Yamaha Star XVS13AA(C) 2011 Service Manual Download Page 372 | Manualshive

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TRANSMISSION

5-93

3. Check:

• Transmission gears

Blue discoloration/pitting/wear

→

Replace

the defective gear(s).

• Transmission gear dogs

Cracks/damage/rounded edges

→

Replace

the defective gear(s).

4. Check:

• Transmission gear engagement

(each pinion gear to its respective wheel
gear)
Incorrect

→

Reassemble the transmission

axle assemblies.

5. Check:

• Transmission gear movement

Rough movement

→

Replace the defective

part(s).

EAS3D81032

ASSEMBLING THE MAIN AXLE AND DRIVE
AXLE

1. Install:

• Toothed washer

• Circlip “1”

TIP

Install the circlip so that both ends “a” rest on the
sides of a spline “b” with both axles aligned.

2. Install:

• Toothed lock washer retainer “1”
• Toothed lock washer “2”

TIP

• With the toothed lock washer retainer “1” in the

groove “a” in the drive axle, align the projection
“c” on the retainer with an axle spline “b”, and
then install the toothed lock washer “2”.

• Be sure to align the projection on the toothed

lock washer that is between the alignment
marks “e” with the alignment mark “d” on the
retainer.

EAS26320

INSTALLING THE SHIFT FORKS AND SHIFT
DRUM ASSEMBLY

1. Install:

• Shift forks 1 “1”
• Shift fork 2 “2”
• Shift drum assembly “3”
• Long shift fork guide bar “4”
• Short shift fork guide bar “5”

TIP

The embossed marks “3D8” on the shift forks
should face towards the left side of the engine.

New

a

b

1

New

d

b

2

1

e

e

1

2

c

b

a

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Summary of Contents for Star XVS13AA(C) 2011

Page 1: ...2011 SERVICE MANUAL XVS13AA C XVS13CTA C XVS13CA C LIT 11616 24 48 3D8 28197 13 ...

Page 2: ...ANUAL 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: ...th 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 sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP This Service Manual contains...

Page 4: ...ub section titles 2 appear in smaller print than the section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a disas sembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction ch...

Page 5: ...cant 4 Special tool 5 Tightening torque 6 Wear limit clearance 7 Engine speed G M E B LS M 9 10 11 12 13 14 15 16 17 18 LT New BF S T R 1 2 3 4 5 6 7 8 8 Electrical data 9 Engine oil 10 Gear oil 11 Molybdenum disulfide oil 12 Brake fluid 13 Wheel bearing grease 14 Lithium soap based grease 15 Molybdenum disulfide grease 16 Silicone grease 17 Apply locking agent LOCTITE 18 Replace the part with a n...

Page 6: ......

Page 7: ...EAS20110 TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9 ...

Page 8: ......

Page 9: ...F 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 1 9 BEARINGS AND OIL SEALS 1 10 CIRCLIPS 1 10 CHECKING THE CONNECTIONS 1 11 SPECIAL TOOLS 1 12 ...

Page 10: ...20140 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 1 1 ...

Page 11: ... performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by using a microprocess...

Page 12: ...rolled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor air temperature sensor coolant temperature sensor lean angle sensor speed sensor and O2 sensor enable the ECU to deter mine the injection duration The injection timing is determined through the signals from the crankshaft position sensor As a result the volume of fuel th...

Page 13: ...e and then return to zero in order to test the electrical circuit Odometer tripmeters fuel reserve tripmeter and clock Push the side of the SELECT switch to switch the display between the odometer mode Odo the tripmeter modes Trip 1 and Trip 2 and the clock mode in the following order Odo Trip 1 Trip 2 Clock Odo TIP Push the side of the SELECT switch to switch the display in the reverse order Push...

Page 14: ...gits will start flashing 5 Push the or side of the SELECT switch to set the minutes 6 Push the RESET switch and then release it to start the clock Self diagnosis device This model is equipped with a self diagnosis de vice for various electrical circuits If any of those circuits are not working correctly the engine trouble warning light will come on and then the odometer tripmeter clock display wil...

Page 15: ...eled since they were last set to zero a fuel reserve tripmeter which shows the dis tance traveled on the fuel reserve a fuel meter a clock a self diagnosis device a brightness control mode TIP Be sure to turn the key to ON before using the SELECT and RESET switches except for setting the brightness control mode Speedometer When the key is turned to ON the speedome ter needle will sweep once across...

Page 16: ...sure to refuel as soon as possible TIP If the display is showing another function when this occurs the display will automatically change to the fuel meter mode The fuel level warning light comes on and the display switches to the fuel reserve tripmeter mode Trip F when the fuel level is very low Refuel as soon as possible to avoid running out of fuel To set the clock 1 Push the SELECT switch to ch...

Page 17: ...ighting conditions To set the brightness 1 Turn the key to OFF 2 Push and hold the SELECT switch 3 Turn the key to ON and then release the SELECT switch after five seconds 4 Adjust the multi function meter unit panel brightness level by pushing the SELECT switch 5 Push the RESET switch The display will change to the prior mode 1 Brightness level 1 ...

Page 18: ... correct installation of all parts 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 inferior in quality EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals ...

Page 19: ...rease Oil bearings liberally when installing if appropri ate NOTICE ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfac es EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned o...

Page 20: ...ral times 3 Check All connections Loose connection Connect properly TIP If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector TIP Make sure all connections are tight 5 Check Continuity with the pocket tester TIP If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at m...

Page 21: ...list provided below to avoid any mistakes TIP For U S A and Canada use part numbers starting with YM YU or ACC For others use part numbers starting with 90890 Tool name Tool No Illustration Reference pages Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 11 8 93 8 94 8 95 8 99 8 101 8 102 8 103 8 104 8 105 8 106 8 107 8 109 8 110 8 111 Thickness gauge 90890 03180 Feeler gauge set YU 269...

Page 22: ...gauge YM 03170 3 25 3 26 Steering nut wrench 90890 01403 Exhaust flange nut wrench YU A9472 3 27 4 83 Damper rod holder 90890 01460 4 72 4 74 T handle 90890 01326 T handle 3 8 drive 60 cm long YM 01326 4 72 4 74 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 74 4 75 Rotor holding tool 90890 01235 Universal magneto rotor holder YU 01235 5 22 5 28 5 29 Tool name Tool No...

Page 23: ...ing compressor attachment 90890 01243 Valve spring compressor adapter 26 mm YM 01253 1 5 36 5 41 Valve guide remover ø6 90890 04064 Valve guide remover 6 0 mm YM 04064 A 5 37 Valve guide installer ø6 90890 04065 Valve guide installer 6 0 mm YM 04065 A 5 37 Valve guide reamer ø6 90890 04066 Valve guide reamer 6 0 mm YM 04066 5 37 Tool name Tool No Illustration Reference pages YU 01083 3 ...

Page 24: ... 51 5 52 5 59 5 62 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 51 Yamaha bond No 1215 90890 85505 Three Bond No 1215 5 53 5 79 6 12 Universal clutch holder 90890 04086 YM 91042 5 59 5 63 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 5 72 7 14 Tool name Tool No Illustration Reference pages YU 01304 ...

Page 25: ...adapter YU 33984 6 3 Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A 6 12 Middle driven shaft bearing driver 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 6 12 Pressure gauge 90890 03153 YU 03153 7 14 Fuel pressure adapter 90890 03176 YM 03176 7 14 Tool name Tool No Illustration Reference pages YU 24460 A YU 33984 ...

Page 26: ...SPECIAL TOOLS 1 17 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 103 Tool name Tool No Illustration Reference pages ...

Page 27: ...CHASSIS TIGHTENING TORQUES for XVS13AA C XVS13CTA C 2 24 CHASSIS TIGHTENING TORQUES for XVS13CA C 2 28 LUBRICATION POINTS AND LUBRICANT TYPES 2 33 ENGINE 2 33 CHASSIS for XVS13AA C XVS13CTA C 2 34 CHASSIS for XVS13CA C 2 35 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 ENGINE OIL LUBRICATION CHART 2 37 LUBRICATION DIAGRAMS 2 39 COOLING SYSTEM DIAGRAMS 2 47 CABLE ROUTING for XVS13AA C XVS13CTA C 2 55 ...

Page 28: ...mm 39 4 in XVS13CA C 860 mm 33 9 in Overall height XVS13AA C 1145 mm 45 1 in XVS13CTA C 1520 mm 59 8 in XVS13CA C 1130 mm 44 5 in Seat height XVS13AA C XVS13CTA C 690 mm 27 2 in XVS13CA C 668 mm 26 3 in Wheelbase XVS13AA C XVS13CTA C 1690 mm 66 5 in XVS13CA C 1750 mm 68 9 in Ground clearance XVS13AA C XVS13CTA C 145 mm 5 71 in XVS13CA C 150 mm 5 91 in Minimum turning radius XVS13AA C XVS13CTA C 35...

Page 29: ...GENERAL SPECIFICATIONS 2 2 Maximum load XVS13AA C 210 kg 463 lb XVS13CTA C 190 kg 419 lb XVS13CA C 204 kg 450 lb ...

Page 30: ... 5 0 L 1 32 US gal 1 10 Imp gal Engine oil Lubrication system Wet sump Recommended brand YAMALUBE Type SAE 10W 30 10W 40 10W 50 15W 40 20W 40 or 20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Total amount 3 70 L 3 91 US qt 3 26 Imp qt Without oil filter cartridge replacement 3 20 L 3 38 US qt 2 82 Imp qt With oil filter cartridge replacement ...

Page 31: ...m 0 31 in Radiator core Width 197 0 mm 7 76 in Height 320 0 mm 12 60 in Depth 22 0 mm 0 87 in Water pump Water pump type Single suction centrifugal pump Reduction ratio 70 45 17 26 1 017 Impeller shaft tilt limit 0 15 mm 0 006 in Spark plug s Manufacturer model NGK LMAR7A 9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Cylinder head Volume 44 20 46 40 cm 2 70 2 83 cu in Warpage limit 0 03 mm 0 0012 in ...

Page 32: ...213 in Valve head diameter A exhaust 31 90 32 10 mm 1 2559 1 2638 in Valve seat width C intake 1 00 1 20 mm 0 0394 0 0472 in Valve seat width C exhaust 1 00 1 20 mm 0 0394 0 0472 in Valve margin thickness D intake 1 15 1 45 mm 0 0453 0 0571 in Valve margin thickness D exhaust 1 15 1 45 mm 0 0453 0 0571 in Valve stem diameter intake 5 975 5 990 mm 0 2352 0 2358 in Limit 5 945 mm 0 2341 in Valve ste...

Page 33: ... 24 75 N mm 2 52 kgf mm 141 32 lb in Spring rate K2 intake 34 93 N mm 3 56 kgf mm 199 45 lb in Spring rate K1 exhaust 24 75 N mm 2 52 kgf mm 141 32 lb in Spring rate K2 exhaust 34 93 N mm 3 56 kgf mm 199 45 lb in Installed compression spring force intake 171 00 197 00 N 17 44 20 09 kgf 38 44 44 29 lbf Installed compression spring force exhaust 171 00 197 00 N 17 44 20 09 kgf 38 44 44 29 lbf Spring...

Page 34: ...alled 0 20 0 35 mm 0 0079 0 0138 in Limit 0 60 mm 0 0236 in Ring side clearance 0 030 0 080 mm 0 0012 0 0032 in Limit 0 130 mm 0 0051 in 2nd ring Ring type Taper Dimensions B T 1 20 4 00 mm 0 05 0 16 in End gap installed 0 45 0 60 mm 0 0177 0 0236 in Limit 0 95 mm 0 0374 in Ring side clearance 0 030 0 070 mm 0 0012 0 0028 in Limit 0 130 mm 0 0051 in Oil ring Dimensions B T 2 50 3 40 mm 0 10 0 13 i...

