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Royal Star Tour Deluxe XVZ13CTT
Yamaha Royal Star Tour Deluxe XVZ13CTT Manuals
Manuals and User Guides for Yamaha Royal Star Tour Deluxe XVZ13CTT. We have
1
Yamaha Royal Star Tour Deluxe XVZ13CTT manual available for free PDF download: Supplementary Service Manual
Yamaha Royal Star Tour Deluxe XVZ13CTT Supplementary Service Manual (575 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 65.29 MB
Table of Contents
Important Manual Information
3
How to Use this Manual
4
Symbols
5
Table of Contents
6
General Specifications
8
Maintenance Specifications
10
Tightening Torques
10
Engine
10
Chassis
11
Electrical
13
Cable Routing
14
Periodic Checks and Adjustments
36
Periodic Maintenance Chart for the Emission Control System
36
General Maintenance and Lubrication Chart
36
Introduction
36
Rider and Passenger Seats
39
Windshield and Fuel Tank
40
Removing the Windshield and Fuel Tank
40
Backrest and Sidecases
41
Checking and Adjusting the Steering Head
42
Chassis
42
Electrical System
44
Adjusting the Headlight Beam
44
Checking the Switches
45
Electrical System
45
Ignition System Circuit Diagram
47
The Ignition System Fails to Operate
48
Troubleshooting
48
Minimum Ignition Spark Gap
49
Spark Plug Cap Resistance
49
Electric Starting System
53
Circuit Diagram
53
Lighting System
54
Circuit Diagram
54
Signaling System
55
Circuit Diagram
55
Checking the Signaling System
57
Cooling System
61
Circuit Diagram
61
The Radiator Fan Motor Fails to Turn
62
Troubleshooting
62
Fuel Pump System
65
Circuit Diagram
65
If the Fuel Pump Fails to Operate
66
Troubleshooting
66
Carburetor Heating System
68
Circuit Diagram
68
The Carburetor Heating System Fails to Operate
69
Troubleshooting
69
Cruise Control System
72
Circuit Diagram
72
Instrument and Control Functions
74
Activating and Setting the Cruise Control System
74
Deactivating the Cruise Control System
75
Checking the Cruise Control System
76
Malfunction Detected During Operation
76
Checking the Cruise Control System
77
Self-Diagnosis Function of the Cruise Control System
78
Entering the Self-Diagnosis Mode
78
Exiting the Self-Diagnosis Mode
78
Switch Trouble Diagnosis
79
Throttle Drive System Trouble Diagnosis
79
Engine Trouble Warning Light
81
Engine Trouble Warning Light Display Sequence
82
Self-Diagnosis
82
Fuel Meter
83
Fuel Meter Display Sequence (Low Fuel)
83
Fuel Meter Display Sequence (Malfunction)
83
Cruise Control “Set” Indicator Light
84
Cruise Control “SET” Indicator Light Display Sequence
84
Xvz13Ctt(C) Wiring Diagram
85
Table of Contents
93
General Information
94
Model Code
95
Motorcycle Identification
95
Vehicle Identification Number
95
Cruise Control
96
Cruise Control Switch Functions
96
Features
96
Cruise Control Function
97
Operation Chart
97
Digital Speedometer
98
Odometer and Trip Meter Modes
98
Audio System and CB Radio
99
Clock Mode
99
Turning On/Off the Audio System
99
Turning On/Off the CB Radio System
99
Cassette Desk Operation
100
Track Searching
100
Blank Skipping
101
Dolby Noise Reduction
101
Ejecting the Cassette Tape
101
Reserving Tape Play Direction
101
Automatic Tuning
102
Manually Tuning
102
Radio Operation
102
Switching the Receiving Bands
102
Programming Preset Stations in Memory Automatically
103
CB Radio Operation
104
Alternating the Squelch Level
105
Changing the Receive Volume for the CB Radio
105
Channel Information
106
AUDIO System
107
AUX Operation
107
Basic Settings
107
CB Radio System
107
Controlling the Bass Level
108
Controlling the Intercom Volume Level
108
Controlling the Treble Level
108
Selecting the Output for Speaker or Headset
108
Changing the Level for Auto Volume Control System
109
Turning the Beep Sound on or off for the Rogger in the CB Radio System
109
Gaskets, Oil Seals and O-Rings
110
Important Information
110
Preparation for Removal and Disassembly
110
Replacement Parts
110
Bearings and Oil Seals
111
Circlips
111
Lock Washers/Plates and Cotter Pins
111
Checking the Connections
112
Special Tools
