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Yamaha Star XVS13AA(C) 2011 Service Manual

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Table of Contents

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SERVICE MANUAL
XVS13CTA(C)
LIT-11616-24-48
XVS13AA(C)
XVS13CA(C)
2011
3D8-28197-13

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Summary of Contents for Yamaha Star XVS13AA(C) 2011

  • Page 1 2011 SERVICE MANUAL XVS13AA(C) XVS13CTA(C) XVS13CA(C) LIT-11616-24-48 3D8-28197-13...
  • Page 2 EAS20050 XVS13AA(C)/XVS13CTA(C)/XVS13CA(C) SERVICE MANUAL ©2010 by Yamaha Motor Corporation, U.S.A. First edition, July 2010 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-24-48...
  • Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.

  • Page 4: How To Use This Manual

    EAS20090 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. •...

  • Page 5: Symbols

    EAS20100 8. Electrical data SYMBOLS 9. Engine oil The following symbols are used in this manual 10. Gear oil for easier understanding. 11. Molybdenum-disulfide oil 12. Brake fluid The following symbols are not relevant to every 13. Wheel-bearing grease vehicle. 14.

  • Page 7: Table Of Contents

    EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 9: General Information

    GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 INSTRUMENT FUNCTIONS ..............1-4 IMPORTANT INFORMATION ................. 1-9 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-9 REPLACEMENT PARTS................1-9 GASKETS, OIL SEALS AND O-RINGS ............ 1-9 LOCK WASHERS/PLATES AND COTTER PINS ........

  • Page 10: Identification

    IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.

  • Page 11: Features

    FEATURES EAS20170 FEATURES EAS3D81037 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.

  • Page 12: Fi System

    FEATURES EAS3D81038 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at 324 kPa (3.24 kg/cm², 46.1 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 13: Instrument Functions

    FEATURES Speedometer EAS3D81033 INSTRUMENT FUNCTIONS Multi-function meter unit (for XVS13AA(C)/XVS13CTA(C)) EWA3D8A001 WARNING Be sure to stop the vehicle before making any setting changes to the multi-function meter unit. Changing settings while riding can distract the operator and increase the risk of an accident. 1.
  • Page 14 FEATURES Trip F→ Trip 1 → Trip 2 → Clock → Odo → Trip Self-diagnosis device Push the “ ” side of the “SELECT” switch to switch the display in the reverse order. To reset a tripmeter, select it by pushing the “ ”...
  • Page 15 FEATURES 1. Turn the key to “OFF”. 2. Push and hold the “ ” side of the “SELECT” switch. 3. Turn the key to “ON”, and then release the “SELECT” switch after five seconds or more. 4. Push the “ ”...
  • Page 16 FEATURES To set the clock Push the “RESET” switch for less than one sec- ond to display the clock for five seconds, regard- less of the currently selected display mode. If the fuel level warning light comes on, the dis- play will automatically change to the fuel reserve tripmeter mode “Trip F”...
  • Page 17 FEATURES Brightness control mode 1. Brightness level This function allows you to adjust the brightness of the multi-function meter unit panel to suit the outside lighting conditions. To set the brightness 1. Turn the key to “OFF”. 2. Push and hold the “SELECT” switch. 3.

  • Page 18: Important Information

    5. Keep all parts away from any source of fire. EAS20200 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...

  • Page 19: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu- facturer’s marks or numbers are visible. When installing oil seals “1”, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropri- ate.

  • Page 20: Checking The Connections

    CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: • Lead • Coupler • If there is no continuity, clean the terminals. •...

  • Page 21: Special Tools

    SPECIAL TOOLS EAS20260 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 inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 22 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Timing light 3-10 90890-03141 YU-03141 Compression gauge 3-10 90890-03081 Engine compression tester YU-33223 Oil filter wrench 3-12 90890-01426 YU-38411 Belt tension gauge 3-25, 3-26 90890-03170 Rear drive belt tension gauge YM-03170 Steering nut wrench 3-27, 4-83 90890-01403 Exhaust flange nut wrench...
  • Page 23 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Slide hammer bolt 5-23 90890-01083 Slide hammer bolt 6 mm YU-01083-1 Weight 5-23 90890-01084 YU-01083-3 YU-01083-3 Valve spring compressor 5-36, 5-41 90890-04019 YM-04019 Valve spring compressor attachment 5-36, 5-41 90890-01243 Valve spring compressor adapter (26 mm) YM-01253-1 Valve guide remover (ø6) 5-37...
  • Page 24 5-51, 5-52, 90890-01701 5-59, 5-62 Primary clutch holder YS-01880-A Flywheel puller 5-51 90890-01362 Heavy duty puller YU-33270-B Yamaha bond No. 1215 5-53, 5-79, 90890-85505 6-12 (Three Bond No.1215®) Universal clutch holder 5-59, 5-63 90890-04086 YM-91042 Digital circuit tester 5-72, 7-14...
  • Page 25 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Radiator cap tester adapter 90890-01352 Pressure tester adapter YU-33984 YU-33984 Mechanical seal installer 6-12 90890-04078 Water pump seal installer YM-33221-A Middle driven shaft bearing driver 6-12 90890-04058 Middle drive bearing installer 40 &...
  • Page 26 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Ignition checker 8-103 90890-06754 Oppama pet-4000 spark checker YM-34487 1-17...

  • Page 27: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-3 CHASSIS SPECIFICATIONS ................2-10 ELECTRICAL SPECIFICATIONS ..............2-15 TIGHTENING TORQUES ................2-18 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-18 ENGINE TIGHTENING TORQUES............2-19 CHASSIS TIGHTENING TORQUES (for XVS13AA(C)/XVS13CTA(C))............2-24 CHASSIS TIGHTENING TORQUES (for XVS13CA(C)) ......2-28 LUBRICATION POINTS AND LUBRICANT TYPES ........

  • Page 28: General Specifications

    GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model XVS13AA 3D8D (USA) XVS13AAC 3D8E (California) XVS13CTA 5S6D (USA) XVS13CTAC 5S6E (California) XVS13CA 1GP1/27D1 (USA) XVS13CAC 1GP2/27D2 (California) Dimensions Overall length XVS13AA(C)/XVS13CTA(C): 2490 mm (98.0 in) XVS13CA(C): 2530 mm (99.6 in) Overall width XVS13AA(C)/XVS13CTA(C): 1000 mm (39.4 in) XVS13CA(C):...
  • Page 29 GENERAL SPECIFICATIONS Maximum load XVS13AA(C): 210 kg (463 lb) XVS13CTA(C): 190 kg (419 lb) XVS13CA(C): 204 kg (450 lb)

  • Page 30: Engine Specifications

    ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, SOHC Displacement 1304 cm³ Cylinder arrangement V-type 2-cylinder Bore × stroke 100.0 × 83.0 mm (3.94 × 3.27 in) Compression ratio 9.50 :1 Standard compression pressure (at sea level) 1450 kPa/400 r/min (14.5 kgf/cm²/400 r/min, 206.2 psi/400 r/min) Minimum–maximum...
  • Page 31 ENGINE SPECIFICATIONS Relief valve operating pressure 391.0–489.0 kPa (3.91–4.89 kgf/cm², 56.7–70.9 psi) Cooling system Radiator capacity (including all routes) 2.10 L (2.22 US qt, 1.85 Imp.qt) Radiator capacity 0.55 L (0.58 US qt, 0.48 Imp.qt) Coolant reservoir capacity (up to the maximum level mark) 0.45 L (0.48 US qt, 0.40 Imp.qt) Radiator cap opening pressure...
  • Page 32 ENGINE SPECIFICATIONS Limit 37.018 mm (1.4574 in) Timing chain Tensioning system Automatic Rocker arm/rocker arm shaft Rocker arm inside diameter 12.000–12.018 mm (0.4724–0.4731 in) Rocker arm shaft outside diameter 11.976–11.991 mm (0.4715–0.4721 in) Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.042 mm (0.0004–0.0017 in) Limit 0.095 mm (0.0037 in) Valve, valve seat, valve guide Valve clearance (cold)
  • Page 33 ENGINE SPECIFICATIONS Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in) Limit 0.100 mm (0.0039 in) Valve stem runout 0.010 mm (0.0004 in) Cylinder head valve seat width (intake) 1.00–1.20 mm (0.0394–0.0472 in) Limit 1.6 mm (0.06 in) Cylinder head valve seat width (exhaust) 1.00–1.20 mm (0.0394–0.0472 in) Limit...
  • Page 34 ENGINE SPECIFICATIONS Height H 8.0 mm (0.31 in) Offset 0.50 mm (0.0197 in) Piston pin bore inside diameter 23.004–23.015 mm (0.9057–0.9061 in) Limit 23.045 mm (0.9073 in) Piston pin outside diameter 22.991–23.000 mm (0.9052–0.9055 in) Limit 22.971 mm (0.9044 in) Piston-pin-to-piston-pin-bore clearance 0.004–0.024 mm (0.0002–0.0009 in) Limit...
  • Page 35 ENGINE SPECIFICATIONS Crankshaft Width A 97.95–98.00 mm (3.856–3.858 in) Runout limit C 0.020 mm (0.0008 in) Big end side clearance D 0.320–0.474 mm (0.0126–0.0187 in) Big end radial clearance E 0.022–0.046 mm (0.0009–0.0018 in) Limit 0.09 mm (0.0035 in) Crankshaft journal diameter 49.968–49.980 mm (1.9672–1.9677 in) Crankshaft journal bearing inside diameter 50.010–50.030 mm (1.9689–1.9697 in)
  • Page 36 ENGINE SPECIFICATIONS Gear ratio 36/13 (2.769) 32/18 (1.778) 29/21 (1.381) 29/26 (1.115) 24/25 (0.960) Main axle runout limit 0.08 mm (0.0032 in) Drive axle runout limit 0.08 mm (0.0032 in) Shifting mechanism Shift mechanism type Guide bar Shift fork guide bar bending limit 0.025 mm (0.0010 in) Shift fork thickness 6.26–6.39 mm (0.2465–0.2516 in)

  • Page 37: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Double cradle Caster angle XVS13AA(C)/XVS13CTA(C): 32.70° XVS13CA(C): 34.00° Trail XVS13AA(C)/XVS13CTA(C): 145.0 mm (5.71 in) XVS13CA(C): 109.0 mm (4.29 in) Front wheel Wheel type Cast wheel Rim size XVS13AA(C)/XVS13CTA(C): 16M/C × MT3.00 XVS13CA(C): 21M/C ×...
  • Page 38 CHASSIS SPECIFICATIONS Rear tire Type Tubeless Size XVS13AA(C)/XVS13CTA(C): 170/70B 16M/C 75H XVS13CA(C): 210/40R 18M/C 73H Manufacturer/model XVS13AA(C)/XVS13CTA(C): DUNLOP/K555 BRIDGESTONE/EXEDRA G722 G XVS13CA(C): BRIDGESTONE/EXEDRA G852 RADIAL G Wear limit (rear) 1.0 mm (0.04 in) Tire air pressure (measured on cold tires) Loading condition 0–90 kg (0–198 lb) Front...
  • Page 39 CHASSIS SPECIFICATIONS Master cylinder inside diameter XVS13AA(C)/XVS13CTA(C): 15.00 mm (0.59 in) XVS13CA(C): 14.00 mm (0.55 in) Caliper cylinder inside diameter 25.40 mm (1.00 in) Caliper cylinder inside diameter 30.16 mm (1.19 in) Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Rear disc brake...
  • Page 40 XVS13CA(C): 55.0–135.0 mm (2.17–5.31 in) Inner tube outer diameter 41.0 mm (1.61 in) Optional spring available Recommended oil Yamaha fork oil 10WT Quantity XVS13AA(C)/XVS13CTA(C): 490.0 cm³ (16.57 US oz, 17.28 Imp.oz) XVS13CA(C): 514.0 cm³ (17.38 US oz, 18.13 Imp.oz) Level XVS13AA(C)/XVS13CTA(C): 105.0 mm (4.13 in)
  • Page 41 CHASSIS SPECIFICATIONS Swingarm Swingarm end free play limit (radial) 1.0 mm (0.04 in) Swingarm end free play limit (axial) 1.0 mm (0.04 in) Drive belt Drive belt slack (on the sidestand) 5.0–7.0 mm (0.20–0.28 in) Drive belt slack (on a suitable stand) XVS13AA(C)/XVS13CTA(C): 4.0–6.0 mm (0.16–0.24 in) XVS13CA(C):...

  • Page 42: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Advancer type Digital Ignition timing (B.T.D.C.) 5.0°/1000 r/min Engine control unit Model/manufacturer FUA0013/MITSUBISHI Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64 Ω Primary coil resistance Secondary coil resistance 8.64–12.96 kΩ...
  • Page 43 ELECTRICAL SPECIFICATIONS 12 V, 21.0 W × 2 Rear turn signal light License plate light XVS13AA(C)/XVS13CTA(C): 12 V, 5.0 W × 1 XVS13CA(C): 12 V, 3.4 W × 2 Meter lighting Indicator light Neutral indicator light Turn signal indicator light Oil level warning light High beam indicator light Fuel level warning light...
  • Page 44 ELECTRICAL SPECIFICATIONS Fuel pump relay 162–198 Ω Coil resistance Fan motor relay 86.40–105.60 Ω Coil resistance Fuses Main fuse 50.0 A Headlight fuse 20.0 A Taillight fuse 10.0 A Signaling system fuse 10.0 A Ignition fuse 15.0 A Radiator fan fuse 20.0 A Fuel injection system fuse 10.0 A...

  • Page 45: Tightening Torques

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.

  • Page 46: Engine Tightening Torques

    TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Cylinder head stud bolt (exhaust 15 Nm (1.5 m·kg, 11 ft·lb) pipe) Oil check bolt 15 Nm (1.5 m·kg, 11 ft·lb) Cylinder head nut 65 Nm (6.5 m·kg, 47 ft·lb) Cylinder head bolt 13 Nm (1.3 m·kg, 9.4 ft·lb) l = 30 mm...
  • Page 47 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Camshaft assembly bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Locknut (rocker arm adjusting 14 Nm (1.4 m·kg, 10 ft·lb) screw) Timing chain guide bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Camshaft sprocket bolt 20 Nm (2.0 m·kg, 14 ft·lb) Oil/water pump assembly bolt 24 Nm (2.4 m·kg, 17 ft·lb)
  • Page 48 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Crankcase stud bolt 15 Nm (1.5 m·kg, 11 ft·lb) Left crankcase bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Right crankcase bolt 36 Nm (3.6 m·kg, 25 ft·lb) Generator cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Stator coil bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Crankshaft position sensor/sta-...
  • Page 49 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear cylinder thermostat inlet 10 Nm (1.0 m·kg, 7.2 ft·lb) pipe 2 bolt*1 Rear cylinder thermostat inlet 7 Nm (0.7 m·kg, 5.1 ft·lb) pipe 2 bolt*1 Rear cylinder thermostat inlet 10 Nm (1.0 m·kg, 7.2 ft·lb) pipe bolt*2 Thermostat bracket bolt*2 10 Nm (1.0 m·kg, 7.2 ft·lb)
  • Page 50 TIGHTENING TORQUES Cylinder head tightening sequence A. Front cylinder head B. Rear cylinder head 2-23...

  • Page 51: Chassis Tightening Torques (For Xvs13Aa(C)/Xvs13Cta(C))

    TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES (for XVS13AA(C)/XVS13CTA(C)) Thread Item Q’ty Tightening torque Remarks size Engine bracket bolt (right front 48 Nm (4.8 m·kg, 35 ft·lb) upper side) Engine bracket bolt (left front up- 48 Nm (4.8 m·kg, 35 ft·lb) per side) Engine mounting bolt (front upper 30 Nm (3.0 m·kg, 22 ft·lb)
  • Page 52 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Lower bracket pinch bolt 45 Nm (4.5 m·kg, 32 ft·lb) Front fork cap bolt 23 Nm (2.3 m·kg, 17 ft·lb) Damper rod bolt 30 Nm (3.0 m·kg, 22 ft·lb) Lower front fork cover bolt 18 Nm (1.8 m·kg, 13 ft·lb) Main switch and upper bracket 30 Nm (3.0 m·kg, 22 ft·lb)
  • Page 53 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front brake caliper retaining bolt 27 Nm (2.7 m·kg, 19 ft·lb) Front brake disc bolt 23 Nm (2.3 m·kg, 17 ft·lb) Bleed screw (front brake caliper) 6 Nm (0.6 m·kg, 4.3 ft·lb) Rear wheel axle nut 150 Nm (15.0 m·kg, 110 ft·lb) Drive belt adjusting locknut...
  • Page 54 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Brake pedal arm bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Rear brake master cylinder bolt 23 Nm (2.3 m·kg, 17 ft·lb) Rear brake master cylinder 23 Nm (2.3 m·kg, 17 ft·lb) bracket bolt Rider footrest assembly bolt (left 64 Nm (6.4 m·kg, 46 ft·lb)

  • Page 55: Chassis Tightening Torques (For Xvs13Ca(C))

    TIGHTENING TORQUES EAS27D1024 CHASSIS TIGHTENING TORQUES (for XVS13CA(C)) Thread Item Q’ty Tightening torque Remarks size Engine bracket nut (front upper 48 Nm (4.8 m·kg, 35 ft·lb) side) Engine mounting bolt (front cen- 30 Nm (3.0 m·kg, 22 ft·lb) ter side) Engine bracket nut (front upper 88 Nm (8.8 m·kg, 64 ft·lb) side)
  • Page 56 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Steering stem nut 110 Nm (11.0 m·kg, 80 ft·lb) Lower ring nut (initial tightening 52 Nm (5.2 m·kg, 37 ft·lb) See TIP. torque) Lower ring nut (final tightening 18 Nm (1.8 m·kg, 13 ft·lb) See TIP.
  • Page 57 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front wheel axle 72 Nm (7.2 m·kg, 52 ft·lb) Front wheel axle pinch bolt 20 Nm (2.0 m·kg, 14 ft·lb) See TIP. Front brake caliper bracket bolt 40 Nm (4.0 m·kg, 29 ft·lb) Front brake caliper retaining bolt 27 Nm (2.7 m·kg, 19 ft·lb) Front brake disc bolt...
  • Page 58 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Starter motor lead bolt (starter 4 Nm (0.4 m·kg, 2.9 ft·lb) relay side) Battery terminal bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Battery box bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Battery box bracket bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Sidestand bracket bolt...
  • Page 59 TIGHTENING TORQUES 2-32...

