6 - Yamaha XJR
Contents
1. While pushing the brake lever forward turn the adjusting dial 1 until the brake lever is in the desired position NOTE Be sure to align the setting on the adjusting dial with the arrow mark 2 on the brake lever hold er Position 1 Distance is the larg est Position 45 id is the small MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA VIEW 1 NO FLOW VIEW 2 FLOW AIR INDUCTION SYSTEM CARB 24 CARBURETOR AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned ex haust 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 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 sudden ly 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 au tomatically closes to guard against a loss of per formance due to self EGR VIEW 1 NO FLOW When decelerat2. 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 sue aure rd 30 ELECTRICAL CARBURETOR HEATING SYSTEM 32 TROUBLESHOCTING 33 XJR1300 2002 WIRING DIAGRAM for EUR XJR1300P 2002 WIRING DIAGRAM for AUS GENERAL SPECIFICATIONS SPEC v SPECIFICATIONS GENERAL SPECIFICATIONS P Model code 5EAT 5EAW EUR 5EAU 5EAX for D 5EAV 5EAY for AUS Dimensions Overall length 2 175 mm Overall width 775 mm Overall height 1 115 mm Seat height 790 mm Wheelbase 1 510 mm Minimum ground clearance 120 mm Minimum turning radius 2 800 mm Basic weight With oil and full fuel tank 247 kg Carburetor Type quantity BSR37 4 Manufacturer MIKUNI Transmission Primary reduction system Spur gear Primary reduction ratio 98 56 1 750 Secondary reduction system Chain drive Secondary reduction ratio 39 18 2 167 Transmission type Constant mesh 5 speed Operation Left foot operation Gear ratio ist 40 14 2 857 2nd 36 18 2 000 3rd 33 21 1 571 4th 31 24 1 292 5th 29 26 1 115 GENERAL SPECIFICATIONS SPEC v XJR1300 P Tubeless front 120 70ZR17 58W 120 70ZR17 M
3. COLOR CODE Bus Black Br Brown Ch Chocolate Dg Dark green G Green Gy Gray Lus Blue Light green eer laei ise B B o I Rim L L HI Orange Sky blue Pink Red Yellow Black Blue Black Red Black Yellow R 0 NR Oto ON JOIOIO _ Br L Br W G Y L B L R L W LY es H B Brown Blue Brown White Green Yellow Blue Black Blue Red Blue White Blue Yellow Red Black R L R W R Y a W G W R Y B Red Blue Red White Red Yellow White Green White Red Yellow Black 1 AC generator 2 Fuse main 3 Battery 4 Starter relay 5 Main switch 6 Fuse ignition 7 Starter motor Starting circuit cut off relay 9 Ignitor unit Ignition coil 1 Spark plug 42 Pickup coil 3 TPS throttle position sensor Neutral switch 5 Sidestand switch Start switch 4D Engine stop switch Lights switch Front brake switch Handlebar switches right Alarm 62 Fuse turn 63 Fuse signal 62 Fuse headlight 5 Horn 6 Flasher relay 7 Rear brake switch Oil level relay 9 Oil level switch Meter assembly 81 Speedometer 62 Neutral indicator light 63 Tachometer Fuel gauge 65 Meter lights Turn signal indicator light left 67 Turn signal indicator light right Oil warning light High beam in
4. a N S NS TL Mes th EZ 1 e o S i As E Al D 15 and the negative lead wire of CABLE ROUTING SPEC v Clamp the starter motor cable Pass the starter cable through Connect the starter cable to face the front of the throttle cable the battery to the seat rail be From left 1 2 3 and 4 tween the air cleaner mounting high tension cords bracket and the tank mounting Secure the wire harness and the bracket Connect the fuel sender coupler neutral switch coupler pickup coupler and side stand switch coupler wires above the air cleaner Thread the wire harness inser tion clamp onto the T stud of the frame 5 7 Mm Ji EY s K SS os gt 25 gt lt oS lt 2S NS M EA Jm 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 be tween the T stud and the clamp at right angles to the vehicle body with contact with the stop pers Direct the crimping side of the battery positive lead wire downward and connect the lead wire Connect the starter motor cable to face outward at an angle of about 45 degrees z j Wi Lh E EU B t B T A LEG Se e DE T a ce 1 B