Page 35: ...late 1 3 thickness 2 90 3 10 mm 0 114 0 122 in Wear limit 2 80 mm 0 1102 in Plate quantity 2 pcs Friction plate 2 thickness 2 92 3 08 mm 0 115 0 121 in Wear limit 2 82 mm 0 1110 in Plate quantity 7 pcs Clutch plate thickness 1 90 2 10 mm 0 075 0 083 in Plate quantity 8 pcs Warpage limit 0 20 mm 0 0079 in Clutch spring height 6 70 mm 0 26 in Minimum height 6 37 mm 0 25 in Spring quantity 1 pc Clutc...

Page 36: ... kgf cm 56 8 psi Fuel injector Model quantity INP 284 2 Throttle body Type quantity ACW40 1 ID mark XVS13AA XVS13CA XVS13CTA 3D8D 40 XVS13AAC XVS13CAC XVS13CTAC 3D8E 50 Throttle valve size 40 Throttle position sensor Resistance 3 10 5 70 kΩ Output voltage at idle 0 63 0 73 V Fuel injection sensor Crankshaft position sensor resistance 248 372 Ω Intake air pressure sensor output voltage 3 57 3 71 V ...

Page 37: ...out limit 1 0 mm 0 04 in Lateral wheel runout limit 0 5 mm 0 02 in Rear wheel Wheel type Cast wheel Rim size XVS13AA C XVS13CTA C 16M C MT4 50 XVS13CA C 18M C MT7 50 Rim material Aluminum Wheel travel XVS13AA C XVS13CTA C 110 0 mm 4 33 in XVS13CA C 100 0 mm 3 94 in Radial wheel runout limit 1 0 mm 0 04 in Lateral wheel runout limit 0 5 mm 0 02 in Front tire Type Tubeless Size XVS13AA C XVS13CTA C ...

Page 38: ...190 kg 198 419 lb XVS13CA C 90 204 kg 198 450 lb Front 250 kPa 2 50 kgf cm 36 psi Rear 280 kPa 2 80 kgf cm 41 psi Front brake Type XVS13AA C XVS13CTA C Dual disc brake XVS13CA C Single disc brake Operation Right hand operation Front disc brake Disc outside diameter thickness XVS13AA C XVS13CTA C 298 0 5 0 mm 11 73 0 20 in XVS13CA C 320 0 4 5 mm 12 60 0 18 in Brake disc thickness limit XVS13AA C XV...

Page 39: ... 23 in Limit 0 8 mm 0 03 in Brake pad lining thickness outer 5 8 mm 0 23 in Limit 0 8 mm 0 03 in Master cylinder inside diameter 12 7 mm 0 50 in Caliper cylinder inside diameter 41 30 mm 1 63 in Recommended fluid DOT 4 Steering Steering bearing type Angular bearing Center to lock angle left 35 0 Center to lock angle right 35 0 Front suspension Type Telescopic fork Spring shock absorber type Coil s...

Page 40: ...3CTA C 105 0 mm 4 13 in XVS13CA C 124 0 mm 4 88 in Rear suspension Type Swingarm link suspension Spring shock absorber type Coil spring gas oil damper Rear shock absorber assembly travel XVS13AA C XVS13CTA C 48 0 mm 1 89 in XVS13CA C 44 0 mm 1 73 in Spring free length XVS13AA C XVS13CTA C 182 0 mm 7 17 in XVS13CA C 174 5 mm 6 87 in Installed length XVS13AA C XVS13CTA C 166 0 mm 6 54 in XVS13CA C 1...

Page 41: ...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 5 0 7 0 mm 0 20 0 28 in ...

Page 42: ...Standard output 14 0 V 32 9 A at 5000 r min Standard output 14 0 V 460 W at 5000 r min Stator coil resistance 0 112 0 168 Ω Rectifier regulator Regulator type Semi conductor short circuit Regulated voltage DC 14 1 14 9 V Rectifier capacity DC 50 0 A Withstand voltage 200 0 V Battery Model YTX20L BS Voltage capacity 12 V 18 0 Ah Manufacturer GS YUASA Ten hour rate amperage 1 80 A Headlight Bulb typ...

Page 43: ...esistance 0 0050 0 0150 Ω Brush overall length 12 0 mm 0 47 in Limit 6 50 mm 0 26 in Brush spring force 6 025 6 515 N 614 664 gf 21 69 23 45 oz Mica undercut depth 0 70 mm 0 03 in Starter relay Amperage 180 0 A Coil resistance 4 18 4 62 Ω Horn Horn type Plane Quantity 1 pc Maximum amperage 3 0 A Turn signal relay Relay type Semi transistor Built in self canceling device Yes Turn signal blinking fr...

Page 44: ...l resistance 86 40 105 60 Ω 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 Backup fuse 10 0 A Spare fuse 20 0 A Spare fuse 15 0 A Spare fuse 10 0 A Spare fuse 10 0 A ...

Page 45: ...l To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kg ft lb 10 mm 6 mm 6 0 6...

Page 46: ... 6 10 Nm 1 0 m kg 7 2 ft lb l 45 mm 1 77 in Rear cylinder head cover bolt 1 M6 1 12 Nm 1 2 m kg 8 7 ft lb l 45 mm 1 77 in Rear cylinder head cover bolt 2 M6 7 10 Nm 1 0 m kg 7 2 ft lb l 45 mm 1 77 in Rear cylinder head cover bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb l 55 mm 2 17 in Front cylinder left cover M6 2 8 Nm 0 8 m kg 5 8 ft lb Front cylinder right cover M6 2 8 Nm 0 8 m kg 5 8 ft lb Rear cylinder...

Page 47: ... Oil delivery pipe 3 bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Intake air pressure sensor bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Intake manifold joint bolt M6 4 10 Nm 1 0 m kg 7 2 ft lb Intake manifold joint clamp screw M5 2 4 Nm 0 4 m kg 2 9 ft lb Throttle body bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Fuel pipe bolt M6 4 10 Nm 1 0 m kg 7 2 ft lb Air filter case bolt M5 3 4 Nm 0 4 m kg 2 9 ft lb Air filter case nu...

Page 48: ...Nm 1 0 m kg 7 2 ft lb Primary drive gear nut M18 1 100 Nm 10 0 m kg 72 ft lb Use the lock washer Clutch cover bolt M6 8 10 Nm 1 0 m kg 7 2 ft lb Clutch cable holder bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Damper cover bolt clutch M6 6 4 Nm 0 4 m kg 2 9 ft lb Damper cover bolt generator M6 6 4 Nm 0 4 m kg 2 9 ft lb Clutch boss nut M20 1 125 Nm 12 5 m kg 90 ft lb Stake Clutch spring plate retainer bolt M...

Page 49: ... m kg 7 2 ft lb Rear cylinder thermostat inlet pipe 2 bolt 1 M6 1 7 Nm 0 7 m kg 5 1 ft lb Rear cylinder thermostat inlet pipe bolt 2 M6 1 10 Nm 1 0 m kg 7 2 ft lb Thermostat bracket bolt 2 M6 1 10 Nm 1 0 m kg 7 2 ft lb Thermostat bolt 2 M6 1 7 Nm 0 7 m kg 5 1 ft lb Coolant temperature sensor M12 1 18 Nm 1 8 m kg 13 ft lb Coolant reservoir bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Radiator outlet pipe bolt...

Page 50: ...TIGHTENING TORQUES 2 23 Cylinder head tightening sequence 6 5 1 3 2 4 B 3 2 4 6 5 1 A A Front cylinder head B Rear cylinder head ...

Page 51: ...t lb Ignition coil bracket bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Rear shock absorber assembly lower nut M10 1 48 Nm 4 8 m kg 35 ft lb Rear shock absorber assembly upper nut M10 1 48 Nm 4 8 m kg 35 ft lb Pivot shaft nut M16 1 85 Nm 8 5 m kg 61 ft lb Relay arm and frame nut M10 1 32 Nm 3 2 m kg 23 ft lb Connecting arm and relay arm nut M12 1 59 Nm 5 9 m kg 43 ft lb Connecting arm and swingarm nut M12 1 ...

Page 52: ...b Front brake hose guide bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Headlight bracket bolt M8 2 23 Nm 2 3 m kg 17 ft lb Headlight body bolt M6 4 7 Nm 0 7 m kg 5 1 ft lb Front turn signal position light bracket bolt M8 2 23 Nm 2 3 m kg 17 ft lb Front turn signal position light nut M10 2 11 Nm 1 1 m kg 8 0 ft lb Air temperature sensor screw M5 1 4 Nm 0 4 m kg 2 9 ft lb Meter assembly bolt M8 2 23 Nm 2 3 m kg...

Page 53: ...lb Passenger seat guide rear fend er and frame bolt M8 2 16 Nm 1 6 m kg 11 ft lb Passenger seat bolt M8 2 16 Nm 1 6 m kg 11 ft lb License plate bracket and rear fender bolt M6 2 11 Nm 1 1 m kg 8 0 ft lb Rear turn signal light nut M10 2 11 Nm 1 1 m kg 8 0 ft lb Left side cover bolt M6 2 4 Nm 0 4 m kg 2 9 ft lb Relay cover bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Sub fuel tank cover bolt M6 1 7 Nm 0 7 m kg...

Page 54: ...ir cover bracket bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Locknut rear brake master cylin der M8 1 16 Nm 1 6 m kg 11 ft lb Brake fluid reservoir bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Rectifier regulator cover bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Rectifier regulator bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Drive pulley nut M22 1 140 Nm 14 0 m kg 100 ft lb Stake Drive pulley cover bolt M6 5 8 Nm 0 8 m kg 5 8 ft lb Drive...

Page 55: ... 0 m kg 7 2 ft lb Ignition coil bracket bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Clutch cable locknut engine side M8 1 7 Nm 0 7 m kg 5 1 ft lb Clutch cable locknut handlebar side M8 1 7 Nm 0 7 m kg 5 1 ft lb Rear shock absorber assembly lower nut M10 1 48 Nm 4 8 m kg 35 ft lb Rear shock absorber assembly upper nut M10 1 50 Nm 5 0 m kg 36 ft lb Pivot shaft nut M16 1 85 Nm 8 5 m kg 61 ft lb Relay arm and f...

Page 56: ...bolt M10 2 30 Nm 3 0 m kg 22 ft lb Front brake hose holder and low er bracket bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Front brake hose holder bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Front fender bolt M8 4 23 Nm 2 3 m kg 17 ft lb Headlight bracket bolt M8 2 23 Nm 2 3 m kg 17 ft lb Headlight body bolt M6 3 7 Nm 0 7 m kg 5 1 ft lb Front turn signal position light and lower bracket bolt M8 2 16 Nm 1 6 m kg 11 ft...

Page 57: ...e Drive pulley housing bolt M8 5 24 Nm 2 4 m kg 17 ft lb Rear wheel pulley nut M12 5 95 Nm 9 5 m kg 68 ft lb Rear wheel drive hub stud bolt M12 5 32 Nm 3 2 m kg 23 ft lb Tail brake light and rear fender nut M6 2 7 Nm 0 7 m kg 5 1 ft lb Tail brake light and rear fender bolt M6 2 18 Nm 1 8 m kg 13 ft lb Seat bracket bolt M8 2 16 Nm 1 6 m kg 11 ft lb Seat guide bolt M8 2 16 Nm 1 6 m kg 11 ft lb Rear ...

Page 58: ...Starter motor lead bolt starter relay side M6 1 4 Nm 0 4 m kg 2 9 ft lb Battery terminal bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Battery box bolt M6 4 7 Nm 0 7 m kg 5 1 ft lb Battery box bracket bolt M6 5 7 Nm 0 7 m kg 5 1 ft lb Sidestand bracket bolt M10 2 56 Nm 5 6 m kg 40 ft lb Sidestand switch bolt M5 2 4 0 Nm 0 4 m kg 2 9 ft lb Sidestand nut M10 1 64 Nm 6 4 m kg 46 ft lb Rear brake master cylinder ...

Page 59: ...TIGHTENING TORQUES 2 32 2 1 ...

Page 60: ...rier bolts Oil pump rotors inner and outer and oil water pump housing Cylinder head bolts Starter clutch idle gear shaft Starter clutch idle gear Starter clutch gear inner and outer surfaces Torque limiter Primary driven gear inner surface Clutch push rod Oil water pump drive sprocket inner surface Clutch thrust washers Clutch boss nut and washer Transmission gears wheel and pinion and collar Driv...