  • Page 60: Lubrication Points And Lubricant Types

    Clutch boss nut and washer Transmission gears (wheel and pinion) and collar Drive pulley nut and washer Shift forks and shift fork guide bars Shift drum Shift shaft and shift shaft oil seal (lip) Yamaha bond Crankcase (mating surface) No.1215 (Three Bond No.1215®) 2-33...

  • Page 61: Chassis (For Xvs13Aa(C)/Xvs13Cta(C))

    LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Yamaha bond Stator assembly lead grommet No.1215 (Three Bond No.1215®) EAS20380 CHASSIS (for XVS13AA(C)/XVS13CTA(C)) Lubrication point Lubricant Steering bearings and upper bearing dust cover (lip) Lower bearing dust seal (lip) Front wheel oil seals (lip)

  • Page 62: Chassis (For Xvs13Ca(C))

    LUBRICATION POINTS AND LUBRICANT TYPES EAS27D1025 CHASSIS (for XVS13CA(C)) Lubrication point Lubricant Steering bearings and upper bearing dust cover (lip) Lower bearing dust seal (lip) Front wheel oil seals (lip) Rear wheel oil seal (lip) Rear wheel drive hub oil seal (lip) Rear wheel drive hub (mating surface) Brake pedal shaft (pivoting point) Shift pedal (pivoting point)
  • Page 63 LUBRICATION POINTS AND LUBRICANT TYPES 2-36...

  • Page 64: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-37...
  • Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil/water pump assembly 3. Oil delivery pipe 3 4. Relief valve assembly 5. Drive axle 6. Oil filter cartridge 7. Main axle 8. Main gallery 9. Crankcase 10. Rear cylinder timing chain tensioner 11.

  • Page 66: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-39...
  • Page 67 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter cartridge 2. Oil delivery pipe 3 3. Relief valve assembly 2-40...
  • Page 68 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-41...
  • Page 69 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Crankshaft 2-42...
  • Page 70 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-43...
  • Page 71 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil delivery pipe 1 2. Timing chain tensioner 2-44...
  • Page 72 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-45...
  • Page 73 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Drive axle 2. Oil delivery pipe 2 3. Main axle 4. Oil delivery pipe 3 5. Oil/water pump assembly 6. Oil strainer 2-46...

  • Page 74: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-47...
  • Page 75 COOLING SYSTEM DIAGRAMS 1. Rear cylinder thermostat inlet pipe 1 2. Front cylinder thermostat inlet pipe 3. Coolant delivery cover 2 4. Coolant delivery cover 1 5. Drain cock 6. Oil/water pump assembly 2-48...
  • Page 76 COOLING SYSTEM DIAGRAMS 2-49...
  • Page 77 COOLING SYSTEM DIAGRAMS 1. Radiator outlet hose 2. Radiator outlet pipe 3. Coolant delivery pipe 4. Oil/water pump assembly 2-50...
  • Page 78 COOLING SYSTEM DIAGRAMS For XVS13AA(C)/XVS13CTA(C) 2-51...
  • Page 79 COOLING SYSTEM DIAGRAMS 1. Rear cylinder thermostat inlet pipe 1 2. Front cylinder thermostat inlet pipe 3. Rear cylinder thermostat inlet hose 4. Front cylinder thermostat inlet hose 5. Coolant reservoir hose 6. Rear cylinder thermostat inlet pipe 2 7. Thermostat housing 8.
  • Page 80 COOLING SYSTEM DIAGRAMS For XVS13CA(C) 2-53...
  • Page 81 COOLING SYSTEM DIAGRAMS 1. Radiator inlet hose 2. Thermostat cover inlet hose 3. Thermostat housing 4. Front cylinder thermostat inlet hose 5. Rear cylinder thermostat inlet hose 6. Rear cylinder thermostat inlet pipe 7. Radiator outlet hose 8. Radiator 9. Front cylinder thermostat inlet pipe A.

  • Page 82: Cable Routing (For Xvs13Aa(C)/Xvs13Cta(C))

    CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) EAS20430 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 2-55...
  • Page 83 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 1. Clutch switch lead 2. Left handlebar switch lead 3. Clutch cable 4. Front brake hose 5. Right handlebar switch lead 6. Throttle cable (accelerator cable) 7. Throttle cable (decelerator cable) 8. Radiator fan motor lead 9.
  • Page 84 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 2-57...
  • Page 85 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 1. Wire harness 2. Front right turn signal/position light lead 3. Front left turn signal/position light lead 4. Main switch couplers 5. Front turn signal/position light couplers 6. Meter assembly couplers 7. Air temperature sensor lead 8.
  • Page 86 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 2-59...
  • Page 87 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 1. Wire harness M. Be sure to install the throttle cable (decelerator cable), identified by the longer nut, on the outer 2. Coolant reservoir hose side of the throttle cable pulley. 3. Rear cylinder spark plug cap N.
  • Page 88 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 2-61...
  • Page 89 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 1. Front cylinder exhaust pipe 2. Rear brake light switch coupler 3. Rear brake hose 4. Brake fluid reservoir hose 5. O sensor 6. O sensor coupler 7. Lean angle sensor 8. Coolant reservoir hose 9. Fuel hose 10.
  • Page 90 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 2-63...
  • Page 91 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 1. Horn 2. Rear brake light switch 3. Rear brake master cylinder 4. Brake fluid reservoir hose 5. Coolant reservoir breather hose 6. Rear brake hose 7. Brake fluid reservoir 8. Coolant reservoir hose 9. Horn lead 10.
  • Page 92 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 4 5 6 2-65...
  • Page 93 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 1. Clutch cable M. Fasten the oil level switch lead and sidestand switch lead with a plastic locking tie. Point the end 2. Left handlebar switch lead of the plastic locking tie rearward, and then cut off 3.
  • Page 94 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 9 10 2-67...
  • Page 95 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 1. Headlight relay O. Fasten the sidestand switch lead with a plastic locking tie, making sure to fit the tie in the gap 2. Radiator fan motor relay between the sidestand bracket and the frame boss. 3.
  • Page 96 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 2-69...
  • Page 97 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 1. Headlight relay 2. Radiator fan motor relay 3. Turn signal relay 4. Wire harness 5. Crankshaft position sensor coupler 6. Tail/brake light coupler 7. Joint coupler A. To fuse box and main fuse B. To starter relay C.
  • Page 98 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 2-71...
  • Page 99 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 1. Wire harness L. Fasten the wire harness and right handlebar switch lead to the frame with a plastic locking tie. 2. Coolant reservoir hose Position the end of the plastic locking tie to the 3. Throttle cable (accelerator cable) inside of the front cylinder thermostat inlet hose.
  • Page 100 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 2-73...
  • Page 101 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 1. Intake air pressure sensor hose 2. Intake air pressure sensor 3. Front cylinder thermostat inlet hose 4. Right handlebar switch lead 5. Wire harness 6. Rear cylinder thermostat inlet hose 7. Front cylinder resonator hose 8.
  • Page 102 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 2-75...
  • Page 103 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 1. Rear cylinder thermostat inlet hose 2. Right handlebar switch lead 3. Wire harness 4. Front cylinder resonator hose 5. Canister purge hose (California only) 6. Throttle position sensor 7. Intake air pressure sensor hose 8. Rear cylinder resonator hose 9.
  • Page 104 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 2-77...
  • Page 105 CABLE ROUTING (for XVS13AA(C)/XVS13CTA(C)) 1. Fuel tank overflow hose 2. Fuel tank 3. Fuel tank breather hose (fuel tank to hose joint) 4. Air vent hose 5. Sub-fuel tank 6. Fuel pump 7. Fuel hose 8. Crankcase breather hose 9. Fuel cock hose 10.

  • Page 106: Cable Routing (For Xvs13Ca(C))

    CABLE ROUTING (for XVS13CA(C)) EAS27D1026 CABLE ROUTING (for XVS13CA(C)) 2-79...
  • Page 107 CABLE ROUTING (for XVS13CA(C)) 1. Clutch cable 2. Front brake hose 3. Throttle cable (accelerator cable) 4. Throttle cable (decelerator cable) 5. Starter motor 6. Starter motor lead 7. Rear brake light switch 8. Rear brake light switch lead 9. Horn 10.
  • Page 108 CABLE ROUTING (for XVS13CA(C)) 2-81...
  • Page 109 CABLE ROUTING (for XVS13CA(C)) 1. Left handlebar switch lead 2. Meter assembly lead 3. Clutch cable 4. Throttle cable (accelerator cable) 5. Throttle cable (decelerator cable) 6. Front brake hose 7. Right handlebar switch lead A. Route the clutch cable to the outside of the left handlebar switch lead and meter assembly lead.
  • Page 110 CABLE ROUTING (for XVS13CA(C)) 2-83...
  • Page 111 CABLE ROUTING (for XVS13CA(C)) 1. Air temperature sensor lead 2. Air temperature sensor 3. Front right turn signal/position light lead 4. Front brake hose 5. Wire harness 6. Main switch lead 7. Front left turn signal/position light lead 8. Throttle cable (decelerator cable) 9.
  • Page 112 CABLE ROUTING (for XVS13CA(C)) 2-85...
  • Page 113 CABLE ROUTING (for XVS13CA(C)) 1. Clutch cable M. Fasten the horn lead and rear brake light switch lead to the frame with a plastic locking tie. Point the 2. Rear cylinder spark plug lead end of the plastic locking tie downward, and then 3.
  • Page 114 CABLE ROUTING (for XVS13CA(C)) 2-87...
  • Page 115 CABLE ROUTING (for XVS13CA(C)) 1. Coolant reservoir hose 2. Clutch cable 3. Lean angle sensor 4. Fuel hose 5. Brake fluid reservoir hose 6. Coolant reservoir breather hose 7. Wire harness 8. O sensor 9. O sensor lead A. Be sure not to pinch the O sensor lead when installing the coolant reservoir cap cover.
  • Page 116 CABLE ROUTING (for XVS13CA(C)) 2-89...
  • Page 117 CABLE ROUTING (for XVS13CA(C)) 1. Brake fluid reservoir hose 2. Rear brake light switch 3. Horn 4. Horn lead 5. Rear brake light switch lead 6. Rear brake hose 7. Coolant reservoir hose 8. Coolant reservoir breather hose A. Install the brake fluid reservoir hose with its paint mark facing upward.
  • Page 118 CABLE ROUTING (for XVS13CA(C)) 2-91...
  • Page 119 CABLE ROUTING (for XVS13CA(C)) 1. Clutch cable 2. Left handlebar switch lead 3. Meter assembly lead 4. Front cylinder spark plug lead 5. Coolant temperature sensor lead 6. Front cylinder injector lead 7. Fuel pipe 8. ISC (idle speed control) unit lead 9.
  • Page 120 CABLE ROUTING (for XVS13CA(C)) 2-93...
  • Page 121 CABLE ROUTING (for XVS13CA(C)) 1. Joint coupler O. Secure the holder by inserting the projection on the holder into the hole in the bracket, and then 2. Tail/brake light wire harness coupler fasten the crankshaft position sensor/stator 3. Crankshaft position sensor coupler assembly lead and speed sensor lead with the 4.
  • Page 122 CABLE ROUTING (for XVS13CA(C)) 2-95...
  • Page 123 CABLE ROUTING (for XVS13CA(C)) 1. Headlight relay 2. Radiator fan motor relay 3. Turn signal relay 4. Wire harness 5. Crankshaft position sensor coupler 6. Tail/brake light coupler 7. Joint coupler A. To fuse box and main fuse B. To starter relay C.
  • Page 124 CABLE ROUTING (for XVS13CA(C)) Q 14 J 14 2-97...
  • Page 125 CABLE ROUTING (for XVS13CA(C)) 1. Left handlebar switch lead R. To O sensor 2. Clutch cable 3. Meter assembly lead 4. Wire harness 5. Throttle cable (accelerator cable) 6. Throttle cable (decelerator cable) 7. Negative battery lead 8. Battery 9. Battery cover band 10.
  • Page 126 CABLE ROUTING (for XVS13CA(C)) 2-99...
  • Page 127 CABLE ROUTING (for XVS13CA(C)) 1. Intake air pressure sensor hose 2. Front cylinder resonator hose 3. Resonator hose joint 4. Rear cylinder resonator hose 5. Canister purge hose (California only) A. Install the intake air pressure sensor hose with its green paint mark facing to the left.
  • Page 128 CABLE ROUTING (for XVS13CA(C)) 2-101...
  • Page 129 CABLE ROUTING (for XVS13CA(C)) 1. Intake air pressure sensor 2. Intake air pressure sensor hose 3. Front cylinder resonator hose 4. Canister purge hose (California only) 5. Throttle body 6. Rear cylinder resonator hose 7. Thermostat cover A. Route the intake air pressure sensor hose between the frame and the thermostat cover.
  • Page 130 CABLE ROUTING (for XVS13CA(C)) 2-103...
  • Page 131 CABLE ROUTING (for XVS13CA(C)) 1. Fuel tank breather hose (fuel tank to hose joint) X. Point the ends of each hose clamp inward. (California only) 2. Fuel tank cap Y. Point the ends of the hose clamp inward. 3. Fuel tank (California only) 4.
  • Page 132 CABLE ROUTING (for XVS13CA(C)) 2-105...
  • Page 133 CABLE ROUTING (for XVS13CA(C)) 1. Fuel tank breather hose (fuel tank to hose joint) 2. Fuel tank breather hose (hose joint to rollover valve) 3. Hose joint 4. Canister purge hose (California only) 5. Radiator fan motor lead 6. Radiator fan motor coupler 7.
  • Page 134 CABLE ROUTING (for XVS13CA(C)) 2-107...

  • Page 135: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM.............. 3-1 GENERAL MAINTENANCE AND LUBRICATION CHART .......3-1 ENGINE ......................3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 SYNCHRONIZING THE THROTTLE BODIES.......... 3-6 ADJUSTING THE THROTTLE CABLE FREE PLAY ........3-8 CHECKING THE SPARK PLUGS .............
  • Page 136 CHASSIS ....................... 3-20 ADJUSTING THE REAR DISC BRAKE ..........3-20 CHECKING THE BRAKE FLUID LEVEL..........3-20 CHECKING THE FRONT BRAKE PADS ..........3-21 CHECKING THE REAR BRAKE PADS ..........3-21 CHECKING THE FRONT BRAKE HOSE(S)...........3-21 CHECKING THE REAR BRAKE HOSES..........3-22 ADJUSTING THE REAR BRAKE LIGHT SWITCH .........3-22 BLEEDING THE HYDRAULIC BRAKE SYSTEM ........

  • Page 138: Periodic Maintenance

    • From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. • Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer perform the service.
  • Page 139 PERIODIC MAINTENANCE INITIAL ODOMETER READINGS 8000 mi 12000 mi 16000 mi 20000 mi 600 mi 4000 mi ITEM ROUTINE (13000 (19000 (25000 (31000 (1000 km) (7000 km) 1 month 6 months 12 months 18 months 24 months 30 months 1 * Air filter element •...
  • Page 140 Front and rear √ √ √ √ √ √ 25 * • Check operation. brake switches • Apply Yamaha chain and ca- √ √ √ √ √ √ 26 * Control cables ble lube or engine oil thor- oughly. • Check operation.

  • Page 141: Engine

    ENGINE EAS20470 ENGINE EAS20530 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or 8.
  • Page 142 ENGINE M MMM M MMM M MMM M MMM M MMM Valve clearance (cold) Rear cylinder Intake a. Turn the crankshaft counterclockwise from 0.09–0.13 mm (0.0035–0.0051 in) the front cylinder piston TDC by 300 degrees. Exhaust b. When the rear cylinder piston is at TDC on 0.14–0.18 mm (0.0055–0.0071 in) the compression stroke, align the TDC mark “c”...

  • Page 143: Synchronizing The Throttle Bodies

    ENGINE 15.Install: Thickness gauge • Crankshaft end screw 90890-03180 (along with the O-ring Feeler gauge set • Timing mark accessing screw YU-26900-9 (along with the O-ring c. Turn the adjusting screw “3” in direction “a” or • Damper cover “b” with the tappet adjusting tool “4” until the specified valve clearance is obtained.
  • Page 144 ENGINE • Digital tachometer Vacuum gauge 90890-03094 Vacuummate YU-44456 6. Install: (for XVS13AA(C)/XVS13CTA(C)) • Fuel tank Refer to “FUEL TANK” on page 7-1. 7. Adjust: • Throttle body synchronization M MMM M MMM M MMM M MMM M MMM a. Measure the vacuum pressure of the front cylinder throttle body and rear cylinder throt- tle body.

