Yamaha 2002 XJR1300 User 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
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.

NOTE:
CAUTION:
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 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 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 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.
!This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
!Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person checking or repairing the mo-
torcycle.
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.

12
6
4
5
7
3
8
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) ap-
pears.
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 sequen-
tially.

21
1
3
5
7
9
2
4
8
6
23 24
2220
18 1917
1615
1413
11 12
10
GEN
INFO SPEC
ENG
CARB
ELEC
CHAS
CHK
ADJ
TRBL
SHTG
EAS00009
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols 1to 8indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Engine
5Carburetor(-s)
6Chassis
7Electrical system
8Troubleshooting
Symbols 9to 16 indicate the following.
9Serviceable with engine mounted
10 Filling fluid
11 Lubricant
12 Special tool
13 Tightening torque
14 Wear limit, clearance
15 Engine speed
16 Electrical data
Symbols 17 to 22 in the exploded diagrams indi-
cate the types of lubricants and lubrication
points.
17 Engine oil
18 Gear oil
19 Molybdenum disulfide oil
20 Wheel bearing grease
21 Lithium soap base grease
22 Molybdenum disulfide grease
Symbols 23 to 24 in the exploded diagrams indi-
cate the following:
23 Apply locking agent (LOCTITE)
24 Replace the part

CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE/LUBRICATION INTERVALS 20. . . . . . .
ENGINE 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE CLUTCH LEVER 22. . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT BRAKE 23. . . . . . . . . . . . . . . . . . . . . . . . .
CARBURETORS
AIR INDUCTION SYSTEM 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INJECTION 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CUTOFF VALVE 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INDUCTION SYSTEM DIAGRAMS 25. . . . . . . . . . . . . . . . . . . . .
CHECKING THE AIR INDUCTION SYSTEM 26. . . . . . . . . . . . . . . .
CHASSIS
FRONT AND REAR BRAKES 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE MASTER CYLINDER 27. . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING AND INSTALLING THE
FRONT BRAKE MASTER CYLINDER 28. . . . . . . . . . . . . . . . . .
REAR BRAKE CALIPER 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL
CARBURETOR HEATING SYSTEM 32. . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XJR1300 2002 WIRING DIAGRAM (for EUR)
XJR1300P 2002 WIRING DIAGRAM (for AUS)

1
SPEC
GENERAL SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model XJR1300 (P)
Model code: 5EAT/5EAW (EUR)
5EAU/5EAX (for D)
5EAV/5EAY (for AUS)
Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
2,175 mm
775 mm
1,115 mm
790 mm
1,510 mm
120 mm
2,800 mm
Basic weight:
With oil and full fuel tank 247 kg
Carburetor:
Type/quantity
Manufacturer
BSR37/4
MIKUNI
Transmission:
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Transmission type
Operation
Gear ratio 1st
2nd
3rd
4th
5th
Spur gear
98/56 (1.750)
Chain drive
39/18 (2.167)
Constant mesh 5-speed
Left foot operation
40/14 (2.857)
36/18 (2.000)
33/21 (1.571)
31/24 (1.292)
29/26 (1.115)

2
SPEC
GENERAL SPECIFICATIONS
Model XJR1300 (P)
Tire:
Type
Size front
rear
Manufacturer front
rear
Type front
rear
Tubeless
120/70ZR17 (58W)/
120/70ZR17 M/C (58W)
180/55ZR17 (73W)/
180/55ZR17 M/C (73W)
MICHELIN/DUNLOP
MICHELIN/DUNLOP
MACADAM90X E/D220F ST M
MACADAM90X E/D220 ST M
Tire pressure (cold tire):
Maximum load-except motorcycle
Loading condition A *
front
rear
Loading condition B *
front
rear
High-speed riding
front
rear
203 kg
0 !90 kg
250 kPa (2.5 kg/cm2, 2.5 bar)
250 kPa (2.5 kg/cm2, 2.5 bar)
90 !203 kg
250 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
SPEC
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
Model Standard Limit
Cylinder head:
Warp limit !!! 0.2 mm
Cylinder:
Bore size
Taper limit
Out of round limit
Wear limit
79.00 !79.01 mm
!!!
!!!
!!!
!!!
0.05 mm
0.1 mm
79.1 mm
Camshaft:
Drive method
Cam cap inside diameter
Camshaft outside diameter
Shaft-to-cap clearance
Cam dimensions
Chain drive (Center)
25.000 !25.021 mm
24.967 !24.980 mm
0.020 !0.054 mm
!!!
!!!
!!!
!!!
Intake “A”
“B”
Exhaust “A”
“B”
Camshaft runout limit
35.95 !36.05 mm
28.058 !28.158 mm
35.95 !36.05 mm
28.045 !28.145 mm
!!!
35.85 mm
27.958 mm
35.85 mm
27.945 mm
0.03 mm