Yamaha Royal Star Tour Deluxe XVZ13CTT Supplementary Service Manual Download Page 1

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LIT-11616-18-02

4XY-28197-E1

XVZ13CTT(C)

SUPPLEMENTARY

SERVICE MANUAL

Summary of Contents for Royal Star Tour Deluxe XVZ13CTT

Page 1: ...LIT 11616 18 02 4XY 28197 E1 XVZ13CTT C SUPPLEMENTARY SERVICE MANUAL ...

Page 2: ...ary Service Manual together with the following manual XVZ13TFL XVZ13TFLC SERVICE MANUAL LIT 11616 12 60 4XY 28197 E0 XVZ13CTT C SUPPLEMENTARY SERVICE MANUAL 2004 by Yamaha Motor Corporation U S A First edition March 2004 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 LIT 11616 18 02 ...

Page 3: ... to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and will appear in future editions of this manual where applicable NOTE ...

Page 4: ...page except in chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number indicates a disas...

Page 5: ...d B Lubricant C Special tool D Tightening torque E Wear limit clearance F Engine speed G Electrical data Symbols H to M in the exploded diagrams indicate the types of lubricants and lubrication points H Engine oil I Gear oil J Molybdenum disulfide oil K Wheel bearing grease L Lithium soap based grease M Molybdenum disulfide grease Symbols N to O in the exploded diagrams indicate the following N Ap...

Page 6: ...DECASES 34 CHASSIS 35 CHECKING AND ADJUSTING THE STEERING HEAD 35 ELECTRICAL SYSTEM 37 ADJUSTING THE HEADLIGHT BEAM 37 ELECTRICAL SYSTEM 38 CHECKING THE SWITCHES 38 IGNITION SYSTEM 40 CIRCUIT DIAGRAM 40 TROUBLESHOOTING 41 ELECTRIC STARTING SYSTEM 46 CIRCUIT DIAGRAM 46 LIGHTING SYSTEM 47 CIRCUIT DIAGRAM 47 SIGNALING SYSTEM 48 CIRCUIT DIAGRAM 48 CHECKING THE SIGNALING SYSTEM 50 COOLING SYSTEM 54 CIR...

Page 7: ...ONTROL SYSTEM 66 CIRCUIT DIAGRAM 66 INSTRUMENT AND CONTROL FUNCTIONS 68 CHECKING THE CRUISE CONTROL SYSTEM 70 SELF DIAGNOSIS FUNCTION OF THE CRUISE CONTROL SYSTEM 72 SELF DIAGNOSIS 75 XVZ13CTT C WIRING DIAGRAM ...

Page 8: ...s 3 500 mm 137 8 in Basic weight Dry weight 357 kg 787 lb With oil and a full fuel tank 383 kg 844 lb Fuel Type Unleaded gasoline only for USA California and Oceania Regular unleaded gasoline only for CDN Fuel tank capacity 20 0 L 4 40 Imp gal 5 28 US gal Fuel reserve amount 3 9 L 0 86 Imp gal 1 03 US gal Carburetor Type quantity BDSR32 4 Manufacturer MIKUNI Chassis Frame type Double cradle Caster...

Page 9: ... 2 for USA California and CDN Front turn signal light 12 V 21 W 2 for Oceania Rear turn signal light 12 V 21 W 2 Meter light LED Indicator light Neutral indicator light LED Turn signal indicator light LED High beam indicator light LED Oil level warning light LED Coolant temperature warning light LED Engine trouble warning light LED Overdrive indicator right LED Cruise control SET indicator light L...

Page 10: ...ze Th V 110 Fuel level F L 13 1 14 1 mm 0 52 0 56 in Engine idle speed 950 1 050 r min Intake vacuum 37 kPa 280 mmHg 11 0 inHg Fuel pump Type Electrical type Model manufacturer 1D6 MITSUBISHI Consumption amperage max 1 A Output pressure 15 20 kPa 0 15 0 20 kgf cm2 2 1 2 8 psi Item Fastener Thread size Q ty Tightening torque Remarks Nm m kg ft lb Heat protector plate Bolt M6 1 0 2 10 1 0 7 2 Air in...

Page 11: ...ng free length 184 5 mm 7 26 in 180 8 mm 7 12 in Fitting length 165 5 mm 6 52 in Spring rate K1 147 N mm 14 99 kgf mm 839 4 lb in Spring stroke K1 0 45 mm 0 00 1 97 in Optional spring No Enclosed gas air pressure 0 kPa 0 kg cm2 0 psi Minimum Maximum 0 490 kPa 0 4 9 kgf cm2 0 69 7 psi Front wheel Type Cast wheel Rim size 16 M C MT3 50 Rim material Aluminum Rim runout limit radial 1 mm 0 04 in later...

