Yamaha 2002 XJR1300 Service Manual Download | Manualshive

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30

FRONT AND REAR BRAKES

CHAS

Order

Job/Part

Q

’

ty

Remarks

1
2
3
4

Removing the rear brake caliper

Brake fluid
Union bolt
Copper washer
Brake hose
Brake caliper

1
2
1
1

Remove the parts in the order listed.
Drain.

For installation, reverse the removal
procedure.

40 Nm (4.0 m

!

kg)

30 Nm (3.0 m

!

kg)

EAS00616

REAR BRAKE CALIPER

«
...
35
36
37
38
39
...
»

Summary of Contents for 2002 XJR1300

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Page 3: ... 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 ...

Page 4: ...is 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 w...

Page 5: ...he 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 i...

Page 6: ... Troubleshooting Symbols 9 to 16 indicate the following 9 Serviceable 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 Lith...

Page 7: ...2 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 2...

Page 8: ... 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 ...

Page 9: ...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 car...

Page 10: ... 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 ...

Page 11: ...18 000 mm 18 045 mm 17 971 mm Carburetor I D mark Main 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 speed Intake vacuum 5EAT 30 107 5 80 5...

Page 12: ...ened Part name Thread size Q ty Tightening torque Remarks g size y Nm m kg Carburetor joint and carburetor Carburetor and air filter joint Air induction system pipe joint Air induction system Band Clamp Bolt M4 0 7 M4 0 7 M6 1 0 4 4 4 2 2 7 2 7 3 7 10 0 27 0 27 0 37 1 0 ...

Page 13: ...ng free length Fitting length Spring rate K1 K2 K3 K4 Stroke K1 K2 K3 K4 93 mm 230 mm 209 mm 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 13 mm 13 50 mm 50 67 5 mm 67 5 93 0 mm 225 mm Front wheel Type Rim size Rim material Rim runout limit radial lateral Cast wheel 17 MT3 50 or 17 M C MT3 50 Aluminum 1 mm 0 5 mm Rear wheel Type Rim size Rim material Rim run...

Page 14: ...TENANCE SPECIFICATIONS Tightening torques Part to be tightened Part name Thread size Q ty Tightening torque Remarks g y Nm m kg Throttle cable and carburetor Ignition coil Nut Nut M6 1 0 M6 1 0 2 2 4 6 5 0 4 0 65 ...

Page 15: ...er No load regulated voltage Semi conductor field control type B3G DENSO 14 2 14 8 V 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 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 A 4 2 4 6 Ω...

Page 16: ... stop switch 17 Relay assy 18 Guide wire 19 Fuel tank drain hose 20 Fuel tank breather hose 1 Starter motor cable 2 Battery negative lead wire 3 Carburetor heater plug 4 A C generator coupler 5 Rear stop switch coupler 6 Neutral lead wire 7 Pickup lead wire 8 Side stand switch lead wire 9 T P S 10 Tank fitting 11 1 and 4 ignition coil lead wires 12 Horn lead wire SPEC CABLE ROUTING CABLE ROUTING ...

Page 17: ... 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 SPEC CABLE ROUTING E Bundle the 3 and 4 high ten sion cords on the head cover mounting bolt at the 3 cord by use of this...

Page 18: ... drain hose and fuel tank breather hose and arrange the two types of hose properly J Match the paint mark of the air cleaner drain hose to the lower end of the guide wire SPEC CABLE ROUTING K Clamp the wire harness to the seat rail at the front end of the bracket The front end of the clamp must be directed down ward L Clamp the wire harness M Pass the wire harness between the handle standing lug m...

Page 19: ...e front end of the band must be directed downward C Bundle the four high tension cords the 1 and 2 cords up and the 3 and 4 cords down by use of this band Position the leading ends of the cords near but not below the lower front end of the air induc tion system assy 1 Gusset 2 Tension pipe 1 3 2 high tension cord 4 1 high tension cord 5 Wire starter 6 A C generator 7 Oil filter cover 8 Side stand ...

Page 20: ...tch lead wire using this clamp first route the lead wire between the pickup cover the oil filter cover the A C generator and the starter motor Next as with the engine lead wire route the lead wire through the right side of the vehicle H Clamp the clutch hose I Secure the grommet of the clutch hose by use of this holder wire of the gusset J Pass the horn lead wire between the clutch hose and the fr...

Page 21: ...ected towards the inside of the vehicle M Pass the main harness through the inside of the clutch hose and insert the harness into the left of the headlight lower hole N Fasten the frame ground lead wire together with the igniter unit mounting screw O Clamp the seat lock wire to the seat rail The front end of the clamp must be directed downward ...

Page 22: ...the HI tone source with H marked label at the right of the vehicle B Connect the 1 4 high tension cords in order of the cord num ber C Pass the T P S lead wire through the clamp of the 4 carburetor D To fuel sender 1 Throttle cable 2 1 and 4 ignition coils 3 T P S 4 Neutral switch coupler 5 Pickup coupler 6 Side stand switch coupler 7 Fuel sender coupler 8 Igniter unit 9 Starter cable 10 2 and 3 i...

Page 23: ...dy with contact with the stop pers L Direct the crimping side of the battery positive lead wire downward and connect the lead wire M Connect the starter motor cable to face outward at an angle of about 45 degrees E Clamp the starter motor cable and the negative lead wire of the battery to the seat rail be tween the air cleaner mounting bracket and the tank mounting bracket F Connect the fuel sende...

