Brake hoseMaster cylinder bracketMaster cylinder

1211

3/211

Remove the parts in the order listed.Drain

Refer to “DISASSEMBLING/ASSEM-BLING AND INSTALLING THE REARBRAKE MASTER CYLINDER” in chapter 6. (Manual No.: 5EA3-AE1)

For installation, reverse the removalprocedure.

10 Nm (1.0 mkg)

30 Nm (3.0 mkg)

CHASSISFRONT AND REAR BRAKESEAS00586

FRONT BRAKE MASTER CYLINDER

28


WARNING

NOTE:

WARNING

CAUTION:

NOTE:

EAS00598

ASSEMBLING AND INSTALLING THEFRONT BRAKE MASTER CYLINDER

Before installation, all internal brake com-ponents should be cleaned and lubricatedwith clean or new brake fluid.

Never use solvents on internal brake com-ponents.

Recommended brake fluidDOT 4

1. Install:brake master cylinder 1

Install the brake master cylinder holder withthe “UP” mark facing up.

Align the end of the brake master cylinder hold-er with the punch mark a on the handlebar.

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

Brake master cylinder bolt10 Nm (1.0 mkg)

2. Install:copper washers (New) 1brake hose 1 2brake hose 2 3union bolt 4

Union bolt30 Nm (3.0 mkg)

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

When installing the brake hose 1 2 ontothe brake master cylinder, make sure thatthe brake pipe touches the projection a asshown. And install the paint mark b to-ward the brake master cylinder side.

Install the brake hose 2 3 at the sameangle as the brake hose 1 2 .

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

29


WARNING

CAUTION:

3. Fill:brake master cylinder reservoir(with the specified amount of the recom-mended brake fluid)

Recommended brake fluidDOT 4

Use only the designated brake fluid. Otherbrake fluids may cause the rubber seals todeteriorate, causing leakage and poorbrake performance.

Refill with the same type of brake fluid thatis already in the system. Mixing brakefluids may result in a harmful chemicalreaction, leading to poor brake perfor-mance.

When refilling, be careful that water doesnot enter the reservoir. Water will signifi-cantly lower the boiling point of the brakefluid and could cause vapor lock.

Brake fluid may damage painted surfacesand plastic parts. Therefore, always cleanup any spilt brake fluid immediately.

4. Bleed:brake systemRefer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3. (Manual No.:5EA3-AE1)

5. Check:brake fluid levelBelow the minimum level mark a Add therecommended brake fluid to the proper level.Refer to “CHECKING THE BRAKE FLUIDLEVEL” in chapter 3. (Manual No.:5EA3-AE1)

6. Check:brake lever operationSoft or spongy feeling Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3. (Manual No.:5EA3-AE1)

30

FRONT AND REAR BRAKES CHAS


1234

Removing the rear brake caliperBrake fluidUnion boltCopper washerBrake hoseBrake caliper

1211

Remove the parts in the order listed.Drain.

For installation, reverse the removalprocedure.

40 Nm (4.0 mkg)

30 Nm (3.0 mkg)

EAS00616

REAR BRAKE CALIPER

31

FRONT AND REAR BRAKES CHAS


Disassembling the rear brake caliperBrake pad clipBrake pad pinBrake pad springBrake padBrake caliper pistonBrake caliper piston sealBleed screw

4212242

Disassemble the parts in the order listed.

For assembly, reverse the disassemblyprocedure.

1234567

6 Nm (0.6 mkg)

EAS00617

32

2 Fuse (main)3 Battery5 Main switch6 Fuse (ignition)14 Neutral switch51 Carburetor heater relay52 Thermo switch53 Carburetor heater

CARBURETOR HEATING SYSTEM ELEC

ELECTRICALCARBURETOR HEATING SYSTEM

33

Check the condition of the battery.Refer to “CHECKING THE BATTERY” inchapter 3. (Manual No.: 5EA3-AE1)

EAS00738

1. Main, and ignition fuses

Check the main and ignition fuses for conti-nuity.Refer to “CHECKING THE FUSES” in chap-ter 3. (Manual No.: 5EA3-AE1)

Are the main and ignition fuses OK?

NOYES

Replace the fuse(-s).

EAS00739

2. Battery

Open-circuit voltage12.8 V or more at 20C

Is the battery OK?

NOYES

Clean the batteryterminals.

Recharge or re-place the battery.

EAS00749

3. Main switch

Check the main switch for continuity.Refer to “CHECKING THE SWITCHES” inchapter 8. (Manual No.: 5EA3-AE1)

Is the main switch OK?

YES NO

Replace the mainswitch.

EAS00751

4. Neutral switch

Check the neutral switch for continuity.Refer to “CHECKING THE SWITCHES” inchapter 8. (Manual No.: 5EA3-AE1)

Is the neutral switch OK?