Page 12: ...r bracket M8 23 2 3 17 Front turn signal light assembly and front turn sig nal light bracket M6 5 0 5 3 6 LT Headlight and headlight bracket M6 7 0 7 5 1 Rear brake hose holder and down tube M6 10 1 0 7 2 Rear brake hose holder and frame M6 10 1 0 7 2 Rear brake hose holder and swingarm M6 10 1 0 7 2 Footrest bracket and frame M10 52 5 2 37 LT Sidecase frame and frame M8 23 2 3 17 LT Backrest brac...

Page 13: ...cturer G8R 30Y U0 OMRON Coil resistance 162 198 Ω Fuel pump relay Model manufacturer G8R 30Y U0 OMRON Coil resistance 162 198 Ω Fuses amperage quantity Main fuse 30 A 1 Headlight fuse 15 A 1 Signaling system fuse 15 A 1 Ignition fuse 10 A 1 Radiator fan fuse 10 A 1 Backup fuse meter assembly 10 A 1 Cruise control fuse 10 A 1 Carburetor heater fuse 15 A 1 Auxiliary DC jack fuse 5 A 1 Spare fuse 30 ...

Page 14: ...ch hose 7 Left handlebar switch lead 8 Wire harness È Fasten the right handlebar switch lead and front brake switch lead at the white tape on each lead with a plastic band The end of the plastic band should be facing downward É The clutch hose should be fastened 20 30 mm 0 79 1 18 in from the end of the protector around the hose Ê É Ë Ì Ì 1 È 3 4 5 2 6 7 8 ...

Page 15: ...ar switch lead at the white tape The end of the plastic band should be facing downward Ë Fasten the clutch hose in front of the left handle bar switch lead as shown in the illustration Fas ten the right handlebar switch lead in front of the front brake switch lead in the same way Ì To headlight Ê É Ë Ì Ì 1 È 3 4 5 2 6 7 8 ...

Page 16: ...Left handlebar switch lead B Front brake switch lead C Right handlebar switch lead D Ignition coil 4 lead E Rear brake switch F Rear brake fluid reservoir hose G Air induction system vacuum hose front side H Wire harness I Rectifier regulator J Fuel hose E D A B F F C C À À À C B A Ú Û Ü Ü H 1 1 2 4 3 5 1 B A C E I 5 L M 7 6 1 H K J ß 0Ö 2É È Ï Ì Ð Î Í Ò B A E D F C C F AA AB AC AD AE AE AH AI AJ ...

Page 17: ...th the holder Ë Fasten the throttle cable accelerator cable on the inside of the cable holder Ì Fasten the throttle cable decelerator cable on the outside of the cable holder Í Make sure that there is no slack in the sidestand switch lead E D A B F F C C À À À C B A Ú Û Ü Ü H 1 1 2 4 3 5 1 B A C E I 5 L M 7 6 1 H K J ß 0Ö 2É È Ï Ì Ð Î Í Ò B A E D F C C F AA AB AC AD AE AE AH AI AJ AG 5 4 3 Ñ Ó Ë Ê...

Page 18: ... under cover Ó Fasten the clutch pipe with the holder Ô Pass the carburetor air vent hose through the hose guide on the air filter case Õ Pass a plastic locking tie through the hole in the frame and then fasten the clutch hose to the frame with the tie Place the end of the plastic locking tie behind the fuel tank bracket Ö Pass the front brake hose through the hose guide 55 75 E D A B F F C C À À ...

Page 19: ...nch them with the panel Ú Fasten the left handlebar switch lead right han dlebar switch lead and front brake switch lead with the holder Û Fasten the wire harness main switch lead fuel sender lead right handlebar switch lead water resistant coupler side and front brake switch lead with the holder Fasten the protectors around the leads and do not fasten the leads themselves Ü 5 10 mm 0 20 0 39 in E...

Page 20: ... band should be facing downward ß Pass a plastic locking tie through the hole in the bracket and then fasten the clutch pipe with the tie The end of the plastic locking tie should be facing inward À To under cover right Á Fasten the ignition coil 2 leads with a plastic locking tie to the frame cross pipe Cut off the end of the plastic locking tie Route the air induction system vacuum hose front si...

Page 21: ...through the channel on the top of the air induction box and fasten it with the holder Fasten the fuel hose with the two holders on the carburetor Route the fuel tank breather hose through the channel on the top of the air induction box and fasten it with the holder A B A C A D A E A F A G A H A I A J E D A B F F C C À À À C B A Ú Û Ü Ü H 1 1 2 4 3 5 1 B A C E I 5 L M 7 6 1 H K J ß 0Ö 2É È Ï Ì Ð Î ...

Page 22: ...ther hose connected to canister for California 0 Canister purge hose California only A Fuel pump B Relay unit C Wire harness D Fuel hose from fuel tank E Coolant reservoir hose F Fuel tank breather hose G Fuel hose from fuel pump H Ground lead I Battery J Positive battery lead Þ 1 I 1 5 5 C H O L Ü K A C J I 1 4 N M 67 E C D 7 0 7 G F J K L P È 5 6 7 9 8 0 Ï Ñ Ó Ý Ý Ð Ô Õ Ö Ø Ù Ú Ø Á À ß Û B C A B...

Page 23: ...e hole in the left side cover bracket and then fasten the speed sensor lead and wire harness with the tie Place the end of the plastic locking tie over the fuse box so that it does not stick out from the left side cover Ê Fasten the tail brake light lead and auxiliary DC jack lead with a plastic band Þ 1 I 1 5 5 C H O L Ü K A C J I 1 4 N M 67 E C D 7 0 7 G F J K L P È 5 6 7 9 8 0 Ï Ñ Ó Ý Ý Ð Ô Õ Ö...

Page 24: ... should be facing upward Î Route the speed sensor lead under the holder bend the lead back and then fasten it with the holder and the plastic locking tie Ï Route the hoses on the left side of the leads Ð From engine Ñ Fasten the starter motor lead pickup coil lead A C magneto lead neutral switch lead ignition coil lead and oil level switch lead with a plastic band Do not fasten the relay unit lead...

Page 25: ...California only Û To wire harness fuel pump lead Ü Fasten the starter relay lead a plastic band The end of the plastic band should be facing forward Ý Forward Þ To wire harness speed sensor lead ß Fasten the wire harness at the white tape with a plastic band The end of the plastic band should be facing forward Do not fasten the starter relay lead À From canister California only Þ 1 I 1 5 5 C H O L...

Page 26: ...ner and the cut end of the plastic locking tie should not be lower than the bottom of the swingarm and the cut end should not contact the rear shock absorber Fasten the speed sensor lead behind the holder on the swingarm with a plastic locking tie The end of the plastic locking tie should be cut off and facing inward A A A B A C A D A E A F Þ 1 I 1 5 5 C H O L Ü K A C J I 1 4 N M 67 E C D 7 0 7 G ...

Page 27: ...ead 4 9 Ignition coil 4 0 Fuel tank breather hose A Throttle cables B Wire harness C Engine stop switch D Front brake hose E Carburetor air vent hose F Rear brake switch G Ignition coil 3 H Horn I Rear brake hose J Air induction system vacuum hose rear side AC AD A D C C B B E E Í Î Ò Û Ü Ú Ù Ô B ß Þ Ç K 6 N 4 0 A B B H J G M L A D D C C B B E A Ê Ì Ë Ï Ñ 7 8 9 C D E F Ð Ó Õ Ý Ö I 2 1 6É 5 3 E Ø À...

Page 28: ...the coolant pipe with the plastic clamps The ends of each plastic clamp should be facing upward Ë Fasten the spark plug lead 4 with the holder on the air induction box Ì Fasten the coolant hose with the screw clamp The fastener of the screw clamp should be fac ing inward with the screwhead facing upward AC AD A D C C B B E E Í Î Ò Û Ü Ú Ù Ô B ß Þ Ç K 6 N 4 0 A B B H J G M L A D D C C B B E A Ê Ì Ë...

Page 29: ...Pass the carburetor air vent hose through the hose guide on the air filter case Ò 0 30 mm 0 1 18 in Ó The fastener of the holder should be facing towards the rear of the motorcycle Ô To air cut off valve assembly front side Õ The fastener of each holder should be facing outward Ö Route the negative battery lead between the wire harness and frame cross pipe Do not pinch the negative battery lead 35...

Page 30: ...ten the turn signal relay lead and thermo switch 2 lead with a plastic band The end of the plastic band should be facing upward Þ Fasten the wire harness to the right side cover bracket with a plastic locking tie The end of the plastic locking tie should be facing in the direc tion shown in the illustration so that it does not stick out from the right side cover ß Fasten the spark plug leads above...

Page 31: ...o that the hoses are contacting each other Make sure that the air induction system vacuum hose front side does not contact the radiator The end of the plastic band should be facing outward Right side A A A B A C A D AC AD A D C C B B E E Í Î Ò Û Ü Ú Ù Ô B ß Þ Ç K 6 N 4 0 A B B H J G M L A D D C C B B E A Ê Ì Ë Ï Ñ 7 8 9 C D E F Ð Ó Õ Ý Ö I 2 1 6É 5 3 E Ø À AB AA È ...

Page 32: ... 8 Negative battery lead 9 Turn signal relay 0 Carburetor heater relay A Air induction system vacuum hose rear side B Tail brake light lead C Auxiliary DC jack D Battery E Positive battery lead F Fuel pump G Fuel hose H Fuel sender lead I Clutch hose J Rear shock absorber air pressure check hose A B B È J K L M A 1 2 3 4É 5 6 7 Ê Ì 8 9 0 Í Ë A BÎ Ï C A D E F G I Õ Ò Ó Ô H Ñ Ð B B ...

Page 33: ... brake switch lead with the holders The fastener of each holder should be facing backward É Route the ignition coil 4 leads under the wire harness Ê Be sure not to twist the leads and hoses Ë Fasten the canister purge hose with the holder California only Ì The ends of the two clamps should be facing upward A B B È J K L M A 1 2 3 4É 5 6 7 Ê Ì 8 9 0 Í Ë A BÎ Ï C A D E F G I Õ Ò Ó Ô H Ñ Ð B B ...

Page 34: ...he air induction system vacuum hose rear side between the intake manifolds Ñ To fuel cock Ò The protector around the wire harness should extend past the end of the holder Ó Fasten the wire harness with a plastic band The end of the plastic band should be facing inward Ô Fasten the clutch hose and left handlebar switch lead with the holders The fastener of each holder should be facing backward A B ...

Page 35: ... DC jack and wire harness to tail brake light with a plastic locking tie The end of the plastic locking tie should be facing inward Do not cut the end of the tie A B B È J K L M A 1 2 3 4É 5 6 7 Ê Ì 8 9 0 Í Ë A BÎ Ï C A D E F G I Õ Ò Ó Ô H Ñ Ð B B ...

Page 36: ...2 Fuel filter Replace Replace 3 Spark plugs Check condition Adjust gap and clean Replace every 8 000 mi 13 000 km or 12 months Replace Replace 4 Valve clearance Check and adjust valve clearance when engine is cold Every 26 600 mi 42 000 km 5 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 6 Carburetor syn chronization Adjust synchronization of carburetors 7 ...

Page 37: ...ly 13 Brake and shift pedal pivot shafts Apply lithium soap based grease all purpose grease lightly 14 Sidestand pivot Check operation Apply lithium soap based grease all purpose grease lightly 15 Sidestand switch Check operation and replace if necessary 16 Front fork Check operation and for oil leakage Replace if necessary 17 Shock absorber assembly Check operation and for oil leakage Replace if ...

Page 38: ...e brake and clutch fluid levels and fill the reser voirs as required Replace the oil seals on the inner parts of the brake or clutch master cylinders caliper cylinders and clutch release cylinder every two years Replace the brake and clutch hoses every four years or if cracked or damaged 23 Control cables Apply Yamaha chain and cable lube or engine oil SAE 10W 30 thoroughly 24 Throttle grip hous i...

Page 39: ...ASSENGER SEATS T R 16 Nm 1 6 m kg 11 ft Ib T R 19 Nm 1 9 m kg 13 ft Ib 1 2 Order Job Part Q ty Remarks Removing the rider and passenger seats Remove the parts in the order listed 1 Rider seat 1 2 Passenger seat 1 For installation reverse the removal pro cedure ...

Page 40: ...moving the windshield and fuel tank Remove the parts in the order listed Rider seat Refer to RIDER AND PASSENGER SEATS 1 Windshield 1 2 Top cover 1 3 Fuel tank breather hose 1 Disconnect 4 Fuel sender lead coupler 1 Disconnect 5 Fuel hose 1 Disconnect 6 Fuel tank 1 NOTE Before disconnecting the hose turn the fuel cock OFF For installation reverse the removal pro cedure ...

Page 41: ...SES 2 2 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 1 Order Job Part Q ty Remarks Removing the backrest and side case Remove the parts in the order listed 1 Backrest 1 2 Sidecase left and right 2 For installation reverse the removal pro cedure ...

Page 42: ...s and gently rock the front fork Binding looseness Adjust the steering head 3 Remove meter assembly 1 1 4 Remove handlebar brackets 1 handlebar 2 5 Loosen upper bracket pinch bolts 3 6 Remove steering stem nut 4 washer upper bracket 5 4 5 2 1 3 3 7 Adjust steering head a Remove the lock washer 1 the upper ring nut 2 and the rubber washer 3 b Loosen the lower ring nut 4 and then tighten it to speci...

Page 43: ... Repeat step e until the lower ring nut does not turn g Install the rubber washer 3 h Install the upper ring nut 2 i Finger tighten the upper ring nut 2 then align the slots of both ring nuts If neces sary hold the lower ring nut and tighten the upper ring nut until their slots are aligned j Install the lock washer 1 NOTE Make sure the lock washer tabs sit correctly in the ring nut slots 8 Install...

Page 44: ...g screw 1 in direction a or b Direction a Headlight beam is raised Direction b Headlight beam is low ered a b 1 2 Adjust headlight beam horizontally a Turn the adjusting screw 1 in direction a or b Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left a b 1 ADJUSTING THE HEADLIGHT BEAM ...