Page 61: ...t Sidestand pivoting point and metal to metal moving parts Throttle grip tube guide inner surface and throttle cables Brake lever pivoting point and metal to metal moving parts Brake master cylinder push rod contact surface Clutch lever pivoting point and metal to metal moving parts Swingarm pivot bearings inner surface Swingarm pivot oil seals lip Rear shock absorber assembly upper bolt Connectin...

Page 62: ...end Throttle grip tube guide inner surface and throttle cables Brake lever pivoting point and metal to metal moving parts Brake master cylinder push rod contact surface Clutch lever pivoting point and metal to metal moving parts Clutch cable end Footrest pivoting point Swingarm pivot bearings inner surface and collars Swingarm pivot oil seals lip Rear shock absorber assembly upper bolt Swingarm be...

Page 63: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 36 ...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 14 11 12 13 10 9 8 7 5 6 4 3 2 1 11 ...

Page 65: ... 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 Valve stem end intake side 12 Rear cylinder camshaft 13 Front cylinder timing chain tensioner 14 Front cylinder camshaft ...

Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39 EAS20410 LUBRICATION DIAGRAMS A A 1 2 2 3 A A ...

Page 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 40 1 Oil filter cartridge 2 Oil delivery pipe 3 3 Relief valve assembly ...

Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 41 1 2 ...

Page 69: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 42 1 Camshaft 2 Crankshaft ...

Page 70: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 43 1 2 ...

Page 71: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 44 1 Oil delivery pipe 1 2 Timing chain tensioner ...

Page 72: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 45 1 2 3 4 5 6 ...

Page 73: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 46 1 Drive axle 2 Oil delivery pipe 2 3 Main axle 4 Oil delivery pipe 3 5 Oil water pump assembly 6 Oil strainer ...

Page 74: ...COOLING SYSTEM DIAGRAMS 2 47 EAS20420 COOLING SYSTEM DIAGRAMS A A A A 2 1 4 3 5 6 ...

Page 75: ...COOLING SYSTEM DIAGRAMS 2 48 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 ...

Page 76: ...COOLING SYSTEM DIAGRAMS 2 49 A B B A 4 3 3 1 2 2 A A B B ...

Page 77: ...COOLING SYSTEM DIAGRAMS 2 50 1 Radiator outlet hose 2 Radiator outlet pipe 3 Coolant delivery pipe 4 Oil water pump assembly ...

Page 78: ...COOLING SYSTEM DIAGRAMS 2 51 For XVS13AA C XVS13CTA C 1 1 2 3 4 5 6 7 8 9 10 11 3 4 7 9 9 8 9 11 8 6 A C B B A C B A ...

Page 79: ... 5 Coolant reservoir hose 6 Rear cylinder thermostat inlet pipe 2 7 Thermostat housing 8 Thermostat cover inlet hose 9 Radiator inlet hose 10 Radiator 11 Radiator outlet hose A Align the paint mark on rear cylinder thermostat inlet pipe 2 with the paint mark on the rear cylinder thermostat inlet hose B Install the front cylinder thermostat inlet hose with its paint mark facing upward ...

Page 80: ...COOLING SYSTEM DIAGRAMS 2 53 For XVS13CA C 4 1 1 5 6 9 8 7 2 3 4 1 2 2 4 2 5 3 3 1 7 C D E E D A B A E E D D A C B ...

Page 81: ... 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 Install the thermostat cover inlet hose with its paint mark facing outward ...

Page 82: ...CABLE ROUTING for XVS13AA C XVS13CTA C 2 55 EAS20430 CABLE ROUTING for XVS13AA C XVS13CTA C LOWER 1 2 3 4 4 5 6 7 6 7 6 7 8 9 10 11 12 13 14 15 16 A A B C C D A A C C D B A B C D E F G H 17 18 19 20 ...

Page 83: ...witch lead 20 Sidestand switch lead A Fasten the left handlebar switch lead with the holder B Route the clutch cable and left handlebar switch lead through the guide making sure to route the cable to the outside of the lead C Route the throttle cables and right handlebar switch lead through the guide making sure to route the cables to the outside of the lead D Route the front brake hose through th...

Page 84: ...CABLE ROUTING for XVS13AA C XVS13CTA C 2 57 A C C D D E E B A E E D D C C B A B C D E F 1 1 1 2 2 2 3 3 4 5 6 7 7 9 8 8 10 11 ...

Page 85: ... from the wire harness in front of the meter assembly couplers and front turn signal position light couplers and then wrap the protective covering around the lead and couplers C Fasten the wire harness front turn signal position light leads meter assembly lead and air temperature sensor lead with the plastic band Align the red tape on the wire harness the gray tape on the front turn signal positio...

Page 86: ...TING for XVS13AA C XVS13CTA C 2 59 A B C D E F G H 1 1 2 3 4 2 4 5 6 7 8 9 9 10 10 11 11 12 13 14 15 16 19 20 19 20 21 21 22 22 19 19 20 20 B B E E D D A A C C A B D D E E F F G G B A I J K L M N 18 17 F F G G E ...

Page 87: ...se and the throttle cables do not contact each other E Fasten the wire harness by sliding the plastic holder on the wire harness onto the stud on the frame F Route the throttle cables to the inside of the thermostat cover inlet hose and under the wire harness making sure that the cables are not pinched by the harness G Route the rear cylinder spark plug lead to the inside of the intake air pressur...

Page 88: ...CABLE ROUTING for XVS13AA C XVS13CTA C 2 61 C C F F D G B E A G H I J 11 10 10 10 A B C D 1 2 3 8 5 4 9 4 5 6 7 8 9 E F C C F F F F B G E D A 10 8 8 9 9 K M N L ...

Page 89: ...uid reservoir hose with the plastic band Align the plastic band with the exhaust pipe protector screw clamp and point the end of the band downward D Position the rear brake light switch coupler to the inside of the rear brake hose and brake fluid reservoir hose E To horn and rear brake light switch F To O2 sensor G To fuel pump H To coolant reservoir I To clutch cover J Route the clutch cable thro...

Page 90: ...CABLE ROUTING for XVS13AA C XVS13CTA C 2 63 C C D D B B A A 1 2 3 4 4 4 5 8 4 6 6 6 6 6 5 6 A A C C B B E G D D A B C D E F M L I I H K J G N N 9 9 7 F E G 10 10 F ...

Page 91: ...s on the brake fluid reservoir hose with the plastic bands C Route the brake fluid reservoir hose through the guide D Fasten the brake fluid reservoir hose with the holder E Point the ends of the hose clamp inward F Fasten the rear brake hose with the holder G Point the end of the hose clamp upward H 20 I Align the ends of the hose clamp on the coolant reservoir cap with the coolant reservoir hose...

Page 92: ...13AA C XVS13CTA C 2 65 E E F F D D C C B B A A D D A A B B F F E E 1 21 21 26 A 1 2 2 2 3 E 4 5 6 7 8 9 10 11 12 14 13 15 B C G I Q R O P N K L M J J C C F D D H 20 17 18 19 16 22 23 24 25 S T 16 17 18 16 17 18 17 18 17 18 ...

Page 93: ...el pipe I To engine J Fasten the sidestand switch lead starter motor lead and oil level switch lead with a plastic locking tie Point the end of the plastic locking tie downward and then cut off the excess end of the tie K Route the starter motor lead so that it does not protrude below the frame L Fasten the starter motor lead at the gray tape to the engine mounting boss with a plastic locking tie ...

Page 94: ...XVS13AA C XVS13CTA C 2 67 B H I J 1 4 3 5 2 6 7 8 9 10 11 12 13 T Q P O N K L M 15 16 U A A B B C C G 8 W 19 14 14 20 E 7 G H H F F E E D D X H H 10 3 V 11 D E F C F F D D C C G B B A A R S E A 17 18 17 18 17 18 17 18 21 ...

Page 95: ...r lead to the inside of the engine bracket on the frame L Fasten the starter motor lead to the engine bracket on the frame with a plastic locking tie Point the end of the plastic locking tie downward and then cut off the excess end of the tie to 10 mm 0 39 in or less M Fasten the starter motor lead with a plastic locking tie Position the plastic locking tie to the rear of the frame weld Point the ...

Page 96: ...CABLE ROUTING for XVS13AA C XVS13CTA C 2 69 C B C B A B A A C B E D 5 6 1 2 3 4 1 2 3 7 5 6 C C ...

Page 97: ...brake light coupler 7 Joint coupler A To fuse box and main fuse B To starter relay C To tail brake light assembly D Connect the lead with white tape to the headlight relay and connect the lead without white tape to the radiator fan motor relay E Insert the projections on the crankshaft position sensor coupler and tail brake light coupler into the holes in the bracket ...

Page 98: ... for XVS13AA C XVS13CTA C 2 71 B B A D C C E D A B B A D 1 1 2 2 3 4 5 5 6 7 8 8 9 10 11 13 13 12 12 15 14 16 16 17 18 19 21 20 22 23 24 25 26 27 27 27 29 31 28 33 33 32 30 C E B F F H I J K L O N M P Q E 17 18 18 G ...

Page 99: ...t the end of the plastic locking tie downward to the inside of the rear cylinder right cover D To fuel sender E Insert the projections on the wire harness holders completely into the holes in the frame F Route the fuel sender lead under the air vent hose G Route the negative battery lead between the battery and the tool kit tray and then fasten the tray and lead with the battery cover band H To ta...

Page 100: ...CABLE ROUTING for XVS13AA C XVS13CTA C 2 73 A D B C 1 2 3 4 5 6 7 8 9 A B 10 11 12 13 14 A B ...

Page 101: ...12 Throttle position sensor 13 ISC idle speed control unit 14 Canister purge hose California only A Install the intake air pressure sensor hose with its white paint mark facing outward B Route the intake air pressure sensor hose over the rear cylinder thermostat inlet hose and front cylinder thermostat inlet hose C Fasten the resonator hose joint wire harness and right handlebar switch lead with a...

Page 102: ...CABLE ROUTING for XVS13AA C XVS13CTA C 2 75 A A A D 1 2 3 4 5 6 7 8 10 11 13 12 E E H I G B C F 9 ...

Page 103: ... the hose clamp with the white paint mark on the canister purge hose California only and point the ends of the clamp forward C Route the canister purge hose California only to the outside of the front cylinder resonator hose and then install it onto the throttle body pipe up to the bend in the pipe making sure to face the white paint mark on the hose upward D 2 4 mm 0 08 0 16 in E Point the ends o...

Page 104: ...for XVS13AA C XVS13CTA C 2 77 G G C A B F F D D E E G G C B A 1 2 1 3 4 5 6 7 7 9 9 8 8 1 1 1 3 10 10 11 14 14 14 15 17 16 12 13 A B C D 4 9 E 9 7 18 F E E F 19 20 20 16 15 21 19 22 E E F F D D 1 N M L K J M F G H I ...

Page 105: ... hose making sure not to install it on the raised portion of the hose fitting D Install the air vent hose to the fuel tank with its white paint mark facing downward E 15 mm 0 59 in or more F Install the air vent hose with its paint mark facing upward G Point the ends of the hose clamp upward Position the hose clamp over the paint mark on the air vent hose H Install the fuel cock hose with its yell...

Page 106: ...CABLE ROUTING for XVS13CA C 2 79 EAS27D1026 CABLE ROUTING for XVS13CA C A B C 1 2 6 5 3 4 7 8 9 2 4 3 A D F 8 E E 10 A A B B A ...

Page 107: ...tle cables as shown in the illustration D Fasten the starter motor lead at the gray tape with a plastic locking tie making sure that the lead contacts the mounting boss on the starter motor Point the end of the plastic locking tie forward and then cut off the excess end of the tie E Pass a plastic locking tie through the center hole in the rear brake light switch bracket and then fasten the rear b...

Page 108: ...CABLE ROUTING for XVS13CA C 2 81 A A B B A C F L G H I J K K M N D E A B 1 4 7 5 6 2 3 2 7 4 5 1 2 7 6 1 2 1 3 A ...