YES NO

Replace the neutralswitch.

EAS00822

YES NO

5. Carburetor heater relay

Disconnect the carburetor heater relay cou-pler from the wire harness.

Connect the pocket tester (Ω 1) to the car-buretor heater relay coupler as shown.

Tester positive probe red/white Tester negative probe black

Replace the carbure-tor heater relay.

Check the carburetor heater relay for nocontinuity.

Is the carburetor heater relay OK?

12


NOTE:

EAS00821

TROUBLESHOOTING

The carburetor heating system fails to op-erate.

Check:1. Main and ignition fuses2. Battery3. Main switch4. Neutral switch5. Carburetor heater relay6. Thermo switch7. Carburetor heater8. Wiring connections

(of the entire carburetor heating system)

Before troubleshooting, remove the followingpart(-s):1) Rider and passenger seatsTroubleshoot with the following special tool(-s).

Pocket tester90890-03112

34

YES NO

6. Thermo switch

Remove the thermo switch from the thermoswitch plate.

Connect the pocket tester to the (Ω 1) tothe thermo switch as shown.

Tester positive probe black Tester negative probe black/red

Replace the thermoswitch.

Check the thermo switch for continuity at thetemperatures indicated below.

12

Does the thermo switch operated properly?

COOL DOWN

HEAT UPA

B

EAS00825

The following procedure applies to all of thecarburetor heating elements.

YES NO

7. Carburetor heater

Remove the carburetor heating elementfrom the carburetor.

Connect the pocket tester to the carburetorheating element as shown.

Tester positive probe heating element

Tester negative probe heating element body

Replace the carbure-tor heating element.

Is the carburetor heating element OK?

2

8. Wiring

Check the entire carburetor heating sys-tem’s wiring.Refer to “CIRCUIT DIAGRAM”.

Is the carburetor heating system’s wiringproperly connected and without defects?

NO

Properly connect orrepair the carburetorheating system’s wir-ing.

EAS00826

1

Carburetor heating element resistance

12 V 15 W: 4 11 Ω at 20C12 V 20 W: 4 11 Ω at 20C

Measure the carburetor heater resistance.11C

ON

OFF

16C


COLOR CODEB 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 generator2 Fuse (main)3 Battery4 Starter relay5 Main switch6 Fuse (ignition)7 Starter motor8 Starting circuit cut-off relay9 Ignitor unit10 Ignition coil11 Spark plug12 Pickup coil13 TPS (throttle position sensor)14 Neutral switch15 Sidestand switch16 Start switch17 Engine stop switch18 Lights switch19 Front brake switch20 Handlebar switches (right)21 Alarm22 Fuse (turn)23 Fuse (signal)24 Fuse (headlight)25 Horn26 Flasher relay27 Rear brake switch28 Oil level relay29 Oil level switch30 Meter assembly31 Speedometer32 Neutral indicator light33 Tachometer34 Fuel gauge35 Meter lights36 Turn signal indicator light (left)37 Turn signal indicator light (right)38 Oil warning light39 High beam indicator light40 Fuel sender41 Auxiliary light42 Tail /brake light43 Clutch switch44 Hazard switch45 Turn signal switch46 Horn switch47 Dimmer switch48 Pass switch49 Handlebar switch (left)50 Headlight51 Carburetor heater relay52 Thermo switch53 Carburetor heater54 Rear turn signal lights55 Front turn signal lights

XJR1300 2002 WIRING DIAGRAM (for EUR)

COLOR CODEB 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 generator2 Fuse (main)3 Battery4 Starter relay5 Main switch6 Fuse (ignition)7 Starter motor8 Starting circuit cut-off relay9 Ignitor unit10 Ignition coil11 Spark plug12 Pickup coil13 TPS (throttle position sensor)14 Neutral switch15 Sidestand switch16 Start switch17 Engine stop switch18 Front brake switch19 Handlebar switches (right)20 Carburetor heater relay21 Thermo switch22 Carburetor heater23 Fuse (signal)24 Fuse (headlight)25 Meter assembly26 Speedometer27 Neutral indicator light28 Tachometer29 Fuel gauge30 Meter lights31 Turn signal indicator light (left)32 Turn signal indicator light (right)33 Oil warning light34 High beam indicator light35 Fuel sender36 Oil level relay37 Oil level switch38 Rear brake switch39 Tail /brake light40 Flasher relay41 Horn42 Handlebar switch (left)43 Pass switch44 Dimmer switch45 Horn switch46 Turn signal switch47 Clutch switch48 Headlight49 Rear turn signal lights50 Front turn signal lights

XJR1300P 2002 WIRING DIAGRAM (for AUS)

p Workshop Manual 2002

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