Page 45: ...ct continuity reading Replace the switch OFF ON ACT RES ACC N SET DEC FREE PUSH P B Y L Y L Y G Y G P W R B R B R W R W R L R L Y B Y B B L W Br R Br R P W L W P B B B ON OFF Y W Y W G Y G Y Br Br GREEN Y R Y R 7 OFF ON Y W Y W Y B Y B G W G W G Y G Y GRAY 8 Lg Sb BLACK 0 9 ON OFF R N L L B Br W Y Dg L Y B Y G Ch B P B Y B Y G Y R L B Br W Y Dg P L Y B Y G Ch B Y B Y G Y R L Y Y B B Y Y G C D E F ...

Page 46: ...se control switch 3 CANCEL switch 4 Engine stop switch 5 Start switch 6 Main switch 7 Front brake switch 8 Rear brake switch 9 Oil level switch 0 Neutral switch A Fuses B Sidestand switch C Dimmer switch D Horn switch E Turn signal switch F Clutch switch ...

Page 47: ...R B Br R L W B G Y B D WIRE HARNESS SUB WIRE HARNESS C WIRE HARNESS IGNITION COIL LEAD 2 B WIRE HARNESS IGNITION COIL LEAD 1 A WIRE HARNESS CARBURETOR HEATER LEAD Y Ch L B Dg Ch Y L B Dg BLACK BLACK BLACK W W W W W W R R B B Y B Y B Y B Y B B W B Y L Y G Y B Br R P W P B R W R B L W R L L W B B W Y R B Br R Br W R Y P Y R Br W L Y B Y Y W Y G Dg Ch B G Y Y B B L W R L B L R Sb W G G R B W G B L Y1...

Page 48: ...3112 1 Main and ignition fuses Check the main and ignition fuses for con tinuity Refer to CHECKING THE FUSES in CHAPTER 3 Manual No 4XY 28197 E0 Are the main and ignition fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in CHAPTER 3 Manual No 4XY 28197 E0 Open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the ...

Page 49: ...is the spark gap within specification The ignition system is OK 5 Spark plug cap resistance The following procedure applies to all of the spark plug caps Remove the spark plug cap Connect the pocket tester Ω 1k range to the spark plug cap as shown Measure the spark plug cap resistance Spark plug cap resistance 10 kΩ at 20 C 68 F Is the spark plug cap OK Replace the spark plug cap 6 Ignition coil r...

Page 50: ...resistance 10 71 14 49 kΩ at 20 C 68 F Is the ignition coil OK Replace the ignition coil 7 Pickup coil resistance Disconnect the pickup coil coupler from the wire harness Connect the pocket tester Ω 100 to the pickup coil terminal as shown Positive tester probe gray 1 Negative tester probe black 2 Measure the pickup coil resistance Pickup coil resistance 189 231 Ω at 20 C 68 F between gray and bla...

Page 51: ...e the neutral switch 11 Relay unit diode Remove the relay unit from the wire har ness Connect the pocket tester Ω 1 to the relay unit terminals as shown Check the diode for continuity Positive tester probe sky blue 1 Negative tester probe blue yellow 2 Continuity Positive tester probe blue yellow 2 Negative tester probe sky blue 1 No conti nuity NOTE _ When you switch the positive and negative tes...

Page 52: ...YES NO 12 Wiring Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM Is the ignition system s wiring properly connected and without defects Replace the ignitor unit Properly connect or repair the ignition system s wiring ...

Page 53: ... W Br R Y B R L R W R B Br R L W B G Y B D WIRE HARNESS SUB WIRE HARNESS C WIRE HARNESS IGNITION COIL LEAD 2 B WIRE HARNESS IGNITION COIL LEAD 1 A WIRE HARNESS CARBURETOR HEATER LEAD Y Ch L B Dg Ch Y L B Dg BLACK BLACK BLACK W W W W W W R R B B Y B Y B Y B Y B B W B Y L Y G Y B Br R P W P B R W R B L W R L L W B B W Y R B Br R Br W R Y P Y R Br W L Y B Y Y W Y G Dg Ch B G Y Y B B L W R L B L R Sb ...

Page 54: ... W B G Y B D WIRE HARNESS SUB WIRE HARNESS C WIRE HARNESS IGNITION COIL LEAD 2 B WIRE HARNESS IGNITION COIL LEAD 1 A WIRE HARNESS CARBURETOR HEATER LEAD Y Ch L B Dg Ch Y L B Dg BLACK BLACK BLACK W W W W W W R R B B Y B Y B Y B Y B B W B Y L Y G Y B Br R P W P B R W R B L W R L L W B B W Y R B Br R Br W R Y P Y R Br W L Y B Y Y W Y G Dg Ch B G Y Y B B L W R L B L R Sb W G G R B W G B L Y1 B L R W B...

Page 55: ...R P W Y G Y L P B P B Y L Y G P W Y W Y B G W G Y GRAY G Y G W R Y L GRAY R B R W R L Y B B L W Br R Y B R L R W R B Br R L W B G Y B D WIRE HARNESS SUB WIRE HARNESS C WIRE HARNESS IGNITION COIL LEAD 2 B WIRE HARNESS IGNITION COIL LEAD 1 A WIRE HARNESS CARBURETOR HEATER LEAD Y Ch L B Dg Ch Y L B Dg BLACK BLACK BLACK W W W W W W R R B B Y B Y B Y B Y B B W B Y L Y G Y B Br R P W P B R W R B L W R L...

Page 56: ... warning light e Overdrive indicator light f Neutral indicator light g Multifunction meter i Turn signal indicator light n Turn signal relay o Horn p Rear brake switch s Horn switch t Turn signal switch v Front turn signal position light right w Front turn signal position light left y Tail brake light z Rear turn signal light right Rear turn signal light left Brake light relay Signaling system fus...

Page 57: ...elay unit from the wire har ness Connect the pocket tester Ω 1 to the relay unit terminals as shown Check the diode for continuity Positive tester probe sky blue 1 Negative tester probe sky blue white 2 Continuity Positive tester probe sky blue white 2 Negative tester probe sky blue 1 No conti nuity NOTE When you switch the positive and negative tester probes the readings in the above chart will b...

Page 58: ... assem bly sub wire harness coupler meter assembly side is faulty and must be repaired G L Y B B W Dg Ch Lg L Sb W G R W G Y G W B L Y R W R G 1 4 Voltage Connect the pocket tester DC 20 V to the neutral switch coupler wire harness side as shown Positive tester probe sky blue 1 Negative tester probe ground Set the main switch to ON Shift the transmission into neutral Measure the voltage DC 12 V of...

Page 59: ...ure the voltage DC 12 V of red white 1 and ground at the meter assem bly sub wire harness coupler Is the voltage within specification This circuit is OK The wiring circuit from the main switch to the meter assem bly sub wire harness coupler meter assembly side is faulty and must be repaired G L Y B B W Dg Ch Lg L Sb W G R W G Y G W B L Y R W R G 1 1 Fuel sender Drain the fuel and remove the fuel s...

Page 60: ...ch for continuity Refer to CHECKING THE SWITCHES Is the neutral switch OK Replace the neutral switch G L Y B B W Dg Ch Lg L Sb W G R W G Y G W B L Y R W R G 1 2 Voltage Connect the pocket tester DC 20 V to the meter assembly sub wire harness coupler meter assembly side as shown Positive tester probe red white 1 Negative tester probe ground Set the main switch to ON Shift the transmission into 5th ...

Page 61: ...Y B B L W Br R Y B R L R W R B Br R L W B G Y B D WIRE HARNESS SUB WIRE HARNESS C WIRE HARNESS IGNITION COIL LEAD 2 B WIRE HARNESS IGNITION COIL LEAD 1 A WIRE HARNESS CARBURETOR HEATER LEAD Y Ch L B Dg Ch Y L B Dg BLACK BLACK BLACK W W W W W W R R B B Y B Y B Y B Y B B W B Y L Y G Y B Br R P W P B R W R B L W R L L W B B W Y R B Br R Br W R Y P Y R Br W L Y B Y Y W Y G Dg Ch B G Y Y B B L W R L B ...

Page 62: ...re warning light fails to come on when the engine is hot Pocket tester YU 03112 C 90890 03112 1 Main ignition and radiator fan fuses Check the main ignition and radiator fan fuses for continuity Refer to CHECKING THE FUSES in CHAPTER 3 Manual No 4XY 28197 E0 Are the main ignition and radiator fan fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGIN...

Page 63: ... to the specified temperature Check the thermo switch 3 for continuity at the temperatures indicated below Test step Coolant temperature Continu ity Thermo switch 3 1 Less than 105 3 C 221 5 4 F NO 2 More than 105 3 C 221 5 4 F YES 3 More than 100 3 C 212 5 4 F YES 4 Less than 100 3 C 212 5 4 F NO Steps 1 2 Heating phase Steps 3 4 Cooling phase WARNING Handle the thermo switch 3 with special care ...

Page 64: ...Continu ity Thermo switch 1 1 Less than 110 3 C 230 5 4 F NO 2 More than 110 3 C 230 5 4 F YES 3 More than 103 C 217 4 F YES 4 Less than 103 C 217 4 F NO Steps 1 2 Heating phase Steps 3 4 Cooling phase WARNING Handle the thermo switch 1 with special care Never subject the thermo switch 1 to strong shocks If the thermo switch 1 is dropped replace it T R Thermo switch 1 8 Nm 0 8 m kg 5 8 ft lb Does ...