  • Page 145: Adjusting The Throttle Cable Free Play

    ENGINE Intake vacuum Throttle cable free play 32.0–37.3 kPa (240–280 mmHg, 4.0–6.0 mm (0.16–0.24 in) 9.4–11.0 inHg) 2. Remove: (for XVS13AA(C)/XVS13CTA(C)) • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. The difference in vacuum pressure between two • Fuel tank throttle bodies should not exceed 1.33 kPa (10 Refer to “FUEL TANK”...

  • Page 146: Checking The Spark Plugs

    ENGINE d. Tighten the locknut. 7. Measure: e. Slide the throttle cable holder to its original • Spark plug gap “a” position. (with a wire thickness gauge) Out of specification → Regap. Spark plug gap 0.8–0.9 mm (0.031–0.035 in) L LLL L LLL L LLL L LLL...

  • Page 147: Measuring The Compression Pressure

    ENGINE The ignition timing is not adjustable. L LLL L LLL L LLL L LLL L LLL 5. Install: • Timing mark accessing screw (along with the O-ring • Damper cover Damper cover bolt 4 Nm (0.4 m·kg, 2.9 ft·lb) 3.

  • Page 148: Checking The Engine Oil Level

    ENGINE Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without Piston ring(s) wear or damage → Repair. Piston, valves, cylin- der head gasket or Same as without oil piston possibly defec- tive → Repair. 7. Measure: L LLL L LLL L LLL...

  • Page 149: Changing The Engine Oil

    ENGINE 4. Drain: Recommended brand • Engine oil YAMALUBE (completely from the crankcase) Type 5. If the oil filter cartridge is also to be replaced, SAE 10W-30, 10W-40, 10W-50, perform the following procedure. 15W-40, 20W-40 or 20W-50 M MMM M MMM M MMM M MMM M MMM...

  • Page 150: Adjusting The Clutch Lever Free Play

    ENGINE 7. Fill: c. Check the engine oil passages, the oil filter • Crankcase cartridge and the oil pump for damage or (with the specified amount of the recom- leakage. Refer to “OIL PUMP” on page 5-80. mended engine oil) d.

  • Page 151: Replacing The Air Filter Element

    ENGINE 2. Remove: • Air filter element “1” If the specified clutch lever free play cannot be obtained using the clutch lever free play adjust- ing bolt, use the clutch lever free play adjusting nut. e. Slide the rubber cover to its original position. L LLL L LLL L LLL...

  • Page 152: Checking The Fuel Line

    ENGINE • Rear cylinder thermostat inlet hose Refer to “THERMOSTAT” on page 6-4. 2. Check: • Intake manifold joints “1” Cracks/damage → Replace. 3. Install: • Rear cylinder thermostat inlet hose • Front cylinder thermostat inlet hose Refer to “THERMOSTAT” on page 6-4. •...

  • Page 153: Checking The Exhaust System

    ENGINE ECA13450 NOTICE Make sure the crankcase breather hose is routed correctly. 3. Install: • Fuel tank Refer to “FUEL TANK” on page 7-1. • Air filter case • Rider seat (for XVS13AA(C)/XVS13CTA(C)) • Seat (for XVS13CA(C)) Refer to “GENERAL CHASSIS” on page 4-1. EAS21080 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex-...

  • Page 154: Checking The Coolant Level

    ENGINE ECA13470 EAS21110 CHECKING THE COOLANT LEVEL NOTICE 1. Stand the vehicle on a level surface. • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if nec- •...

  • Page 155: Changing The Coolant

    ENGINE 4. Disconnect: • Radiator outlet hose “2” 3. Install: • Front cylinder exhaust pipe Refer to “ENGINE REMOVAL” on page 5-1. 5. Drain: • Coolant EAS21130 (from the engine and radiator) CHANGING THE COOLANT 6. Remove: 1. Remove: • Coolant reservoir cover bracket “1” •...
  • Page 156 ENGINE • If coolant comes into contact with painted Coolant reservoir cover bracket surfaces, immediately wash them with wa- bolt ter. 7 Nm (0.7 m·kg, 5.1 ft·lb) • Do not mix different types of antifreeze. 14.Install: 11.Connect: • Radiator cap •...

  • Page 157: Chassis

    CHASSIS EAS21140 ECA3D81019 CHASSIS NOTICE After adjusting the brake pedal adjusting EAS21190 bolt position, make sure there is no brake ADJUSTING THE REAR DISC BRAKE drag. 1. Check: • Brake pedal adjusting bolt position L LLL L LLL L LLL L LLL L LLL Check that the end “a”...

  • Page 158: Checking The Front Brake Pads

    CHASSIS EWA3D81007 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.

  • Page 159: Checking The Rear Brake Hoses

    CHASSIS 3. Hold the vehicle upright and apply the brake several times. 4. Check: • Brake hoses Brake fluid leakage → Replace the damaged hose. Refer to “REAR BRAKE” on page 4-42. EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH The rear brake light switch is operated by move- ment of the brake pedal.
  • Page 160 CHASSIS • brake operation is faulty. 1. Remove: • Rider seat (for XVS13AA(C)/XVS13CTA(C)) • Seat (for XVS13CA(C)) • Sub-fuel tank cover Refer to “GENERAL CHASSIS” on page 4-1. 2. Remove: • Brake fluid reservoir bolt “1” • Remove the brake fluid reservoir bolt, and then A.

  • Page 161: Adjusting The Shift Pedal

    CHASSIS EWA13110 WARNING After bleeding the hydraulic brake system, check the brake operation. L LLL L LLL L LLL L LLL L LLL 5. Tighten: • Brake fluid reservoir bolt Brake fluid reservoir bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) c.
  • Page 162 CHASSIS b. Loosen both locknuts “2”. Drive belt slack (on the side- c. Turn both adjusting bolts “3” in direction “a” or stand) “b” until the specified drive belt slack is ob- 5.0–7.0 mm (0.20–0.28 in) tained. Drive belt slack (on a suitable stand) Direction “a”...
  • Page 163 CHASSIS EAS27D1002 ADJUSTING THE DRIVE BELT SLACK (for • The level marks of the level window on the XVS13CA(C)) drive belt lower guard are in units of 5 mm (0.20 in). Use them as a standard for measur- The drive belt slack must be checked at the tight- ing the drive belt slack.

  • Page 164: Checking And Adjusting The Steering Head

    CHASSIS Using the alignment marks “4” on each side of the swingarm, make sure that both belt pullers are in the same position for proper wheel align- ment. 3. Remove: (for XVS13AA(C)/XVS13CTA(C)) • Upper bracket Refer to “FRONT FORK” on page 4-65. 4.

  • Page 165: Checking The Front Fork

    CHASSIS EAS21530 CHECKING THE FRONT FORK Lower ring nut (initial tightening 1. Stand the vehicle on a level surface. torque) EWA13120 52 Nm (5.2 m·kg, 37 ft·lb) WARNING Securely support the vehicle so that there is c. Loosen the lower ring nut “4” completely, and no danger of it falling over.

  • Page 166: Checking The Tires

    CHASSIS • Coolant reservoir cover Refer to “ENGINE REMOVAL” on page 5-1. EAS21650 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: • Tire pressure Out of specification → Regulate. 3. Adjust: • Spring preload M MMM M MMM M MMM...
  • Page 167 No guarantee con- 1. Tire tread depth cerning handling characteristics can be giv- 2. Side wall en if a tire combination other than one 3. Wear indicator approved by Yamaha is used on this vehicle. 3-30...

  • Page 168: Checking The Wheels

    CHASSIS EAS21670 CHECKING THE WHEELS Front tire The following procedure applies to both of the Size wheels. XVS13AA(C)/XVS13CTA(C): 130/90 16M/C 67H 1. Check: XVS13CA(C): • Wheel 120/70 21M/C 62H Damage/out-of-round → Replace. Manufacturer/model EWA13260 XVS13AA(C)/XVS13CTA(C): WARNING DUNLOP/D404F X Never attempt to make any repairs to the BRIDGESTONE/EXEDRA G721 wheel.

  • Page 169: Lubricating The Brake Pedal

    CHASSIS Recommended lubricant Lithium-soap-based grease EAS21710 LUBRICATING THE BRAKE PEDAL Lubricate the pivoting point and metal-to-metal moving parts of the brake pedal. Recommended lubricant Lithium-soap-based grease EAS3D84002 LUBRICATING THE SHIFT PEDAL Lubricate the pivoting point and metal-to-metal moving parts of the shift pedal. Recommended lubricant Lithium-soap-based grease EAS21720...

  • Page 170: Electrical System

    ELECTRICAL SYSTEM 5. Detach: EAS21750 ELECTRICAL SYSTEM • Headlight bulb holder “5” 6. Remove: EAS21760 • Headlight bulb “6” CHECKING AND CHARGING THE BATTERY Refer to “ELECTRICAL COMPONENTS” on page 8-89. EAS21770 CHECKING THE FUSES Refer to “ELECTRICAL COMPONENTS” on page 8-89.

  • Page 171: Replacing The Headlight Bulb (For Xvs13Ca(C))

    ELECTRICAL SYSTEM EAS27D1004 ECA13690 REPLACING THE HEADLIGHT BULB (for NOTICE XVS13CA(C)) Avoid touching the glass part of the head- 1. Remove: light bulb to keep it free from oil, otherwise • Headlight lens unit “1” the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected.
  • Page 172 ELECTRICAL SYSTEM 2. Adjust: • Headlight beam (horizontally) M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting screw “1” with a screwdriv- er in direction “a” or “b”. Direction “a” Headlight beam moves to the left. Direction “b”...
  • Page 173 CHASSIS GENERAL CHASSIS..................4-1 FRONT WHEEL..................... 4-12 REMOVING THE FRONT WHEEL............4-15 DISASSEMBLING THE FRONT WHEEL..........4-15 CHECKING THE FRONT WHEEL ............4-15 ASSEMBLING THE FRONT WHEEL............4-16 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-16 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC)....4-17 REAR WHEEL ....................4-19 REMOVING THE REAR WHEEL (DISC) ..........
  • Page 174 HANDLEBAR ....................4-57 REMOVING THE HANDLEBAR..............4-61 CHECKING THE HANDLEBAR ..............4-61 INSTALLING THE HANDLEBAR (for XVS13AA(C)/XVS13CTA(C)) ..4-61 INSTALLING THE HANDLEBAR (for XVS13CA(C)).......4-63 FRONT FORK....................4-65 REMOVING THE FRONT FORK LEGS..........4-72 DISASSEMBLING THE FRONT FORK LEGS ........4-72 CHECKING THE FRONT FORK LEGS ..........4-73 ASSEMBLING THE FRONT FORK LEGS ..........

  • Page 176: General Chassis

    GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the windshield (for XVS13CTA(C)) 23 Nm (2.3 m kg, 17 ft 48 Nm (4.8 m kg, 35 ft • • • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft •...
  • Page 177 Sidebag (left and right) tions to clean the leather on the sidebags. Polish the dry leather with a soft cloth, and then treat with Yamaha Mink Oil or another high-quality leather protectant for increased water resistance. Backrest...
  • Page 178 GENERAL CHASSIS Removing the seats and left side cover (for XVS13AA(C)/XVS13CTA(C)) 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 4 Nm (0.4 m kg, 2.9 ft 7 Nm (0.7 m kg, 5.1 ft...
  • Page 179 GENERAL CHASSIS Removing the seat (for XVS13CA(C)) 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Seat Sub-fuel tank cover Relay cover Seat lock cable Disconnect.
  • Page 180 GENERAL CHASSIS Removing the headlight (for XVS13AA(C)/XVS13CTA(C)) 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Front turn signal/position light bracket cover Headlight lens unit Headlight coupler Disconnect.
  • Page 181 GENERAL CHASSIS Removing the headlight (for XVS13CA(C)) 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Headlight lens unit Headlight coupler Disconnect. Front turn signal/position light coupler Disconnect. Main switch coupler Disconnect. Headlight body For installation, reverse the removal proce- dure.
  • Page 182 GENERAL CHASSIS Removing the battery 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks For XVS13AA(C)/XVS13CTA(C) Rider seat/Sub-fuel tank cover Refer to “GENERAL CHASSIS” on page 4-1.
  • Page 183 GENERAL CHASSIS Removing the battery 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Brake fluid reservoir bolt Battery box For installation, reverse the removal proce- dure.
  • Page 184 GENERAL CHASSIS Removing the air filter case 4 Nm (0.4 m kg, 2.9 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Air filter case cover Air filter element Air filter case bracket...
  • Page 185 GENERAL CHASSIS Removing the relays A 7 Nm (0.7 m kg, 5.1 ft • • B 4 Nm (0.4 m kg, 2.9 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks For XVS13AA(C)/XVS13CTA(C) Rider seat/Sub-fuel tank cover/Battery box Refer to “GENERAL CHASSIS”...
  • Page 186 GENERAL CHASSIS Removing the relays A 7 Nm (0.7 m kg, 5.1 ft • • B 4 Nm (0.4 m kg, 2.9 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Relay bracket For installation, reverse the removal proce- dure.

  • Page 187: Front Wheel

    FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs (for XVS13AA(C)/XVS13CTA(C)) 40 Nm (4.0 m kg, 29 ft • • 59 Nm (5.9 m kg, 43 ft • • 23 Nm (2.3 m kg, 17 ft • •...
  • Page 188 FRONT WHEEL Removing the front wheel and brake disc (for XVS13CA(C)) 72 Nm (7.2 m kgf, 52 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • •...
  • Page 189 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-14...

  • Page 190: Removing The Front Wheel

    FRONT WHEEL EAS21900 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Front brake caliper(s) Do not apply the brake lever when removing the L LLL L LLL L LLL...

  • Page 191: Assembling The Front Wheel

    FRONT WHEEL • Lateral wheel runout “2” Over the specified limits → Replace. Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) L LLL L LLL L LLL L LLL L LLL EAS21970 ADJUSTING THE FRONT WHEEL STATIC BALANCE •...

  • Page 192: Installing The Front Wheel (Front Brake Disc)

    FRONT WHEEL M MMM M MMM M MMM M MMM M MMM a. Turn the front wheel and make sure it stays at each position shown. f. Repeat steps (c) through (e) several times until all the marks come to rest at the same spot.
  • Page 193 FRONT WHEEL outer edge of the axle with the fork, making sure that the axle does not protrude past the Install the tire and wheel with the marks “1” fork. pointing in the direction of wheel rotation. c. In the order pinch bolt “1” → pinch bolt “2” → pinch bolt “1”, tighten each bolt to 20 Nm (2.0 m·kg, 14 ft·lb) without performing temporary tightening.

  • Page 194: Rear Wheel

    REAR WHEEL EAS22020 REAR WHEEL Removing the rear fender (for XVS13AA(C)/XVS13CTA(C)) 16 Nm (1.6 m kg, 11 ft • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Parts to remove Q’ty Remarks Rider seat/Passenger seat/Seat lock brack-...
  • Page 195 REAR WHEEL Removing the rear fender (for XVS13CA(C)) 23 Nm (2.3 m kg, 17 ft 16 Nm (1.6 m kg, 11 ft • • • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
  • Page 196 REAR WHEEL Removing the rear wheel (for XVS13AA(C)/XVS13CTA(C)) 27 Nm (2.7 m kg, 19 ft • • 16 Nm (1.6 m kg, 11 ft • • 150 Nm (15.0 m kg, 110 ft • • 16 Nm (1.6 m kg, 11 ft •...
  • Page 197 REAR WHEEL Removing the rear wheel (for XVS13AA(C)/XVS13CTA(C)) 27 Nm (2.7 m kg, 19 ft • • 16 Nm (1.6 m kg, 11 ft • • 150 Nm (15.0 m kg, 110 ft • • 16 Nm (1.6 m kg, 11 ft •...
  • Page 198 REAR WHEEL Removing the rear wheel (for XVS13CA(C)) 7 Nm (0.7 m kg, 5.1 ft • • 150 Nm (15.0 m kg, 110 ft • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 199 REAR WHEEL Removing the rear wheel (for XVS13CA(C)) 7 Nm (0.7 m kg, 5.1 ft • • 150 Nm (15.0 m kg, 110 ft • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 200 REAR WHEEL Removing the rear brake disc and rear wheel drive hub A 23 Nm (2.3 m kg, 17 ft • • B 18 Nm (1.8 m kg, 13 ft • • Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel pulley Oil seal Circlip...
  • Page 201 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Collar Bearing Oil seal Circlip Bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-26...

  • Page 202: Removing The Rear Wheel (Disc)

    REAR WHEEL EAS28760 EAS22080 REMOVING THE REAR WHEEL (DISC) DISASSEMBLING THE REAR WHEEL 1. Stand the vehicle on a level surface. 1. Remove: EWA13120 • Oil seals WARNING • Wheel bearings Securely support the vehicle so that there is Refer to “DISASSEMBLING THE FRONT no danger of it falling over.

  • Page 203: Checking And Replacing The Rear Wheel Pulley

    REAR WHEEL 1. Adjust: EAS22130 CHECKING AND REPLACING THE REAR • Rear wheel static balance WHEEL PULLEY Refer to “ADJUSTING THE FRONT WHEEL 1. Check: STATIC BALANCE” on page 4-16. • Rear wheel pulley Surface plating has come off → Replace the EAS28770 INSTALLING THE REAR WHEEL (REAR rear wheel pulley.
  • Page 204 REAR WHEEL 5. Adjust: • Drive belt slack Refer to “ADJUSTING THE DRIVE BELT SLACK (for XVS13AA(C)/XVS13CTA(C))” on page 3-24 and “ADJUSTING THE DRIVE BELT SLACK (for XVS13CA(C))” on page 3-26. 6. Tighten: • Rear wheel axle nut Rear wheel axle nut 150 Nm (15.0 m·kg, 110 ft·lb) 7.

