This is the cut pages sample.

Download all 383 page(s) at

Full download: http://manualplace.com/download/yamaha-

Yamaha Xjr1300 (1999 2003) Service Manual
Thank you for purchasing an e-book through Korn’s Bookshop. If you have any problems
or questions you can get in touch with me via email on [email protected]. I hope you are
satisfied with your purchase and enjoy your book, happy reading!

Check out my other great books by visiting Korn’s Bookshop on eBay.

Please note:
You may not copy, reproduce or redistribute this e-book in any form for commercial purposes. You are hereby
granted a licence to read, store and print this book for personal use only. If you think you may have purchased
this book from an unauthorised source either on eBay or elsewhere please contact me for clarification. Kornel
Lambert (eBay ID ‘korn_london’) is the only permitted distribution agent for these books. Help stamp out piracy!
EAS00002

NOTICE
This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their
qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is
assumed that persons using this book to perform maintenance and repairs on Yamaha motorcycle has
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.

NOTE:
PARTICURARLY IMPORTANT INFORMATION
This materials distinguished by the following notation.

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.

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.

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.
1 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.
8 Jobs requiring more information (such as special tools and technical data) are described sequen-
tially.
2 1 4

5
8

7
 EAS00009

1 2

GEN SYMBOLS
SPEC The following symbols are not relevant to every
INFO vehicle.
Symbols 1 to 8 indicate the subject of each
3 4
chapter.
CHK 1 General information
ADJ ENG
2 Specifications
3 Periodic checks and adjustments
5 6
4 Engine
CHAS 5 Carburetor(-s)
CARB
6 Chassis
7 8 7 Electrical system
8 Troubleshooting
TRBL
ELEC SHTG
Symbols 9 to 16 indicate the following.
9 10
9 Serviceable with engine mounted
10 Filling fluid
11 Lubricant
12 Special tool
11 12
13 Tightening torque
14 Wear limit, clearance
15 Engine speed

13 14 16 Electrical data

15 16

17 18 19
Symbols 17 to 22 in the exploded diagrams indi-
cate the types of lubricants and lubrication
points.
17 Engine oil
18 Gear oil
20 21 22
19 Molybdenum disulfide oil
20 Wheel bearing grease
21 Lithium soap base grease
22 Molybdenum disulfide grease
23 24
Symbols 23 to 24 in the exploded diagrams indi-
cate the following:
23 Apply locking agent (LOCTITE)
24 Replace the part
EAS00013

INDEX
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC
2
PERIODIC INSPECTION AND
ADJUSTMENTS CHK
ADJ 3
ENGINE OVERHAUL ENG
4
CARBURETORS CARB
5
CHASSIS CHAS
6
ELECTRICAL ELEC
7
TROUBLESHOOTING TRBL
SHTG 8
GEN
INFO 1
 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
MOTORCYCLE IDENTIFICATION INFO
EAS00014

GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017

VEHICLE IDENTIFICATION NUMBER (For E)

The vehicle identification number 1 is stamped
into the right side of the steering head.

EAS00018

MODEL CODE
The model code label 1 is affixed to the frame.
This information will be needed to order spare
parts.

1-1
 GEN
IMPORTANT INFORMATION INFO
EAS00020

IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DIS-
ASSEMBLY
1. Before removal and 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
must always be reused or replaced as an as-
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.

1-2
 GEN
IMPORTANT INFORMATION INFO
EAS00023

LOCK WASHERS/PLATES AND COTTER

PINS
After removal, replace all lock washers/plates
1 and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock washer
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.
1 Oil seal

CAUTION:
Do not spin the bearing with compressed air
because this will damage the bearing sur-
faces.

1 Bearing

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 2 is positioned opposite
the thrust 3 that the circlip receives.
4 Shaft

1-3
 GEN
CHECKING THE CONNECTIONS INFO
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.
NOTE:
If the pin 1 on the terminal is flattened, bend it
up.

4. Connect:

lead

coupler

connector
NOTE:
Make sure that all connections are tight.

5. Check:

continuity
(with a pocket tester)

Pocket tester
90890-03112

NOTE:

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.

1-4
 GEN
SPECIAL TOOLS INFO
EB104000

SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly.
Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri-
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 Exhaust & steering nut wrench
90890-01403 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 Fork seal driver weight
90890-01374 Fork seal driver attachment (ø43)
These tools are used when installing the
fork seal.

90890-01326 T-handle
90890-01327 Damper rod holder
These tools are used to hold the damper
rod assembly when loosening or tightening
the damper rod assembly bolt.
90890-03081 Compression gauge
90890-04082 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.

1-5
 GEN
SPECIAL TOOLS INFO

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 Oil pressure gauge
90890-03124 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.

1-6
 GEN
SPECIAL TOOLS INFO

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).

