Yamaha XJR1300(L) 99 User manual

EAS00000
XJR1300(L) ’99
SERVICE MANUAL
1998 by Yamaha Motor Co., Ltd.
1st Edition, August 1998
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.

NOTE:
CAUTION:
EAS00002 NOTICE
ThismanualwaswrittenbytheYamahaMotorCompanyprimarilyforusebyYamahadealersandtheir
qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is
assumedthatpersonsusingthisbooktoperformmaintenanceandrepairsonYamahamotorcyclehas
a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair
technology. Without such knowledge, attempted repairs or service to this model may render it unfit to
use and/or unsafe.
Yamaha Motor Cmpany, Ltd. is continually striving to improve all models manufactured by Yamaha.
Modifications and significant changes in specifications or procedures will be forwarded to all Autho-
rized yamaha dealers and will, where applicable, appear in future editions of this manual.
PARTICURARLY IMPORTANT INFORMATION
This materials distinguished by the following notation.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failureto followWARNINGinstructionscouldresultinsevereinjuryor deathto
themotorcycle operator,abystanderora personchecking orrepairing themo-
torcycle.
ACAUTIONindicates specialprecautions thatmustbe takentoavoid damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

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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,
exceptinChapter3(“PERIODICCHECKSANDADJUSTMENTS”),wherethesub-sectiontitle(-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 intheexplodeddiagramsindi-
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 intheexplodeddiagramsindi-
cate the following:
23 Apply locking agent (LOCTITE)
24 Replace the part

GEN
INFO
SPEC
ENG
CARB
CHAS
ELEC
CHK
ADJ
TRBL
SHTG
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION AND
ADJUSTMENTS
ENGINE OVERHAUL
CARBURETORS
CHASSIS
ELECTRICAL
TROUBLESHOOTING
1
2
3
4
5
6
7
8
EAS00013 INDEX

GEN
INFO
CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . .
MODEL CODE 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPORTANT INFORMATION 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION FOR REMOVAL AND DISASSEMBLY 1-2. . . . . . . . . .
REPLACEMENT PARTS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKETS, OIL SEALS AND O-RINGS 1-2. . . . . . . . . . . . . . . . . . . . . . . .
LOCK WASHERS/PLATES AND COTTER PINS 1-3. . . . . . . . . . . . . . . .
BEARINGS AND OIL SEALS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCLIPS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING OF THE CONNECTIONS 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEN
INFO

1-1
GEN
INFO
MOTORCYCLE IDENTIFICATION
EAS00014
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER (For E)
Thevehicleidentificationnumber 1isstamped
into the right side of the steering head.
EAS00018
MODEL CODE
The model code label 1is affixed to the frame.
This information will be needed to order spare
parts.

1-2
GEN
INFO
IMPORTANT INFORMATION
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DIS-
ASSEMBLY
1. Beforeremovaland disassembly, remove all
dirt, mud, dust, and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to “SPECIAL TOOLS”.
3. When disassembling, always keep mated
parts together. This includes gears, cylin-
ders, pistons and other parts that have been
“mated” through normal wear. Mated parts
mustalways bereusedorreplacedasanas-
sembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of disas-
sembly. This will speed up assembly and al-
low for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS00021
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
EAS00022
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket sur-
faces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.

1-3
GEN
INFO
IMPORTANT INFORMATION
CAUTION:
EAS00023
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
1andcotterpins.Aftertheboltornuthas been
tightenedto specification,bendthelockwasher
tabs and the cotter pin ends along a flat of the
bolt or nut.
EAS00024
BEARINGS AND OIL SEALS
1. Install bearings and oil seals so that the
manufacturer’s marks or numbers are vis-
ible. When installing oil seals, lubricate the
oil seal lips with a light coat of lithium soap
base grease. Oil bearings liberally when
installing, if appropriate.
1Oil seal
Donot spinthebearing withcompressedair
because this will damage the bearing sur-
faces.
1Bearing
EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip 1, make sure that the
sharp-edged corner 2is positioned opposite
the thrust 3that the circlip receives.
4Shaft

1-4
GEN
INFO
CHECKING THE CONNECTIONS
NOTE:
NOTE:
NOTE:
EAS00026
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
lead
coupler
connector
2. Check:
lead
coupler
connector
Moisture Dry with an air blower.
Rust/stains Connect and disconnect sev-
eral times.
3. Check:
all connections
Loose connection Connect properly.
If the pin 1on the terminal is flattened, bend it
up.
4. Connect:
lead
coupler
connector
Make sure that all connections are tight.
5. Check:
continuity
(with a pocket tester)
Pocket tester
90890-03112
If there is no continuity, clean the terminals.
When checking the wire harness, perform
steps (1) to (3).
As a quick remedy, use a contact revitalizer
available at most part stores.

1-5
GEN
INFO
SPECIAL TOOLS
EB104000
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly.
Useonlytheappropriatespecialtoolsasthiswillhelppreventdamagecausedbytheuseofinappropri-
ate tools or improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name/Function Illustration
90890-01268
90890-01403 Exhaust & steering nut wrench Ring nut wrench
This tools are used to loosen and tighten
the steering ring nut.
90890-01304 Piston pin puller
This tool is used to remove the piston pins.
90890-01312 Fuel level gauge
This tool is used to measure the fuel level in
the float chamber.
90890-01367
90890-01374 Fork seal driver weight Fork seal driver attachment (ø43)
These tools are used when installing the
fork seal.
90890-01326
90890-01327 T-handle Damper rod holder
These tools are used to hold the damper
rod assembly when loosening or tightening
the damper rod assembly bolt.
90890-03081
90890-04082 Compression gauge Adapter
These tools are used to measure engine
compression.
90890-03094 Vacuum gauge
This guide is used to synchronize the car-
buretors.
90890-03112 Pocket tester
This tool is used to check the electrical sys-
tem.

1-6
GEN
INFO
SPECIAL TOOLS
Tool No. Tool name/Function Illustration
90890-03113 Engine tachometer
This tool is used to check engine speed.
90890-03141 Timing light
This tool is used to check the ignition tim-
ing.
90890-03158 Carburetor angle driver
This tool is used to turn the pilot screw
when adjusting the engine idling speed.
90890-04016 Valve guide reamer, remover and installer
(5.5 mm)
These tools are used to rebore, remove and
install the valve guide.
90890-04019 Valve spring compressor
This tool is used to remove or install the
valve assemblies.
90890-03153
90890-03124 Oil pressure gauge Oil pressure adaptor B
These tools are used to measure the engine
oil pressure.
90890-04086 Clutch holding tool
This tool is used to hold the clutch boss
when removing or installing the clutch boss
nut.
90890-04101 Valve lapper
This tool is used for removing and installing
the valve lifter and for lapping the valve.
90890-04110 Tappet adjusting tool
This tool is necessary to replace valve ad-
justing pads.

1-7
GEN
INFO
SPECIAL TOOLS
Tool No. Tool name/Function Illustration
90890-06754 Ignition checker
This tool is used to check the ignition sys-
tem components.
90890-85505 Yamaha bond No. 1215
This bond is used to seal two mating sur-
faces (e.g., crankcase mating surfaces).

GEN
INFO

SPEC
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SPECIFICATIONS 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONVERSION TABLE 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL TIGHTENING TORQUES 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION POINT AND GRADE OF LUBRICANT 2-21. . . . . . . . . . . . .
ENGINE 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION DIAGRAMS 2-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPEC