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Manuals / Brands / Yamaha Manuals / Motorcycle / XVZ13TFL / Service manual / PDF

YAMAHA XVZ13TFL SERVICE MANUAL

Table of Contents
Notice
Important information
Symbols
Table of contents
General information
Motorcycle identification
Vehicle identification number
Model code
Features
Cruise control
Cruise control switch functions
Operation chart
Cruise control function
Digital Speedometer
Odometer and trip meter modes
Clock mode
Audio system and CB Radio
Turning on/off the audio system
Turning on/off the CB radio system
Cassette deck operation
Track searching
Reserving tape play direction
Dolby noise reduction
Ejecting the cassette tape
Blank skipping
Radio operation
Switching the receiving bands
Automatic tuning
Manually turning
Programming preset stations in memory automatically
CB Radio Operation
Changing the transmitting and receiving channel
Alternating the squelch level
Changing the receive volume for the CB radio
Channel information
Receiving/transmitting
AUX operation
Basic setting
Audio system
Selecting the output for speaker or headset
Controlling the bass level
Controlling the treble level
Controlling the fader
Changing the level for auto volume control system
Preparation for removal and disassembly
Replacement Parts
Gaskets, Oil Seals and O-Rings
Lock Washers/Plates and Cotter Pins
Bearings and Oil Seals
Circlips
Checking the connections
Special Tools
Specifications
General specifications
Maintenance specifications
Crankcase tightening sequence
Tightening torques
Chassis
Electrical
Audio system and C.B. radio specifications
Conversion table
General tightening torque specifications
Lubrication points and lubricant types
Cooling system diagrams
Lubrication diagrams
Cable Routing
Contents
Periodic Maintenance Chart for Emission control system
General maintenance and lubrication chart
Front cowling
Removing the front cowling cover
Installing the front cowling cover
Rider and passenger seats
Removing the rider and passenger seats
Fuel tank
Removing the fuel tank
Saddlebags
Removing the trunk and saddlebags
Engine
Adjusting the valve clearance
Intake
Exhaust
Synchronizing the carburetors
Adjusting the engine idling speed
Adjusting the throttle cable free play
Checking the sark plugs
Checking the ignition timing
Measuring the compression pressure
Checking the engine oil level
Changing the engine oil
Measuring the engine oil pressure
Checking the clutch fluid level
Bleeding the hydraulic clutch system
Cleaning the air filter element
The carburetor joints and intake manifolds
Checking te fuel hoses and fuel filter
Checking the crankcase breather hose
Checking the exhaust system
Checking the coolant level
Checking the cooling system
Changing the coolant
Adjusting the rear brake
Checking the brake fluid level
Checking the brake pads
Adjusting the rear brake light switch
Checking the brake hoses
Bleeding the hydraulic brake system
Adjusting the shift pedal
Checking the final drive oil level
Changing the final drive oil
Checking and adjusting the steering head
Checking the front fork
Adjusting the front and rear shock absorber assembly
Checking the tires
Checking the wheels
Checking and lubricating the cables
Lubricating the levers and pedals
Lubricating the sidestand
Lubricating the rear suspension
Electrical system
Checking and charging the system
Charging method using a variable-current type charger
Charging method using a constant-voltage type charger
Checking and charging the battery
Checking the fuses
Replacing the headlight bulb
Adjusting the headlight beam
Engine removal
Leads, cables and hoses
Disconnecting the leads, cables and hoses
Radiator and AIS
Removing the radiator and AIS
Mufflers and exhausts
Removing the mufflers and exhausts
Horn and Brake Pedal
Removing the Horn and brake pedal
Removing the engine
Installing the engine
Camshafts
Cylinder Head Covers
Removing the cylinder head covers
Removing the camshafts
Rear cylinder head
Front cylinder head
Checking the camshafts
Checking the timing chains, camshaft Sprockets/timing chain guides
Checking the timing chain tensioners
Installing the camshafts
Cylinder heads
Checking the cylinder heads
Valves and Valve Springs
Removing the valves and valve springs
Removing the valves
Checking the valves and valve guides
Checking the valve seats
Checking the valve springs
Checking the valve lifters
Installing the valves
Clutch
Clutch master cylinder
Removing the clutch master cylinder
Disassembling the clutch master cylinder
Checking the clutch master cylinder
Assembling the clutch master cylinder
Installing the clutch master cylinder
Clutch release cylinder
Removing the clutch release cylinder
Disassembling the clutch release cylinder
Installing the clutch release cylinder
Clutch cover
Removing the clutch cover
Removing the clutch
Checking the friction plates
Checking the clutch plates
Checking the pressure plate
Checking the clutch push rods
Installing the clutch
Shift Shaft
Shift arm
Shift shaft and stopper lever
Removing the shift shaft and stopper lever
Checking the shift shaft
Checking the stopper lever
Installing the shift shaft
Starter clutch and generator
Starter coil
Removing the stator coil
Removing the starter clutch and generator rotor
Removing the generator
Checking the starter clutch
Installing the generator
Oil pan and oil pump
Removing the oil pan and oil pump
Disassembling the oil pump
Removing the oil pan
Checking the oil pump
Checking the relief valve
Checking the oil gallery pipes
Checking the oil strainer
