Yamaha Royal Star Tour Deluxe XVZ13CTT Manuals

Manuals and User Guides for Yamaha Royal Star Tour Deluxe XVZ13CTT. We have 1 Yamaha Royal Star Tour Deluxe XVZ13CTT manual available for free PDF download: Supplementary Service Manual

Yamaha Royal Star Tour Deluxe XVZ13CTT Supplementary Service Manual

Yamaha Royal Star Tour Deluxe XVZ13CTT Supplementary Service Manual (575 pages)

Brand: Yamaha | Category: Motorcycle | Size: 65.29 MB

Table of Contents

Important Manual Information
3
How to Use this Manual
4
Symbols
5
Table of Contents
6
General Specifications
8
Maintenance Specifications
10
Tightening Torques
10
Engine
10
Chassis
11
Electrical
13
Cable Routing
14
Periodic Checks and Adjustments

36
Electrical System

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

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