5. cables 26 Lights signals e Check operation N and switches e Adjust headlight beam NOTE e he air filler needs more frequent service if you are riding in unusually wet or dusty areas e Hydraulic brake and clutch service e Regularly check and if necessary correct the brake and clutch fluid levels e 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 e Replace the brake and clutch hoses every four years and if cracked or damaged 21 CHK ADJUSTING THE CLUTCH LEVER ADJ 22 ENGINE ADJUSTING THE CLUTCH LEVER 1 Adjust e clutch lever position distance 8 from the handlebar grip to the clutch lever While pushing the clutch lever forward turn the adjusting dial until the clutch lever is in the desired position NOTE ass Be sure to align the setting on the adjusting dial with the arrow mark 2 on the clutch lever hold er Position 1 Distance 3 is the larg est Position 45 m 8 is the small MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHK ADJUSTING THE FRONT BRAKE ADJ 23 00107 CHASSIS ADJUSTING THE FRONT BRAKE 1 Adjust e brake lever position distance a from the throttle grip to the brake lever
6. Check and ignition fuses els the main switch Battery Main switch Neutral switch Carburetor heater relay Thermo switch switch Carburetor heater Wiring connections of the entire carburetor heating system Marital ewes NOTE Before troubleshooting remove the following ee Ce n Ana hapter 8 M No 5EA3 AE1 1 Rider and passenger seats chapter 8 Manual No Troubleshoot with the following special tool s els the neutral switch OK i YES J NO Pocket tester A 90890 03112 Replace the neutral EAS00738 switch 1 Main and ignition fuses e Check the main and ignition fuses for conti nuity Referto CHECKING THE 5 5 in chap ter 3 Manual No 5EA3 AE1 e Connect the pocket tester Q x 1 tothe car buretor heater relay coupler as shown YES NO i Tester positive probe red white 1 00739 Z N e Check the condition of the battery Refer to CHECKING THE BATTERY in chapter Manual No 5EA3 AE1 Open circuit voltage 12 8 V or more at 20 C els the battery OK YES y NO YES NO Clean the battery Replace the carbure terminals tor heater relay e Recharge re EAS00822 5 Carburetor heater relay e Disconnect the carburetor heater relay cou pler from the wire harness eCheck the carburetor heater relay for no continuity el
7. amp YAMAHA 2002 Ndi UD P SUPPLEMENTARY SERVICE MANUAL 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 Supple mentary Service Manual together with the following manual XJR1300 L 99 SERVICE MANUAL 5EA3 AE1 00000 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 500003 NOTICE This manual was produced by the Yamaha Motor Company Ltd primarily for use by Yamaha dealers and their qualified mechanics Itis 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 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 ve hicle 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 ve hicle will operate as designed If there is any question about a se
8. EAS00616 REAR BRAKE CALIPER 94 30 Nm 3 0 mekg 40 Nm 4 0 Removing the rear brake caliper Hemove the parts in the order listed Brake fluid Drain Union bolt Copper washer Brake hose Brake caliper For installation reverse the removal procedure 30 FRONT AND REAR BRAKES 5 EAS00617 Sa 6 0 6 mekg Job Part Remarks Disassembling the rear brake caliper Disassemble the parts in the order listed Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw C636 C For assembly reverse the disassembly procedure 31 62 Thermo switch gt ees 3 a s 258 E Of l 5 cog z D o9cozg 5 6 55 LmeawZzo B lt I Q LLI I gt c I lt LLI H lt a B B B ov LLI I o gt o c H t LLI L LLI lt L R L Br L Br R B 63 Carburetor heater 32 CARBURETOR HEATING SYSTEM ELEC 00821 00749 The carburetor heating system fails to op e Check the main switch for continuity erate Refer to CHECKING THE SWITCHES in chapter 8 Manual No 1