Page 24: ...re harness to the seat rail on the wire harness positioning tape and at the im mediate rear of the side cover mounting bracket on the seat rail The front end of the clamp must face downward and be posi tioned inside the back stay N Secure the two positive lead wires of the battery the nega tive lead wire coupler of the battery and the wire harness by use of this battery band O Clamp the wire harne...

Page 25: ...eft flasher lead wire 8 Front right flasher lead wire 9 Brake hose 2 10 Brake hose 1 11 Right handle switch lead wire 12 Wire harness 13 Taillight lead wires 14 Taillight bracket 15 Rib of the rear fender SPEC CABLE ROUTING C Bundle the handle switch lead wire the clutch hose and the starter cable under the crown handle by use of this band The handle switch lead wire must be passed outside the clu...

Page 26: ...he 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 J Bundle the front left and right flasher lead wires by use of the clamp E 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 F Insert the right lead ...

Page 27: ... OR MAINTENANCE JOB 1 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 Chec...

Page 28: ...e 21 Carburetors Check starter choke operation Adjust engine idling speed and synchronization 22 Engine oil Change Check oil level and vehicle for oil leakage 23 Engine oil filter element Replace 24 Front and rear brake switches Check operation 25 Moving parts and cables Lubricate 26 Lights signals and switches Check operation Adjust headlight beam The air filter needs more frequent service if you...

Page 29: ...from the handlebar grip to the clutch lever a While pushing the clutch lever forward turn the adjusting dial 1 until the clutch lever is in the desired position Be sure to align the setting on the adjusting dial with the arrow mark 2 on the clutch lever hold er Position 1 Distance is the larg est Position 5 Distance is the small est ...

Page 30: ... from the throttle grip to the brake lever a While pushing the brake lever forward turn the adjusting dial 1 until the brake lever is in the desired position 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 5 Distance is the small est ...

Page 31: ...VE 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 pres...

Page 32: ...ION SYSTEM CARB EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Reed valve 2 Air cleaner 3 Air cutoff valve 4 Vacuum hose cylinder 3 A To the air cutoff valve B To cylinder 1 C To cylinder 2 D To cylinder 3 E To cylinder 4 ...

Page 33: ...y Cracks damage Replace pipes Cracks damage Replace 2 Check fibre reed 1 fibre reed stopper reed valve seat Cracks damage Replace the reed valve 3 Measure fibre reed bending limit a Out of specification Replace the reed valve Fibre reed bending limit 0 2 mm 1 Surface plate 4 Check air cutoff valve Cracks damage Replace ...

Page 34: ...lt Copper washers Brake hose Master cylinder bracket Master cylinder 1 2 1 1 3 2 1 1 Remove the parts in the order listed Drain Refer to DISASSEMBLING ASSEM BLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER in chapter 6 Manual No 5EA3 AE1 For installation reverse the removal procedure 10 Nm 1 0 m kg 30 Nm 3 0 m kg CHASSIS FRONT AND REAR BRAKES EAS00586 FRONT BRAKE MASTER CYLINDER ...

Page 35: ...r First tighten the upper bolt then the lower bolt Brake master cylinder bolt 10 Nm 1 0 m kg 2 Install copper washers New 1 brake hose 1 2 brake hose 2 3 union bolt 4 Union bolt 30 Nm 3 0 m kg Proper brake hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTING When installing the brake hose 1 2 onto the brake master cylinder make sure that the brake pipe touches the ...

Page 36: ... 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 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 Manual No 5EA3 AE1 5 Check brake fluid level Below the ...

Page 37: ... 1 2 3 4 Removing the rear brake caliper Brake fluid Union bolt Copper washer Brake hose Brake caliper 1 2 1 1 Remove the parts in the order listed Drain For installation reverse the removal procedure 40 Nm 4 0 m kg 30 Nm 3 0 m kg EAS00616 REAR BRAKE CALIPER ...

Page 38: ...e rear brake caliper Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw 4 2 1 2 2 4 2 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 6 Nm 0 6 m kg EAS00617 ...

Page 39: ... 2 Fuse main 3 Battery 5 Main switch 6 Fuse ignition 14 Neutral switch 51 Carburetor heater relay 52 Thermo switch 53 Carburetor heater CARBURETOR HEATING SYSTEM ELEC ELECTRICAL CARBURETOR HEATING SYSTEM ...

Page 40: ...ES in chapter 8 Manual No 5EA3 AE1 Is the neutral switch OK YES NO Replace the neutral switch 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 carburet...

Page 41: ...rburetor heating element from the carburetor Connect the pocket tester to the carburetor heating 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 wiri...

Page 42: ......

Page 43: ... Sidestand switch 16 Start switch 17 Engine stop switch 18 Lights switch 19 Front brake switch 20 Handlebar switches right 21 Alarm 22 Fuse turn 23 Fuse signal 24 Fuse headlight 25 Horn 26 Flasher relay 27 Rear brake switch 28 Oil level relay 29 Oil level switch 30 Meter assembly 31 Speedometer 32 Neutral indicator light 33 Tachometer 34 Fuel gauge 35 Meter lights 36 Turn signal indicator light le...

Page 44: ... position sensor 14 Neutral switch 15 Sidestand switch 16 Start switch 17 Engine stop switch 18 Front brake switch 19 Handlebar switches right 20 Carburetor heater relay 21 Thermo switch 22 Carburetor heater 23 Fuse signal 24 Fuse headlight 25 Meter assembly 26 Speedometer 27 Neutral indicator light 28 Tachometer 29 Fuel gauge 30 Meter lights 31 Turn signal indicator light left 32 Turn signal indi...

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