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YAMAHA_XJR1300(L)_99-(1999-2003)_SERVICE REPAIR_MANUAL
YAMAHA_XJR1300(L)_‘99-(1999-2003)_SERVICE REPAIR_MANUAL
Pages 383
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER MODEL CODE
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY REPLACEMENT PARTS GASKETS, OIL SEALS AND O-RINGS LOCK WASHERS/PLATES AND COTTER PINS BEARINGS AND OIL SEALS CIRCLIPS
CHECKING OF THE CONNECTIONSC
SPECIAL TOOLS
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS MAINTENANCE SPECIFICATIONS
ENGINE CHASSIS ELECTRICAL
CONVERSION TABLE GENERAL TIGHTENING TORQUES LUBRICATION POINT AND GRADE OF LUBRICANT
ENGINE CHASSIS
LUBRICATION DIAGRAMS CABLE ROUTING
CHAPTER 3
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
SEAT SIDE COVER AND FUEL TANK
ENGINE
ADJUSTING THE VALVE CLEARANCE SYNCHRONIZING THE CARBURETOR ADJUSTING THE IDLING SPEED ADJUSTING THE THROTTLE CABLE FREE PLAY CHECKING THE SPARK PLUGS CHECKING THE IGNITION TIMING MEASURING THE COMPRESSION PRESSURE CHECKING THE ENGINE OIL LEVEL CHECKING THE ENGINE OIL MEASURING THE ENGINE OIL PRESSURE ADJUSTING THE CLUTCH LEVER CHECKING THE CLUTCH FLUID LEVEL BLEEDING THE HYDRAULIC CLUTCH SYSTEM CLEANING THE AIR FILTER ELEMENT CHECKING THE CARBURETOR JOINTS AND INTAKE
MANIFOLDS CHECKING THE FUEL AND VACUUM HOSES CHECKING THE CRANKCASE BREATHER HOSE CHECKING THE EXHAUST SYSTEM
CHASSIS
CHECKING THE TIRES CHECKING THE WHEELS CHECKING AND LUBRICATING THE CABLES LUBRICATING THE LEVERS AND PEDALS
ADJUSTING THE FRONT BRAKE ADJUSTING THE REAR BRAKE CHECKING THE BRAKE FLUID LEVEL CHECKING THE BRAKE PADS ADJUSTING THE REAR BRAKE LIGHT SWITCH BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJUSTING THE SHIFT PEDAL ADJUSTING THE DRIVE CHAIN SLACK LUBRICATING THE DRIVE CHAIN CHECKING AND ADJUSTING THE STEERING HEAD CHECKING THE FRONT FORK
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY CHECKING THE FUSES REPLACING THE HEADLIGHT BULB ADJUSTING THE HEADLIGHT BEAM
CHAPTER 4
ENGINE OVERHAUL
ENGINE
LEADS, HOSES AND EXHAUST PIPES LEADS AND DRIVE SPROCET ENGINE INSTALLING THE ENGINE
CAMSHAFT
CYLINDER HEAD COVER CAMSHAFTS REMOVING THE CAMSHAFTS CHECKING THE CAMSHAFTS CHECKING THE CAMSHAFT SPROCKETS AND TIMING CHAIN GUIDES CHECKING THE TIMING CHAIN TENSIONER INSTALLING THE CAMSHAFTS
CYLINDER HEAD
REMOVING THE CYLINDER HEAD CHECKING THE CYLINDER HEAD INSTALLING THE CYLINDER HEAD
VALVES AND VALVE SPRINGS
REMOVING THE VALVES CHECKING THE VALVES AND VALVE GUIDES CHECKING THE VALVE SEATS CHECKING THE VALVE SPRINGS CHECKING THE VALVE LIFTERS INSTALLING THE VALVES
CYLINDERS AND PISTONS
REMOVING THE CYLINDERS AND PISTONS CHECKING THE CYLINDERS AND PISTONS CHECKING THE PISTON RINGS INSTALLING THE PISTONS AND CYLINDERS
CLUTCH
CLUTCH COVER CLUTCH REMOVING THE CLUTCH CHECKING THE FRICTION PLATES CHECKING THE PRESSURE PLATE CHECKING THE CLUTCH PUSH RODS INSTALLING THE CLUTCH MASTER CYLINDER CHECKING THE CLUTCH MASTER CYLINDER ASSEMBLING THE CLUTCH MASTER CYLINDER INSTALLING THE CLUTCH MASTER CYLINDER CLUTCH RELEASE CYLINDER DISASSEMBLING THE CLUTCH RELEASE CYLINDER CHECKING THE CLUTCH RELEASE CYLINDER INSTALLING THE CLUTCH RELEASE CYLINDER
OIL PUMP CHECKING THE OIL PUMP ASSEMBLING THE OIL PUMP INSTALLING THE OIL PUMP
SHIFT SHAFT CHECKING THE SHIFT SHAFT CHECKING THE STOPPER LEVER INSTALLING THE SHIFT SHAFT
TIMING PLATE AND PICKUP COIL
OIL PAN REMOVING THE OIL PAN CHECKING THE RELIEF VALVE CHECKING THE OIL DELIVERY PIPES CHECKING THE OIL STRAINER INSTALLING THE OIL STRAINER INSTALLING THE OIL PAN
CRANKCASE DISASSEMBLING THE CRANKCASE CHECKING THE CRANKCASE ASSEMBLING THE CRANKCASE
STARTER CLUTCH CHECKING THE STARTER CLUTCH CHECKING THE GENERATOR SHAFT INSTALLING THE STARTER CLUTCH ROLLER
CRANKSHAFT