  • Page 205: Front Brake

    FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of...
  • Page 206 FRONT BRAKE Removing the front brake master cylinder 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft • • 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Drain.
  • Page 207 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder push rod Dust boot Circlip Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-32...
  • Page 208 FRONT BRAKE Removing the front brake caliper(s) 40 Nm (4.0 m kg, 29 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. (for XVS13AA(C)/XVS13CTA(C)) For XVS13AA(C)/XVS13CTA(C) Reflector...
  • Page 209 FRONT BRAKE Disassembling the front brake caliper(s) 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft • • 9 11 Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.

  • Page 210: Introduction

    FRONT BRAKE EAS22220 INTRODUCTION Brake disc deflection limit EWA14100 XVS13AA(C)/XVS13CTA(C): WARNING 0.12 mm (0.0047 in) Disc brake components rarely require disas- XVS13CA(C): sembly. Therefore, always follow these pre- 0.15 mm (0.0059 in) ventive measures: M MMM M MMM M MMM M MMM M MMM •...

  • Page 211: Replacing The Front Brake Pads

    FRONT BRAKE Tighten the brake disc bolts in stages and in a crisscross pattern. d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. f. If the brake disc deflection cannot be brought within specification, replace the brake disc.

  • Page 212: Removing The Front Brake Caliper(S)

    FRONT BRAKE Bleed screw Before removing the brake caliper, drain the 6 Nm (0.6 m·kg, 4.3 ft·lb) brake fluid from the entire brake system. d. Install a new brake pad shim (inner), a new 1. Remove: brake pad spring (outer) (for XVS13CA(C)) •...

  • Page 213: Checking The Front Brake Caliper(S)

    FRONT BRAKE • Never try to pry out the brake caliper pis- tons. 2. Check: • Brake caliper bracket Cracks/damage → Replace. b. Remove the brake caliper piston dust seals and brake caliper piston seals. EAS27D1031 ASSEMBLING THE FRONT BRAKE L LLL L LLL L LLL...

  • Page 214: Removing The Front Brake Master Cylinder

    FRONT BRAKE • Refill with the same type of brake fluid that EWA27D1001 WARNING is already in the system. Mixing brake fluids Proper brake hose routing is essential to in- may result in a harmful chemical reaction, sure safe vehicle operation. Refer to “CABLE leading to poor brake performance.

  • Page 215: Checking The Front Brake Master Cylinder

    FRONT BRAKE EAS22530 INSTALLING THE FRONT BRAKE MASTER To collect any remaining brake fluid, place a CYLINDER container under the master cylinder and the end 1. Install: of the brake hose. • Front brake master cylinder “1” • Front brake master cylinder holder “2” Front brake master cylinder hold- er bolt 10 Nm (1.0 m·kg, 7.2 ft·lb)
  • Page 216 FRONT BRAKE LOWER 30–50˚ 3. Fill: 6. Check: • Brake master cylinder reservoir • Brake lever operation Soft or spongy feeling → Bleed the brake sys- (with the specified amount of the recom- mended brake fluid) tem. Refer to “BLEEDING THE HYDRAULIC Recommended fluid BRAKE SYSTEM”...

  • Page 217: Rear Brake

    REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads (for XVS13AA(C)/XVS13CTA(C)) 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Parts to remove Q’ty Remarks Rear brake caliper retaining bolt Rear brake caliper Rear brake pad Brake pad spring...
  • Page 218 REAR BRAKE Removing the rear brake pads (for XVS13CA(C)) 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Parts to remove Q’ty Remarks Muffler Refer to “ENGINE REMOVAL” on page 5-1. Rear brake caliper retaining bolt Rear brake caliper Rear brake pad...
  • Page 219 REAR BRAKE Removing the rear brake master cylinder (for XVS13AA(C)/XVS13CTA(C)) 16 Nm (1.6 m kg, 11 ft • • 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft 30 Nm (3.0 m kg, 22 ft...
  • Page 220 REAR BRAKE Removing the rear brake master cylinder (for XVS13AA(C)/XVS13CTA(C)) 16 Nm (1.6 m kg, 11 ft • • 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft 30 Nm (3.0 m kg, 22 ft...
  • Page 221 REAR BRAKE Removing the rear brake master cylinder (for XVS13CA(C)) 23 Nm (2.3 m kg, 17 ft • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft 30 Nm (3.0 m kg, 22 ft •...
  • Page 222 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Brake master cylinder kit Circlip Brake hose joint O-ring Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-47...
  • Page 223 REAR BRAKE Removing the rear brake caliper (for XVS13AA(C)/XVS13CTA(C)) 30 Nm (3.0 m kg, 22 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
  • Page 224 REAR BRAKE Removing the rear brake caliper (for XVS13CA(C)) 27 Nm (2.7 m kg, 19 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Muffler Refer to “ENGINE REMOVAL” on page 5-1. Drain.
  • Page 225 REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.

  • Page 226: Introduction

    REAR BRAKE Refer to “CHECKING THE FRONT BRAKE EAS22560 INTRODUCTION DISC(S)” on page 4-35. EWA14100 WARNING Brake disc thickness limit Disc brake components rarely require disas- 5.5 mm (0.22 in) sembly. Therefore, always follow these pre- ventive measures: 5. Adjust: •...

  • Page 227: Removing The Rear Brake Caliper

    REAR BRAKE • Brake pads Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-22. Always install new brake pads, brake pad EAS22590 springs, and brake pad shims as a set. REMOVING THE REAR BRAKE CALIPER M MMM M MMM M MMM M MMM M MMM...

  • Page 228: Checking The Rear Brake Caliper

    REAR BRAKE b. Remove the brake caliper piston dust seal EAS22650 ASSEMBLING THE REAR BRAKE CALIPER and brake caliper piston seal. EWA3D84004 L LLL L LLL L LLL L LLL L LLL WARNING EAS22640 • Before installation, all internal brake com- CHECKING THE REAR BRAKE CALIPER ponents should be cleaned and lubricated Recommended brake component replace-...

  • Page 229: Removing The Rear Brake Master Cylinder

    REAR BRAKE 5. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-22. 6. Check: • Brake fluid level Below the minimum level mark “a” → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”...

  • Page 230: Checking The Rear Brake Master Cylinder

    REAR BRAKE Recommended fluid DOT 4 EAS22750 INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: • Copper washers “1” • Rear brake hose “2” • Rear brake hose union bolt “3” Rear brake hose union bolt 30 Nm (3.0 m·kg, 22 ft·lb) EWA13530 WARNING Proper brake hose routing is essential to in-...
  • Page 231 REAR BRAKE Recommended fluid DOT 4 EWA13090 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system.
  • Page 232 HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar (for XVS13AA(C)/XVS13CTA(C)) 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • 28 Nm (2.8 m kg, 20 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 233 HANDLEBAR Removing the handlebar (for XVS13AA(C)/XVS13CTA(C)) 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • 28 Nm (2.8 m kg, 20 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 234 HANDLEBAR Removing the handlebar (for XVS13CA(C)) 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft •...
  • Page 235 HANDLEBAR Removing the handlebar (for XVS13CA(C)) 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft •...

  • Page 236: Handlebar

    HANDLEBAR • Turn the handlebar all the way to the left EAS22860 REMOVING THE HANDLEBAR and right. If there is any contact with the 1. Stand the vehicle on a level surface. fuel tank, adjust the handlebar position. EWA13120 WARNING Securely support the vehicle so that there is Align the punch mark “a”...
  • Page 237 HANDLEBAR 5. Install: • Handlebar grip “1” M MMM M MMM M MMM M MMM M MMM a. Apply a thin coat of rubber adhesive onto the left end of the handlebar. b. Slide the handlebar grip over the left end of the handlebar.

  • Page 238: Installing The Handlebar (For Xvs13Ca(C))

    HANDLEBAR EAS27D1019 INSTALLING THE HANDLEBAR (for XVS13CA(C)) 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Install: • Rubber damper “1” • Handlebar a. 0.5–1 mm (0.02–0.04 in) 4.
  • Page 239 HANDLEBAR b. Slide the handlebar grip over the left end of • Align the end of the front brake master cylinder the handlebar. holder with the punch mark “a” on the handle- c. Wipe off any excess rubber adhesive with a bar.

  • Page 240: Front Fork

    FRONT FORK EAS22950 FRONT FORK Removing the front fork legs (for XVS13AA(C)/XVS13CTA(C)) 18 Nm (1.8 m kg, 13 ft 110 Nm (11.0 m kg, 80 ft • • • • 20 Nm (2.0 m kg, 14 ft • • 20 Nm (2.0 m kg, 14 ft •...
  • Page 241 FRONT FORK Removing the front fork legs (for XVS13AA(C)/XVS13CTA(C)) 110 Nm (11.0 m kg, 80 ft 18 Nm (1.8 m kg, 13 ft • • • • 20 Nm (2.0 m kg, 14 ft • • 20 Nm (2.0 m kg, 14 ft •...
  • Page 242 FRONT FORK Removing the front fork legs (for XVS13CA(C)) 19 Nm (1.9 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 24 Nm (2.4 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 243 FRONT FORK Disassembling the front fork legs (for XVS13AA(C)/XVS13CTA(C)) 23 Nm (2.3 m kg, 17 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs.
  • Page 244 FRONT FORK Disassembling the front fork legs (for XVS13AA(C)/XVS13CTA(C)) 23 Nm (2.3 m kg, 17 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Spring Oil flow stopper Outer tube For assembly, reverse the disassembly pro- cedure.
  • Page 245 FRONT FORK Disassembling the front fork legs (for XVS13CA(C)) 24 Nm (2.4 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs.
  • Page 246 FRONT FORK Disassembling the front fork legs (for XVS13CA(C)) 24 Nm (2.4 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Parts to remove Q’ty Remarks Outer tube bushing Inner tube bushing Oil flow stopper Outer tube For assembly, reverse the disassembly pro- cedure.

  • Page 247: Removing The Front Fork Legs

    FRONT FORK EAS22960 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 3.

  • Page 248: Checking The Front Fork Legs

    FRONT FORK • Oil flow stopper Damage → Replace. ECA14200 NOTICE • The front fork leg has a built-in damper ad- justing rod and a very sophisticated inter- nal construction, which are particularly sensitive to foreign material. • When disassembling and assembling the front fork leg, do not allow any foreign ma- terial to enter the front fork.
  • Page 249 2. Lubricate: • Inner tube’s outer surface • Outer tube bushing “1” • Washer Recommended oil (with the fork seal driver “2”) Yamaha fork oil 10WT Fork seal driver 3. Install: 90890-01442 • Inner tube Adjustable fork seal driver (36–46 (in the outer tube) 4.
  • Page 250 514.0 cm³ (17.38 US oz, 18.13 Imp.oz) Recommended oil 8. Install: Yamaha fork oil 10WT • Oil seal clip “1” 11.Measure: Adjust the oil seal clip so that it fits into the outer • Front fork leg oil level “a”...

  • Page 251: Installing The Front Fork Legs (For Xvs13Aa(C)/Xvs13Cta(C))

    FRONT FORK • Spring seat 2. Tighten: • Spacer • Lower bracket pinch bolts • Cap bolt Lower bracket pinch bolt (along with the O-ring 45 Nm (4.5 m·kg, 32 ft·lb) • Install the fork spring with the smaller pitch fac- ing up.

  • Page 252: Installing The Front Fork Legs (For Xvs13Ca(C))

    FRONT FORK EAS27D1020 INSTALLING THE FRONT FORK LEGS (for XVS13CA(C)) The following procedure applies to both of the front fork legs. 1. Install: • Front fork leg “1” Temporarily tighten the lower bracket pinch bolts. Make sure the inner tube end is flush with the top of the upper bracket.

  • Page 253: Steering Head

    STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket (for XVS13AA(C)/XVS13CTA(C)) 1st 52 Nm (5.2 m kg, 37 ft • • 2nd 18 Nm (1.8 m kg, 13 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 254 STEERING HEAD Removing the lower bracket (for XVS13AA(C)/XVS13CTA(C)) 1st 52 Nm (5.2 m kg, 37 ft • • 2nd 18 Nm (1.8 m kg, 13 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 255 STEERING HEAD Removing the headlight bracket and front brake hose holder (for XVS13CA(C)) 4 Nm (0.4 m kg, 2.9 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 16 Nm (1.6 m kg, 11 ft • • 23 Nm (2.3 m kg, 17 ft •...
  • Page 256 STEERING HEAD Removing the lower bracket (for XVS13CA(C)) 1st 52 Nm (5.2 m kg, 37 ft • • 2nd 18 Nm (1.8 m kg, 13 ft • • 110 Nm (11.0 m kg, 80 ft • • 32 Nm (3.2 m kg, 23 ft •...
  • Page 257 STEERING HEAD Removing the lower bracket (for XVS13CA(C)) 1st 52 Nm (5.2 m kg, 37 ft • • 2nd 18 Nm (1.8 m kg, 13 ft • • 110 Nm (11.0 m kg, 80 ft • • 32 Nm (3.2 m kg, 23 ft •...

  • Page 258: Removing The Lower Bracket

    STEERING HEAD b. Remove the bearing race from the lower EAS23110 REMOVING THE LOWER BRACKET bracket with a floor chisel “2” and hammer. 1. Stand the vehicle on a level surface. c. Install a new dust seal and new bearing rac- EWA13120 WARNING ECA14270...

  • Page 259: Installing The Steering Head (For Xvs13Ca(C))

    STEERING HEAD • Lower bracket cap • Upper bracket Refer to “FRONT FORK” on page 4-65. Face the hole “a” in the lower bracket cap rear- EAS27D1033 ward. INSTALLING THE STEERING HEAD (for XVS13CA(C)) 1. Lubricate: • Upper bearing • Lower bearing •...
  • Page 260 STEERING HEAD Temporarily tighten the steering stem nut. 5. Install: • Front fork legs Refer to “FRONT FORK” on page 4-65. Temporarily tighten the upper and lower bracket pinch bolts. 6. Tighten: • Steering stem nut Steering stem nut 110 Nm (11.0 m·kg, 80 ft·lb) 7.

  • Page 261: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly (for XVS13AA(C)/XVS13CTA(C)) 48 Nm (4.8 m kg, 35 ft • • 48 Nm (4.8 m kg, 35 ft • • 32 Nm (3.2 m kg, 23 ft •...
  • Page 262 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly (for XVS13AA(C)/XVS13CTA(C)) 48 Nm (4.8 m kg, 35 ft • • 48 Nm (4.8 m kg, 35 ft • • 32 Nm (3.2 m kg, 23 ft • • 59 Nm (5.9 m kg, 43 ft •...
  • Page 263 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly (for XVS13CA(C)) 48 Nm (4.8 m kg, 35 ft • • 50 Nm (5.0 m kg, 36 ft • • 32 Nm (3.2 m kg, 23 ft • • 59 Nm (5.9 m kg, 43 ft •...
  • Page 264 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly (for XVS13CA(C)) 48 Nm (4.8 m kg, 35 ft • • 50 Nm (5.0 m kg, 36 ft • • 32 Nm (3.2 m kg, 23 ft • • 59 Nm (5.9 m kg, 43 ft •...

  • Page 265: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY EAS23180 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that the EWA13740 WARNING rear wheel is elevated. This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling • Connecting arm nuts “1” the rear shock absorber, read and make sure •...

  • Page 266: Checking The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY • Rear shock absorber Gas leaks/oil leaks → Replace the rear shock Place the vehicle on a suitable stand so that the absorber assembly. rear wheel is elevated. • Spring 2. Remove: Damage/wear → Replace the rear shock ab- •...

  • Page 267: Installing The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY Rear shock absorber assembly upper nut (for XVS13AA(C)/XVS13CTA(C)) 48 Nm (4.8 m·kg, 35 ft·lb) Rear shock absorber assembly upper nut (for XVS13CA(C)) 50 Nm (5.0 m·kg, 36 ft·lb) Rear shock absorber assembly lower nut 48 Nm (4.8 m·kg, 35 ft·lb) 5.

  • Page 268: Swingarm

    SWINGARM EAS23330 SWINGARM Removing the swingarm (for XVS13AA(C)/XVS13CTA(C)) 85 Nm (8.5 m kg, 61 ft • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 269 SWINGARM Removing the swingarm (for XVS13AA(C)/XVS13CTA(C)) 85 Nm (8.5 m kg, 61 ft • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 270 SWINGARM Removing the swingarm (for XVS13CA(C)) 85 Nm (8.5 m kg, 61 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 271 SWINGARM Removing the swingarm (for XVS13CA(C)) 85 Nm (8.5 m kg, 61 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 272: Removing The Swingarm

    SWINGARM EAS23350 REMOVING THE SWINGARM 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated. L LLL L LLL L LLL...

  • Page 273: Installing The Swingarm

    SWINGARM 5. Check: • Bearings When installing the rectifier/regulator, first tight- Damage/pitting → Replace. en the upper bolt, then the lower bolt. EAS28780 INSTALLING THE SWINGARM Rectifier/regulator bolt 1. Lubricate: 7 Nm (0.7 m·kg, 5.1 ft·lb) • Bearings • Spacers 5.

  • Page 274: Belt Drive

    BELT DRIVE EAS23510 BELT DRIVE Removing the drive belt 140 Nm (14.0 m kg, 100 ft • • 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to “REAR WHEEL” on page 4-19. Swingarm Refer to “SWINGARM”...