113
Specifications
117
Crankcase Tightening Sequence
128
Audio System and C.B. Radio Specifications
138
Conversion Table
139
General Tightening Torque Specifications
139
Lubrication Points and Lubricant Types
140
Cooling System Diagrams
142
Lubrication Diagrams
143
Periodic Maintenance Chart for Emission Control System
164
Front Cowling
167
Installing the Front Cowling Cover
168
Removing the Front Cowling Cover
168
Fuel Tank
170
Saddlebags
171
Adjusting the Valve Clearance
172
Engine
172
Exhaust
175
Intake
175
Synchronizing the Carburetors
177
Adjusting the Engine Idling Speed
179
Adjusting the Throttle Cable Free Play
179
Handlebar Side
180
Checking the Ignition Timing
182
Checking the Spark Plugs
182
Measuring the Compression Pressure
183
Compression Gauge
184
Compression Pressure
184
Checking the Engine Oil Level
185
Changing the Engine Oil
187
Measuring the Engine Oil Pressure
188
Checking the Clutch Fluid Level
190
Bleeding the Hydraulic Clutch System
191
Cleaning the Air Filter Element
192
Checking the Carburetor Joints and Intake Manifolds
193
Checking the Fuel Hoses and Fuel Filter
194
Checking the Coolant Level
195
Checking the Crankcase Breather Hose
195
Checking the Exhaust System
195
Checking the Cooling System
196
Changing the Coolant
197
Handling Notes for Coolant
199
Adjusting the Rear Brake
201
Checking the Brake Fluid Level
202
Checking the Brake Pads
202
Adjusting the Rear Brake Light Switch
203
Bleeding the Hydraulic Brake System
204
Checking the Brake Hoses
204
Adjusting the Shift Pedal
205
Changing the Final Drive Oil
206
Checking the Final Drive Oil Level
206
Adjusting the Front and Rear Shock Absorber Assembly
209
Checking the Front Fork
209
Checking the Tires
210
Checking the Wheels
212
Checking and Lubricating the Cables
213
Lubricating the Levers and Pedals
213
Lubricating the Rear Suspension
213
Lubricating the Sidestand
213
Checking and Charging the Battery
214
Charging Method Using a Variable-Current Type Charger
217
Charging Method Using a Constant-Voltage Type Charger
218
Checking the Fuses
219
Replacing the Headlight Bulb
221
Disconnecting the Leads, Cables and Hoses
226
Engine Removal
226
Leads, Cables and Hoses
226
Radiator and Ais
228
Removing the Radiator and AIS
228
Mufflers and Exhausts
229
Removing the Mufflers and Exhausts
229
Horn and Brake Pedal
230
Removing the Horn and Brake Pedal
230
Removing the Engine
231
Installing the Engine
233
Camshafts
234
Cylinder Head Covers
234
Removing the Cylinder Head Covers
234
Removing the Camshafts
236
Rear Cylinder Head
237
Checking the Camshafts
239
Front Cylinder Head
239
Checking the Timing Chain Tensioners
241
Installing the Camshafts
242
Front Cylinder
246
Cylinder Heads
248
Removing the Cylinder Heads
248
Checking the Cylinder Heads
249
Installing the Cylinder Heads
249
Rear Cylinder
249
Valves and Valve Springs
251
Removing the Valves
252
Checking the Valves and Valve Guides
253
Checking the Valve Seats
255
Checking the Valve Lifters
257
Checking the Valve Springs
257
Installing the Valves
258
Clutch
260
Clutch Master Cylinder
260
Removing the Clutch Master Cylinder
260
Disassembling the Clutch Master Cylinder
261
Checking the Clutch Master Cylinder
262
Assembling the Clutch Master Cylinder
263
Installing the Clutch Master Cylinder
263
Clutch Release Cylinder
266
Disassembling the Clutch Release Cylinder
267
Installing the Clutch Release Cylinder
269
Clutch Cover
271
Removing the Clutch Cover
271
Removing the Clutch
272
Checking the Friction Plates
274
Checking the Clutch Boss
275
Checking the Clutch Housing
275
Checking the Clutch Plates
275
Checking the Clutch Spring Plate
275
Checking the Clutch Push Rods
276
Checking the Pressure Plate
276
Installing the Clutch
276
Shift Arm
279
Shift Shaft
279
Removing the Shift Shaft and Stopper Lever
280
Shift Shaft and Stopper Lever
280
Checking the Shift Shaft
281
Checking the Stopper Lever
281
Installing the Shift Shaft
281
Removing the Stator Coil
282
Starter Clutch and Generator
282
Stator Coil
282
