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Yamaha Royal Star Tour Deluxe XVZ13CTTC, Supplementary Service Manual


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– 28 –

SPEC

CABLE ROUTING

Õ

Fasten the auxiliary 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.

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Summary of Contents for Royal Star Tour Deluxe XVZ13CTTC

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

Page 2: ...ry 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...

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 mo...

Page 4: ...age 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 p...

Page 5: ...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...

Page 6: ...ECASES 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 4...

Page 7: ...NTROL 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...

Page 8: ...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...

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...

Page 10: ...e 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 Consumpti...

Page 11: ...g 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 a...

Page 12: ...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...

Page 13: ...turer G8R 30Y U0 OMRON Coil resistance 162 198 Fuel pump relay Model manufacturer G8R 30Y U0 OMRON Coil resistance 162 198 Fuses amperage quantity Main fuse 30 A 1 Headlight fuse 15 A 1 Signaling syst...

Page 14: ...6 Clutch hose 7 Left handlebar switch lead 8 Wire harness 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...

Page 15: ...ndle bar switch lead at the white tape The end of the plastic band should be facing downward Fasten the clutch hose in front of the left handle bar switch lead as shown in the illustration Fas ten the...

Page 16: ...oil 2 0 Front brake hose A 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 inducti...

Page 17: ...sten the throttle cables with the holder Fasten the throttle cable accelerator cable on the inside of the cable holder Fasten the throttle cable decelerator cable on the outside of the cable holder Ma...

Page 18: ...should be facing inward To under cover Fasten the clutch pipe with the holder Pass the carburetor air vent hose through the hose guide on the air filter case Pass a plastic locking tie through the hol...

Page 19: ...ght side panel and do not pinch them with the panel Fasten the left handlebar switch lead right han dlebar switch lead and front brake switch lead with the holder Fasten the wire harness main switch l...

Page 20: ...band The end of the plastic band should be facing downward 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 s...

Page 21: ...ion Route the wire harness 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 breathe...

Page 22: ...rnia only 9 Fuel tank breather 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 ho...

Page 23: ...ic locking tie through the 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...

Page 24: ...The end of the plastic band should be facing upward Route the speed sensor lead under the holder bend the lead back and then fasten it with the holder and the plastic locking tie Route the hoses on th...

Page 25: ...ors canister purge hose California only To wire harness fuel pump lead Fasten the starter relay lead a plastic band The end of the plastic band should be facing forward Forward To wire harness speed s...

Page 26: ...To wire harness The fastener 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...

Page 27: ...lant pipe 8 Spark plug lead 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 Igni...

Page 28: ...lant reservoir hose to the coolant pipe with the plastic clamps The ends of each plastic clamp should be facing upward Fasten the spark plug lead 4 with the holder on the air induction box Fasten the...

Page 29: ...t To under cover right Pass the carburetor air vent hose through the hose guide on the air filter case 0 30 mm 0 1 18 in The fastener of the holder should be facing towards the rear of the motorcycle...

Page 30: ...embly rear side Fasten the turn signal relay lead and thermo switch 2 lead with a plastic band The end of the plastic band should be facing upward Fasten the wire harness to the right side cover brack...

Page 31: ...with a plastic band so 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 faci...

Page 32: ...reather hose 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...

Page 33: ...lead and front brake switch lead with the holders The fastener of each holder should be facing backward Route the ignition coil 4 leads under the wire harness Be sure not to twist the leads and hoses...

Page 34: ...rame Route the air induction system vacuum hose rear side between the intake manifolds To fuel cock The protector around the wire harness should extend past the end of the holder Fasten the wire harne...

Page 35: ...e auxiliary 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 J K L M A 1 2 3 4 5 6...

Page 36: ...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 en...

Page 37: ...y 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 Side...

Page 38: ...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...

Page 39: ...SSENGER 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 Passe...

Page 40: ...oving 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...

Page 41: ...ES 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 r...

Page 42: ...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...

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...

Page 44: ...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 Dir...

Page 45: ...t 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 GREE...

Page 46: ...e 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 swit...

Page 47: ...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...

Page 48: ...112 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...

Page 49: ...d 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...

Page 50: ...resistance 10 71 14 49 k 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 100...

Page 51: ...e the neutral switch 11 Relay unit diode Remove the relay unit from the wire har ness Connect the pocket tester 1 to the relay unit terminals as shown Check the diode for continuity Positive tester pr...

Page 52: ...ES 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 r...

Page 53: ...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...

Page 54: ...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...

Page 55: ...r 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 LEA...

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 switc...

Page 57: ...elay unit from the wire har ness Connect the pocket tester 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...

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 neutr...

Page 59: ...ON Measure 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...

Page 60: ...h 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...

Page 61: ...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...

Page 62: ...e 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...

Page 63: ...o 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 Mo...

Page 64: ...ntinu 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...

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...

Page 66: ...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 condi...

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 1 to the fuel pump c...

Page 68: ...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...

Page 69: ...0890 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 heat...

Page 70: ...terminal 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 Therm...

Page 71: ...obe heater terminal 1 Negative tester probe carburetor heater 2 Measure the carburetor heater resistance Carburetor heater resistance 1 and 3 6 10 at 20 C 68 F 2 and 4 6 12 at 20 C 68 F Is the carbure...

Page 72: ...Br 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 LE...

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 indic...

Page 74: ...t 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 P...

Page 75: ...he 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...

Page 76: ...tch 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 contr...

Page 77: ...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 Re...

Page 78: ...de 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 tim...

Page 79: ...hes 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 l...

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 DThro...

Page 81: ...or 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 i...

Page 82: ...lfunction 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 secon...

Page 83: ...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 T...

Page 84: ...d 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...

Page 85: ...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 IG...

Page 86: ...control 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 tur...

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

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