Page 65: ...Y L P B P B Y L Y G P W Y W Y B G W G Y GRAY G Y G W R Y L GRAY R B R W R L Y B B L W Br R Y B R L R W R B Br R L W B BLACK BLACK BLACK W W W W W W R R B B W B Y L Y G Y B Br R P W P B R W R B L W R L L W B B W Y R B Br R Br W R Y P Y R Br W L Y B Y Y W Y G Dg Ch B G Y R W B Y L W Sb L Y L R L W L B L B B L R R L L R R W Br L R R Br P Br P W Lg B W G R W G Sb W G W L Y B G L R G Y Ch Dg L Y B R B ...

Page 66: ...n fuses Check the main and ignition fuses for con tinuity Refer to CHECKING THE FUSES in CHAPTER 3 Manual No 4XY 28197 E0 Are the main and ignition fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in CHAPTER 3 Manual No 4XY 28197 E0 Open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recha...

Page 67: ...ue black Replace the relay unit Sb W R B L L B L R L W L Y Sb L W B Y 1 3 2 6 Fuel pump resistance Disconnect the fuel pump coupler from the wire harness Connect the pocket tester Ω 1 to the fuel pump coupler as shown Positive tester probe black blue 1 Negative tester probe black 2 Measure the fuel pump resistance Fuel pump resistance 4 30 Ω at 20 C 68 F Is the fuel pump OK Replace the fuel pump 7...

Page 68: ... Br R Y B R L R W R B Br R L W B G Y B D WIRE HARNESS SUB WIRE HARNESS C WIRE HARNESS IGNITION COIL LEAD 2 B WIRE HARNESS IGNITION COIL LEAD 1 A WIRE HARNESS CARBURETOR HEATER LEAD Y Ch L B Dg Ch Y L B Dg BLACK BLACK BLACK W W W W W W R R B B Y B Y B Y B Y B B W B Y L Y G Y B Br R P W P B R W R B L W R L L W B B W Y R B Br R Br W R Y P Y R Br W L Y B Y Y W Y G Dg Ch B G Y Y B B L W R L B L R Sb W ...

Page 69: ...90890 03112 1 Main and carburetor heater fuses Check the main and carburetor heater fuses for continuity Refer to CHECKING THE FUSES in CHAPTER 3 Manual No 4XY 28197 E0 Are the main and carburetor heater fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in CHAPTER 3 Manual No 4XY 28197 E0 Open circuit voltage 12 8 V or more at 20 C ...

Page 70: ...erminal sky blue 4 No conti nuity Positive tester probe brown 1 Negative tester probe black white 2 Is the carburetor heater relay OK Replace the carbure tor heater relay 2 1 4 3 Br Sb Br B W 6 Thermo switch 2 Remove the thermo switch 2 from the wire harness Connect the pocket tester to the Ω 1 to the thermo switch 2 as shown Positive tester probe black 1 Negative tester probe black 2 Check the th...

Page 71: ...be heater terminal 1 Negative tester probe carburetor heater 2 Measure the carburetor heater resistance Carburetor heater resistance 1 and 3 6 10 Ω at 20 C 68 F 2 and 4 6 12 Ω at 20 C 68 F Is the carburetor heater OK Replace the carbure tor heater 8 Wiring Check the entire carburetor heating sys tem s wiring Refer to CIRCUIT DIAGRAM Is the carburetor heating system s wiring properly connected and ...

Page 72: ... R P W Y G Y L P B P B Y L Y G P W Y W Y B G W G Y GRAY G Y G W R Y L GRAY R B R W R L Y B B L W Br R Y B R L R W R B Br R L W B G Y B D WIRE HARNESS SUB WIRE HARNESS C WIRE HARNESS IGNITION COIL LEAD 2 B WIRE HARNESS IGNITION COIL LEAD 1 A WIRE HARNESS CARBURETOR HEATER LEAD Y Ch L B Dg Ch Y L B Dg BLACK BLACK BLACK W W W W W W R R B B Y B Y B Y B Y B B W B Y L Y G Y B Br R P W P B R W R B L W R ...

Page 73: ... Cruise control switch F CANCEL switch Q Ignition coil 1 U Spark plug Speed sensor Vacuum pump _ Cruise control unit g Multifunction meter k Cruise control ON indicator light l Cruise control SET indicator light m Cruise control relay p Rear brake switch u Clutch switch y Tail brake light Brake light relay Signaling system fuse ...

Page 74: ...ht comes on 3 Set the desired traveling speed as follows Press the RES ACC resume accelerate side of the cruise control switch to increase the set speed or the SET DEC side to decrease the speed NOTE Pressing the cruise control switch once will change the speed in increments of 1 6 km h 1 mi h Holding the cruise control switch down will increase or decrease the speed con tinuously until the switch...

Page 75: ...The traveling speed will return to the previously set speed Once the cruise control system is reactivated the cruise control SET indicator light will come on Push the CRUISE switch to the OFF posi tion to completely cancel the cruise control system The cruise control ON indicator light will go off until the cruise control system is acti vated again NOTE Even if the CRUISE switch is in the ON posit...