Removing the Starter Clutch and Generator Rotor
284
Checking the Starter Clutch
285
Removing the Generator
285
Installing the Generator
286
Oil Pan and Oil Pump
287
Removing the Oil Pan and Oil Pump
287
Disassembling the Oil Pump
288
Checking the Oil Pump
290
Removing the Oil Pan
290
Checking the Oil Gallery Pipes
291
Checking the Oil Strainer
291
Checking the Relief Valve
291
Installing the Oil Gallery Pipes
291
Assembling the Oil Pump
292
Installing the Oil Pump
292
Installing the Oil Pan
293
Installing the Oil Strainer
293
Crankcase
294
Crankcase Separation
294
Disassembling the Crankcase
296
Checking the Crankcase
298
Assembling the Crankcase
299
Crankshaft
302
Removing the Crankshaft Assembly
302
Checking the Crankshaft
303
Checking the Balancer Shaft
307
Connecting Rod and Piston Removal
312
Connecting Rods and Pistons
312
Removing the Connecting Rods and Pistons
313
Checking the Cylinder and Pistons
314
Checking the Piston Rings
315
Checking the Piston Pins
317
Checking the Crankshaft and Connecting Rods
318
Big End Bearing Color Code
320
Installing the Pistons and Connecting Rods
320
Transmission
323
Disassembling the Transmission
324
Checking the Bearings and Oil Seals
326
Checking the Shift Forks
326
Checking the Shift Drum Assembly
327
Checking the Transmission
327
Installing the Shift Forks
328
Installing the Transmission
328
Middle Gear
329
Disassembling the Middle Drive Shaft Assembly
331
Checking the Middle Drive Shaft Assembly
332
Disassembling the Middle Driven Shaft Assembly
332
Assembling the Middle Drive Shaft Assembly
333
Checking the Middle Driven Shaft Assembly
333
Assembling the Middle Driven Shaft Assembly
334
Aligning the Middle Gear
336
Adjusting the Middle Gear Backlash
338
Radiator
341
Removing the Radiator
341
Checking the Radiator
342
Installing the Radiator
343
Removing the Thermostat
344
Thermostat
344
Disassembling the Thermostat
346
Thermostat Housing
346
Assembling the Themorstat
347
Checking the Thermostat
347
Installing the Thermostat
348
Removing the Water Pump
349
Water Pump
349
Disassembling the Water Pump
350
Checking the Water Pump
351
Assembling the Water Pump
353
Installing the Water Pump
354
Carburetors
356
Removing the Carburetors
357
Separating the Carburetors
358
Disassembling the Carburetor
360
Checking the Carburetors
362
Assembling the Carburetors
364
Installing the Carburetors
366
Measuring and Adjusting the Fuel Level
366
Checking and Adjusting the Throttle Position Sensor
367
Checking the Fuel Pump
370
Checking the Fuel Cock
371
Checking the Fuel Cock Operation
371
Air Cut-Off Valve
372
Air Induction System
372
Air Injection
372
Air Induction System Diagrams
373
Checking the Air Induction System
374
Chassis
375
Front Wheel and Brake Discs
378
Removing the Front Wheel and Brake Discs
378
Disassembling the Front Wheel
380
Front Wheel
380
Checking the Front Wheel
381
Removing the Front Wheel
381
Checking the Brake Discs
383
Installing the Front Wheel
384
Adjusting the Front Wheel Static Balance
385
Rear Fender
387
Rear Wheel and Brake Disc
387
Removing the Rear Fender
387
Removing the Rear Wheel and Brake Disc
388
Disassembling the Rear Wheel
390
Checking the Rear Wheel
391
Removing the Rear Wheel
391
Adjusting the Rear Wheel Static Balance
392
Checking the Rear Wheel Drive Hub
392
Installing the Rear Wheel
392
Front Brake Pads
393
Removing the Front Brake Pads
393
Rear Brake Pads
394
Removing the Rear Brake Pad
394
Replacing the Front Brake Pads
395
Front Brake Master Cylinder
400
Removing the Front Brake Master Cylinder
400
Disassembling the Front Brake Master Cylinder
401
Rear Brake Master Cylinder
402
Removing the Rear Brake Master Cylinder
402
Disassembling the Rear Brake Master Cylinder
404
Checking the Front and Rear Brake Master Cylinders
406
Installing the Front Brake Master Cylinder
407
Installing the Rear Brake Master Cylinder
409
Front Brake Calipers
411
Removing the Front Brake Calipers
411
Disassembling the Front Brake Caliper
412
Removing the Rear Brake Caliper
413