  • Page 275: Removing The Drive Belt And Drive Pulley

    BELT DRIVE • The drive belt can not be bent smaller than EAS23520 REMOVING THE DRIVE BELT AND DRIVE 127 mm (5 in) “a”. PULLEY • The removed drive belt can not be twisted inside out. Loosen the drive pulley nut before removing the rear wheel.
  • Page 276 BELT DRIVE • When tightening the drive pulley nut, press down on the brake pedal so the drive pulley does not move. 5. Adjust: • Drive belt slack Refer to “ADJUSTING THE DRIVE BELT SLACK (for XVS13AA(C)/XVS13CTA(C))” on page 3-24 and “ADJUSTING THE DRIVE BELT SLACK (for XVS13CA(C))”...

  • Page 277: Engine

    ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE COOLANT RESERVOIR COVER ....... 5-3 INSTALLING THE EXHAUST PIPE COVER SCREW CLAMPS ....5-3 INSTALLING THE CYLINDER COVERS ..........5-8 INSTALLING THE SHIFT ARM ..............5-8 INSTALLING THE ENGINE (for XVS13AA(C)/XVS13CTA(C))....5-14 INSTALLING THE ENGINE (for XVS13CA(C))........5-15 CAMSHAFTS....................5-17 REMOVING THE CAMSHAFT ASSEMBLIES ........
  • Page 278 CLUTCH ......................5-54 REMOVING THE CLUTCH ..............5-59 REMOVING THE PRIMARY DRIVE GEAR ..........5-59 CHECKING THE FRICTION PLATES.............5-59 CHECKING THE CLUTCH PLATES ............5-60 CHECKING THE CLUTCH SPRING PLATE...........5-60 CHECKING THE CLUTCH HOUSING ............5-60 CHECKING THE CLUTCH BOSS............5-61 CHECKING THE PRESSURE PLATE ............5-61 CHECKING THE PRIMARY DRIVE GEAR..........
  • Page 279 CRANKSHAFT ....................5-83 REMOVING THE CONNECTING RODS ..........5-84 CHECKING THE CRANKSHAFT AND CONNECTING RODS....5-84 INSTALLING THE CONNECTING RODS..........5-86 INSTALLING THE CRANKSHAFT ASSEMBLY........5-87 TRANSMISSION.................... 5-88 CHECKING THE SHIFT FORKS............. 5-92 CHECKING THE SHIFT DRUM ASSEMBLY..........5-92 CHECKING THE TRANSMISSION ............5-92 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ......5-93 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY ..

  • Page 280: Engine Removal

    ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the muffler and exhaust pipes (for XVS13AA(C)/XVS13CTA(C)) 10 Nm (1.0 m kg, 7.2 ft • • 44 Nm (4.4 m kg, 32 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 281 ENGINE REMOVAL Removing the muffler and exhaust pipes (for XVS13CA(C)) 45 Nm (4.5 m kg, 32 ft • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 53 Nm (5.3 m kg, 38 ft •...

  • Page 282: Installing The Coolant Reservoir Cover

    ENGINE REMOVAL EAS3D8A001 INSTALLING THE COOLANT RESERVOIR COVER 1. Install: • Coolant reservoir cover Coolant reservoir cover bolt (for XVS13AA(C)/XVS13CTA(C)) 10 Nm (1.0 m·kg, 7.2 ft·lb) Coolant reservoir cover bolt (for XVS13CA(C)) 10 Nm (1.0 m·kg, 7.2 ft·lb) LOCTITE® First, tighten the bolt “1”, then the bolt “2”. The bolts “3”...
  • Page 283 ENGINE REMOVAL Removing the sidestand and drive pulley housing (for XVS13AA(C)/XVS13CTA(C)) 8 Nm (0.8 m kg, 5.8 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 24 Nm (2.4 m kg, 17 ft •...
  • Page 284 ENGINE REMOVAL Removing the sidestand and drive pulley housing (for XVS13AA(C)/XVS13CTA(C)) 8 Nm (0.8 m kg, 5.8 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 24 Nm (2.4 m kg, 17 ft •...
  • Page 285 ENGINE REMOVAL Removing the sidestand and drive pulley housing (for XVS13CA(C)) 8 Nm (0.8 m kg, 5.8 ft • • 24 Nm (2.4 m kg, 17 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 8 Nm (0.8 m kg, 5.8 ft •...
  • Page 286 ENGINE REMOVAL Removing the sidestand and drive pulley housing (for XVS13CA(C)) 8 Nm (0.8 m kg, 5.8 ft • • 24 Nm (2.4 m kg, 17 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 8 Nm (0.8 m kg, 5.8 ft •...

  • Page 287: Installing The Cylinder Covers

    ENGINE REMOVAL EAS3D81039 INSTALLING THE CYLINDER COVERS 1. Install: • Rear cylinder right cover “1” • Rear cylinder left cover “2” • Front cylinder right cover “3” • Front cylinder left cover “4” Cylinder cover bolt 8 Nm (0.8 m·kg, 5.8 ft·lb) Tighten the cover bolts temporarily, and then tighten the intake-side bolts, then the exhaust- side bolts, to specification.
  • Page 288 ENGINE REMOVAL Disconnecting the leads and hoses 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Sub-fuel tank cover/Relay cover 4-1. Radiator Refer to “RADIATOR” on page 6-1. Thermostat Refer to “THERMOSTAT”...
  • Page 289 ENGINE REMOVAL Removing the down tube and engine (for XVS13AA(C)/XVS13CTA(C)) 48 Nm (4.8 m kg, 35 ft • • 88 Nm (8.8 m kg, 64 ft • • 48 Nm (4.8 m kg, 35 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 290 ENGINE REMOVAL Removing the down tube and engine (for XVS13AA(C)/XVS13CTA(C)) 48 Nm (4.8 m kg, 35 ft • • 88 Nm (8.8 m kg, 64 ft • • 48 Nm (4.8 m kg, 35 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 291 ENGINE REMOVAL Removing the down tube and engine (for XVS13CA(C)) 48 Nm (4.8 m kg, 35 ft 7 Nm (0.7 m kg, 5.1 ft • • • • 88 Nm (8.8 m kg, 64 ft • • 30 Nm (3.0 m kg, 22 ft •...
  • Page 292 ENGINE REMOVAL Removing the down tube and engine (for XVS13CA(C)) 48 Nm (4.8 m kg, 35 ft 7 Nm (0.7 m kg, 5.1 ft • • • • 88 Nm (8.8 m kg, 64 ft • • 30 Nm (3.0 m kg, 22 ft •...

  • Page 293: Installing The Engine (For Xvs13Aa(C)/Xvs13Cta(C))

    ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE (for XVS13AA(C)/XVS13CTA(C)) 1. Install: • Engine bracket (front upper side) “1” • Engine bracket bolts (front upper side) “2” Engine bracket bolt (front upper side) 30 Nm (3.0 m·kg, 22 ft·lb) 2. Install: 3. Tighten: •...

  • Page 294: Installing The Engine (For Xvs13Ca(C))

    ENGINE REMOVAL 4. Tighten: Engine mounting bolt (front cen- • Engine mounting bolts (front right upper side) ter side) “4” 30 Nm (3.0 m·kg, 22 ft·lb) • Engine mounting bolts (front left upper side) “5” • Engine mounting nut (rear lower side) “11” •...
  • Page 295 ENGINE REMOVAL Engine bracket bolt (rear lower side) 48 Nm (4.8 m·kg, 35 ft·lb) LOCTITE® Engine bracket nut (rear upper side) 48 Nm (4.8 m·kg, 35 ft·lb) Engine bracket bolt (front lower side) 48 Nm (4.8 m·kg, 35 ft·lb) Engine bracket nut (front upper side) (M10) 48 Nm (4.8 m·kg, 35 ft·lb) 4.

  • Page 296: Camshafts

    CAMSHAFTS EAS23740 CAMSHAFTS Removing the cylinder head covers (for XVS13AA(C)/XVS13CTA(C)) 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 297 CAMSHAFTS Removing the cylinder head covers (for XVS13AA(C)/XVS13CTA(C)) 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 298 CAMSHAFTS Removing the cylinder head covers (for XVS13CA(C)) 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 299 CAMSHAFTS Removing the camshaft assemblies 10 Nm (1.0 m kg, 7.2 ft • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • •...
  • Page 300 CAMSHAFTS Removing the rocker arms and camshafts 14 Nm (1.4 m kg, 10 ft • • 14 Nm (1.4 m kg, 10 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the camshaft assemblies. Locknut Loosen.

  • Page 301: Removing The Camshaft Assemblies

    CAMSHAFTS EAS3D81020 REMOVING THE CAMSHAFT ASSEMBLIES 1. Align: • “I” mark on the front cylinder camshaft sprocket (with the arrow mark on the front cylinder camshaft carrier) M MMM M MMM M MMM M MMM M MMM Front cylinder a. Turn the crankshaft counterclockwise. 3.

  • Page 302: Removing The Rocker Arms And Camshafts

    CAMSHAFTS 5. Align: EAS3D81034 REMOVING THE ROCKER ARMS AND • “I” mark on the rear cylinder camshaft sprock- CAMSHAFTS The following procedure applies to all of the (with the arrow mark on the rear cylinder rocker arms and camshafts. camshaft carrier) 1.

  • Page 303: Checking The Camshafts

    CAMSHAFTS EAS23840 EAS23870 CHECKING THE CAMSHAFTS CHECKING THE CAMSHAFT SPROCKETS 1. Check: 1. Check: • Camshaft lobes • Camshaft sprockets Blue discoloration/pitting/scratches → Re- More than 1/4 tooth wear “a” → Replace the place the camshaft. camshaft sprocket and the timing chain as a 2.

  • Page 304: Checking The Timing Chain Tensioners

    CAMSHAFTS 4. Measure: • Rocker arm shaft outside diameter “a” Out of specification → Replace. Rocker arm shaft outside diame- 11.976–11.991 mm (0.4715– 0.4721 in) 1. Timing chain tensioner rod 2. Timing chain tensioner spring seat 3. Timing chain tensioner inner spring 4.

  • Page 305: Installing The Camshafts And Rocker Arms

    CAMSHAFTS b. Install the timing chain tensioner inner spring, EAS24040 INSTALLING THE CAMSHAFTS AND timing chain tensioner spring seat, and timing ROCKER ARMS chain tensioner rod. The following procedure applies to all of the c. Squeeze timing chain tensioner clip 2 “1”, rocker arms and camshafts.

  • Page 306: Installing The Camshaft Assemblies

    CAMSHAFTS ECA3D81017 NOTICE Make sure the cutouts in the rocker arm shafts faces inward. A. Intake side B. Exhaust side 3. Install: • Front cylinder camshaft sprocket EAS3D81021 INSTALLING THE CAMSHAFT ASSEMBLIES M MMM M MMM M MMM M MMM M MMM 1.
  • Page 307 CAMSHAFTS • When installing the front cylinder camshaft sprocket, be sure to keep the timing chain as tight as possible on the exhaust side. d. Remove the wire from the timing chain. L LLL L LLL L LLL L LLL L LLL 4.
  • Page 308 CAMSHAFTS • When installing the rear cylinder camshaft sprocket, be sure to keep the timing chain as tight as possible on the intake side. A. Intake side B. Exhaust side 8. Install: d. Remove the wire from the timing chain. •...

  • Page 309: Installing The Cylinder Head Covers (For Xvs13Aa(C)/Xvs13Cta(C))

    CAMSHAFTS B. Exhaust side 2. Install: • Front cylinder head cover • Front cylinder head cover bracket “1” Front cylinder head cover bolt “2”, “3”, “5” 10 Nm (1.0 m·kg, 7.2 ft·lb) Front cylinder head cover bolt “4” 12 Nm (1.2 m·kg, 8.7 ft·lb) Bolts “2”: l = 30 mm (1.18 in) Bolts “3”: l = 45 mm (1.77 in) Bolt “4”: l = 45 mm (1.77 in)
  • Page 310 CAMSHAFTS 2. Install: • Front cylinder head cover • Front cylinder head cover bracket “1” • Front cylinder head cover holder “2” Front cylinder head cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Bolts “3”: l = 30 mm (1.18 in) Bolts “4”: l = 45 mm (1.77 in) Bolt “5”: l = 50 mm (1.97 in) Bolts “6”: l = 55 mm (2.17 in)

  • Page 311: Cylinder Heads

    CYLINDER HEADS EAS24110 CYLINDER HEADS Removing the cylinder heads 13 Nm (1.3 m kg, 9.4 ft 13 Nm (1.3 m kg, 9.4 ft • • • • 15 Nm (1.5 m kg, 11 ft • • 65 Nm (6.5 m kg, 47 ft •...

  • Page 312: Removing The Cylinder Heads

    CYLINDER HEADS EAS24150 REMOVING THE CYLINDER HEADS 1. Remove: • Cylinder head bolts • Cylinder head nuts • Loosen the nuts and bolts in the proper se- quence as shown. • Loosen each nut and bolt 1/2 of a turn at a time.
  • Page 313 CYLINDER HEADS Cylinder head nut 65 Nm (6.5 m·kg, 47 ft·lb) Cylinder head bolt 13 Nm (1.3 m·kg, 9.4 ft·lb) • Lubricate the cylinder head nuts and washers with engine oil. • Tighten the cylinder head nuts and bolts in the proper tightening sequence as shown and torque them in two stages.
  • Page 314 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both cyl- inders. Cylinder heads Refer to “CYLINDER HEADS” on page 5-32. Valve cotter Upper spring seat Valve spring Intake valve...

  • Page 315: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components. Before removing the internal parts of the cylinder head (e.g., valves, valve springs, and valve seats), make sure the valves properly seal. 1.
  • Page 316 VALVES AND VALVE SPRINGS b. Install the new valve guide with the valve Valve-stem-to-valve-guide clear- guide installer “2” and valve guide remover ance (intake) “1”. 0.010–0.037 mm (0.0004–0.0015 Valve guide position Limit 14.5–14.9 mm (0.571–0.587 in) 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clear- ance (exhaust) 0.025–0.052 mm (0.0010–0.0020...

  • Page 317: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 4. Check: 1. Eliminate: • Valve face • Carbon deposits Pitting/wear → Grind the valve face. (from the valve face and valve seat) • Valve stem end 2. Check: Mushroom shape or diameter larger than the •...

  • Page 318: Checking The Valve Springs

    VALVES AND VALVE SPRINGS e. Apply a fine lapping compound to the valve face and repeat the above steps. After replacing the cylinder head or replacing the f. After every lapping procedure, be sure to valve and valve guide, the valve seat and valve clean off all of the lapping compound from the face should be lapped.

  • Page 319: Installing The Valves

    VALVES AND VALVE SPRINGS 2. Measure: EAS24340 INSTALLING THE VALVES • Compressed valve spring force “a” Out of specification → Replace the valve The following procedure applies to all of the valves and related components. spring. 1. Deburr: Installed compression spring •...
  • Page 320 VALVES AND VALVE SPRINGS • Valve stem seal “2” • Valve “3” • Valve spring “4” • Upper spring seat “5” (into the cylinder head) • Make sure each valve is installed in its original place. • Install the valve springs with the larger pitch “a” facing up.

  • Page 321: Cylinders And Pistons

    CYLINDERS AND PISTONS EAS24360 CYLINDERS AND PISTONS Removing the cylinders and pistons Order Job/Parts to remove Q’ty Remarks Cylinder heads Refer to “CYLINDER HEADS” on page 5-32. Timing chain guide Front cylinder Rear cylinder Front cylinder gasket Rear cylinder gasket Dowel pin Circlip Piston pin...

  • Page 322: Removing The Pistons

    CYLINDERS AND PISTONS EAS24380 REMOVING THE PISTONS When removing a piston ring, open the end gap The following procedure applies to all of the pis- with your fingers and lift the other side of the ring tons. over the piston crown. 1.

  • Page 323: Checking The Piston Rings

    CYLINDERS AND PISTONS EAS24430 CHECKING THE PISTON RINGS The following procedure applies to all of the pis- ton rings. 1. Measure: • Piston ring side clearance Out of specification → Replace the piston and piston rings as a set. Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston b.

  • Page 324: Checking The Piston Pins

    CYLINDERS AND PISTONS Piston pin outside diameter 22.991–23.000 mm (0.9052– 0.9055 in) Limit 22.971 mm (0.9044 in) a. 10 mm (0.39 in) 3. Measure: • Piston ring end gap Out of specification → Replace the piston ring. 3. Measure: The oil ring expander spacer end gap cannot be •...

  • Page 325: Installing The Pistons And Cylinders

    CYLINDERS AND PISTONS EAS24460 INSTALLING THE PISTONS AND CYLINDERS The following procedure applies to all of the pis- tons and cylinders. 1. Install: • Top ring “1” • 2nd ring “2” • Oil ring expander “3” • Lower oil ring rail “4” •...
  • Page 326 CYLINDERS AND PISTONS 6. Install: • Cylinder “1” • While compressing the piston rings with one hand, install the cylinder with the other hand. • Pass the timing chain and timing chain guide through the timing chain cavity. 5-47...
  • Page 327 GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the stator coil 10 Nm (1.0 m kg, 7.2 ft • • (12) 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Rectifier/regulator cover Refer to “SWINGARM”...

  • Page 328: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH Removing the stator coil 10 Nm (1.0 m kg, 7.2 ft • • (12) 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Stator coil For installation, reverse the removal proce- dure.
  • Page 329 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch 90 Nm (9.0 m kg, 65 ft • • 24 Nm (2.4 m kg, 17 ft • • Order Job/Parts to remove Q’ty Remarks Generator rotor Starter clutch Woodruff key Starter clutch gear Torque limiter Starter clutch idle gear shaft...