9. 225 2 d j q 10 RI d N B JN a 7 t3 17 1 Meter lead wire 2 Main switch lead wire 8 Crown handle 4 Starter cable 5 Left handle switch lead wire 6 Clutch hose 7 Front left flasher lead wire Front right flasher lead wire 9 Brake hose 2 Brake hose 1 41 Right handle switch lead wire 2 Wire harness 13 Taillight lead wires Taillight bracket 5 Rib of the rear fender 9 ie A CE Nc I 1 CABLE ROUTING SPEC v Rear fender Bundle the handle switch lead 12 Rear left flasher lead wire wire the clutch hose and the Rear right flasher lead wire starter cable under the crown Wire harness handle by use of this band The handle switch lead wire Pass the throttle cable through must be passed outside the the guide wire of the stay head clutch hose light The starter cable must be Insert the meter lead wire and passed inside the clutch hose the main switch lead wire intothe D Pass the front left and right flash upper hole of the headlight er lead wires through the front of the stay headlight Securely mount the cap to face upward iN 14 VK NS OK B pe e Ce V 17 M 18 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 Insert the righ
10. Him material Aluminum Him runout limit radial lateral Hear wheel Type Cast wheel Him size 17 x MT3 50 or 17 M C x MT3 50 Him material Aluminum Him runout limit radial lateral Drive chain Type manufacturer 50VA8 DAIDO No of links 112 Chain free play 20 30mm Brake lever amp brake pedal Brake pedal position MAINTENANCE sPECIFICATIONs SPEC v Tightening torques Tightening Part to be tightened Part name Thread size Qty torque Remarks Throttle cable and carburetor Nut M6 x 1 0 2 4 0 4 Ignition coil Nut M6 x 1 0 2 6 5 0 65 MAINTENANCE sPECIFICATIONs SPEC ELECTRICAL TGI Pickup coil resistance color 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 Circuit breaker Type Amperage for individual circuit MAIN HEAD LIGHT SIGNAL IGNITION TURN Reserve 248 372 Q 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 0
11. Turn signal indicator light left 62 Turn signal indicator light right 83 Oil warning light High beam indicator light 85 Fuel sender Oil level relay 87 Oil level switch Rear brake switch Tail brake light Flasher relay Horn 45 Handlebar switch left Pass switch Dimmer switch Horn switch Turn signal switch 42 Clutch switch Headlight Rear turn signal lights Front turn signal lights
12. hose and arrange the two types and the rear fender of hose properly Match the paint mark of the air cleaner drain hose to the lower end of the guide wire 0 D fes B hee XO 4 VA YR EX aS E P lt N 2 2065222 EU 7 s AS ZA E ud TJ 11 CABLE ROUTING SPEC v 1 Gusset 3 Flasher relay coupler gusset by use of this band 2 Tension pipe 1 Oil lamp relay coupler The front end of the band must 8 2 high tension cord 15 Igniter unit coupler be directed downward 4 1 high tension cord Bundle the four high tension 5 Wire starter Pass the wire harness and the cords the 1 and 2 cords up 6 A C generator starter cable through the holder and the 3 and 4 cords down 7 Oil filter cover wire of the gusset by use of this band Side stand switch Pass the starter cable under the Position the leading ends of the 9 Side stand switch lead wire wire harness cords near but not below the Horn lead wire secure the lead wire branch of lower front end of the air induc 1 2 and 3 ignition coil lead wires the main harness to tension pipe tion system assy 2 Frame ground lead wire 1 at the immediate rear of the mr x m lt lt gt TRS uU 12 CABLE ROUTING SPEC v Bundle the 1 and 2 high ten G After securing the side stand l Secure the grommet of the sion cords us
13. fluid 11 Lubricant 12 Special tool 3 Tightening torque Wear limit clearance 5 Engine speed Electrical data Symbols 17 to 62 in the exploded diagrams indi cate the types of lubricants and lubrication points 47 Engine oil Gear oil Molybdenum disulfide oil 60 Wheel bearing grease 61 Lithium soap base grease 62 Molybdenum disulfide grease Symbols 3 to 4 in the exploded diagrams indi cate the following 63 Apply locking agent LOCTITE Replace the part CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS 1 MAINTENANCE SPECIFICATIONS 3 ENGINE P 3 CHASSIS area n iit a adonde ence Minas ghee Sr REA UE 6 PLECIRIGAL e ere nar fa Ard 8 CABLE ROUTING 9 PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION 20 PERIODIC MAINTENANCE LUBRICATION INTERVALS 20 ENGINE 22 ADJUSTING THE CLUTCH LEVER 4 x none ina 22 CHASSIS 23 ADJUSTING THE FRONT BRAKE 23 CARBURETORS AIR INDUCTION SYSTEM 24 AIR INJECTION senescere bot de nae aan Marne drs decani dien 24 Alla GCUTOFF VALVE dies aote aba qa Paesi eer Rer ad dE es 24 AIR INDUCTION SYSTEM DIAGRAMS