Page 109: ... into the hole in the cable guide E Route the throttle cables through the guide F Route the right handlebar switch lead to the inside of the throttle cables G Fasten the right handlebar switch lead with the holder Face the catch of the holder rearward H Fasten the right handlebar switch lead with the holder Face the catch of the holder outward I Route the right handlebar switch lead to the rear of...

Page 110: ...CABLE ROUTING for XVS13CA C 2 83 A B J I C D E F G H A 1 1 5 5 4 4 9 8 2 2 2 5 6 4 7 3 A A A B B C D D 10 17 11 12 14 16 15 13 A A B B D D C ...

Page 111: ...ght bracket B Route the front right turn signal position light lead to the front of the front brake hose C Route the front left turn signal position light lead to the front of the front brake hose D Fasten the main switch leads with the holder E Route the main switch leads through the left side of the hole in the headlight body F Route the front turn signal position light leads through the lower l...

Page 112: ...BLE ROUTING for XVS13CA C 2 85 A B C D 9 1 2 3 4 5 E 6 F 7 G H I J K 8 9 10 16 11 12 13 14 15 16 17 16 15 16 15 17 18 17 18 18 16 15 19 20 15 A E B B B C C D D E E A L M N O P 10 C C C D B C D E T U R S Q ...

Page 113: ...the band Align the tape on the wire harness and right handlebar switch lead with the plastic band Cut off the excess end of the plastic band Route the throttle cable accelerator cable over the throttle cable decelerator cable L Fasten the horn lead and rear brake light switch lead to the frame with a plastic locking tie Point the end of the plastic locking tie downward and then cut off the excess ...

Page 114: ...CABLE ROUTING for XVS13CA C 2 87 H A B D G E C C D E G F E E B A N O M L K J I C D 2 4 4 2 2 5 6 1 1 1 9 8 4 2 3 1 2 1 4 2 7 A G B F F F F C C F F ...

Page 115: ...or D To horn and rear brake light switch E Route the clutch cable through the guide F To clutch cover G To coolant reservoir H To fuel pump I Install the fuel hose with its white paint mark facing forward J Secure the holder by inserting the projection on the holder into the hole in the frame and then fasten the wire harness with the holder K Fasten the O2 sensor lead to the coolant reservoir cove...

Page 116: ...CABLE ROUTING for XVS13CA C 2 89 A C F E H D B C A A E D B 1 1 1 1 7 G 8 6 6 6 2 3 4 5 6 6 A A B E D C C I E J 7 8 ...

Page 117: ... facing upward B Fasten the rear brake hose with the holder C Point the ends of the hose clamp upward D Connect the curved end of the coolant reservoir hose to the coolant reservoir E Align the ends of the hose clamp on the coolant reservoir cap with the coolant reservoir hose F Point the ends of the hose clamp outward G Route the coolant reservoir breather hose through the guide H Point the ends ...

Page 118: ...CABLE ROUTING for XVS13CA C 2 91 G J A B C H 1 2 3 D 4 E F 5 6 M 7 8 I N 10 9 K L 11 O P 12 12 ...

Page 119: ...ebar switch coupler into the hole in the bracket D Route the left handlebar switch lead under the fuel tank bracket E Route the front cylinder spark plug lead to the outside of the left handlebar switch lead F Route the clutch cable to the inside of the leads G To right side of vehicle H Route the front cylinder injector lead to the inside of the fuel pipe I Route the ISC idle speed control unit l...

Page 120: ...ING for XVS13CA C 2 93 A C K Q R U V W Z 1 1 2 3 14 B D E 4 5 6 F G H 7 I J L M N 8 9 O P 10 11 A A A A C C C B B B B F F F F D D D E E E E 6 9 10 12 S T 11 13 Y 9 11 10 X 11 14 C C D D E E A A B B F F AA AB AC 5 ...

Page 121: ...ad to the outside of the shift rod M Install the neutral switch lead terminal so that the lead is routed rearward Make sure that there is no slack in the neutral switch lead N Route the sidestand switch lead starter motor lead and oil level switch lead to the front of the swingarm pivot O Secure the holder by inserting the projection on the holder into the hole in the bracket and then fasten the c...

Page 122: ...CABLE ROUTING for XVS13CA C 2 95 C B C B A B A A C B E D 5 6 1 2 3 4 1 2 3 7 5 6 C C ...

Page 123: ... light coupler 7 Joint coupler A To fuse box and main fuse B To starter relay C To tail brake light assembly D Connect the lead with white tape to the headlight relay and connect the lead without white tape to the radiator fan motor relay E Insert the projections on the crankshaft position sensor coupler and tail brake light coupler into the holes in the bracket ...

Page 124: ...CABLE ROUTING for XVS13CA C 2 97 A C D A O P C E K I L M B B C G C D E F 1 2 3 4 5 6 7 8 9 16 15 J 14 13 13 Q 14 19 20 20 N R 17 18 12 10 11 H B B A C D B B ...

Page 125: ...ver the frame E Fasten the wire harness to the frame with a plastic locking tie at the location shown in the illustration Face the buckle of the plastic locking tie upward with the end pointing inward F Route the clutch cable under the wire harness G Route the negative battery lead between the battery and the tool kit tray and then fasten the tray and lead with the battery cover band H Route the t...

Page 126: ...CABLE ROUTING for XVS13CA C 2 99 E A B C D C C A B A B C C 1 1 5 3 2 4 ...

Page 127: ...hose to the resonator hose joint with the holder Be sure to route the intake air pressure sensor hose to the left of the front cylinder resonator hose and to the right of the rear cylinder resonator hose C Fasten the canister purge hose with the holder at the location shown in the illustration Fasten the hose only not the hose protector California only D Route the canister purge hose to the right ...

Page 128: ...CABLE ROUTING for XVS13CA C 2 101 A H G B C D E F 2 J I 1 5 2 3 4 A A 7 6 ...

Page 129: ... paint mark facing upward California only D Point the ends of the hose clamp forward Position the hose clamp over the green paint mark on the canister purge hose California only E 2 4 mm 0 08 0 16 in California only F Point the ends of the hose clamp outward G Align the projections on the intake manifold joints with the slots in the intake manifold joint clamps H Point the ends of the hose clamp o...

Page 130: ...E E J J F F G G K K I C H B D L A J J K K E E F F G G A B C C D E F G H I I J K L M N O Q Q R R R R S T U V W X Y Z 1 2 3 4 4 4 5 6 7 7 7 8 8 9 10 10 10 10 16 10 11 11 12 12 12 13 13 17 17 17 17 14 14 14 14 14 15 16 16 16 17 16 17 18 Q 16 19 P P Q Q ...

Page 131: ... its yellow paint mark facing upward H Face the crimped section of the hose clamp upward Position the hose clamp over the marking on the fuel cock hose I Make sure not to install the hose clamps on the raised portions of the hose fittings J Point the open ends of the holder downward K 15 mm 0 59 in L Point the ends of the hose clamp outward M 3 mm 0 12 in N Install the fuel tank breather hose onto...

Page 132: ...CABLE ROUTING for XVS13CA C 2 105 B A A B C C D D E E A A B B C C D D E E A F B B C E 1 1 6 2 2 2 3 4 4 E E D 5 4 4 2 D 5 4 7 ...

Page 133: ...ose joint and fuel tank breather hose hose joint to rollover valve onto the hose joint Make sure that the breather hoses contact the flange on the hose joint B Inward C Install the fuel tank breather hose fuel tank to hose joint onto the hose joint and then fasten the hose with the holder D Route the canister purge hose to the inside of the fuel tank breather hose hose joint to rollover valve Cali...

Page 134: ...CABLE ROUTING for XVS13CA C 2 107 ...

Page 135: ...ING THE SPARK PLUGS 3 9 CHECKING THE IGNITION TIMING 3 9 MEASURING THE COMPRESSION PRESSURE 3 10 CHECKING THE ENGINE OIL LEVEL 3 11 CHANGING THE ENGINE OIL 3 12 ADJUSTING THE CLUTCH LEVER FREE PLAY 3 13 REPLACING THE AIR FILTER ELEMENT 3 14 CHECKING THE INTAKE MANIFOLD JOINTS 3 14 CHECKING THE FUEL LINE 3 15 CHECKING THE CRANKCASE BREATHER HOSE 3 15 CHECKING THE EXHAUST SYSTEM 3 16 CHECKING THE CA...

Page 136: ... 3 26 CHECKING AND ADJUSTING THE STEERING HEAD 3 27 CHECKING THE FRONT FORK 3 28 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3 28 CHECKING THE TIRES 3 29 CHECKING THE WHEELS 3 31 CHECKING AND LUBRICATING THE CABLES 3 31 LUBRICATING THE BRAKE LEVER 3 31 LUBRICATING THE CLUTCH LEVER 3 31 LUBRICATING THE BRAKE PEDAL 3 32 LUBRICATING THE SHIFT PEDAL 3 32 LUBRICATING THE SIDESTAND 3 32 LUBRICATING THE R...

Page 137: ......

Page 138: ... 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 No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 2...

Page 139: ...cessary 9 Swingarm pivot bearings Check bearing assemblies for looseness Moderately repack with lithi um soap based grease Repack 10 Drive belt Check belt condition Replace if damaged Check belt tension Adjust if necessary Every 2500 mi 4000 km 11 Steering bearings Check bearing assemblies for looseness Moderately repack with lithi um soap based grease every 16000 mi 25000 km or 24 months Repack 1...

Page 140: ...ked or damaged 21 Rear suspension link pivots Apply lithium soap based grease lightly 22 Engine oil Change warm engine before draining 23 Engine oil filter cartridge Replace 24 Cooling system Check hoses for cracks or damage Replace if necessary Change with ethylene glycol anti freeze coolant every 24 months Change 25 Front and rear brake switches Check operation 26 Control cables Apply Yamaha cha...

Page 141: ...ar cylinder left cover Rear cylinder right cover Refer to ENGINE REMOVAL on page 5 1 2 Remove Throttle body Intake manifold assembly Refer to THROTTLE BODIES on page 7 9 3 Drain Coolant Refer to CHANGING THE COOLANT on page 3 18 4 Remove Front cylinder thermostat inlet hose Rear cylinder thermostat inlet hose Refer to THERMOSTAT on page 6 4 5 Disconnect Spark plug caps Refer to ENGINE REMOVAL on p...

Page 142: ...egrees b When the rear cylinder piston is at TDC on the compression stroke align the TDC mark c on the generator rotor with the slot d in the generator cover TIP When the piston is at TDC on the compression stroke there should be clearance between the valve stem tips and their respective rocker arm adjusting screws If there is no clearance rotate the crankshaft counterclockwise one turn c Measure ...

Page 143: ...throttle bodies the valve clearance and the engine idling speed should be properly adjusted and the ignition tim ing should be checked 1 Stand the vehicle on a level surface TIP Place the vehicle on a suitable stand 2 Remove for XVS13AA C XVS13CTA C Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 3 Remove Cap 1 4 Disconnect Intake air pressure sensor hose 2...

Page 144: ...he lower pressure is out of specification adjust it to specification first and then syn chronize the throttle bodies TIP After each step rev the engine two or three times each time for less than a second and check the synchronization again If the air screw was removed turn the screw in fully and then turn it out 1 1 4 turns Then syn chronize the throttle bodies NOTICE ECA14900 Do not use the throt...

Page 145: ...t Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 3 Adjust Throttle cable free play Throttle body side a Loosen the locknut 1 on the accelerator ca ble b Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained c Tighten the locknut TIP If the specified throttle cable free play cannot be obtained on the throttle body side o...

Page 146: ...lug Insulator Abnormal color Replace the spark plug Normal color is medium to light tan 6 Clean Spark plug with a spark plug cleaner or wire brush 7 Measure Spark plug gap a with a wire thickness gauge Out of specification Regap 8 Install Spark plug TIP Before installing the spark plug clean the spark plug and gasket surface 9 Connect Spark plug cap 10 Install Rear cylinder right cover Front cylin...