  • Page 330: Removing The Generator

    GENERATOR AND STARTER CLUTCH EAS24490 REMOVING THE GENERATOR 1. Remove: • Generator rotor bolt “1” • Washer • Starter clutch bolts “2” • While holding the generator rotor “3” with the sheave holder “4”, loosen the generator rotor bolt. • Do not allow the sheave holder to touch the EAS24560 projection on the generator rotor.

  • Page 331: Checking The Torque Limiter

    GENERATOR AND STARTER CLUTCH M MMM M MMM M MMM M MMM M MMM a. Install the starter clutch gear “1” onto the gen- erator rotor “2” and hold the generator rotor. b. When turning the starter clutch gear clock- wise “A”, the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be replaced.
  • Page 332 GENERATOR AND STARTER CLUTCH 3. Apply: • Sealant (onto the crankshaft position sensor/stator assembly lead grommet) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) 5-53...

  • Page 333: Clutch

    CLUTCH EAS25060 CLUTCH Removing the clutch cover 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Muffler/Coolant reservoir cover Refer to “ENGINE REMOVAL” on page 5-1. Drain.
  • Page 334 CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Pull lever shaft Oil seal Bearing Bearing For installation, reverse the removal proce- dure. 5-55...
  • Page 335 CLUTCH Removing the clutch 125 Nm (12.5 m kg, 90 ft • • 14 13 12 11 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Parts to remove Q’ty Remarks Clutch spring plate retainer Clutch spring plate Clutch spring plate seat Pressure plate Pull rod Friction plate 1...
  • Page 336 CLUTCH Removing the clutch 125 Nm (12.5 m kg, 90 ft • • 14 13 12 11 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Parts to remove Q’ty Remarks Clutch housing Collar Oil/water pump drive chain Oil/water pump drive sprocket Thrust washer 2 For installation, reverse the removal proce- dure.
  • Page 337 CLUTCH Removing the primary drive gear 100 Nm (10.0 m kg, 72 ft • • 10 Nm (1.0 m kg, 7.2 ft • • (12) 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...

  • Page 338: Removing The Clutch

    CLUTCH EAS25080 EAS25090 REMOVING THE CLUTCH REMOVING THE PRIMARY DRIVE GEAR 1. Straighten the clutch boss nut rib “a”. 1. Straighten the lock washer tab. 2. Remove: • Primary drive gear nut “1” • Lock washer “2” • While holding the generator rotor “3” with the sheave holder “4”, loosen the primary drive gear nut.

  • Page 339: Checking The Clutch Plates

    CLUTCH Out of specification → Replace the clutch Friction plate 1, 3 thickness plates as a set. 2.90–3.10 mm (0.114–0.122 in) Wear limit Warpage limit 2.80 mm (0.1102 in) 0.20 mm (0.0079 in) Friction plate 2 thickness 2.92–3.08 mm (0.115–0.121 in) Wear limit 2.82 mm (0.1110 in) EAS25130...

  • Page 340: Checking The Clutch Boss

    CLUTCH EAS25210 CHECKING THE PRIMARY DRIVEN GEAR 1. Check: • Primary driven gear Damage/wear → Replace the primary drive and primary driven gears as a set. Excessive noise during operation → Replace the primary drive and primary driven gears as a set.

  • Page 341: Installing The Clutch

    CLUTCH Primary drive gear nut 100 Nm (10.0 m·kg, 72 ft·lb) • Make sure that the side of the primary drive gear “1” with the groove “a” is facing outward. • Align the tab “b” on the lock washer “3” with the groove “c”...
  • Page 342 CLUTCH 6. Install: • Friction plates 2 “1” • Clutch plates • Friction plate 1 “2” • First, install a friction plate and then alternate between a clutch plate and a friction plate. • Align the cutout in the tab of each friction plate 2 “1”...
  • Page 343 CLUTCH 9. Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-13. 5-64...
  • Page 344 SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever 22 Nm (2.2 m kg, 16 ft • • Order Job/Parts to remove Q’ty Remarks Drive pulley cover Refer to “BELT DRIVE” on page 4-99. Shift arm Refer to “ENGINE REMOVAL” on page 5-1. Primary drive gear cover Refer to “CLUTCH”...

  • Page 345: Shift Shaft

    SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft Bends/damage/wear → Replace. • Shift shaft spring Damage/wear → Replace. EAS25430 CHECKING THE STOPPER LEVER 1. Check: • Stopper lever Bends/damage → Replace. Roller turns roughly → Replace the stopper lever.

  • Page 346: Balancer Gears

    BALANCER GEARS EAS3D81023 BALANCER GEARS Removing the right balancer assembly 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Primary drive gear Refer to “CLUTCH” on page 5-54. Straight key Right balancer drive gear Right balancer assembly...
  • Page 347 BALANCER GEARS Removing the left balancer assembly 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERATOR AND STARTER Generator rotor/Starter clutch idle gear CLUTCH”...

  • Page 348: Checking The Right Balancer Gears

    BALANCER GEARS 2. Install: EAS3D81024 CHECKING THE RIGHT BALANCER GEARS • Left balancer drive gear “1” 1. Check: • Right balancer drive gear • Align the punch mark “a” in the left balancer • Right balancer driven gear driven gear with the punch mark “b” in the left •...

  • Page 349: Electric Starter

    ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m kg, 7.2 ft • • 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Parts to remove Q’ty Remarks Starter motor lead Disconnect. Starter motor For installation, reverse the removal proce- dure.
  • Page 350 ELECTRIC STARTER Disassembling the starter motor 11 Nm (1.1 m kg, 8.0 ft • • 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Oil seal Bearing Armature assembly Starter motor yoke Gasket Starter motor rear cover...

  • Page 351: Checking The Starter Motor

    ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR 1. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. L LLL L LLL L LLL...

  • Page 352: Assembling The Starter Motor

    ELECTRIC STARTER EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: • Starter motor yoke “1” • Starter motor front cover “2” • Starter motor rear cover “3” Align the match marks “a” on the starter motor yoke with the match marks “b” on the starter mo- tor front and rear covers.

  • Page 353: Crankcase

    CRANKCASE EAS25540 CRANKCASE Removing the oil delivery pipes and timing chains 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 17 Nm (1.7 m kg, 12 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 354 CRANKCASE Removing the oil delivery pipes and timing chains 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 17 Nm (1.7 m kg, 12 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 355 CRANKCASE Separating the crankcase kg, 7.2 ft 10 Nm (1.0 m • • 10 Nm (1.0 m kg, 7.2 ft • • 36 Nm (3.6 m kg, 25 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 356 CRANKCASE Removing the oil seal and bearings 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Oil/water pump assembly Refer to “OIL PUMP” on page 5-80. Crankshaft Refer to “CRANKSHAFT”...

  • Page 357: Disassembling The Crankcase

    CRANKCASE • Oil delivery passages EAS25560 DISASSEMBLING THE CRANKCASE Obstruction → Blow out with compressed air. 1. Remove: • Crankcase bolts EAS3D81029 CHECKING THE BEARINGS AND OIL SEAL 1. Check: Loosen each bolt 1/4 of a turn at a time, in stag- •...

  • Page 358: Installing The Bearing Retainers

    1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 2. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) Do not allow any sealant to come into contact with the oil gallery.
  • Page 359 OIL PUMP EAS24910 OIL PUMP Removing the oil/water pump assembly 24 Nm (2.4 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 9 10 24 Nm (2.4 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 360: Oil Pump

    OIL PUMP EAS24960 3. Oil/water pump housing CHECKING THE OIL PUMP 3. Check: 1. Check: • Oil pump operation • Oil pump housing Rough movement → Repeat steps (1) and • Water pump housing Cracks/damage/wear → Replace the defec- (2) or replace the defective part(s). tive part(s).

  • Page 361: Assembling The Oil Pump

    OIL PUMP EAS25000 ASSEMBLING THE OIL PUMP 1. Lubricate: • Inner rotor • Outer rotor (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: • Pin “1” • Oil pump inner rotor “2” • Oil pump outer rotor “3” •...

  • Page 362: Crankshaft

    CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft 1st 15 Nm (1.5 m kg, 11 ft • • 2nd Specified angle 125–135˚ Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-74. Crankshaft Connecting rod cap Big end lower bearing Connecting rod Big end upper bearing For installation, reverse the removal proce-...

  • Page 363: Removing The Connecting Rods

    CRANKSHAFT The following procedure applies to all of the EAS26010 REMOVING THE CONNECTING RODS connecting rods. 1. Remove: ECA13930 • Connecting rod caps “1” NOTICE • Connecting rods Do not interchange the big end bearings and • Big end bearings connecting rods.
  • Page 364 CRANKSHAFT • Make sure the characters “d” on both the con- necting rod and connecting rod cap are aligned. e. Tighten the connecting rod bolts. Refer to “INSTALLING THE CONNECTING RODS” on page 5-86. f. Remove the connecting rod and big end bearings.

  • Page 365: Installing The Connecting Rods

    CRANKSHAFT EAS26150 INSTALLING THE CONNECTING RODS Crankshaft journal diameter 1. Lubricate: 49.968–49.980 mm (1.9672– • Bolt threads 1.9677 in) (with the recommended lubricant) Recommended lubricant Molybdenum disulfide grease 2. Lubricate: • Crankshaft pin • Connecting rod bearing inner surface (with the recommended lubricant) Recommended lubricant Engine oil 6.

  • Page 366: Installing The Crankshaft Assembly

    CRANKSHAFT 4. Tighten: ECA3D81012 NOTICE • Connecting rod nuts • Do not use a torque wrench to tighten the M MMM M MMM M MMM M MMM M MMM EWA3D81005 bolt to the specified angle. WARNING • Tighten the bolt until it is at the specified •...

  • Page 367: Transmission

    TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-74. Long shift fork guide bar Short shift fork guide bar Shift drum assembly Shift fork 1 Shift fork 2 Main axle assembly Drive axle assembly...
  • Page 368 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks Circlip 2nd pinion gear Circlip 3rd/4th pinion gear Circlip Toothed washer 5th pinion gear Collar Main axle/1st pinion gear For assembly, reverse the disassembly pro- cedure. 5-89...
  • Page 369 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Washer 1st wheel gear Collar 5th wheel gear Circlip Toothed washer 4th wheel gear Toothed spacer Toothed lock washer Toothed lock washer retainer 3rd wheel gear Toothed spacer Toothed washer Circlip Dog clutch...
  • Page 370 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks 2nd wheel gear Collar Drive axle For assembly, reverse the disassembly pro- cedure. 5-91...

  • Page 371: Checking The Shift Forks

    TRANSMISSION EAS26260 EAS26270 CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY The following procedure applies to all of the shift 1. Check: forks and shift fork guide bars. • Shift drum grooves Damage/scratches/wear → Replace the shift 1. Check: •...

  • Page 372: Assembling The Main Axle And Drive Axle

    TRANSMISSION 3. Check: 2. Install: • Transmission gears • Toothed lock washer retainer “1” Blue discoloration/pitting/wear → Replace • Toothed lock washer “2” the defective gear(s). • Transmission gear dogs • With the toothed lock washer retainer “1” in the Cracks/damage/rounded edges →...
  • Page 373 TRANSMISSION 2. Check: • Transmission Rough movement → Repair. • Apply engine oil to each gear and bearing thor- oughly. • Before assembling the crankcase, make sure that the transmission is in neutral and that the gears turn freely. 5-94...
  • Page 374 TRANSMISSION 5-95...

  • Page 375: Cooling System

    COOLING SYSTEM RADIATOR ...................... 6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR..............6-3 THERMOSTAT ....................6-4 CHECKING THE THERMOSTAT.............. 6-8 INSTALLING THE THERMOSTAT ASSEMBLY ........6-8 WATER PUMP....................6-9 DISASSEMBLING THE WATER PUMP..........6-11 CHECKING THE WATER PUMP ............6-11 ASSEMBLING THE WATER PUMP............6-11...

  • Page 376: Radiator

    RADIATOR EAS26380 RADIATOR Removing the radiator 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 2 Nm (0.2 m kg, 1.4 ft •...
  • Page 377 RADIATOR Removing the radiator 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 2 Nm (0.2 m kg, 1.4 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 378: Checking The Radiator

    RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. Straighten any flattened fins with a thin, flathead screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.

  • Page 379: Thermostat

    THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat (for XVS13AA(C)/XVS13CTA(C)) 7 Nm (0.7 m kg, 5.1 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 10 Nm (1.0 m kg, 7.2 ft • • kg, 13 ft 18 Nm (1.8 m •...
  • Page 380 THERMOSTAT Removing the thermostat (for XVS13AA(C)/XVS13CTA(C)) 7 Nm (0.7 m kg, 5.1 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 10 Nm (1.0 m kg, 7.2 ft • • 18 Nm (1.8 m kg, 13 ft •...
  • Page 381 THERMOSTAT Removing the thermostat (for XVS13CA(C)) 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 18 Nm (1.8 m kg, 13 ft •...
  • Page 382 THERMOSTAT Removing the thermostat (for XVS13CA(C)) 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 18 Nm (1.8 m kg, 13 ft •...

  • Page 383: Checking The Thermostat

    THERMOSTAT 2. Check: EAS26450 CHECKING THE THERMOSTAT • Thermostat housing cover 1. Check: • Thermostat housing • Thermostat • Thermostat pipes Does not open at 82–95 °C (179.6–203.0 °F) • Thermostat hoses → Replace. • Radiator inlet hose • Radiator filler pipe Cracks/damage/wear →...

  • Page 384: Water Pump

    WATER PUMP EAS26500 WATER PUMP Removing the water pump 10 Nm (1.0 m kg, 7.2 ft • • 24 Nm (2.4 m kg, 17 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 385 WATER PUMP Removing the water pump 10 Nm (1.0 m kg, 7.2 ft • • 24 Nm (2.4 m kg, 17 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 386: Disassembling The Water Pump

    • Install the water pump seal with the special Remove the bearing and oil seal from the inside tools. of the water pump housing. • Before installing the water pump seal, apply Yamaha bond No.1215 (Three Bond No.1215®) “2” to the water pump housing “3”. 6-11...
  • Page 387 Water pump seal installer YM-33221-A Middle driven shaft bearing driv- 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) 1. Straightedge 2. Impeller A. Push down 4. Mechanical seal installer 5. Middle driven shaft bearing driver 3.
  • Page 388 WATER PUMP 6-13...

  • Page 389: Fuel System

    FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL TANK ..............7-6 REMOVING THE FUEL PUMP ..............7-6 CHECKING THE FUEL COCK..............7-6 CHECKING THE FUEL COCK OPERATION..........7-6 CHECKING THE FUEL PUMP BODY............7-7 CHECKING THE ROLLOVER VALVE ............7-7 INSTALLING THE FUEL PUMP..............7-7 INSTALLING THE FUEL TANK HOSES (for XVS13AA(C)/XVS13CTA(C)).............
  • Page 390 FUEL TANK EAS26620 FUEL TANK Removing the fuel tank (for XVS13AA(C)/XVS13CTA(C)) 23 Nm (2.3 m kg, 17 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 391 FUEL TANK Removing the fuel tank (for XVS13CA(C)) 8 Nm (0.8 m kg, 5.8 ft 7 Nm (0.7 m kg, 5.1 ft • • • • 23 Nm (2.3 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 392 FUEL TANK Removing the fuel tank (for XVS13CA(C)) 8 Nm (0.8 m kg, 5.8 ft 7 Nm (0.7 m kg, 5.1 ft • • • • 23 Nm (2.3 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 393: Fuel Tank

    FUEL TANK Removing the sub-fuel tank 10 Nm (1.0 m kg, 7.2 ft • • ( 3 ) ( 3 ) ( 3 ) ( 6 ) 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks For XVS13AA(C)/XVS13CTA(C)
  • Page 394 FUEL TANK Removing the rollover valve and canister 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Fuel tank/Side panels Refer to “FUEL TANK” on page 7-1. Front cylinder covers Refer to “ENGINE REMOVAL” on page 5-1. Canister purge hose California only Fuel tank breather hose (rollover valve to canis-...

  • Page 395: Removing The Fuel Tank

    FUEL TANK EAS3D81001 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel cock hose Before removing the fuel cock hose, turn the fuel cock to “OFF”. 3.

  • Page 396: Checking The Fuel Pump Body

    FUEL TANK • Align the projection “a” on the fuel pump with the slot in the fuel pump bracket and the inden- tation “b” in the sub-fuel tank. • Tighten the fuel pump bolts in the proper tight- ening sequence as shown. L LLL L LLL L LLL...

  • Page 397: Installing The Fuel Tank Breather Hose (For Xvs13Ca(C))

    FUEL TANK Install the fuel tank overflow hose and fuel tank breather hose (fuel tank to hose joint) as shown in the illustration, making sure that they are not pinched by the fuel tank “3”. EAS27D1005 INSTALLING THE FUEL TANK BREATHER HOSE (for XVS13CA(C)) 1.
  • Page 398 THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle body and ISC (idle speed control) unit 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks For XVS13AA(C)/XVS13CTA(C) Rider seat/Air filter case Refer to “GENERAL CHASSIS” on page 4-1.

  • Page 399: Throttle Bodies

    THROTTLE BODIES Removing the throttle body and ISC (idle speed control) unit 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Throttle position sensor For installation, reverse the removal proce- dure. 7-10...
  • Page 400 THROTTLE BODIES Removing the intake manifold assembly (for XVS13AA(C)/XVS13CTA(C)) 12 Nm (1.2 m kg, 8.7 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 4 Nm (0.4 m kg, 2.9 ft •...
  • Page 401 THROTTLE BODIES Removing the intake manifold assembly (for XVS13CA(C)) 4 Nm (0.4 m kg, 2.9 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
  • Page 402 THROTTLE BODIES Disassembling the intake manifold 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks For XVS13AA(C)/XVS13CTA(C) Front cylinder injector coupler Disconnect. For XVS13AA(C)/XVS13CTA(C) Rear cylinder injector coupler Disconnect. Sub-wire harness For XVS13AA(C)/XVS13CTA(C) Injector Fuel pipe Intake manifold For assembly, reverse the disassembly pro-...