Page 76: ...utch switch Check the switches for continuity Refer to CHECKING THE SWITCHES Are the switches OK Replace the faulty switch es 3 Cruise control unit Connect the pocket tester DC 20 V to the cruise control unit coupler as shown Positive tester probe red 1 or green white 2 Negative tester probe black 3 Set the main switch to ON and the CRUISE switch to ON When operating the cancel switches CANCEL fro...

Page 77: ...e vacuum hose for clogging and or damage Is the vacuum hose OK Repair or replace the vacuum hose 5 Throttle cables Check the throttle cables and throttle housing condition Are the throttle cables OK Replace the cruise control unit Repair or replace the throttle cables ...

Page 78: ...ode 3 Start the engine 4 Use the engine stop switch 2 to stop the engine 5 Wait for 10 seconds 6 Push the SET DEC and RES ACC sides of the cruise control switch 3 alternately three times total of 6 times within 2 sec onds while pressing the CANCEL switch 4 NOTE The cruise control SET indicator light flashes three times to indicate that the cruise control system has entered the self diagno sis mode...

Page 79: ...ches If the cruise control SET indicator light goes off while any one of these switches is operated the switch is defective Example If the CANCEL switch is pushed and the cruise control SET indicator light goes off the CANCEL switch is defective 2 Throttle drive system trouble diagnosis 1 Push the RES ACC side of the cruise con trol switch 1 The throttle grip will turn to the fully open position i...

Page 80: ... vacuum pump but the throttle grip does not turn the throttle cables are malfunctioning If no noises are heard from the vacuum pump the vacuum pump is malfunctioning BVacuum pump CVacuum actuator DThrottle cable joint GThrottle valve 0 7 8 A D B J F G H C 1 9 ...

Page 81: ...for 1 4 seconds then goes off However if there is a malfunction it comes on for 1 4 sec onds goes off and then begins flashing Note that the light will remain on while the engine is run ning if there is a malfunction Item Condition Response Engine trouble warning light When engine is stopped When engine is running Throttle position sensor TPS Disconnected Short circuited Locked The ignition timing...

Page 82: ...alfunction is detected 1 Light on 0 5 seconds 2 Light off 0 5 seconds 3 Number of flashes 3 Fault code 3 4 Light off 3 seconds Light on Light off Repetition 1 Light on 0 5 seconds 2 Light off 0 5 seconds 3 Number of flashes 4 Fault code 4 4 Light off 3 seconds 5 Number of flashes 3 Fault code 3 Light on Light off Repetition ...

Page 83: ...5 seconds 2 Light off 0 5 seconds 3 Number of flashes 8 Fault code 8 4 Light off 3 seconds 5 1 cycle repeated 3 times Light on Light off Repetition 1 Light on 0 5 seconds 2 Light off 0 5 seconds NOTE The fuel sender is not malfunctioning if the last segment on the right of the fuel meter is flash ing The last segment flashes when the fuel level is low If the last segment is flashing fill the fuel ...

Page 84: ...ed When engine is running Fault code Cruise control unit Disconnected Short circuited Flashes Flashes 1 Vacuum pump Disconnected Short circuited Flashes Flashes 2 CANCEL switch front brake switch rear brake switch or clutch switch Disconnected Short circuited Flashes Flashes 3 Speed sensor Incorrect signal Flashes Flashes 4 Ignition coil Incorrect signal Disconnected Short circuited Flashes Flashe...

Page 85: ... Y L Y G P W Y W Y B G W G Y GRAY G Y G W R Y L GRAY R B R W R L Y B B L W Br R Y B R L R W R B Br R L W B G Y B D WIRE HARNESS SUB WIRE HARNESS C WIRE HARNESS IGNITION COIL LEAD 2 B WIRE HARNESS IGNITION COIL LEAD 1 A WIRE HARNESS CARBURETOR HEATER LEAD Y Ch L B Dg Ch Y L B Dg BLACK BLACK BLACK W W W W W W R R B B Y B Y B Y B Y B B W B Y L Y G Y B Br R P W P B R W R B L W R L L W B B W Y R B Br R...

Page 86: ...ntrol SET indicator light m Cruise control relay n Turn signal relay o Horn p Rear brake switch q Left handlebar switch r Dimmer switch s Horn switch t Turn signal switch u Clutch switch v Front turn signal position light right w Front turn signal position light left x Headlight y Tail brake light z Rear turn signal light right Rear turn signal light left Carburetor heater relay Thermo switch 2 Br...

Page 87: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U S A ...

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Yamaha Royal Star Tour Deluxe XVZ13CTT, Supplementary Service Manual

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Summary of Contents for Royal Star Tour Deluxe XVZ13CTT

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