14. that the brake hose does not touch other parts e g wire harness cables leads Correct if necessary 29 FRONT AND REAR BRAKES 5 3 Fill e brake master cylinder reservoir with the specified amount of the recom mended brake fluid Recommended brake fluid DOT 4 A WARNING Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance 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 perfor mance e When refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed e brake system to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter Manual No 5EA3 AE1 5 Check e brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 Manual No 5EA3 AE1 6 Check e brake lever operation Soft or spongy feeling Bleed the brake System Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter Manual No 5EA3 AE1 FRONT AND REAR BRAKES 5
15. 86 12 Nm 7 0 m kg 3 Remove 8 eclutch boss nut 1 washer clutch boss 3 thrust washer e bearing clutch housing NOTE __ Insert two 6 mm bolts into the spacer and then remove the spacer by pulling on the bolts 8 Nm 0 8 CHECKING THE FRICTION PLATES 7 Job Part Remarks The following procedure applies to all of the fric tion plates Clutch boss 1 Check Stopper ring friction plate Clutch plate Damage wear Replace the friction plates Clutch spring plate as a set Clutch spring plate seat Refer to REMOVING INSTALLING 2 Measure THE CLUTCH e friction plate thickness u Out of specification Replace the friction plates as a set NOTE Measure the friction plate at four places Friction plates narrow Thrust washer Spacer Bearing Clutch housing For installation reverse the removal procedure Friction plate thickness 2 9 3 1 mm Limit 2 8 mm 00009 SYMBOLS The following symbols are not relevant to every vehicle Symbols 1 to 8 indicate the subject of each chapter 1 General information 2 Specifications 8 Periodic checks and adjustments 4 Engine 5 Carburetor s 6 Chassis 7 Electrical system Troubleshooting Symbols 9 to 6 indicate the following 9 Serviceable with engine mounted Filling
16. 9 0 2 0 19 0 21 13 7 mm 5 10 5 69 N 0 52 0 58 kg Semi conductor field control type B3G DENSO 14 2 14 8V 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 4 2 4 6Q G8R 30Y P OMRON 162 1980 Yes CABLE ROUTING SPEC v CABLE ROUTING 1 Starter motor cable 3 3 high tension cord Pass the starter motor cable and 2 Battery negative lead wire 4 high tension cord the negative lead wire of the 8 Carburetor heater plug 15 Engine frame ground lead wire battery through the inside of the 4 A C generator coupler Rear stop switch seat rail 5 Rear stop switch coupler 7 Relay assy 6 Neutral lead wire Guide wire 7 Pickup lead wire Fuel tank drain hose Side stand switch lead wire 60 Fuel tank breather hose 9 T P S Tank fitting 1 1 and 4 ignition coil lead wires 42 Horn lead wire T D DIESE X 4 6 BI Sh eZ e VA N A TK lt 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 mount ing screw by use of this band The front end of the band must be directed towards the front of the vehicle CABLE ROUTING SPEC v oecure the carburetor
17. C 58W rear 180 55ZR17 73W 180 55ZR17 M C 73W Manufacturer front MICHELIN DUNLOP rear MICHELIN DUNLOP Type front MACADAM90X E D220F STM rear MACADAM90X E D220 STM Tire pressure cold tire Maximum load except motorcycle 203 kg Loading condition A 0 90 kg front 250 kPa 2 5 kg cm 2 5 bar rear 250 kPa 2 5 kg cm 2 5 bar Loading condition B 90 203 kg front 250 kPa 2 5 kg cm 2 5 bar rear 290 kPa 2 9 2 9 bar High speed riding front 250 kPa 2 5 kg cm2 2 5 bar rear 290 kPa 2 9 kg cm 2 9 bar Load is the total weight of cargo rider passenger and accessories MAINTENANCE sPECIFICATIONs SPEC MAINTENANCE