  • Page 403: Checking The Injectors

    THROTTLE BODIES EAS26980 CHECKING THE INJECTORS Pressure gauge 1. Check: 90890-03153 • Injectors YU-03153 Damage → Replace. Fuel pressure adapter 90890-03176 EAS26990 YM-03176 CHECKING THE THROTTLE BODIES 1. Check: • Throttle bodies Cracks/damage → Replace the throttle bod- ies as a set. 2.

  • Page 404: Installing The Intake Manifold Assembly

    THROTTLE BODIES c. Turn the main switch to “ON”. d. Measure the throttle position sensor output • Lubricate the rear cylinder intake manifold joint voltage. and intake manifold assembly mating surfaces e. Adjust the throttle position sensor angle so with engine oil. that the output voltage is within the specified •...

  • Page 405: Electrical System

    ELECTRICAL SYSTEM IGNITION SYSTEM ..................8-1 CIRCUIT DIAGRAM (for XVS13AA(C)/XVS13CTA(C)) ......8-1 CIRCUIT DIAGRAM (for XVS13CA(C)) ............ 8-3 ENGINE STOPPING DUE TO SIDESTAND OPERATION.......8-5 TROUBLESHOOTING ................8-6 ELECTRIC STARTING SYSTEM ..............8-9 CIRCUIT DIAGRAM (for XVS13AA(C)/XVS13CTA(C)) ......8-9 CIRCUIT DIAGRAM (for XVS13CA(C)) ..........8-11 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......
  • Page 406 ELECTRICAL COMPONENTS..............8-89 CHECKING THE SWITCHES ..............8-93 CHECKING THE BULBS AND BULB SOCKETS ........8-98 CHECKING THE FUSES ................8-99 CHECKING AND CHARGING THE BATTERY........8-100 CHECKING THE RELAYS ..............8-103 CHECKING THE TURN SIGNAL RELAY ..........8-105 CHECKING THE DIODES..............8-105 CHECKING THE IGNITION SPARK GAP..........8-107 CHECKING THE SPARK PLUG CAPS..........8-107 CHECKING THE IGNITION COILS............8-108 CHECKING THE CRANKSHAFT POSITION SENSOR......8-108...
  • Page 408 IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM (for XVS13AA(C)/XVS13CTA(C))
  • Page 409 IGNITION SYSTEM 3. Main fuse 5. Main switch 6. Battery 12.Relay unit 15.Neutral switch 17.Sidestand switch 19.Crankshaft position sensor 22.Lean angle sensor 25.ECU (engine control unit) 26.Rear cylinder ignition coil 27.Front cylinder ignition coil 28.Spark plug 63.Engine stop switch 71.Ignition fuse...
  • Page 410 IGNITION SYSTEM EAS27D1007 CIRCUIT DIAGRAM (for XVS13CA(C))
  • Page 411 IGNITION SYSTEM 3. Main fuse 5. Main switch 6. Battery 12.Relay unit 15.Neutral switch 17.Sidestand switch 19.Crankshaft position sensor 22.Lean angle sensor 25.ECU (engine control unit) 26.Rear cylinder ignition coil 27.Front cylinder ignition coil 28.Spark plug 63.Engine stop switch 71.Ignition fuse...
  • Page 412 IGNITION SYSTEM EAS3D81009 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the neutral switch and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark.
  • Page 413 IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Rider seat (for XVS13AA(C)/XVS13CTA(C)) 2. Seat (for XVS13CA(C)) 3. Tool kit tray 4. Fuel tank 5. Battery box 6.
  • Page 414 IGNITION SYSTEM NG → 8. Check the main switch. Replace the main switch. Refer to “CHECKING THE SWITCHES” on page 8-93. OK ↓ NG → 9. Check the engine stop switch. Replace the right handlebar switch. Refer to “CHECKING THE SWITCHES”...
  • Page 415 IGNITION SYSTEM...
  • Page 416 ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM (for XVS13AA(C)/XVS13CTA(C)) W1 W2 (GRAY) Sb/W B/R R1 Sb/W B/R L R/L L/R L/G L/Y Sb (BLACK) B L/G (BLACK) (BLACK) R/L B (DARK GREEN) P O/R L W/Y (BLACK) Br/L R/W1 R/W2...
  • Page 417 ELECTRIC STARTING SYSTEM 3. Main fuse 5. Main switch 6. Battery 8. Starter relay 9. Starter motor 10.Diode 12.Relay unit 13.Starting circuit cut-off relay 15.Neutral switch 17.Sidestand switch 50.Clutch switch 63.Engine stop switch 64.Start switch 71.Ignition fuse 8-10...
  • Page 418 ELECTRIC STARTING SYSTEM EAS27D1010 CIRCUIT DIAGRAM (for XVS13CA(C)) Sb/W W1 W2 (GRAY) B/R L/W1 R/L L1 L/R R/W L/G L/Y Sb B/Y Sb/W L/W1 (BLACK) B1 B2 B2 L/G (BLACK) (BLACK) R/L B (DARK GREEN) L W/Y P O/R (BLACK) (BLACK) Br/L Br/W...
  • Page 419 ELECTRIC STARTING SYSTEM 3. Main fuse 5. Main switch 6. Battery 8. Starter relay 9. Starter motor 10.Diode 12.Relay unit 13.Starting circuit cut-off relay 15.Neutral switch 17.Sidestand switch 49.Clutch switch 63.Engine stop switch 64.Start switch 71.Ignition fuse 8-12...
  • Page 420 ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...
  • Page 421 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEUTRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6.
  • Page 422 ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Rider seat (for XVS13AA(C)/XVS13CTA(C)) 2. Seat (for XVS13CA(C)) 3. Tool kit tray 4. Fuel tank 5. Headlight lens unit NG → 1.
  • Page 423 ELECTRIC STARTING SYSTEM NG → 8. Check the starter relay. Refer to “CHECKING THE RE- Replace the starter relay. LAYS” on page 8-103. OK ↓ NG → 9. Check the main switch. Replace the main switch. Refer to “CHECKING THE SWITCHES”...
  • Page 424 CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM W1 W2 (GLAY) Sb/W (BLACK) (BLACK) Br/L R/W1 R/W2 (BLACK) Br/L R/W2 R/W1 (BLACK) Br/W Br/W Br/W P/W P/B Y P/B P/W P/B RESET 8-17...
  • Page 425 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 3. Main fuse 6. Battery 8-18...
  • Page 426 CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Rider seat (for XVS13AA(C)/XVS13CTA(C)) 2. Seat (for XVS13CA(C)) 3. Tool kit tray 4. Rectifier/regulator cover NG → 1. Check the fuse. (Main) Replace the fuse.
  • Page 427 CHARGING SYSTEM 8-20...
  • Page 428 LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM (for XVS13AA(C)/XVS13CTA(C)) 8-21...
  • Page 429 LIGHTING SYSTEM 3. Main fuse 5. Main switch 6. Battery 25.ECU (engine control unit) 36.Multi-function meter 39.High beam indicator light 41.Meter light 47.Headlight relay 49.Dimmer switch 55.Front right turn signal/position light 56.Front left turn signal/position light 57.Headlight 58.Accessory light (OPTION) 65.License plate light 66.Tail/brake light 70.Headlight fuse...
  • Page 430 LIGHTING SYSTEM EAS27D1011 CIRCUIT DIAGRAM (for XVS13CA(C)) 8-23...
  • Page 431 LIGHTING SYSTEM 3. Main fuse 5. Main switch 6. Battery 25.ECU (engine control unit) 36.Multi-function meter 39.High beam indicator light 41.Meter light 46.Headlight relay 48.Dimmer switch 55.Front right turn signal/position light 56.Front left turn signal/position light 57.Headlight 58.Accessory light (OPTION) 65.License plate light 66.Tail/brake light 70.Headlight fuse...
  • Page 432 LIGHTING SYSTEM EAS27260 TROUBLESHOOTING (XVS13AA(C)/XVS13CTA(C)) Any of the following fail to light: headlight, high beam indicator light, taillight, license plate light, position light, meter light or accessory light (OPTION). • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3.
  • Page 433 LIGHTING SYSTEM NG → 7. Check the entire lighting system’s wiring. Properly connect or repair the lighting sys- Refer to “CIRCUIT DIAGRAM (for tem’s wiring. XVS13AA(C)/XVS13CTA(C))” on page 8-21. OK ↓ Replace the ECU or meter assembly. 8-26...
  • Page 434 LIGHTING SYSTEM EAS27D1012 TROUBLESHOOTING (XVS13CA(C)) Any of the following fail to light: headlight, high beam indicator light, taillight, license plate light, position light, meter light or accessory light (OPTION). • Before troubleshooting, remove the following part(s): 1. Seat 2. Tool kit tray 3.
  • Page 435 LIGHTING SYSTEM NG → 7. Check the entire lighting system Properly connect or repair the lighting sys- wiring. tem wiring. Refer to “CIRCUIT DIAGRAM (for XVS13CA(C))” on page 8-23. OK ↓ Replace the ECU or meter assembly, or tail/brake light. 8-28...
  • Page 436 SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM (for XVS13AA(C)/XVS13CTA(C)) 8-29...
  • Page 437 SIGNALING SYSTEM 3. Main fuse 4. Backup fuse (odometer and clock) 5. Main switch 6. Battery 12.Relay unit 15.Neutral switch 18.Speed sensor 23.Coolant temperature sensor 25.ECU (engine control unit) 33.Fuel level warning light 34.Oil level warning light 35.Neutral indicator light 36.Multi-function meter 38.Coolant temperature warning light 40.Turn signal indicator light...
  • Page 438 SIGNALING SYSTEM EAS27D1013 CIRCUIT DIAGRAM (for XVS13CA(C)) 8-31...
  • Page 439 SIGNALING SYSTEM 3. Main fuse 4. Backup fuse (odometer and clock) 5. Main switch 6. Battery 12.Relay unit 15.Neutral switch 18.Speed sensor 23.Coolant temperature sensor 25.ECU (engine control unit) 33.Fuel level warning light 34.Oil level warning light 35.Neutral indicator light 36.Multi-function meter 38.Coolant temperature warning light 40.Turn signal indicator light...
  • Page 440 SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The speedometer fails to operate. • Before troubleshooting, remove the following part(s): 1.
  • Page 441 SIGNALING SYSTEM Checking the signaling system The horn fails to sound. NG → 1. Check the horn switch. The horn switch is faulty. Replace the left Refer to “CHECKING THE handlebar switch. SWITCHES” on page 8-93. OK ↓ NG → 2.
  • Page 442 SIGNALING SYSTEM The tail/brake light fails to come on. (For XVS13CA(C)) NG → 1. Check the front brake light switch. Replace the front brake light switch. Refer to “CHECKING THE SWITCHES” on page 8-93. OK ↓ NG → 2. Check the rear brake light switch. Replace the rear brake light switch.
  • Page 443 SIGNALING SYSTEM The neutral indicator light fails to come on. NG → 1. Check the neutral switch. Replace the neutral switch. Refer to “CHECKING THE SWITCHES” on page 8-93. OK ↓ NG → 2. Check the relay unit (diode). Refer to “CHECKING THE DI- Replace the relay unit.
  • Page 444 SIGNALING SYSTEM NG → 2. Check the entire signaling system’s wiring. Refer to “CIRCUIT DIAGRAM (for Properly connect or repair the signaling XVS13AA(C)/XVS13CTA(C))” on system’s wiring. page 8-29 and “CIRCUIT DIA- GRAM (for XVS13CA(C))” on page 8-31. OK ↓ Replace the meter assembly. The coolant temperature warning light fails to come on.
  • Page 445 SIGNALING SYSTEM 8-38...
  • Page 446 COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM (for XVS13AA(C)/XVS13CTA(C)) 8-39...
  • Page 447 COOLING SYSTEM 3. Main fuse 5. Main switch 6. Battery 11.Radiator fan motor fuse 23.Coolant temperature sensor 25.ECU (engine control unit) 67.Radiator fan motor 69.Radiator fan motor relay 71.Ignition fuse 8-40...
  • Page 448 COOLING SYSTEM EAS27D1014 CIRCUIT DIAGRAM (for XVS13CA(C)) 8-41...
  • Page 449 COOLING SYSTEM 3. Main fuse 5. Main switch 6. Battery 11.Radiator fan motor fuse 23.Coolant temperature sensor 25.ECU (engine control unit) 67.Radiator fan motor 69.Radiator fan motor relay 71.Ignition fuse 8-42...
  • Page 450 COOLING SYSTEM EAS27320 TROUBLESHOOTING The radiator fan motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Rider seat (for XVS13AA(C)/XVS13CTA(C)) 2. Seat (for XVS13CA(C)) 3. Tool kit tray 4. Fuel tank 5. Headlight lens unit NG → 1.
  • Page 451 COOLING SYSTEM NG → 7. Check the entire cooling system’s wiring. Refer to “CIRCUIT DIAGRAM (for Properly connect or repair the cooling sys- XVS13AA(C)/XVS13CTA(C))” on tem’s wiring. page 8-39 and “CIRCUIT DIA- GRAM (for XVS13CA(C))” on page 8-41. OK ↓ Replace the ECU.