Page 147: ...f the cyl inders TIP Insufficient compression pressure will result in a loss of performance 1 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 4 2 Start the engine warm it up for several min utes and then turn it off 3 Remove Front cylinder covers Rear cylinder covers Refer to ENGINE REMOVAL on page 5 1 4 Disconnect Spark plug caps 5 Remove Spar...

Page 148: ...park plug caps 10 Install Rear cylinder covers Front cylinder covers Refer to ENGINE REMOVAL on page 5 1 EAS20750 CHECKING THE ENGINE OIL LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Check Engine oil level The engine oil level should be between the minimum level mark a and maximum level mark b Below the minimum level mark...

Page 149: ...oil filter cartridge is also to be replaced perform the following procedure a Remove the oil filter cartridge 1 with an oil filter wrench 2 b Lubricate the O ring 3 of the new oil filter cartridge with a thin coat of engine oil NOTICE ECA13390 Make sure the O ring 3 is positioned cor rectly in the groove of the oil filter cartridge c Tighten the new oil filter cartridge to specifi cation with an o...

Page 150: ...il pressure again e Remove the throttle body Refer to THROT TLE BODIES on page 7 9 f Tighten the oil check bolts to specification g Install the throttle body Refer to THROTTLE BODIES on page 7 9 EAS20870 ADJUSTING THE CLUTCH LEVER FREE PLAY 1 Check Clutch lever free play a Out of specification Adjust 2 Adjust Clutch lever free play Clutch lever free play adjusting bolt a Slide back the rubber cove...

Page 151: ...ce TIP The air filter needs more frequent service if you are riding in unusually wet or dusty areas 4 Install Air filter element Air filter case cover NOTICE ECA3D81015 Never operate the engine without the air filter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect throttle body syn...

Page 152: ...nt hose 2 Fuel cock hose 3 Fuel tank breather hose 4 Fuel tank overflow hose 5 for XVS13AA C XVS13CTA C Cracks damage Replace Loose connection Connect properly NOTICE ECA3D81009 Make sure the fuel tank breather hose and fuel tank overflow hose are routed correctly 3 Install Fuel tank Refer to FUEL TANK on page 7 1 Rider seat for XVS13AA C XVS13CTA C Seat for XVS13CA C Refer to GENERAL CHASSIS on p...

Page 153: ...ler and rear cylinder exhaust pipe bolt 8 Muffler bracket and frame bolts 9 Muffler bracket and muffler bolts 10 EAS21090 CHECKING THE CANISTER California only 1 Check Canister 1 Canister purge hose 2 Fuel tank breather hose rollover valve to canister 3 Canister breather hose 4 Cracks damage Replace T R Exhaust pipe nut 20 Nm 2 0 m kg 14 ft lb Front cylinder exhaust pipe and rear cylinder exhaust ...

Page 154: ... If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water However if dis tilled water is not available soft water may be used 3 Install Coolant reservoir cap Coolant reservoir cap cover 4 Start the engine warm it up for several min utes and then turn it off 5 Check Coolant level TIP Before checking the coolant level w...

Page 155: ...ollows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter clockwise toward the detent to allow any re sidual pressure to escape When the hissing sound has stopped press down on the radi ator cap and turn it counterclockwise to re move 3 Remove Coolant drain bolt radiator 1 along with the copper washer 4 Disconnect Radiator outlet hose 2 5 Drain Coolant from...

Page 156: ...be used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 14 Install Radiator cap 15 Fill Coolant reservoir with the recommended coolant to the maxi mum level mark a 16 Install Coolant reservoir cap 17 Start the engine warm it up for several min utes and then stop it 18 Check Coolant level Refer to CHECKING THE COOLANT LE...

Page 157: ... in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance NOTICE ECA3D81019 After adjusting the brake pedal adjusting bolt position make sure there is no brake drag 3 Adjust Rear brake light switch Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 22 EAS21240 CHECKING THE BRA...

Page 158: ...luid immediately TIP In order to ensure a correct reading of the brake fluid level make sure the top of the brake fluid reservoir is horizontal EAS21250 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Front brake pad Wear indicator grooves a almost disap peared Replace the brake pads as a set Refer to FRONT BRAKE on page 4 30 EAS21...

Page 159: ...ch is operated by move ment of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts 1 Check Rear brake light operation timing Incorrect Adjust 2 Adjust Rear brake light operation timing a Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b unti...

Page 160: ...rake master cylinder reservoir or brake fluid reservoir to the proper level with the recommended brake fluid b Install the diaphragm brake master cylinder reservoir or brake fluid reservoir c Connect a clear plastic hose 1 tightly to the bleed screw 2 d Put the other end of the hose into an open container e Slowly apply the brake several times f Fully pull the brake lever or fully press down the b...

Page 161: ...e belt NOTICE ECA14950 A drive belt that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive belt slack within the specified lim its TIP Measure the drive belt slack when the engine is cold and when the drive belt is dry 1 Stand the vehicle on a level surface WARNING EWA13120 Securely ...

Page 162: ...bolts 3 in direction a or b until the specified drive belt slack is ob tained TIP Using the alignment marks on each side of the swingarm make sure that both belt pullers are in the same position for proper wheel alignment d Tighten the locknuts to specification e Tighten the rear wheel axle nut to specifica tion 5 Install Muffler Refer to ENGINE REMOVAL on page 5 1 Drive belt slack on the side sta...

Page 163: ...ve belt slack a Out of specification Adjust TIP The level marks of the level window on the drive belt lower guard are in units of 5 mm 0 20 in Use them as a standard for measur ing the drive belt slack Measure the drive belt slack when the drive belt has been pushed with 45 N 4 5 kgf 10 lbf of pressure using a belt tension gauge 1 3 Remove Muffler Refer to ENGINE REMOVAL on page 5 1 4 Adjust Drive...

Page 164: ...hat the front wheel is elevated 2 Check Steering head Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the steering head 3 Remove for XVS13AA C XVS13CTA C Upper bracket Refer to FRONT FORK on page 4 65 4 Remove for XVS13CA C Upper bracket Washer Refer to STEERING HEAD on page 4 78 5 Adjust Steering head a Remove the lock washer 1 the upper ring nut 2 ...

Page 165: ...r Upper bracket Refer to STEERING HEAD on page 4 78 EAS21530 CHECKING THE FRONT FORK 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Check Inner tube Damage scratches Replace Oil seal Oil leakage Replace 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handleb...

Page 166: ...res 1 Check Tire pressure Out of specification Regulate WARNING EWA13180 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature The tire pressure and the suspension must be adjusted according to the total weight including cargo rider passenger and ac cessories and the anticipated riding speed Operation of an overloaded vehicle could caus...

Page 167: ...e tests the tires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tires should always be by the same manufacturer and of the same design No guarantee con cerning handling characteristics can be giv en if a tire combination other than one approved by Yamaha is used on this vehicle Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Fr...

Page 168: ...rrode and interfere with its movement Re place damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubricate TIP Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubricating device EAS21700 LUBRICATING THE BRAKE LEVER Lubricate the pivoting point and metal to metal mo...

Page 169: ...CATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting points and metal to metal moving parts of the rear suspension Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease Recommended lubricant Lithium s...

Page 170: ...e the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down 7 Install Headlight bulb Secure the new headlight bulb with the head light bulb holder NOTICE ECA13690 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adver...

Page 171: ...g the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 7 Attach Headlight bulb holder 8 Install Bulb cover 9 Connect Headlight coupler 10 Install Headlight lens unit EAS21...

Page 172: ...ght beam horizontally 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 Headlight beam moves to the right A For XVS13AA C XVS13CTA C B For XVS13CA C b a 1 A b a 1 B ...

Page 173: ...REPLACING THE FRONT BRAKE PADS 4 36 REMOVING THE FRONT BRAKE CALIPER S 4 37 DISASSEMBLING THE FRONT BRAKE CALIPER S 4 37 CHECKING THE FRONT BRAKE CALIPER S 4 38 ASSEMBLING THE FRONT BRAKE CALIPER S 4 38 INSTALLING THE FRONT BRAKE CALIPER S 4 38 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 39 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 40 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 40 INSTALLING THE ...

Page 174: ...RING HEAD for XVS13AA C XVS13CTA C 4 83 INSTALLING THE STEERING HEAD for XVS13CA C 4 84 REAR SHOCK ABSORBER ASSEMBLY 4 86 HANDLING THE REAR SHOCK ABSORBER 4 90 DISPOSING OF A REAR SHOCK ABSORBER 4 90 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY for XVS13AA C XVS13CTA C 4 90 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY for XVS13CA C 4 90 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 91 CHECKING THE CONNECT...

Page 175: ......

Page 176: ...ty Remarks Front turn signal position light bracket cover Refer to GENERAL CHASSIS on page 4 1 1 Windshield 1 2 Windshield bracket left and right 2 For installation reverse the removal proce dure 1 2 2 T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib ...

Page 177: ... cloth and then treat with Yamaha Mink Oil or another high quality leather protectant for increased water resistance 2 Backrest 1 3 Passenger footrest left and right 2 4 Sidebag bracket plate 2 5 Sidebag bracket left and right 2 6 Backrest bracket left and right 2 For installation reverse the removal proce dure T R 18 Nm 1 8 m kg 13 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R...

Page 178: ...seat 1 2 Passenger seat 1 3 Sub fuel tank cover 1 4 Relay cover 1 5 Seat lock cable 1 Disconnect 6 Seat lock bracket 1 7 Left side cover 1 For installation reverse the removal proce dure 7 4 2 1 3 6 5 R 7 Nm 0 7 m kg 5 1 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib R 16 Nm 1 6 m kg 11 ft Ib 4 Nm 0 4 m kg 2 9 ft Ib T R ...

Page 179: ...Order Job Parts to remove Q ty Remarks 1 Seat 1 2 Sub fuel tank cover 1 3 Relay cover 1 4 Seat lock cable 1 Disconnect 5 Seat lock bracket 1 For installation reverse the removal proce dure 1 2 3 4 5 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R ...

Page 180: ...er 1 2 Headlight lens unit 1 3 Headlight coupler 1 Disconnect 4 Front turn signal position light coupler 2 Disconnect 5 Meter assembly coupler 3 Disconnect 6 Main switch coupler 2 Disconnect 7 Plastic band bracket 1 8 Headlight body 1 For installation reverse the removal proce dure 3 4 2 7 1 8 5 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 6 ...

Page 181: ... remove Q ty Remarks 1 Headlight lens unit 1 2 Headlight coupler 1 Disconnect 3 Front turn signal position light coupler 2 Disconnect 4 Main switch coupler 2 Disconnect 5 Headlight body 1 For installation reverse the removal proce dure 2 3 3 4 4 5 1 7 Nm 0 7 m kg 5 1 ft Ib T R ...

Page 182: ...NERAL CHASSIS on page 4 1 1 Battery cover band 1 2 Battery cover 1 For XVS13AA C XVS13CTA C 3 Tool kit 1 4 Tool kit tray 1 5 Negative battery lead 1 Disconnect 6 Positive battery lead 1 Disconnect 7 Battery 1 8 Battery band 1 9 ECU coupler 2 Disconnect 10 ECU engine control unit 1 11 Fuse box 1 12 Main fuse 1 13 Relay unit 1 LT 2 1 3 4 9 10 9 5 6 7 8 15 14 11 12 13 4 T R 7 Nm 0 7 m kg 5 1 ft Ib T ...

Page 183: ...servoir bolt 1 15 Battery box 1 For installation reverse the removal proce dure Removing the battery Order Job Parts to remove Q ty Remarks LT 2 1 3 4 9 10 9 5 6 7 8 15 14 11 12 13 4 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib ...

Page 184: ... 1 Air filter case cover 1 2 Air filter element 1 3 Air filter case bracket 1 4 Crankcase breather hose 1 Disconnect 5 Air filter case 1 For installation reverse the removal proce dure T R 4 Nm 0 4 m kg 2 9 ft Ib 6 Nm 0 6 m kg 4 3 ft Ib T R New New 1 2 3 5 4 4 T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 185: ...RAL CHASSIS on page 4 1 1 Positive battery lead 1 Disconnect 2 Starter motor lead 1 Disconnect 3 Starter relay coupler 1 Disconnect 4 Starter relay 1 5 Crankshaft position sensor coupler 1 Disconnect 6 Tail brake light wire harness coupler 1 Disconnect 7 Joint coupler 1 8 Turn signal relay 1 9 Radiator fan motor relay 1 10 Headlight relay 1 4 1 2 9 8 11 10 7 6 5 3 A 7 Nm 0 7 m kg 5 1 ft Ib B 4 Nm ...