1-7
SPEC
2
 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

 GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
Model XJR1300(L)
Model code: 5EA2/5EA3/5EA4
Dimensions:
Overall length 2175 mm (GB) (D) (NL) (B) (F) (E) (P) (I) (GR)
(SF) (AUS)
2250 mm (N) (SF) (G) (A)
Overall width 775 mm
Overall height 1115 mm
Seat height 775 mm
Wheelbase 1500 mm
Minimum ground clearance 120 mm
Minimum turning radius 2800 mm
Basic weight:
With oil and full fuel tank 253 kg
Engine:
Engine type Air-cooled 4-stroke, DOHC
Cylinder arrangement Forward-inclined parallel 4-cylinder
Displacement 1250 cm3
Bore
stroke 79.0
63.8 mm
Compression ratio 9.7: 1
Compression pressure (STD) 1050 kPa (10.5 kg/cm2,10.5 bar) at 400 r/min
Starting system Electric starter
Lubrication system: Wet sump
Oil type or grade: SE or higher grade
Engine oil

Engine oil
Periodic oil change 3.0 L
With oil filter replacement 3.35 L
Total amount 4.2 L
Oil cooler capacity (including all routes) 0.2 L
Air filter: Dry type element
Fuel:
Type Regular unleaded gasoline
Fuel tank capacity 21 L
Fuel reserve amount 4.5 L

2-1
 GENERAL SPECIFICATIONS SPEC

Model XJR1300(L)
Carburetor:
Type/quantity BS36/4
Manufacturer MIKUNI
Spark plug:
Type quantity DPR8EA-9/X24EPR-U9 4
Manufacturer NGK/DENSO
Spark plug gap 0.8 X 0.9 mm
Clutch type: Wet, multiple-disc
Transmission:
Primary reduction system Spur gear
Primary reduction ratio 98/56 (1.750)
Secondary reduction system Chain drive
Secondary reduction ratio 38/17 (2.235)
Transmission type Constant mesh 5-speed
Operation Left foot operation
Gear ratio 1st 40/14 (2.857)
2nd 36/18 (2.000)
3rd 33/21 (1.571)
4th 31/24 (1.292)
5th 29/26 (1.115)
Chassis:
Frame type Double cradle
Caster angle 25.5

Trail 100 mm
Tire:
Type Tubeless
Size front 120/70ZR17 (58W)
rear 180/55ZR17 (73W)
Manufacturer front MICHELIN/DUNLOP/BRIDGESTONE
rear MICHELIN/DUNLOP/BRIDGESTONE
Type front MACADAM 90X/D207F/BT57F
rear MACADAM 90X/D207/BT57R
Tire pressure (cold tire):
Maximum load-except motorcycle 207 kg
Loading condition A * 0 X 90 kg
front 250 kPa (2.5 kg/cm2, 2.5 bar)
rear 250 kPa (2.5 kg/cm2, 2.5 bar)
Loading condition B * 90 X 207 kg
front 250 kPa (2.5 kg/cm2, 2.5 bar)
rear 290 kPa (2.9 kg/cm2, 2.9 bar)
High-speed riding
front 250 kPa (2.5 kg/cm2, 2.5 bar)
rear 290 kPa (2.9 kg/cm2, 2.9 bar)
*Load is the total weight of cargo, rider, passenger, and accessories.

2-2
 GENERAL SPECIFICATIONS SPEC

Model XJR1300(L)
Brake:
Front brake type Dual disc brake
operation Right hand operation
Rear brake type Single disc brake
operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm
Shock absorber:
Front shock absorber Coil spring/Oil Damper
Rear shock absorber Coil spring/Gas-oil damper
Wheel travel:
Front wheel travel 130 mm
Rear wheel travel 110 mm
Electrical:
Ignition system T.C.I. (Digital)
Generator system A.C. generator
Battery type GT14B-4
Battery capacity 12 V 12AH
Headlight type: Halogen bulb
Bulb wattage
quantity:
Headlight 12 V 60 W/55 W
1
Auxiliary light 12 V 4 W
1
Tail/brake light 12 V 5 W/21 W
2
Flasher light 12 V 21 W
4
Meter light 12 V 1.7 W
4
Neutral indicator light 12 V 1.7 W
1
High beam indicator light 12 V 3.4 W
1
Oil level indicator light 12 V 1.7 W
1
Turn indicator light 12 V 1.7 W
2

2-3
Yamaha Xjr1300 (1999 2003) Service Manual
Full download: http://manualplace.com/download/yamaha-xjr1300-1999-2003-service-manual/

MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONS
ENGINE

Model Standard Limit

Cylinder head:
Warp limit


0.1 mm

Cylinder:
Bore size 79.00
79.01 mm



Taper limit


0.05 mm
Out of round limit


0.05 mm
Wear limit


79.1 mm
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 “A” 35.95
36.05 mm 35.85 mm

“B” 28.248
28.348 mm 28.15 mm
“C” 7.95
8.05 mm



Exhaust “A” 35.95
36.05 mm 35.85 mm
“B” 28.248
28.348 mm 28.15 mm
“C” 7.95
8.05 mm



Camshaft runout limit


0.03 mm

2-4
This is the cut pages sample. Download all 383 page(s) at: ManualPlace.com