Disassembling the Rear Brake Caliper
414
Disassembling the Front Brake Calipers
415
Disassembling the Rear Barke Caliper
415
Checking the Front and Rear Brake Calipers
417
Installing the Front Brake Calipers
418
Installing the Rear Brake Caliper
420
Front Fork
423
Removing the Front Fork
423
Disassembling the Front Fork
425
Disassembling the Front Fork Legs
427
Removing the Front Fork Legs
427
Checking the Front Fork Legs
428
Assembling the Front Fork Legs
429
Installing the Front Fork Legs
432
Handlebar
433
Removing the Handlebar
433
Checking the Handlebar
435
Installing the Handlebar
436
Removing the Steering Head
438
Steering Head
438
Checking the Steering Head
440
Removing the Lower Bracket
440
Installing the Steering Head
441
Rear Shock Absorber Assembly
443
Removing the Rear Shock Absorber Assembly
443
Checking the Rear Shock Absorber
445
Installing the Rear Shock Absorber Assembly
446
Removing the Swingarm
447
Swingarm
447
Checking the Swingarm
449
Installing the Swingarm
450
Shaft Drive
451
Final Drive Assembly and Drive Shaft
455
Removing the Final Drive Assembly and Drive Shaft
455
Measuring the Ring Gear Backlash
456
Adjusting the Ring Gear Backlash
457
Adjusting the Ring-Gear-To-Stop-Per-Bolt Clearance
458
Measuring the Ring-Gear-To-Stop Clearance
458
Disassembling the Final Drive Assembly
460
Final Drive Assembly
460
Removing and Installing the Ring Gear Bearings
463
Aligning the Final Drive Pinion Gear and Ring Gear
464
Checking the Drive Shaft
468
Installing the Drive Shaft
468
Electrical
470
Electrical Components
472
Checking Switch Continuity
473
Switches
473
Switch Continuity Inspection
474
Checking the Bulbs and Bulb Sockets
475
Checking the Condition of the Bulbs
475
Types of Bulbs
475
Cheking the Condition of the Bulb Sockets
477
Ignition System
478
Ignition System Fails to Operate
479
Starting Circuit Cutoff System Operation
484
The Starter Motor Fails to Turn
485
Removing the Starter Motor
488
Starter Motor
488
Disassembling the Starter Motor
489
Checking the Starter Motor
490
Assembling the Starter Motor
491
Cahrging System
493
The Battery Is Not Being Charged
494
Fuel Pump Circuit Operation
515
Audio System Circuit Operation
524
Audio System Does Not Operation
525
Speaker Does Not Sound
527
Headset Does Not Sound
528
Front Remote Controller Does Not Operate
531
Rear Remote Controller Does Not Operate
531
CB Unit Does Not Operate
532
Cruise Control Circuit Operation
536
Cruise Control System Components
537
Cruise Control System Troubleshooting
538
Detecting an Abnormality with the Motorcycle Stopped
539
Detecting and Abnormality During Operation
540
Exiting the Self Diagnosis Mode
544
Operating Procedure for the Self Diagnosis Mode
544
Self Diagnosis Function of the Cruise Control System
544
The Cruise Control System Has a Self Diagnosis Function
544
Trouble Diagnosis of the Cancel Switch Signal
545
Trouble Diagnosis of the Brake Light Signal
546
Trouble Diagnosis of the Throttle Drive
546
Engine Warning Light
547
Self-Diagnosis
547
Display Order on the Engine Warning Light
548
When Mode than One Item Is Being Monitored
548
When One Item Being Monitored
548
Throttle Position Sensor
549
Emergency Stop Switch
550
Speed Sensor
550
Fuel Meter Display Sequence
552
Fuel Sender
552
Fuel Thermistor
553
"SET/RES" Indicator Light
556
Display Order on the SET/RES Indicator Light
556
Circuit Diagram
559
Ignition Coil
560
Cruise Control Switch
561
Air Filter
566
Cylinder and Cylinder Head
566
Starting Problems
566
Incorrect Engine Idling Speed
567
Clutch Slips
568
Faulty Clutch
568
Faulty Gear Shifting
568
Poor Medium-And-High-Speed Performance
568
Overcooling
569
Overheating
569
Poor Braking Performance
569
Faulty Front Fork Legs
570
Leaking Oil
570
Malfunction
570
Unstable Handling
570
Faulty Signaling System
571
Headlight Does Not Light
571
Horn Does Not Sound
571
Turn Signal Does Not Light
571
Wiring Diagram
572
Cruise Control Unit
573
Cruise Switch
573
D.C. Outlet
573
Mcu
573
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