Page 186: ...B For XVS13CA C 11 Relay bracket 1 For installation reverse the removal proce dure Removing the relays Order Job Parts to remove Q ty Remarks 4 1 2 9 8 11 10 7 6 5 3 A 7 Nm 0 7 m kg 5 1 ft Ib B 4 Nm 0 4 m kg 2 9 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R ...

Page 187: ...Reflectors Refer to FRONT BRAKE on page 4 30 1 Front brake caliper 2 2 Front wheel axle pinch bolt 1 Loosen 3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Front brake disc 2 For installation reverse the removal proce dure T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 59 Nm 5 9 m kg 43 ft Ib 6 5 4 6...

Page 188: ...so that the front wheel is elevated 1 Front brake caliper 1 2 Front wheel axle pinch bolt 2 Loosen 3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Front brake disc 1 For installation reverse the removal proce dure 6 5 5 1 2 3 5 4 20 Nm 2 0 m kgf 14 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 72 Nm 7 2 m kgf 52 ft Ibf T R LT ...

Page 189: ...FRONT WHEEL 4 14 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing 2 3 Spacer 1 For assembly reverse the disassembly pro cedure 2 1 2 1 3 LS LS New New ...

Page 190: ... Wheel bearings a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flathead screwdriver TIP To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings 3 with a gener al bearing puller EAS21920 CHECKING THE FRONT WHEEL 1 Check Wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING EWA13460 Do not atte...

Page 191: ... of the wheel bearing outer race and oil seal EAS21970 ADJUSTING THE FRONT WHEEL STATIC BALANCE TIP After replacing the tire wheel or both the front wheel static balance should be adjusted Adjust the front wheel static balance with the brake discs installed 1 Remove Balancing weight s 2 Find Front wheel s heavy spot TIP Place the front wheel on a suitable balancing stand a Spin the front wheel b W...

Page 192: ... Repeat steps b and c until the front wheel is balanced 4 Check Front wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it EAS22000 INSTALLING THE FRONT WHEEL FRONT BRAKE DISC The following procedure applies to both of the brake discs 1 Install Front brake disc TIP Tighten the ...

Page 193: ...ont wheel axle is flush with the front fork If necessary manually push the front wheel axle or lightly tap it with a soft hammer until its end is flush with the front fork However if the surface of the front wheel axle end is not parallel to the surface of the front fork align a point on the outer edge of the axle with the fork making sure that the axle does not protrude past the fork c In the ord...

Page 194: ... et Tool kit tray Refer to GENERAL CHASSIS on page 4 1 1 Tail brake light wire harness coupler 1 Disconnect 2 Rear fender bracket 2 3 Passenger seat bracket 1 4 Passenger seat guide 1 5 Rear fender assembly 1 6 Mudguard 1 For installation reverse the removal proce dure 1 2 2 5 4 3 6 T R T R T R 23 Nm 2 3 m kg 17 ft Ib 16 Nm 1 6 m kg 11 ft Ib 23 Nm 2 3 m kg 17 ft Ib ...

Page 195: ...y Refer to GENERAL CHASSIS on page 4 1 1 Tail brake light wire harness coupler 1 Disconnect 2 Rear fender bracket 2 3 Seat bracket 1 4 Seat guide 1 5 Rear fender assembly 1 6 Mudguard 1 For installation reverse the removal proce dure 6 2 4 3 2 5 1 23 Nm 2 3 m kg 17 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R ...

Page 196: ... 3 Brake pad spring 2 4 Drive belt adjusting locknut 2 Loosen 5 Drive belt adjusting bolt 2 Loosen 6 Rear wheel axle nut 1 7 Washer 1 8 Rear wheel axle 1 9 Right drive belt puller 1 10 Left drive belt puller 1 11 Rear brake caliper bracket 1 12 Collar 1 Black 13 Collar 1 Silver 3 1 2 11 8 3 12 14 6 7 13 4 5 9 4 5 10 LS T R 27 Nm 2 7 m kg 19 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib T R 150 Nm 15 0 m kg 11...

Page 197: ...re Removing the rear wheel for XVS13AA C XVS13CTA C Order Job Parts to remove Q ty Remarks 3 1 2 11 8 3 12 14 6 7 13 4 5 9 4 5 10 LS T R 27 Nm 2 7 m kg 19 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib T R 150 Nm 15 0 m kg 110 ft lb T R 16 Nm 1 6 m kg 11 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib S S ...

Page 198: ... Brake pad spring 2 5 Drive belt upper guard 1 6 Drive belt case stay 1 7 Drive belt adjusting locknut 2 Loosen 8 Drive belt adjusting nut 2 Loosen 9 Plate 2 10 Rear wheel axle nut 1 11 Washer 2 12 Rear wheel axle 1 13 Right drive belt puller 1 5 6 11 12 14 9 8 7 13 11 9 8 7 18 19 17 16 15 4 4 3 3 1 2 150 Nm 15 0 m kg 110 ft lb T R 16 Nm 1 6 m kg 11 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 27 Nm 2 7 ...

Page 199: ...el 1 For installation reverse the removal proce dure Removing the rear wheel for XVS13CA C Order Job Parts to remove Q ty Remarks 5 6 11 12 14 9 8 7 13 11 9 8 7 18 19 17 16 15 4 4 3 3 1 2 150 Nm 15 0 m kg 110 ft lb T R 16 Nm 1 6 m kg 11 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 10 S ...

Page 200: ...e Q ty Remarks 1 Rear brake disc 1 2 Rear wheel pulley 1 3 Oil seal 1 4 Circlip 1 5 Rear wheel drive hub 1 6 Circlip 1 7 Bearing 1 8 Collar 1 9 Bearing 1 10 Rear wheel drive hub damper 6 11 Rear wheel 1 For installation reverse the removal proce dure 1 11 2 3 4 9 8 7 6 10 5 LT 6 LS A 23 Nm 2 3 m kg 17 ft Ib B 18 Nm 1 8 m kg 13 ft Ib T R ...

Page 201: ... 26 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Collar 1 2 Bearing 1 3 Oil seal 1 4 Circlip 1 5 Bearing 1 6 Spacer 1 For assembly reverse the disassembly pro cedure 5 3 New New LS 4 6 2 1 ...

Page 202: ...LING THE REAR WHEEL 1 Remove Oil seals Wheel bearings Refer to DISASSEMBLING THE FRONT WHEEL on page 4 15 EAS22090 CHECKING THE REAR WHEEL 1 Check Rear wheel axle Rear wheel Wheel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 15 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 29 and CHECKING THE WHEELS on page 3 31 3 Measure Radial wheel runout La...

Page 203: ...tic balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust Rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4 16 EAS28770 INSTALLING THE REAR WHEEL REAR BRAKE DISC 1 Lubricate Rear wheel axle Oil seal lips 2 Install Rear brake disc TIP Apply locking agent LOCTITE to the threads of the brake ...

Page 204: ... on page 3 24 and ADJUSTING THE DRIVE BELT SLACK for XVS13CA C on page 3 26 6 Tighten Rear wheel axle nut 7 Install Rear brake caliper WARNING EWA13500 Make sure the brake hose is routed properly T R Rear wheel axle nut 150 Nm 15 0 m kg 110 ft lb T R Rear brake caliper retaining bolt 27 Nm 2 7 m kg 19 ft lb ...

Page 205: ... C 1 Reflector 1 For XVS13AA C XVS13CTA C 2 Front brake caliper retaining bolt 2 3 Front brake caliper 1 4 Front brake pad 2 5 Brake pad shim inner 1 6 Brake pad shim outer 1 For XVS13CA C 7 Front brake pad spring 1 8 Front brake pad support 2 For installation reverse the removal proce dure 3 1 2 2 4 6 4 5 7 8 8 T R 27 Nm 2 7 m kg 19 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib S T R 6 Nm 0 6 m kg 4 3 ft Ib ...

Page 206: ...r diaphragm hold er 1 4 Brake master cylinder reservoir diaphragm 1 5 Brake lever 1 6 Front brake light switch connector 2 Disconnect 7 Front brake hose union bolt 1 8 Copper washer 2 9 Front brake hose 1 10 Front brake master cylinder holder 1 11 Front brake master cylinder 1 12 Front brake light switch 1 For installation reverse the removal proce dure 1 5 6 7 9 8 2 3 4 10 11 12 New S 10 Nm 1 0 m...

Page 207: ...aster cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder push rod 1 2 Dust boot 1 3 Circlip 1 4 Brake master cylinder kit 1 5 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure New 2 1 4 5 New 3 BF BF S ...

Page 208: ...ctor For XVS13AA C XVS13CTA C Refer to FRONT BRAKE on page 4 30 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 1 Front brake hose union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Front brake caliper bracket bolt 2 5 Front brake caliper 1 For installation reverse the removal proce dure 1 2 5 3 4 4 T R 30 Nm 3 0 m kg 22 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib New ...

Page 209: ...pad spring 1 3 Brake pad 2 4 Brake pad shim inner 1 5 Brake pad shim outer 1 For XVS13CA C 6 Brake pad support 2 7 Brake caliper bracket 1 8 Rubber boot 2 9 Brake caliper piston 2 10 Brake caliper piston dust seal 2 11 Brake caliper piston seal 2 12 Bleed screw 1 For assembly reverse the disassembly pro cedure 7 2 3 5 6 12 1 1 9 11 10 9 8 11 10 T R 27 Nm 2 7 m kg 19 ft Ib T R 6 Nm 0 6 m kg 4 3 ft ...

Page 210: ...efer to FRONT WHEEL on page 4 12 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflec tion turn the handlebar to the left or right to ensure that the front wheel is stationary...

Page 211: ...sure Brake pad wear limit a Out of specification Replace the brake pads as a set 2 Install Brake pad supports Brake pad shim inner Brake pad shim outer for XVS13CA C Brake pads Brake pad spring TIP Always install new brake pads brake pad shims brake pad supports and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open ...

Page 212: ...C XVS13CTA C TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Front brake hose union bolt 1 Copper washers Front brake hose 2 TIP Put the end of the brake hose into a container and pump out the brake fluid carefully EAS27D1029 DISASSEMBLING THE FRONT BRAKE CALIPER S The following procedure applies to both of the brake calipers For XVS13AA C XVS13CTA...

Page 213: ...A3D84002 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents as they will cause the brake caliper piston dust seals and brake caliper piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston dust seals and brake caliper piston seals EAS27...

Page 214: ...mful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Ref...

Page 215: ...TER CYLINDER 1 Install Front brake master cylinder 1 Front brake master cylinder holder 2 TIP Install the brake master cylinder holder with the UP mark facing up Align the end of the brake master cylinder hold er with the punch mark a on the handlebar First tighten the upper bolt then the lower bolt 2 Install Copper washers Front brake hose 1 Front brake hose union bolt 2 WARNING EWA27D1001 Proper...

Page 216: ...ter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 5 Check Brake fluid level Below the minimum level ...

Page 217: ...3AA C XVS13CTA C Order Job Parts to remove Q ty Remarks 1 Rear brake caliper retaining bolt 2 2 Rear brake caliper 1 3 Rear brake pad 2 4 Brake pad spring 2 For installation reverse the removal proce dure S 1 2 4 4 3 1 T R 6 Nm 0 6 m kg 4 3 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib ...

Page 218: ...Remarks Muffler Refer to ENGINE REMOVAL on page 5 1 1 Rear brake caliper retaining bolt 2 2 Rear brake caliper 1 3 Rear brake pad 2 4 Brake pad shim 2 5 Brake pad spring 2 For installation reverse the removal proce dure 1 2 5 4 4 5 3 S 6 Nm 0 6 m kg 4 3 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib T R ...