SPECIFICATIONS ENGINE Cylinder head Warp limit Cylinder Bore size 79 00 79 01 mm Taper limit Out of round limit Wear limit Camshaft Drive method Chain drive Center Cam cap inside diameter 25 000 25 021 mm Camshaft outside diameter 24 967 24 980 mm Shaft to cap clearance 0 020 0 054 mm Cam dimensions Intake 35 95 36 05 35 85 mm 28 058 28 158 mm 27 958 Exhaust 35 95 36 05 35 85 28 045 28 145 27 945 Camshaft runout limit 0 03 MAINTENANCE sPECIFICATIONs SPEC v Piston Piston to cylinder clearance Piston size D Measuring point H Piston off set Piston off set direction Piston pin bore inside diameter Piston pin outside diameter Carburetor I
18. D mark Main jet Main air jet Jet needle Needle jet Pilot jet Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Pilot screw Valve seat size Starter jet Starter jet Throttle valve size Float height Fuel level using special tool Engine idle speed Intake vacuum 0 015 0 040 mm 78 970 78 985 mm 5 mm 1 mm IN side 18 004 18 015 mm 18 045 mm 17 991 18 000 mm 17 971 mm 5EAT 30 107 5 80 5D118 53 3 P OM 140 01 0 15 950 1 150 31 3 kPa 235 mmHg MAINTENANCE sPECIFICATIONs SPEC v Tightening torques Tightening Part to be tightened Part name Q ty torque Remarks 2 7 2 7 3 7 10 Carburetor joint and carburetor Carburetor and air filter joint Air induction system pipe joint Air induction system MAINTENANCE sPECIFICATIONs SPEC v CHASSIS Front suspension Front fork travel Fork spring free length Fitting length Collar length Spring rate 130 mm 308 3 mm 287 3 mm 245 mm 6 4 N mm 0 65 10 8 N mm 1 1 kg mm 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 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 13mm 13 50mm 50 67 5 mm 67 5 93 0 mm AARABARA A pM EIC Front wheel Type Cast wheel Him size 17 x MT3 50 or 17 M C x MT3 50
19. OTE Replace brake pads Replace brake pads pads Whenever worn to the limit e Check for cracks or damage mu e Replace See NOTE 4 e Check tread depth and for damage e Replace if necessary e Check air pressure e Correct if necessary Wheel e Check bearing for looseness or damage 98 vp ve e Check operation and for excessive play y y y y e Lubricate with lithium soap based grease Every 50 000 km aligned the motorcycle or riding in the rain Clean and lubricate e Check chain slack 14 Drive chain e Make sure that the rear wheel is properly Every 1 000 km and after washing 20 CHK PERIODIC MAINTENANCE LUBRICATION INTERVALS ADJ Q mm CHECK OR MAINTENANCE JOB ODOMETER READING x 1 000 km ANNUAL ITEM eee mE e Check bearing play and steering for r J 15 Steering bearings roughness Lubricate with lithium soap based grease with lithium soap based Lubricate with lithium soap based grease Every 20 000 km Make sure that all nuts bolts and T J N N N screws are properly tightened 17 Sidestand e Check operation centeratand 20 Shock absorber ee operation and shock absorbers for assemblies oil leakage e Check starter choke operation Carburetors e Adjust engine idling speed and synchronization e Change element Front and rear 25 e Lubricate
20. dicator light Fuel sender Auxiliary light 42 Tail brake light Clutch switch Hazard switch Turn signal switch Horn switch 42 Dimmer switch Pass switch Handlebar switch left Headlight 61 Carburetor heater relay 62 Thermo switch 63 Carburetor heater Rear turn signal lights 65 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 NEP Blue Light green Orange Sky blue Pink Red Yellow Black Blue Black Red Black Yellow Brown Blue Brown White Green Yellow Blue Black Blue Red Blue White Blue Yellow Red Black FUE R W HY W G W R Y B sa Red Blue Red White Red Yellow White Green White Red Yellow Black MAIN HARNESS SUB LEAD NEUTRAL 1 AC generator 2 Fuse main 3 Battery 4 Starter relay 5 Main switch 6 Fuse ignition 7 Starter motor Starting circuit cut off relay 9 Ignitor unit Ignition coil 4D Spark plug 2 Pickup coil 3 TPS throttle position sensor Neutral switch 5 Sidestand switch Start switch 4D Engine stop switch Front brake switch Handlebar switches right 60 Carburetor heater relay 61 Thermo switch 62 Carburetor heater 63 Fuse signal 4 Fuse headlight 5 Meter assembly 6 Speedometer 67 Neutral indicator light Tachometer 69 Fuel gauge Meter lights 61