  • Page 452: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM (for XVS13AA(C)/XVS13CTA(C)) 8-45...
  • Page 453 FUEL INJECTION SYSTEM 3. Main fuse 5. Main switch 6. Battery 7. Fuel injection system fuse 12.Relay unit 14.Fuel pump relay 15.Neutral switch 16.Fuel pump 17.Sidestand switch 18.Speed sensor 19.Crankshaft position sensor 20.Throttle position sensor 21.Intake air pressure sensor 22.Lean angle sensor 23.Coolant temperature sensor 24.Air temperature sensor 25.ECU (engine control unit)
  • Page 454 FUEL INJECTION SYSTEM EAS27D1015 CIRCUIT DIAGRAM (for XVS13CA(C)) 8-47...
  • Page 455 FUEL INJECTION SYSTEM 3. Main fuse 5. Main switch 6. Battery 7. Fuel injection system fuse 12.Relay unit 14.Fuel pump relay 15.Neutral switch 16.Fuel pump 17.Sidestand switch 18.Speed sensor 19.Crankshaft position sensor 20.Throttle position sensor 21.Intake air pressure sensor 22.Lean angle sensor 23.Coolant temperature sensor 24.Air temperature sensor 25.ECU (engine control unit)
  • Page 456 FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
  • Page 457 FUEL INJECTION SYSTEM a. Main switch “OFF” d. Engine trouble warning light on for 1.4 seconds b. Main switch “ON” c. Engine trouble warning light off EAS27380 SELF-DIAGNOSTIC FUNCTION TABLE If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.
  • Page 458 FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive Lean angle sensor The vehicle has overturned. Unable Unable (latch up detected) Able Able (depending (depending Front cylinder ignition Malfunction detected in the prima- on the on the coil...
  • Page 459 FUEL INJECTION SYSTEM Communication error with the meter Able / un- Fault Able / un- Item Symptom able to code No. able to start drive ECU internal malfunc- No signals are received from the Er-1 tion Unable Unable ECU. (output signal error) ECU internal malfunc- No signals are received from the Er-2...
  • Page 460 FUEL INJECTION SYSTEM EAS27420 DIAGNOSTIC MODE Setting the diagnostic mode (for XVS13AA(C)/XVS13CTA(C)) 1. Turn the main switch to “OFF” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Press and hold the “RESET” switch “1” and the “ ”...
  • Page 461 FUEL INJECTION SYSTEM 8. Turn the main switch to “OFF” to cancel the diagnostic mode. Setting the diagnostic mode (for XVS13CA(C)) 1. Turn the main switch to “OFF” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3.
  • Page 462 FUEL INJECTION SYSTEM 8. Turn the main switch to “OFF” to cancel the diagnostic mode. Diagnostic code table Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in wire harness. • Defective crankshaft position sensor. No normal signals are re- •...
  • Page 463 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in wire harness. Malfunction detected in the • Malfunction in rear cylinder ignition coil. primary wire of the rear cyl- • Malfunction in ECU. inder ignition coil.
  • Page 464 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • This fault code number does not indicate a malfunction. Engine has been left idling. • If the engine was stopped by the ECU after (The ECU automatically idling for 20 minutes, the fault code number —...
  • Page 465 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Vehicle speed pulse 0–999 Check that the number in- creases when the rear wheel is rotated. The num- ber is cumulative and does not reset each time the wheel is stopped. Lean angle sensor Remove the lean angle sensor and incline it more...
  • Page 466 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Malfunction history code — display • No history • History exists Fault codes 12-70 • (If more than one code number is detected, the dis- play alternates every two seconds to show all the de- tected code numbers.
  • Page 467 FUEL INJECTION SYSTEM Actuator operation table Diag- nostic Item Actuation Checking method code Actuates the front cylinder ig- nition coil five times at one- Check the spark five times. Front cylinder ignition coil second intervals. • Connect an ignition Illuminates the engine trou- checker.
  • Page 468 FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates and fully closes the ISC valve, then opens it to the standby opening position when the engine is started. The ISC unit vibrates when ISC valve This operation takes approxi- the ISC valve operates.
  • Page 469 FUEL INJECTION SYSTEM EAS27460 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part has been completed, reset the meter display ac- cording to the reinstatement method.
  • Page 470 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor: open or short circuit detected. Diagnostic code No. Intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of intake air pres- •...
  • Page 471 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor: hose system malfunction (clogged or detached hose). Diagnostic code No. Intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Intake air pressure sensor hose •...
  • Page 472 FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor: open or short circuit detected. Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle position • Check for looseness or pinch- Turning the sensor.
  • Page 473 FUEL INJECTION SYSTEM Fault code No. Symptom A break or disconnection of the blue/black lead of the ECU is detected. Diagnostic code No. Sidestand switch Order Item/components and probable Check or maintenance job Reinstatement cause method Connection • Check the coupler for any pins If the transmis- •...
  • Page 474 FUEL INJECTION SYSTEM Fault code No. Symptom Coolant temperature sensor: open or short circuit detect- Diagnostic code No. Coolant temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of coolant tempera- Check for looseness or pinching. Turning the ture sensor.
  • Page 475 FUEL INJECTION SYSTEM Fault code No. Symptom Air temperature sensor: open or short circuit detected. Diagnostic code No. Air temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of air temperature Check for looseness or pinching. Turning the sensor.
  • Page 476 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signal is received from the O sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of O sensor. Check for looseness or pinching. Starting the en- gine and oper- Connections •...
  • Page 477 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the front cylin- der ignition coil. Diagnostic code No. Front cylinder ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of front cylinder ig- •...
  • Page 478 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the rear cylin- der ignition coil. Diagnostic code No. Rear cylinder ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of rear cylinder ig- •...
  • Page 479 FUEL INJECTION SYSTEM Fault code No. Symptom Engine speed is high when the engine is idling. Diagnostic code No. Component other than ISC (idle speed control) unit is de- fective (ISC operating sound is heard). Defective ISC (idle speed control) unit (ISC operating sound is not heard).
  • Page 480 FUEL INJECTION SYSTEM Fault code No. Symptom Fuel injector: open or short circuit detected. Diagnostic code No. 36, 37 Fuel injector Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the couplers for any pins Start the en- •...
  • Page 481 FUEL INJECTION SYSTEM Fault code No. Symptom Lean angle sensor: open or short circuit detected. Diagnostic code No. Lean angle sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 482 FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. C. Open circuit is detected in the clutch switch. Diagnostic code No. Speed sensor Neutral switch —...
  • Page 483 FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. C. Open circuit is detected in the clutch switch. Diagnostic code No. Speed sensor Neutral switch —...
  • Page 484 FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. C. Open circuit is detected in the clutch switch. Diagnostic code No. Speed sensor Neutral switch —...
  • Page 485 FUEL INJECTION SYSTEM Fault code No. Symptom The ECU is unable to monitor the battery voltage (an open or short circuit in the line to the ECU). Diagnostic code No. Fuel system voltage Fuel pump relay Order Item/components and probable Check or maintenance job Reinstatement cause...
  • Page 486 FUEL INJECTION SYSTEM Fault code No. Symptom Charging voltage is abnormal. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Malfunction in charging system. • Check the charging system. Start the en- Refer to “CHARGING SYS- gine and let it TEM”...
  • Page 487 FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signals are received from the ECU. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 488 FUEL INJECTION SYSTEM Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 489 FUEL INJECTION SYSTEM 8-82...
  • Page 490 FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM (for XVS13AA(C)/XVS13CTA(C)) 8-83...
  • Page 491 FUEL PUMP SYSTEM 3. Main fuse 5. Main switch 6. Battery 7. Fuel injection system fuse 14.Fuel pump relay 16.Fuel pump 25.ECU (engine control unit) 63.Engine stop switch 71.Ignition fuse 8-84...
  • Page 492 FUEL PUMP SYSTEM EAS27D1017 CIRCUIT DIAGRAM (for XVS13CA(C)) 8-85...
  • Page 493 FUEL PUMP SYSTEM 3. Main fuse 5. Main switch 6. Battery 7. Fuel injection system fuse 14.Fuel pump relay 16.Fuel pump 25.ECU (engine control unit) 63.Engine stop switch 71.Ignition fuse 8-86...
  • Page 494 FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING The fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Rider seat (for XVS13AA(C)/XVS13CTA(C)) 2. Seat (for XVS13CA(C)) 3. Tool kit tray 4. Fuel tank 5. Battery box 6. Headlight lens unit NG →...
  • Page 495 FUEL PUMP SYSTEM NG → 7. Check the entire fuel pump sys- tem’s wiring. Refer to “CIRCUIT DIAGRAM (for Properly connect or repair the fuel pump XVS13AA(C)/XVS13CTA(C))” on system’s wiring. page 8-83 and “CIRCUIT DIA- GRAM (for XVS13CA(C))” on page 8-85.
  • Page 496 ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 8-89...
  • Page 497 ELECTRICAL COMPONENTS 1. Coolant temperature sensor (for XVS13AA(C)/XVS13CTA(C)) 2. Intake air pressure sensor (for XVS13CA(C)) 3. Intake air pressure sensor (for XVS13AA(C)/XVS13CTA(C)) 4. Rear cylinder ignition coil 5. Front cylinder ignition coil 6. Sub-wire harness (for XVS13AA(C)/XVS13CTA(C)) 7. Sub-wire harness (for XVS13CA(C)) 8.
  • Page 498 ELECTRICAL COMPONENTS 8-91...
  • Page 499 ELECTRICAL COMPONENTS 1. Main switch 2. Rectifier/regulator 3. Fuse box 4. Headlight fuse 5. Backup fuse 6. Radiator fan motor fuse 7. Taillight fuse 8. Ignition fuse 9. Signaling system fuse 10. Main fuse 11. Battery 12. Lean angle sensor 13.

  • Page 500: Checking The Switches

    ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES XVS13AA(C)/XVS13CTA(C) Br/L L/B L/Y Br/L (BLACK) L/Y B/Y (BLACK) Y/G B/Y RESET Ch Br/W Dg B Y/R P/W P/B L/Y B Br/W (BLUE) B/Y P (BLACK) 8-93...
  • Page 501 ELECTRICAL COMPONENTS 1. Main switch 2. Front brake light switch 3. Reset switch 4. Select switch 5. Engine stop switch 6. Start switch 7. Rear brake light switch 8. Neutral switch 9. Dimmer switch 10. Turn signal switch 11. Horn switch 12.
  • Page 502 ELECTRICAL COMPONENTS XVS13CA(C) Br B Br/L L/B L/Y Br/L Ch Br/W Dg B Y/R L/Y B Br/W (BLUE) B/Y P L/Y B/Y Y/G B/Y RESET (BLACK) P/W B/Y P/W Br SELECT (BLACK) (BLACK) 8-95...
  • Page 503 ELECTRICAL COMPONENTS 1. Main switch 2. Front brake light switch 3. Reset switch 4. Select switch 5. Engine stop switch 6. Start switch 7. Rear brake light switch 8. Neutral switch 9. Sidestand switch 10. Clutch switch 11. Dimmer switch 12.
  • Page 504 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 NOTICE Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
  • Page 505 ELECTRICAL COMPONENTS EAS27990 EWA13320 CHECKING THE BULBS AND BULB WARNING SOCKETS Since the headlight bulb gets extremely hot, Check each bulb and bulb socket for damage or keep flammable products and your hands wear, proper connections, and also for continuity away from the bulb until it has cooled down.
  • Page 506 ELECTRICAL COMPONENTS Checking the condition of the bulb sockets b. If the pocket tester indicates “∞”, replace the The following procedure applies to all of the bulb fuse. sockets. L LLL L LLL L LLL L LLL L LLL 1. Check: 3.
  • Page 507 ELECTRICAL COMPONENTS specific gravity of the electrolyte. Therefore, the EAS28030 CHECKING AND CHARGING THE BATTERY charge of the battery has to be checked by mea- EWA13290 suring the voltage at the battery terminals. WARNING Batteries generate explosive hydrogen gas 1. Remove: and contain electrolyte which is made of poi- •...
  • Page 508 ELECTRICAL COMPONENTS • When charging a battery, be sure to remove it from the vehicle. (If charging has to be done with the battery mounted on the vehi- cle, disconnect the negative battery lead from the battery terminal.) • To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery.
  • Page 509 ELECTRICAL COMPONENTS c. Make sure that the current is higher than the standard charging current written on the bat- Voltage should be measured 30 minutes after tery. the engine is stopped. b. Connect a charger and ammeter to the bat- If the current is lower than the standard charging tery and start charging.
  • Page 510 ELECTRICAL COMPONENTS Recommended lubricant Result Dielectric grease Continuity (between “3” and “4”) 10.Install: • Rider seat (for XVS13AA(C)/XVS13CTA(C)) Relay unit (starting circuit cut-off relay) • Seat (for XVS13CA(C)) • Tool kit tray Refer to “GENERAL CHASSIS” on page 4-1. EAS28040 CHECKING THE RELAYS Check each relay for continuity with the pocket tester.
  • Page 511 ELECTRICAL COMPONENTS Relay unit (fuel pump relay) Headlight relay Sb/W R/L L/R L/G L/Y Sb B/Y L/W 1. Positive battery terminal 1. Positive battery terminal 2. Negative battery terminal 2. Negative battery terminal 3. Positive tester probe 3. Positive tester probe 4.
  • Page 512 ELECTRICAL COMPONENTS EAS3D81010 • Positive tester probe → CHECKING THE TURN SIGNAL RELAY brown/white “1” or yellow/red “2” 1. Check: • Negative tester probe → • Turn signal relay input voltage ground Out of specification → The wiring circuit from the main switch to the turn signal relay cou- pler is faulty and must be repaired.
  • Page 513 ELECTRICAL COMPONENTS Continuity Positive tester probe → sky blue “1” Negative tester probe → black/yellow “2” No continuity Positive tester probe → Sb/W R/L L/R black/yellow “2” L/G L/Y Sb B/Y Negative tester probe → sky blue “1” Continuity Positive tester probe → sky blue “1”...
  • Page 514 ELECTRICAL COMPONENTS Continuity If the ignition spark gap is within specification, Positive tester probe → white the ignition system circuit is operating normally. “1” or red/white “1” Negative tester probe → M MMM M MMM M MMM M MMM M MMM red/white “2”...
  • Page 515 ELECTRICAL COMPONENTS Secondary coil resistance 8.64–12.96 kΩ M MMM M MMM M MMM M MMM M MMM a. Disconnect the spark plug cap from the igni- tion coil. b. Connect the pocket tester (Ω × 1k) to the ig- nition coil as shown. Pocket tester 90890-03112 c.
  • Page 516 ELECTRICAL COMPONENTS • Positive tester probe → gray “1” • Negative tester probe → black “2” c. Turn the main switch to “ON”. d. Tilt the lean angle sensor 65°. e. Measure the lean angle sensor output volt- age. L LLL L LLL L LLL L LLL...
  • Page 517 ELECTRICAL COMPONENTS EAS28150 CHECKING THE STATOR COIL Charging voltage 1. Disconnect: 14 V at 5000 r/min • Stator coil coupler (from the wire harness) M MMM M MMM M MMM M MMM M MMM a. Attach the engine tachometer to the spark 2.
  • Page 518 ELECTRICAL COMPONENTS • Positive tester probe → Pocket tester green “1” 90890-03112 • Negative tester probe → Analog pocket tester black “2” YU-03112-C Minimum level position “A” • Positive tester probe → connector (white) “1” • Negative tester probe → body ground “2”...
  • Page 519 ELECTRICAL COMPONENTS EAS3D81015 CHECKING THE OIL LEVEL WARNING LIGHT This model is equipped with a self-diagnosis de- vice for the oil level detection circuit. 1. Check: • Oil level warning light “1” (Turn the main switch to “ON”.) Warning light comes on for a few seconds, then goes off →...

  • Page 520: Specifications

    ELECTRICAL COMPONENTS EAS28260 CHECKING THE COOLANT TEMPERATURE Pocket tester SENSOR 90890-03112 1. Remove: Analog pocket tester YU-03112-C • Coolant temperature sensor Refer to “THERMOSTAT” on page 6-4. • Positive tester probe → EWA14130 WARNING white/yellow “1” • Negative tester probe → •...
  • Page 521 ELECTRICAL COMPONENTS EAS28300 CHECKING THE THROTTLE POSITION Intake air pressure sensor output SENSOR voltage 1. Remove: 3.57–3.71 V • Throttle position sensor M MMM M MMM M MMM M MMM M MMM (from the throttle body) a. Connect the pocket tester (DC 20 V) to the in- 2.
  • Page 522 ELECTRICAL COMPONENTS • Never subject the air temperature sensor to strong shocks. If the air temperature sen- sor is dropped, replace it. 2. Check: • Air temperature sensor resistance Out of specification → Replace. Air temperature sensor resis- tance 290–390 Ω at 80 °C (176 °F) M MMM M MMM M MMM...

  • Page 523: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING..................9-1 GENERAL INFORMATION ............... 9-1 STARTING FAILURES................9-1 INCORRECT ENGINE IDLING SPEED ............ 9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING................ 9-2 SHIFT PEDAL DOES NOT MOVE ............9-2 JUMPS OUT OF GEAR................9-2 FAULTY CLUTCH ..................9-2 OVERHEATING ..................9-3 OVERCOOLING..................9-3 POOR BRAKING PERFORMANCE............
  • Page 524 TROUBLESHOOTING 4. Throttle body(-ies) EAS28450 TROUBLESHOOTING • Deteriorated or contaminated fuel • Sucked-in air EAS28460 GENERAL INFORMATION Electrical system 1. Battery The following guide for troubleshooting does not • Discharged battery cover all the possible causes of trouble. It should •...
  • Page 525 TROUBLESHOOTING Fuel system • Bent shift fork guide bar 1. Throttle body(-ies) Transmission • Damaged or loose throttle body joint • Seized transmission gear • Improperly synchronized throttle bodies • Foreign object between transmission gears • Improper throttle cable free play •...
  • Page 526 TROUBLESHOOTING EAS28600 EAS28610 OVERHEATING OVERCOOLING Engine Cooling system 1. Clogged coolant passages 1. Thermostat • Cylinder head(s) and piston(s) • Thermostat stays open • Heavy carbon buildup EAS28620 2. Engine oil POOR BRAKING PERFORMANCE • Incorrect oil level • Worn brake pad •...
  • Page 527 TROUBLESHOOTING • Unevenly tensioned fork spring (both front • Faulty tail/brake light LED (for XVS13CA(C)) fork legs) Tail/brake light bulb burnt out • Broken fork spring • Wrong tail/brake light bulb (for • Bent or damaged inner tube XVS13AA(C)/XVS13CTA(C)) • Bent or damaged outer tube •...

  • Page 528: Wiring Diagram

    EAS28740 55. Front right turn signal/position EAS28750 WIRING DIAGRAM COLOR CODE light Black 56. Front left turn signal/position XVS13AA(C)/XVS13CTA(C) Brown light 2011 Chocolate 57. Headlight 1. AC magneto Dark green 58. Accessory light (OPTION) 2. Rectifier/regulator Green 59. Right handlebar switch 3.
  • Page 529 EAS27D1008 55. Front right turn signal/position EAS27D1009 WIRING DIAGRAM COLOR CODE light Black 56. Front left turn signal/position XVS13CA(C) 2011 Brown light 1. AC magneto Chocolate 57. Headlight 2. Rectifier/regulator Dark green 58. Accessory light (OPTION) 3. Main fuse Green 59.
  • Page 532 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
  • Page 533 XVS13AA(C)/XVS13CTA(C) 2011 WIRING DIAGRAM W1 W2 Gy W W Gy R/B R/G R/Y W/L (GRAY) Br/L Sb/W B/R R1 Sb/W B/R L R/L L/R WIRE HARNESS SUB-WIREHARNESS WIRE HARNESS SUB-WIREHARNESS WIRE HARNESS TAIL/ BRAKE LIGHT WIRE HARNESS L/G L/Y Sb (BLACK) Br/W L/B B/Y R/L R/W...
  • Page 534 XVS13AA(C)/XVS13CTA(C) 2011 WIRING DIAGRAM (GRAY) WIRE HARNESS SUB-WIREHARNESS WIRE HARNESS SUB-WIREHARNESS WIRE HARNESS TAIL/ BRAKE LIGHT WIRE HARNESS (BLACK) (BLACK) (BLACK) (DARK GREEN) (BLACK) (BLACK) (BLACK) (BLACK) (DARK GRAY) (DARK GREEN) (GRAY) (BLACK) RESET (BLACK) (BLACK) (BLUE) (BLUE) (BLACK) (BLACK) (BLACK) (BLACK) (BLACK)
  • Page 535 XVS13CA(C) 2011 WIRING DIAGRAM Sb/W W1 W2 (GRAY) B/R L/W1 R/L R/B1 R/G R/Y1 W/L L1 L/R R/W L/G L/Y Sb B/Y Sb/W Br/L R/B2 R/Y2 WIRE HARNESS SUB-WIRE HARNESS Br/W L/B B/Y R/L R/W B/W1 Br/L L/W1 Gy/G (BLACK) Gy/W Gy/R B1 B2...
  • Page 536 XVS13CA(C) 2011 WIRING DIAGRAM (GRAY) WIRE HARNESS SUB-WIRE HARNESS (BLACK) TAIL/ BRAKE LIGHT WIRE HARNESS (BLACK) (BLACK) WIRE HARNESS (DARK GREEN) (BLACK) (BLACK) (BLACK) (BLACK) (DARK GRAY) (DARK GREEN) (BLACK) (GRAY) (BLACK) (BLACK) SELECT RESET (BLACK) (BLUE) (BLUE) (BLACK) (BLACK) (BLACK) (BLACK) (BLACK)

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