Installing the oil gallery pipes
Assembling the oil pump
Installing the oil pump
Installing the oil strainer
Installing the oil pan
Crankcase
Crankcase separation
Disassembling the crankcase
Checking the crankcase
Assembling the crankcase
Crankshaft
Removing the crankshaft assembly
Checking the crankshaft
Checking the balancer shaft
Connecting rods and pistons
Connecting rod and piston removal
Removing the connecting rods and pistons
Checking the cylinders and pistons
Checking the crankshaft and connecting rods
Transmission
Removing the transmission
Checking the bearings and oil seals
Checking the shift forks
Checking the shift drum assembly
Checking the transmission
Installing the shift forks
Installing the transmission
Middler gear
Removing the middle gear
Disassembling the middle drive shaft assembly
Disassembling the middle driven shaft assembly
Checking the middle drive shaft assembly
Checking the middle driven shaft assembly
Assembling the middle drive shaft assembly
Assembling the middle driven shaft assembly
Adjusting the middle gear backlash
Cooling system
Radiator
Removing the radiator
Checking the radiator
Installing the radiator
Thermostat
Removing the thermostat
Thermostat housing
Disassembling the thermostat
Checking the thermostat
Assembling the thermostat
Installing the thermostat
Water pump
Removing the water pump
Disassembling the water pump
Checking the water pump
Assembling the water pump
Carburetors
Removing the carburetors
Separating the carubretors
Disassembling the carburetors
Checking the carburetors
Assembling the carburetors
Installing the carburetors
Checking and adjusting the throttle position sensor
Air induction system diagrams
Checking the air induction system
Front wheel and brake discs
Removing the front wheen and brake discs
Removing the front wheel
Checking the front wheel
Checking the brake discs
Installing the front wheel
Adjusting the front wheel static balance
Rear wheel and brake disc
Rear fender
Removing the rear fender
Removing the rear wheel and brake disc
Disassembling the rear wheel
Removing the rear wheel
Checking the rear wheel drive hub
Installing the rear wheel
Adjusting the rear wheel static balance
Removing the front brake pads
Removing the rear brake pad
Replacing the front brake pads
Removing the front brake master cylinder
Disassembling the front brake master cylinder
Removing the rear brake master cylinder
Disassembling the rear brake master cylinder
Removing the front brake calipers
Disassembling the front brake caliper
Removing the rear brake caliper
Disassembling the rear brake caliper
Disassembling the front brake calieprs
Checking the front and rear brake calipers
Installing the front brake calipers
Installing the rear brake caliper
Front fork
Removing the front fork
Disassembling the front fork
Removing the front fork legs
Disassembling the front fork legs
Checking the front fork legs
Assembling the front fork legs
Handlebar
Removing the handlebar
Checking the handlebar
Installing the handlebar
Steering head
Removing the steering head
Removing the lower bracket
Checking the steering head
Installing the steering head
Rear shock absorber assembly
Removing the rear shock absorber assembly
Swingarm
Removing the swingarm
Checking the swingarm
Installing the swingarm
Shift drive
Inspection notes
Final drive assembly and drive shaft
Removing the final drive assembly and drive shaft
Measuring the ring gear backlash
Adjusting the ring gear backlash
Measuring the ring-gear-to-stop clearance
Adjusting the ring-gear-to-stop-per-bolt clearance
Final drive assembly
Disassembling the final drive assembly
Removing and installing the ring gear bearings
Aligning the final drive pinion gear and ring gear
Checking the drive shaft
Installing the drive shaft
Electrical components
Switches
Checking switch continuity
Switch continuity inspection
Checking the bulbs and bulb sockets
Types of bulbs
Ignition system circuit diagram
Electric starting system
Starting circuit cutoff system operation
The starter motor fails to turn
Starter motor
Removing the starter motor
Disassembling the starter motor
Checking the starter motor
Assembling the starter motor
Charging system
The battery is not being charged
Lighting system
Signal system
Fuel pump circuit operation
If the fuel pump fails to operate
Checking the fuel pump
Carburetor heating system
The carburetor heating system fails to operate
Audio system circuit operation
Speaker does not sound
Headset does not sound
Front remote controller does not operation
Rear remote controller does not operation
CB unit does not operation
Cruise control system
Cruise control circuit operation
Cruise control system components
Self diagnosis function of the cruise control system
Trouble diagnosis of the cancel switch signal
Trouble diagnosis of the brake light signal
Trouble diagnosis of the throttle drive
Engine warning light
Display order on the engine warning light
When more than one item is being monitored
Speed sensor
Emergency stop switch
Fuel Meter
Fuel thermistor
"SET/RES" Indicator Light
Cruise control switch
Troubleshooting
Starting problems
Incorrect engine and speed
Poor medium-and-high speed performance
Faulty gear shifting
Faulty clutch
Clutch slips
Overheating
Overcooling
Poor braking performance
Faulty front fork legs
Unstable handling
Faulty signaling system
Headlight does not light
Turn signal does not light
Horn does not sound
Wiring diagram
MCU
Cruise Control Unit
Cruise Switch
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