21. e MR S imas B zt Va Qv e B N 9 x 16 CABLE ROUTING SPEC v Secure the two positive lead Store the wire harness the tail After connecting the lead wire of wires of the battery the nega light lead wire and the rear left the thermoswitch store the lead tive lead wire coupler of the and right flasher lead wires into wire into the space under the battery and the wire harness by the space between the taillight wire harness use of this battery band bracket and the rib of the rear Clamp the wire harness to the Clamp the wire harness to the fender seat rail on the wire harness seat rail on the wire harness Q The seat lock wire must not ex positioning tape and at the im positioning tape and at the im tend to the outside of the brack mediate rear of the side cover mediate rear of the side cover et mounting bracket on the seat mounting bracket on the seat Pass the lead wire leading to the rail rail fuse box under the wire harness The front end of the clamp must The front end of the clamp must face downward and be posi face downward and be posi tioned inside the back stay tioned inside the back stay N lt gt es LLL eS 2 X 2 NF D m SU Lik JB SAGE Ti EM AN N N g C EN AA MO n n JE e
22. ecommended 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 All service technicians should be familiar with this entire chapter PERIODIC MAINTENANCE LUBRICATION INTERVALS NOTE e The annual checks must be performed every year except if a kilometer based maintenance is per formed instead e From 50 000 km repeat the maintenance intervals starting from 10 000 km e tems marked with an asterisk should be performed by Yamaha dealer as they require special tools data and technical skills ODOMETER READING x 1 000 km ANNUAL ITEM CHECK OR MAINTENANCE JOB e Check fuel hoses and vacuum hose for cracks or damage Le ae gt Check condition condition m condition Spark plugs e Clean and regap Repace Replace C tt ff 4 Valves Every 20 000 km e Adjust BN E memi Check ate fluid E and vehicle for e Check operation fluid level and vehicle for 7 Front brake fluid leakage See NOTE Replace brake pads Replace brake pads pads Whenever worn to the limit e Check operation fluid level and vehicle for N 4 4 J Rear brake fluid leakage See N
23. er cylinder bracket BRAKE MASTER CYLINDER in Master cylinder chapter 6 Manual No 5EA3 AE1 For installation reverse the removal procedure 27 FRONT AND REAR BRAKES CHAS 28 g EAS00598 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents Recommended brake fluid DOT 4 1 Install e brake master cylinder 1 NOTE e Install the brake master cylinder holder with the UP mark facing up Align the end of the brake master cylinder hold er with the punch mark 8 on the handlebar e First tighten the upper bolt then the lower bolt Brake master cylinder bolt 10 Nm 1 0 2 Install e copper washers New 1 brake hose 1 2 e brake hose 2 3 eunion bolt 4 Xss Union bolt A 30 Nm 3 0 mekg WARNING Proper brake hose routing is essential to sure safe motorcycle operation Refer to CABLE ROUTING CAUTION When installing the brake hose 1 2 onto the brake master cylinder make sure that the brake pipe touches the projection 8 as shown And install the paint mark b to ward the brake master cylinder side eInstall the brake hose 2 3 at the same angle as the brake hose 1 2 NOTE ms Turn the handlebar to the left and to the right to make sure