Page 219: ...agm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir 1 5 Brake fluid reservoir hose 1 6 Locknut rear brake master cylinder 1 Loosen 7 Brake pedal adjusting bolt 1 Loosen 8 Rear brake hose union bolt 1 9 Copper washer 2 10 Rear brake hose 1 11 Rear brake master cylinder bracket 1 12 Rear brake master cylinder cover 1 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 16...

Page 220: ...oce dure Removing the rear brake master cylinder for XVS13AA C XVS13CTA C Order Job Parts to remove Q ty Remarks T R 7 Nm 0 7 m kg 5 1 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib 3 4 2 5 1 6 7 13 8 10 11 12 9 New LT ...

Page 221: ...ervoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir 1 5 Brake fluid reservoir hose 1 6 Locknut rear brake master cylinder 1 Loosen 7 Brake pedal adjusting bolt 1 Loosen 8 Rear brake hose union bolt 1 9 Copper washer 2 10 Rear brake hose 1 11 Rear brake master cylinder 1 For installation reverse the removal proce dure 3 4 2 5 1 6 7 11 8 10 9 LT 7 Nm 0 7 m kg 5 1 ft...

Page 222: ...linder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Circlip 1 5 Brake hose joint 1 6 O ring 1 7 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure S 1 2 3 4 5 6 7 New New New New ...

Page 223: ...luid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 1 Rear brake hose union bolt 1 2 Copper washer 2 3 Rear brake hose 1 4 Rear brake caliper retaining bolt 2 5 Rear brake caliper 1 For installation reverse the removal proce dure S 4 5 2 3 4 1 T R 30 Nm 3 0 m kg 22 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib New ...

Page 224: ... page 5 1 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 1 Rear brake hose union bolt 1 2 Copper washer 2 3 Rear brake hose 1 4 Rear brake caliper retaining bolt 2 5 Rear brake caliper 1 For installation reverse the removal proce dure S 4 5 2 3 4 1 T R 30 Nm 3 0 m kg 22 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib New ...

Page 225: ...aliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 For assembly reverse the disassembly pro cedure BF S 1 4 New New T R 6 Nm 0 6 m kg 4 3 ft Ib 2 3 ...

Page 226: ...sure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISC S on page 4 35 TIP Measure the deflection 1 5 mm 0 06 in below the edge of the brake disc 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISC S...

Page 227: ...RAKE SYSTEM on page 3 22 EAS22590 REMOVING THE REAR BRAKE CALIPER TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Rear brake hose union bolt 1 Copper washers 2 Rear brake hose 3 TIP Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22600 DISASSEMBLING THE REAR BRAKE CALIPER 1 Remove Brake caliper piston Brake ...

Page 228: ...ll cause the brake caliper piston dust seal and brake caliper piston seal to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston dust seal and brake caliper piston seal EAS22670 INSTALLING THE REAR BRAKE CALIPER 1 Install Rear brake caliper 1 temporarily Copper washers Rear brake hose 2 Rear brake hose union bolt 3 WARNING EWA27D1001 Proper brake hose routin...

Page 229: ...use vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 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 on page 3 20 7 Check Br...

Page 230: ...ke fluid Never use solvents on internal brake com ponents EAS22750 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install Copper washers 1 Rear brake hose 2 Rear brake hose union bolt 3 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING for XVS13AA C XVS13CTA C on page 2 55 and CABLE ROUTING for XVS13CA C on page 2 79 NOTICE ECA14160 When ...

Page 231: ...e fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 4 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 on ...

Page 232: ...t 8 Grip end 2 9 Throttle grip 1 10 Clutch switch coupler 1 Disconnect 11 Left handlebar switch 1 12 Handlebar grip 1 13 Clutch cable 1 Disconnect 14 Clutch lever 1 15 Clutch switch 1 16 Meter assembly cover 1 LT 9 8 8 7 7 6 6 2 17 11 13 15 14 10 19 11 21 18 18 20 12 16 5 2 1 1 4 3 LS LS LS 22 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 10 Nm 1 0 m kg 7 2 ft...

Page 233: ... handlebar for XVS13AA C XVS13CTA C Order Job Parts to remove Q ty Remarks LT 9 8 8 7 7 6 6 2 17 11 13 15 14 10 19 11 21 18 18 20 12 16 5 2 1 1 4 3 LS LS LS 22 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib T R 32 Nm 3 2 m kg ...

Page 234: ...embly 1 7 Right handlebar switch 1 8 Throttle cable 2 Disconnect 9 Grip end 2 10 Throttle grip 1 11 Clutch switch coupler 1 Disconnect 12 Left handlebar switch 1 13 Handlebar grip 1 14 Clutch cable 1 Disconnect 15 Clutch lever 1 16 Clutch switch 1 17 Meter assembly cover 1 1 6 8 7 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 32 N...

Page 235: ... dure Removing the handlebar for XVS13CA C Order Job Parts to remove Q ty Remarks 1 6 8 7 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 32 Nm 3 2 m kg 23 ft Ib T R LT LS LS 17 18 7 5 19 4 10 9 2 2 3 2 11 12 12 16 15 13 9 1 14 ...

Page 236: ...hicle so that there is no danger of it falling over 2 Install Handlebar 1 Front handlebar holders 2 NOTICE ECA27D1004 First tighten the bolts on the lower side of the handlebar holders and then tighten the bolts on the upper side Turn the handlebar all the way to the left and right If there is any contact with the fuel tank adjust the handlebar position TIP Align the punch mark a on the handlebar ...

Page 237: ...Install Right handlebar switch 1 TIP Align the projection a on the right handlebar switch with the hole b in the handlebar 8 Install Front brake master cylinder 1 Front brake master cylinder holder 2 TIP Install the front brake master cylinder holder with the UP mark facing up Align the end of the front brake master cylinder holder with the punch mark a on the handle bar First tighten the upper bo...

Page 238: ...efer to CA BLE ROUTING for XVS13CA C on page 2 79 3 Affix Rubber damper 1 to the meter assembly cover TIP Before affixing the dampers to the bottom of the meter assembly cover remove any dust and grease from the areas where the dampers will be affixed 4 Install Clutch lever 1 Clutch cable 2 TIP Align the mating surfaces of the clutch lever with the punch mark a on the handlebar 5 Install Left hand...

Page 239: ...handlebar 8 Install Front brake master cylinder 1 Front brake master cylinder holder 2 TIP Install the front brake master cylinder holder with the UP mark facing up Align the end of the front brake master cylinder holder with the punch mark a on the handle bar First tighten the upper bolt then the lower bolt 9 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 13...

Page 240: ...12 Rear handlebar holder Refer to HANDLEBAR on page 4 57 1 Front reflector 2 2 Brake hose guide 2 3 Reflector bracket 2 4 Front fender 1 5 Main switch coupler 2 Disconnect 6 Upper bracket pinch bolt 2 Loosen 7 Cap bolt 1 Loosen 8 Steering stem nut 1 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 20 Nm ...

Page 241: ...the removal proce dure Removing the front fork legs for XVS13AA C XVS13CTA C Order Job Parts to remove Q ty Remarks T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 110 Nm 11 0 m kg 80 ft lb 45 Nm 4 5 m kg 32 ft Ib T R 1 ...

Page 242: ...lder 1 3 Reflector bracket 2 4 Front fender 1 5 Upper bracket pinch bolt 2 Loosen 6 Cap bolt 1 Loosen 7 Front turn signal position light pinch bolt 1 Loosen 8 Lower bracket pinch bolt 2 Loosen 9 Front fork leg 1 For installation reverse the removal proce dure 3 2 4 1 3 1 9 6 7 5 8 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 19 Nm 1 9 m kg 13 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 45 Nm ...

Page 243: ...1 2 O ring 1 3 Spacer 1 4 Spring seat 1 5 Fork spring 1 6 Dust seal 1 7 Oil seal clip 1 8 Damper rod bolt 1 9 Copper washer 1 10 Damper rod 1 11 Rebound spring 1 12 Inner tube 1 13 Oil seal 1 14 Washer 1 15 Outer tube bushing 1 16 Inner tube bushing 1 6 7 13 14 12 16 17 18 9 8 19 15 5 10 11 1 2 3 4 T R 30 Nm 3 0 m kg 22 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib LS LT New New New New New New New ...

Page 244: ...mbly reverse the disassembly pro cedure Disassembling the front fork legs for XVS13AA C XVS13CTA C Order Job Parts to remove Q ty Remarks 6 7 13 14 12 16 17 18 9 8 19 15 5 10 11 1 2 3 4 T R 30 Nm 3 0 m kg 22 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib LS LT New New New New New New New ...

Page 245: ...r 1 2 Cap bolt 1 3 O ring 1 4 Spacer 1 5 Spring seat 1 6 Fork spring 1 7 Dust seal 1 8 Oil seal clip 1 9 Damper rod bolt 1 10 Copper washer 1 11 Damper rod 1 12 Damper rod ring 1 13 Rebound spring 1 14 Inner tube 1 15 Oil seal 1 16 Washer 1 7 8 15 16 14 18 19 10 9 20 1 17 6 11 13 2 3 12 4 5 New New New New New New LT New 23 Nm 2 3 m kg 17 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R ...

Page 246: ...20 Outer tube 1 For assembly reverse the disassembly pro cedure Disassembling the front fork legs for XVS13CA C Order Job Parts to remove Q ty Remarks 7 8 15 16 14 18 19 10 9 20 1 17 6 11 13 2 3 12 4 5 New New New New New New LT New 23 Nm 2 3 m kg 17 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R ...

Page 247: ...ain ing the fork oil 2 Remove Dust seal 1 Oil seal clip 2 with a flathead screwdriver NOTICE ECA14180 Do not scratch the inner tube 3 Remove Damper rod bolt 1 Copper washer TIP While holding the damper rod with the damper rod holder 2 and T handle 3 loosen the damper rod bolt 4 Remove Inner tube a Hold the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft j...

Page 248: ...n ma terial to enter the front fork EAS23020 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING EWA13660 Make sure the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability TIP When assembling the front fork leg be sure to replace the following parts Inner tube bushing Outer tube bushin...

Page 249: ... faces up TIP Before installing the oil seal lubricate its lips with lithium soap based grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation Recommended oil Yamaha fork oil 10WT T R Damper rod bolt for XVS13AA C XVS13CTA C 30 Nm 3 0 m kg 22 ft lb LOCTITE D...

Page 250: ... fully compressed and without the fork spring Out of specification Correct TIP While filling the front fork leg keep it upright After filling slowly pump the front fork leg up and down to distribute the fork oil 12 Install Fork spring Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 1 2 New New New Quantity XVS13AA C XVS13CTA C 490 0 cm 16 57 US oz 17 28 Imp oz XVS13CA C ...

Page 251: ...pper bracket 2 Tighten Lower bracket pinch bolts TIP Tighten the lower bracket pinch bolts to specifi cation twice Tighten the upper and lower bolts alternately starting with the upper bolts 3 Remove Upper bracket 4 Tighten Lower front fork cover bolts 5 Install Upper front fork cover spacer 1 Upper front fork cover 2 Upper bracket TIP Align the grooves a in the upper front fork cover spacer 1 and...

Page 252: ...inch bolts Front turn signal position light pinch bolts 3 Tighten Cap bolt Upper bracket pinch bolts TIP Tighten the upper bracket pinch bolts to specifi cation twice Tighten the upper and lower bolts alternately starting with the upper bolts WARNING EWA13680 Make sure the brake hoses are routed prop erly T R Lower bracket pinch bolt 45 Nm 4 5 m kg 32 ft lb Front turn signal position light pinch b...

Page 253: ... signal position light 2 5 Front brake hose holder 1 6 Front brake hose joint 1 7 Lock washer 1 8 Upper ring nut 1 9 Rubber washer 1 10 Lower ring nut 1 11 Lower bracket 1 12 Upper bearing cover 1 13 Upper bearing inner race 1 14 Upper bearing 1 15 Washer 1 LT T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 18 Nm 1 8 m kg 13 ft lb T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 10 Nm 1 0 m kg 7 2 ...

