Yamaha XVZ13TFL Manuals

Manuals and User Guides for Yamaha XVZ13TFL. We have 1 Yamaha XVZ13TFL manual available for free PDF download: Service Manual

Yamaha XVZ13TFL Service Manual (488 pages)

Brand: Yamaha | Category: Motorcycle | Size: 56.18 MB

Notice
3
Important Information
3
Symbols
5
Table of Contents
6
General Information
7
Motorcycle Identification
8
Vehicle Identification Number
8
Model Code
8
Features
9
Cruise Control
9
Cruise Control Switch Functions
9
Operation Chart
10
Cruise Control Function
10
Digital Speedometer
11
Odometer and Trip Meter Modes
11
Clock Mode
12
Audio System and CB Radio
12
Turning On/Off the Audio System
12
Turning On/Off the CB Radio System
12
Cassette Deck Operation
13
Track Searching
13
Reserving Tape Play Direction
14
Dolby Noise Reduction
14
Ejecting the Cassette Tape
14
Blank Skipping
14
Radio Operation
15
Switching the Receiving Bands
15
Automatic Tuning
15
Manually Turning
15
Programming Preset Stations in Memory Automatically
16
CB Radio Operation
17
Changing the Transmitting and Receiving Channel
17
Alternating the Squelch Level
18
Changing the Receive Volume for the CB Radio
18
Channel Information
19
Receiving/Transmitting
19
AUX Operation
20
Basic Setting
20
Audio System
20
Selecting the Output for Speaker or Headset
21
Controlling the Bass Level
21
Controlling the Treble Level
21
Controlling the Fader
21
Changing the Level for Auto Volume Control System
22
Preparation for Removal and Disassembly
23
Replacement Parts
23
Gaskets, Oil Seals and O-Rings
23
Lock Washers/Plates and Cotter Pins
24
Bearings and Oil Seals
24
Circlips
24
Checking the Connections
25
Special Tools
26
Specifications
30
General Specifications
31
Maintenance Specifications
34
Crankcase Tightening Sequence
41
Tightening Torques
42
Chassis
44
Electrical
48
Audio System and C.B. Radio Specifications
51
Conversion Table
52
General Tightening Torque Specifications
52
Lubrication Points and Lubricant Types
53
Cooling System Diagrams
55
Lubrication Diagrams
56
Cable Routing
60
Contents
75
Periodic Maintenance Chart for Emission Control System
77
General Maintenance and Lubrication Chart
78
Front Cowling
80
Removing the Front Cowling Cover
81
Installing the Front Cowling Cover
81
Rider and Passenger Seats
82
Removing the Rider and Passenger Seats
82
Fuel Tank
83
Removing the Fuel Tank
83
Saddlebags
84
Removing the Trunk and Saddlebags
84
Engine
85
Adjusting the Valve Clearance
85
Intake
88
Exhaust
88
Synchronizing the Carburetors
90
Adjusting the Engine Idling Speed
92
Adjusting the Throttle Cable Free Play
92
Checking the Sark Plugs
94
Checking the Ignition Timing
95
Measuring the Compression Pressure
96
Checking the Engine Oil Level
98
Changing the Engine Oil
99
Measuring the Engine Oil Pressure
101
Checking the Clutch Fluid Level
103
Bleeding the Hydraulic Clutch System
104
Cleaning the Air Filter Element
105
The Carburetor Joints and Intake Manifolds
106
Checking te Fuel Hoses and Fuel Filter
107
Checking the Crankcase Breather Hose
108
Checking the Exhaust System
108
Checking the Coolant Level
108
Checking the Cooling System
109
Changing the Coolant
110
Adjusting the Rear Brake
114
Checking the Brake Fluid Level
115
Checking the Brake Pads
115
Adjusting the Rear Brake Light Switch
116
Checking the Brake Hoses
117
Bleeding the Hydraulic Brake System
117
Adjusting the Shift Pedal
118
Checking the Final Drive Oil Level
119
Changing the Final Drive Oil
119
Checking and Adjusting the Steering Head
120
Checking the Front Fork
122
Adjusting the Front and Rear Shock Absorber Assembly
122
Checking the Tires
123
Checking the Wheels
125
Checking and Lubricating the Cables
126
Lubricating the Levers and Pedals
126
Lubricating the Sidestand
126
Lubricating the Rear Suspension
126
Electrical System
127
Checking and Charging the System
127
Charging Method Using a Variable-Current Type Charger
130
Charging Method Using a Constant-Voltage Type Charger
131
Checking and Charging the Battery
132
Checking the Fuses
132
Replacing the Headlight Bulb
134
Adjusting the Headlight Beam
135
Engine Removal
139
Leads, Cables and Hoses
139
Disconnecting the Leads, Cables and Hoses
139
Radiator and AIS
141
Removing the Radiator and AIS
141
Mufflers and Exhausts
142