24. heater Clamp the throttle cables to the Bundle the 3 and 4 high ten fuel tank rail on the tank fitting by use of this band The front end of the band must be directed down ward D Thread this clamp through the upper hole in the gusset and se cure the two throttle cables The front end of the clamp must be di sion cords on the head cover mounting bolt at the 3 cord by use of this band Do not entangle the lead wires and the hosing Pass the bundle of lead wires and that of hosing orderly as shown rected towards the inside of the Pass the air cleaner drain hose vehicle the fuel tank drain hose and the fuel tank breather hose total 3 hoses through the guide wire of the engine gt gt S gt SA DL W x SCAM AN p eus N KALAN 2 WE A 4 o NON ez 7 5 ow SFIS Is Qui 101 SA LAS M UR 10 CABLE ROUTING SPEC v Bundle the A C generator lead Clamp the wire harness to the wire the pickup lead wire the seat rail at the front end of the side stand switch lead wire the bracket The front end of the starter motor cable and the car clamp must be directed down buretor heater lead wire total 5 ward wires by use of this clamp Clamp the wire harness 1 Match the marks of the fuel tank Pass the wire harness between drain hose and fuel tank breather the handle standing lug member
25. ing the throttle closes the valve will close VIEW 2 FLOW During normal operation the valve is open From the air cleaner To the cylinder To the carburetor joint CARB AIR INDUCTION SYSTEM 500509 AIR INDUCTION SYSTEM DIAGRAMS M i We 1 Reed valve 2 Air cleaner 3 Air cutoff valve 4 Vacuum hose cylinder 3 To the air cutoff valve To cylinder 1 To cylinder 2 D To cylinder 3 To cylinder 4 25 AIR INDUCTION SYSTEM CARB ie 26 00510 CHECKING THE AIR INDUCTION SYSTEM 1 Check ehoses Loose connection Connect properly Cracks damage Replace e pipes Cracks damage Replace 2 Check e fibre reed 1 efibre reed stopper e reed valve seat Cracks damage Replace the reed valve 3 Measure e fibre reed bending limit Out of specification Replace the reed valve X Fibre reed bending limit 0 2 mm 1 Surface plate 4 Check e air cutoff valve Cracks damage Replace FRONT AND REAR BRAKES 5 CHASSIS FRONT AND REAR BRAKES FRONT BRAKE MASTER CYLINDER Sa 10 Nm 1 0 mekg lt S YN 30 Nm 3 0 mekg 1 5 Removing the front brake master cylinder Brake fluid Remove the parts in the order listed Drain Brake lever Brake switch lead Front brake switch Union bolt Refer to DISASSEMBLING ASSEM Copper washers Brake hose BLING AND INSTALLING THE REAR Mast
26. ing this clamp switch lead wire using this clutch hose by use of this holder Clamp these cords above the 2 clamp first route the lead wire wire of the gusset head cover mounting bolt between the pickup cover the oil Pass the horn lead wire between Route the air cleaner drain hose filer cover the A C generator the clutch hose and the frame through the right side of the ve and the starter motor Next as then pull the lead wire out to the hicle with a clearance above the with the engine lead wire route front and connect the lead wire starter motor the lead wire through the right to the horn Mount the square fixture of the side of the vehicle Connect the black coupler clutch hose in parallel with the Clamp the clutch hose equipped lead wire to the 1 and cover 4 ignition coils LETT ERA aN Pere AS 20 7 A lt AP XJ 2 A AN 8 lt SSS 2 a 13 CABLE ROUTING SPEC v Pass this clamp through the low Fasten the frame ground lead er hole of the gusset and secure wire together with the igniter unit the clutch hose mounting screw The front end of the clamp must Clamp the seat lock wire to the be directed towards the inside of seat rail the vehicle The front end of the clamp must Pass the main harness through be directed downward the inside of the clutch hose and insert the harness i
27. nto the left of the headlight lower hole ge S A y 26 2 3 D LETT RT TS e A 20 1 Y 55 adf SS 9i NSA SSNS 1 Throttle cable 2 1 and 4 ignition coils 8 5 4 Neutral switch coupler 5 Pickup coupler 6 Side stand switch coupler 7 Fuel sender coupler Igniter unit 9 Starter cable 2 and 3 ignition coils 1 Stoppers 12 Negative lead wire of the bat tery 3 Relay assy S eS 5 Sse 57 di oS 2 eS eS xe ap 2S N CABLE ROUTING SPEC v Starter motor cable Right horn 5 Thermoswitch Install the HI tone source with H Starter relay marked label at the right of the vehicle Connect the 1 4 high tension cords in order of the cord num 12 Rib of the rear fender Seat lock wire Positive lead wire of the bat tery ber 60 Starter relay coupler Pass the T P S lead wire through 61 Fuse box the clamp of the 4 carburetor 62 Negative lead wire coupler of D To fuel sender the battery 63 Flasher relay 62 Oil lamp relay 65 Battery band CZ XD H de WT a LIN LS NS B EL N 1 4 Si ANA N IS M 24 42 c N 4 63 SA FN UA IS 9 Y ES 1 8 S nm 20 SH