CRANKSHAFT CONNECTING ROD REMOVING THE CRANKSHAFT ASSEMBLY REMOVING THE CONNECTING RODS
CHECKING THE TIMING CHAIN CHECKING THE HY-VO CHAIN
CHAPTER 5
CARBURETORS
CARBURETORS
CHECKING THE CARBURETORS ASSEMBLING THE CARBURETORS INSTALLING THE CARBURETORS MEASURING AND ADJUSTING THE FUEL LEVEL CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR CHECKING THE FUEL COCK CHECKING THE FUEL COCK OPERATION CHAPTER 6
CHASSIS
FRONT WHEEL AND BRAKE DISCS
REMOVING THE FRONT WHEEL CHECKING THE FRONT WHEEL CHECKING THE BRAKE DISCS INSTALLING THE FRONT WHEEL ADJUSTING THE FRONT WHEEL STATIC BALANCE
REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET
REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET REMOVING THE REAR WHEEL CHECKING THE REAR WHEEL CHECKING THE REAR WHEEL DRIVE HUB CHECKING AND REPLACING THE REAR WHEEL SPROCKET INSTALLING THE REAR WHEEL ADJUSTING THE REAR WHEEL STATIC BALANCE
FRONT AND REAR BRAKES
FRONT BRAKE PADS REAR BRAKE PADS REPLACING THE FRONT BRAKE PADS REPLACING THE REAR BRAKE PADS FRONT BRAKE MASTER CYLINDER REAR BRAKE MASTER CYLINDER DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER DISASSEMBLING THE REAR BRAKE MASTER CYLINDER CHECKING THE FRONT AND REAR BRAKE MASTER
CYLINDERS ASSEMBLING AND INSTALLING THE FRONT BRAKE
MASTER CYLINDERS ASSEMBLING THE REAR BRAKE MASTER CYLINDER FRONT BRAKE CALIPER REAR BRAKE CALIPER DISASSEMBLING THE FRONT BRAKE CALIPERS DISASSEMBLING THE REAR BRAKE CALIPER CHECKING THE FRONT AND REAR BRAKE CALIPERS ASSEMBLING AND INSTALLING THE FRONT BRAKE
CALIPERS ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER
FRONT FORK
REMOVING THE FRONT FORK LEGS DISASSEMBLING THE FRONT FORK LEGS CHECKING THE FRONT FORK LEGS ASSEMBLING THE FRONT FORK LEGS INSTALLING THE FRONT FORK LEGS
HANDLEBAR
REMOVING THE HANDLEBAR CHECKING THE HANDLEBAR INSTALLING THE HANDLEBAR
STEERING HEAD
LOWER BRACKET REMOVING THE LOWER BRACKET CHECKING THE STEERING HEAD INSTALLING THE STEERING HEAD
REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN
HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER DISPOSING OF A REAR SHOCK ABSORBER AND
GAS CYLINDER REMOVING THE SWINGARM CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND
GAS CYLINDER CHECKING THE SWINGARM CHECKING THE DRIVE CHAIN CHAPTER 7
ELECTRICAL
ELECTRICAL COMPONENTS
SWITCHES
CHECKING SWITCH CONTINUITY
CHECKING THE SWITCHES
CHECKING THE BULBS AND BULB SOCKETS
TYPES OF BULBS CHECKING THE CONDITION OF THE BULBS CHECKING THE CONDITION OF THE BULB SOCKETS
IGNITION SYSTEM
CIRCUIT DIAGRAM TROUBLESHOOTING
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM STARTING CIRCUIT CUTOFF SYSTEM OPERATION TROUBLESHOOTING STARTER MOTOR
CHARGING SYSTEM
CIRCUIT DIAGRAM TROUBLESHOOTING AC GENERATOR
LIGHTING SYSTEM
CIRCUIT DIAGRAM TROUBLESHOOTING CHECKING THE LIGHTING SYSTEM
SIGNALING SYSTEM
CIRCUIT DIAGRAM TROUBLESHOOTING CHECKING THE SIGNALING SYSTEM
SELF-DIAGNOSIS
TROUBLESHOOTING
CHAPTER 8
TROUBLESHOOTING
STARTING PROBLEMS
ENGINE FUEL SYSTEM ELECTRICAL SYSTEMS
INCORRECT ENGINE IDLING SPEED
ENGINE FUEL SYSTEM ELECTRICAL SYSTEMS
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
ENGINE FUEL SYSTEM
FAULTY GEAR SHIFTING
SHIFTING IS DIFFICULT SHIFT PEDAL DOES NOT MOVE JUMPS OUT OF GEAR
FAULTY CLUTCH
CLUTCH SLIPS CLUTCH DRAGS
OVERHEATING
ENGINE FUEL SYSTEM CHASSIS ELECTRICAL SYSTEMS
POOR BRAKING PERFORMANCE
FAULTY FRONT FORK LEGS
LEAKING OIL MALFUNCTION
UNSTABLE HANDLING
FAULTY LIGHTING AND SIGNALING SYSTEM
HEADLIGHT DOES NOT LIGHT HEADLIGHT BULB BURNT OUT TAIL/BRAKE LIGHT DOES NOT LIGHT TAIL/BRAKE LIGHT BULB BURNT OUT TURN SIGNAL DOES NOT LIGHT TURN SIGNAL BUNKS SLOWLY TURN SIGNAL REMAINS LIT TURN SIGNAL BLINKS QUICKLY HORN DOES NOT SOUND
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