Removing the Mufflers and Exhausts
142
Horn and Brake Pedal
143
Removing the Horn and Brake Pedal
143
Removing the Engine
144
Installing the Engine
146
Camshafts
147
Cylinder Head Covers
147
Removing the Cylinder Head Covers
147
Removing the Camshafts
149
Rear Cylinder Head
150
Front Cylinder Head
152
Checking the Camshafts
152
Checking the Timing Chains, Camshaft Sprockets/Timing Chain Guides
154
Checking the Timing Chain Tensioners
154
Installing the Camshafts
155
Cylinder Heads
161
Checking the Cylinder Heads
162
Valves and Valve Springs
164
Removing the Valves and Valve Springs
164
Removing the Valves
165
Checking the Valves and Valve Guides
166
Checking the Valve Seats
168
Checking the Valve Springs
170
Checking the Valve Lifters
170
Installing the Valves
171
Clutch
173
Clutch Master Cylinder
173
Removing the Clutch Master Cylinder
173
Disassembling the Clutch Master Cylinder
174
Checking the Clutch Master Cylinder
175
Assembling the Clutch Master Cylinder
176
Installing the Clutch Master Cylinder
176
Clutch Release Cylinder
179
Removing the Clutch Release Cylinder
179
Disassembling the Clutch Release Cylinder
180
Installing the Clutch Release Cylinder
182
Clutch Cover
184
Removing the Clutch Cover
184
Removing the Clutch
185
Checking the Friction Plates
187
Checking the Clutch Plates
188
Checking the Pressure Plate
189
Checking the Clutch Push Rods
189
Installing the Clutch
189
Shift Shaft
192
Shift Arm
192
Shift Shaft and Stopper Lever
193
Removing the Shift Shaft and Stopper Lever
193
Checking the Shift Shaft
194
Checking the Stopper Lever
194
Installing the Shift Shaft
194
Starter Clutch and Generator
195
Starter Coil
195
Removing the Stator Coil
195
Removing the Starter Clutch and Generator Rotor
197
Removing the Generator
198
Checking the Starter Clutch
198
Installing the Generator
199
Oil Pan and Oil Pump
200
Removing the Oil Pan and Oil Pump
200
Disassembling the Oil Pump
201
Removing the Oil Pan
203
Checking the Oil Pump
203
Checking the Relief Valve
204
Checking the Oil Gallery Pipes
204
Checking the Oil Strainer
204
Installing the Oil Gallery Pipes
204
Assembling the Oil Pump
205
Installing the Oil Pump
205
Installing the Oil Strainer
206
Installing the Oil Pan
206
Crankcase
207
Crankcase Separation
207
Disassembling the Crankcase
209
Checking the Crankcase
211
Assembling the Crankcase
212
Crankshaft
215
Removing the Crankshaft Assembly
215
Checking the Crankshaft
216
Checking the Balancer Shaft
220
Connecting Rods and Pistons
225
Connecting Rod and Piston Removal
225
Removing the Connecting Rods and Pistons
226
Checking the Cylinders and Pistons
227
Checking the Crankshaft and Connecting Rods
231
Transmission
236
Removing the Transmission
236
Checking the Bearings and Oil Seals
239
Checking the Shift Forks
239
Checking the Shift Drum Assembly
240
Checking the Transmission
240
Installing the Shift Forks
241
Installing the Transmission
241
Middler Gear
242
Removing the Middle Gear
242
Disassembling the Middle Drive Shaft Assembly
244
Disassembling the Middle Driven Shaft Assembly
245
Checking the Middle Drive Shaft Assembly
245
Checking the Middle Driven Shaft Assembly
246
Assembling the Middle Drive Shaft Assembly
246
Assembling the Middle Driven Shaft Assembly
247
Adjusting the Middle Gear Backlash
251
Cooling System
253
Radiator
254
Removing the Radiator
254
Checking the Radiator
255
Installing the Radiator
256
Thermostat
257
Removing the Thermostat
257
Thermostat Housing
259
Disassembling the Thermostat
259
Checking the Thermostat
260
Assembling the Thermostat
260
Installing the Thermostat
261
Water Pump
262
Removing the Water Pump
262
Disassembling the Water Pump
263
Checking the Water Pump
264
Assembling the Water Pump
266
Carburetors
269
Removing the Carburetors
270
Separating the Carubretors
271
Disassembling the Carburetors
273
Checking the Carburetors
275
Assembling the Carburetors
277
Installing the Carburetors
279
Checking and Adjusting the Throttle Position Sensor
280
Air Induction System Diagrams
286
Checking the Air Induction System
287
Front Wheel and Brake Discs
291
Removing the Front Wheen and Brake Discs
291
Removing the Front Wheel
294
Checking the Front Wheel
294
Checking the Brake Discs
296
Installing the Front Wheel
297