28. prehensive explanations of all installation removal disassembly assembly repair and check procedures are laid out with the individual steps in sequential order CD 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 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 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 Jobs requiring more information such as special tools and technical data are described sequen tially 9 2 CLUTCH ENG REMOVING THE CLUTCH 3 1 Straighten the lock washer tab 2 Loosen clutch boss nut NOTE While holding the clutch boss 2 with the univer sal clutch holder loosen the clutch boss nut gt Universal clutch holder 90890 040
29. rvice 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 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 and will appear in future editions of this manual where applicable NOTE e This Service Manual contains information regarding periodic maintenance to the emission control system Please read this material carefully e Designs and specifications are subject to change without notice EAS00004 IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator a bystander or a person checking or repairing the mo torcycle CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer 00007 HOW USE THIS MANUAL This manual is intended as a handy easy to read reference book for the mechanic Com
30. s the carburetor heater relay OK place the battery CARBURETOR HEATING SYSTEM 6 Thermo switch e Remove the thermo switch from the thermo switch plate e Connect the pocket tester to the Q x 1 to the thermo switch as shown Tester positive probe black 1 Tester negative probe black red 2 e Check the thermo switch for continuity at the temperatures indicated below J Al COOL DOWN e Does the thermo switch operated properly YES the thermo switch The following procedure applies to all of the carburetor heating elements 7 Carburetor heater eRemove the carburetor heating element from the carburetor e Connect the pocket tester to the carburetor heating element as shown Tester positive probe heating element 1 Tester negative probe heating element body 2 I 9 e Measure the carburetor heater resistance _ Carburetor heating element resistance 12V 15 4 11 at 20 C 12 V 20 W 4 11 Q at 20 els the carburetor heating element OK V Replace the carbure tor heating element EAS00826 eCheck the entire carburetor heating sys tem s wiring Refer to CIRCUIT DIAGRAM els the carburetor heating system s wiring properly connected and without defects Properly connect or repair the carburetor heating system s wir ing XJR1300 2002 WIRING DIAGRAM for EUR
31. t lead wire of the handle switch and the right lead wire of the front flasher into the right of the headlight lower hole Bundle the handle switch lead wire and brake hose 2 near the guide wire of the stay headlight by use of this band 54 CABLE ROUTING SPEC v Match the wire harness the main switch lead wire and the meter lead wire to the wire har ness 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 Bundle the front left and right flasher lead wires by use of the clamp e 9 The wire harness the taillight lead wires and the rear left and right flasher lead wires must be arranged below the rib ofthe rear fender Clamp the wire harness and the rear left and right flasher lead wires The front end of the clamp must be directed forward Pass the rear left and right flash erlead wires through the respec tive holes in the rear fender CC EE CA Gem NC is Miz WV WV XA S eS 7 Uv JI abu D i E i JEN V wA gt I 1 ng LA OX TIT UD C Juri d i8 Ni 19 INTRODUCTION CHK PERIODIC MAINTENANCE LUBRICATION INTERVALS ADJ Q PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform r
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