Adjusting the Front Wheel Static Balance
298
Rear Wheel and Brake Disc
300
Rear Fender
300
Removing the Rear Fender
300
Removing the Rear Wheel and Brake Disc
301
Disassembling the Rear Wheel
303
Removing the Rear Wheel
304
Checking the Rear Wheel Drive Hub
305
Installing the Rear Wheel
305
Adjusting the Rear Wheel Static Balance
305
Removing the Front Brake Pads
306
Removing the Rear Brake Pad
307
Replacing the Front Brake Pads
308
Removing the Front Brake Master Cylinder
313
Disassembling the Front Brake Master Cylinder
314
Removing the Rear Brake Master Cylinder
315
Disassembling the Rear Brake Master Cylinder
317
Removing the Front Brake Calipers
324
Disassembling the Front Brake Caliper
325
Removing the Rear Brake Caliper
326
Disassembling the Rear Brake Caliper
327
Disassembling the Front Brake Calieprs
328
Checking the Front and Rear Brake Calipers
330
Installing the Front Brake Calipers
331
Installing the Rear Brake Caliper
333
Front Fork
336
Removing the Front Fork
336
Disassembling the Front Fork
338
Removing the Front Fork Legs
340
Disassembling the Front Fork Legs
340
Checking the Front Fork Legs
341
Assembling the Front Fork Legs
342
Handlebar
346
Removing the Handlebar
346
Checking the Handlebar
348
Installing the Handlebar
349
Steering Head
351
Removing the Steering Head
351
Removing the Lower Bracket
353
Checking the Steering Head
353
Installing the Steering Head
354
Rear Shock Absorber Assembly
356
Removing the Rear Shock Absorber Assembly
356
Swingarm
360
Removing the Swingarm
360
Checking the Swingarm
362
Installing the Swingarm
363
Shift Drive
364
Inspection Notes
365
Final Drive Assembly and Drive Shaft
368
Removing the Final Drive Assembly and Drive Shaft
368
Measuring the Ring Gear Backlash
369
Adjusting the Ring Gear Backlash
370
Measuring the Ring-Gear-To-Stop Clearance
371
Adjusting the Ring-Gear-To-Stop-Per-Bolt Clearance
371
Final Drive Assembly
373
Disassembling the Final Drive Assembly
373
Removing and Installing the Ring Gear Bearings
376
Aligning the Final Drive Pinion Gear and Ring Gear
377
Checking the Drive Shaft
381
Installing the Drive Shaft
381
Electrical Components
385
Switches
386
Checking Switch Continuity
386
Switch Continuity Inspection
387
Checking the Bulbs and Bulb Sockets
388
Types of Bulbs
388
Ignition System Circuit Diagram
391
Electric Starting System
396
Starting Circuit Cutoff System Operation
397
The Starter Motor Fails to Turn
398
Starter Motor
401
Removing the Starter Motor
401
Disassembling the Starter Motor
402
Checking the Starter Motor
403
Assembling the Starter Motor
404
Charging System
406
The Battery Is Not Being Charged
407
Lighting System
409
Signal System
414
Fuel Pump Circuit Operation
428
If the Fuel Pump Fails to Operate
429
Checking the Fuel Pump
431
Carburetor Heating System
432
The Carburetor Heating System Fails to Operate
433
Audio System Circuit Operation
437
Speaker Does Not Sound
440
Headset Does Not Sound
441
Front Remote Controller Does Not Operation
444
Rear Remote Controller Does Not Operation
444
CB Unit Does Not Operation
445
Cruise Control System
447
Cruise Control Circuit Operation
449
Cruise Control System Components
450
Self Diagnosis Function of the Cruise Control System
457
Trouble Diagnosis of the Cancel Switch Signal
458
Trouble Diagnosis of the Brake Light Signal
459
Trouble Diagnosis of the Throttle Drive
459
Engine Warning Light
460
Display Order on the Engine Warning Light
461
When more than One Item Is Being Monitored
461
Speed Sensor
463
Emergency Stop Switch
463
Fuel Meter
465
Fuel Thermistor
466
"SET/RES" Indicator Light
469
Cruise Control Switch
474
Troubleshooting
477
Starting Problems
479
Incorrect Engine and Speed
480
Poor Medium-And-High Speed Performance
481
Faulty Gear Shifting
481
Faulty Clutch
481
Clutch Slips
481
Overheating
482
Overcooling
482
Poor Braking Performance
482
Faulty Front Fork Legs
483
Unstable Handling
483
Faulty Signaling System
484
Headlight Does Not Light
484
Turn Signal Does Not Light
484
Horn Does Not Sound
484
Wiring Diagram
485
Mcu
486
Cruise Control Unit
486
Cruise Switch
486

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Yamaha XVZ13TFL Service Manual (488 pages)

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