Page 254: ...roce dure Removing the lower bracket for XVS13AA C XVS13CTA C Order Job Parts to remove Q ty Remarks LT T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 18 Nm 1 8 m kg 13 ft lb T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LS LS LS 4 Nm 0 4 m kg 2 9 ft Ib T R 10 9 8 7 19 13 14 12 16 15 11 18 19 17 2 1 4 3 5 4 6 LT LT ...

Page 255: ...age 4 65 1 Main switch cover 1 2 Cable guide 1 3 Front turn signal position light 2 4 Headlight bracket 1 5 Air temperature sensor coupler 1 Disconnect 6 Air temperature sensor 1 7 Lower bracket cover 1 8 Front brake hose holder 1 For installation reverse the removal proce dure 1 2 3 5 6 4 7 8 3 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 16 Nm 1 6 m kg 1...

Page 256: ...r 1 7 Upper ring nut 1 8 Rubber washer 1 9 Lower ring nut 1 10 Lower bracket 1 11 Upper bearing cover 1 12 Upper bearing inner race 1 13 Upper bearing 1 14 Lower bearing 1 15 Dust seal 1 16 Lower bearing inner race 1 10 9 8 7 5 6 11 12 17 13 17 14 16 15 2 1 3 4 LS LS T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 18 Nm 1 8 m kg 13 ft lb 32 Nm 3 2 m kg 23 ft Ib T R 110 Nm 11 0 m kg 80 ft lb T R ...

Page 257: ...he removal proce dure Removing the lower bracket for XVS13CA C Order Job Parts to remove Q ty Remarks 10 9 8 7 5 6 11 12 17 13 17 14 16 15 2 1 3 4 LS LS T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 18 Nm 1 8 m kg 13 ft lb 32 Nm 3 2 m kg 23 ft Ib T R 110 Nm 11 0 m kg 80 ft lb T R ...

Page 258: ... steering head pipe with a long rod 1 and hammer b Remove the bearing race from the lower bracket with a floor chisel 2 and hammer c Install a new dust seal and new bearing rac es NOTICE ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged TIP Always replace the bearings and bearing races as a set Whenever the steering head is disassembled replace the dust...

Page 259: ...tion c on the front brake hose holder with the hole d in the lower bracket 5 Install Front fork legs Upper bracket Refer to FRONT FORK on page 4 65 EAS27D1033 INSTALLING THE STEERING HEAD for XVS13CA C 1 Lubricate Upper bearing Lower bearing Bearing races 2 Install Lower bracket Lower bracket cap TIP Face the hole a in the lower bracket cap rear ward 3 Install Lower ring nut 1 Rubber washer 2 Uppe...

Page 260: ... FRONT FORK on page 4 65 TIP Temporarily tighten the upper and lower bracket pinch bolts 6 Tighten Steering stem nut 7 Install Front brake hose holder 1 TIP Align the projection a on the front brake hose holder with the hole b in the lower bracket T R Steering stem nut 110 Nm 11 0 m kg 80 ft lb a 1 b ...

Page 261: ...rvoir Refer to RADIATOR on page 6 1 Sub fuel tank Refer to FUEL TANK on page 7 1 Rear wheel Refer to REAR WHEEL on page 4 19 1 Connecting arm nut Washer Bolt 2 2 2 2 Connecting arm 2 3 Rear shock absorber assembly lower nut Wash er Bolt Collar 1 1 1 1 4 Rear shock absorber assembly upper nut Bolt 1 1 5 Rear shock absorber assembly 1 6 Relay arm nut Bolt Spacer Collar 1 1 1 1 7 Relay arm 1 LS New N...

Page 262: ...rse the removal proce dure Removing the rear shock absorber assembly for XVS13AA C XVS13CTA C Order Job Parts to remove Q ty Remarks LS New New T R T R 9 10 11 9 1 1 2 7 2 1 8 10 12 6 6 6 3 3 3 5 4 4 6 T R 1 1 3 48 Nm 4 8 m kg 35 ft Ib 48 Nm 4 8 m kg 35 ft Ib 59 Nm 5 9 m kg 43 ft Ib LS LS LS 32 Nm 3 2 m kg 23 ft Ib T R ...

Page 263: ... to FUEL TANK on page 7 1 Rear wheel Refer to REAR WHEEL on page 4 19 1 Rear shock absorber assembly lower nut Wash er Bolt Collar 1 1 1 1 2 Connecting arm nut upper Washer Bolt up per 1 1 1 3 Connecting arm nut lower Washer Bolt lower 1 1 1 4 Connecting arm 2 5 Rear shock absorber assembly upper nut Bolt 1 1 6 Rear shock absorber assembly 1 7 Relay arm nut Bolt Spacer Collar 1 1 1 1 8 Relay arm 1...

Page 264: ...on reverse the removal proce dure Removing the rear shock absorber assembly for XVS13CA C Order Job Parts to remove Q ty Remarks 10 11 12 10 4 8 4 2 3 9 11 13 7 7 7 1 1 1 6 3 2 7 5 5 LS LS LS LS New New 32 Nm 3 2 m kg 23 ft Ib T R 59 Nm 5 9 m kg 43 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib T R 50 Nm 5 0 m kg 36 ft Ib T R ...

Page 265: ...k absorber at a point 15 20 mm 0 60 0 79 in from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23230 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY for XVS13AA C XVS13CTA C 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on a suitable...

Page 266: ...KING THE REAR SHOCK ABSORBER ASSEMBLY 1 Check Rear shock absorber rod Bends damage Replace the rear shock absorber assembly Rear shock absorber Gas leaks oil leaks Replace the rear shock absorber assembly Spring Damage wear Replace the rear shock ab sorber assembly Bushing Damage wear Replace Spacer Damage scratches Replace Bolts Bends damage wear Replace EAS23260 CHECKING THE CONNECTING ARM AND R...

Page 267: ...assembly lower nut 5 Install Connecting arms TIP When installing the connecting arms lift up the swingarm A Left side B Right side Recommended lubricant Lithium soap based grease T R Relay arm nut for XVS13AA C XVS13CTA C 32 Nm 3 2 m kg 23 ft lb Relay arm nut for XVS13CA C 50 Nm 5 0 m kg 36 ft lb 2 2 4 3 4 1 a a A B T R Rear shock absorber assembly upper nut for XVS13AA C XVS13CTA C 48 Nm 4 8 m kg...

Page 268: ...t 3 Rectifier regulator 1 4 Drive belt adjusting bolt 2 5 Drive belt adjusting locknut 2 6 Drive belt upper guard 1 7 Drive belt lower guard 1 8 Pivot shaft nut 1 9 Pivot shaft 1 10 Swingarm 1 11 Spacer 1 12 Bearing 2 13 Dust cover 2 14 Washer 2 LS LS LS LS LT LT T R 16 Nm 1 6 m kg 11 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 85 Nm 8 5 m kg 61 ft...

Page 269: ...ing the swingarm for XVS13AA C XVS13CTA C Order Job Parts to remove Q ty Remarks LS LS LS LS LT LT T R 16 Nm 1 6 m kg 11 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 85 Nm 8 5 m kg 61 ft Ib 1 3 2 7 8 4 5 4 5 10 6 9 14 14 15 16 13 12 12 11 13 16 ...

Page 270: ...r 2 Disconnect 3 Rectifier regulator 1 4 Drive belt upper guard 1 5 Drive belt lower guard 1 6 Pivot shaft nut 1 7 Pivot shaft 1 8 Swingarm 1 9 Spacer 1 10 Bearing 2 11 Collar 2 12 Oil seal 2 13 Spacer 2 14 Bearing 2 10 9 6 14 12 11 12 11 14 13 15 7 8 10 4 3 5 1 2 15 LS LS LS LS LS LT LT New New New New T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 85 Nm 8...

Page 271: ...e Removing the swingarm for XVS13CA C Order Job Parts to remove Q ty Remarks 10 9 6 14 12 11 12 11 14 13 15 7 8 10 4 3 5 1 2 15 LS LS LS LS LS LT LT New New New New T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 85 Nm 8 5 m kg 61 ft Ib ...

Page 272: ...d down If the swingarm vertical movement is not smooth or if there is binding check the spac er bearings washers and dust covers For XVS13AA C XVS13CTA C f Check the swingarm vertical movement B by moving the swingarm up and down If the swingarm vertical movement is not smooth or if there is binding check the spacers bear ings oil seals and collars For XVS13CA C EAS23360 CHECKING THE SWINGARM 1 Ch...

Page 273: ...r bolt then the lower bolt 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 Recommended lubricant Lithium soap based grease Installed depth a 0 1 0 mm 0 0 04 in 2 Swingarm A Left side B Right side C For XVS13AA C XVS13CTA C D For XVS13CA C T R Pivot shaft nut 85 Nm 8 5 m kg 61 ft lb...

Page 274: ...l Refer to REAR WHEEL on page 4 19 Swingarm Refer to SWINGARM on page 4 93 1 Drive pulley cover 1 2 Drive belt 1 3 Drive pulley nut 1 4 Conical spring washer 1 5 Drive pulley 1 For installation reverse the removal proce dure O U T 1 5 2 3 4 5 E New E 140 Nm 14 0 m kg 100 ft lb T R 8 Nm 0 8 m kg 5 8 ft Ib T R ...

Page 275: ... belt from damage han dle it with care The drive belt can not be bent smaller than 127 mm 5 in a The removed drive belt can not be twisted inside out 3 Check Drive pulley Rear wheel pulley Bent teeth Replace the drive belt and pul leys as a set EAS23540 INSTALLING THE DRIVE BELT AND DRIVE PULLEY 1 Install Drive belt NOTICE ECA14710 Install the drive belt facing the same way it was removed Do not t...

Page 276: ... 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 on page 3 26 a ...

Page 277: ...E CYLINDER HEAD COVERS for XVS13AA C XVS13CTA C 5 30 INSTALLING THE CYLINDER HEAD COVERS for XVS13CA C 5 30 CYLINDER HEADS 5 32 REMOVING THE CYLINDER HEADS 5 33 CHECKING THE CYLINDER HEADS 5 33 INSTALLING THE CYLINDER HEADS 5 33 VALVES AND VALVE SPRINGS 5 35 REMOVING THE VALVES 5 36 CHECKING THE VALVES AND VALVE GUIDES 5 36 CHECKING THE VALVE SEATS 5 38 CHECKING THE VALVE SPRINGS 5 39 INSTALLING T...

Page 278: ...ALLING THE SHIFT SHAFT 5 66 BALANCER GEARS 5 67 CHECKING THE RIGHT BALANCER GEARS 5 69 CHECKING THE LEFT BALANCER GEARS 5 69 INSTALLING THE RIGHT BALANCER GEARS 5 69 INSTALLING THE LEFT BALANCER GEARS 5 69 ELECTRIC STARTER 5 70 CHECKING THE STARTER MOTOR 5 72 ASSEMBLING THE STARTER MOTOR 5 73 CRANKCASE 5 74 DISASSEMBLING THE CRANKCASE 5 78 CHECKING THE CRANKCASE 5 78 CHECKING THE BEARINGS AND OIL ...

Page 279: ... 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 5 93 ...

Page 280: ...r exhaust pipe 1 9 Muffler bracket 1 10 O2 sensor 1 11 Coolant reservoir cover 1 For installation reverse the removal proce dure 6 1 New New 9 11 2 3 10 6 3 New New New New New 5 8 New 4 7 New 6 Nm 0 6 m kg 4 3 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 ...

Page 281: ...e 1 10 O2 sensor 1 11 Coolant reservoir cover 1 For installation reverse the removal proce dure 1 11 3 3 3 4 5 8 7 7 2 10 6 9 New New New New New LT New LT LT LT 6 Nm 0 6 m kg 4 3 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m...

Page 282: ...TALLING THE EXHAUST PIPE COVER SCREW CLAMPS 1 Install Exhaust pipe cover screw clamps TIP Do not retighten the exhaust pipe cover screw clamps always replace them with new ones if they are loosened T R 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 T R Exhaust pipe cover screw clamp 6 Nm 0 6...

Page 283: ...Sidestand 1 3 Shift arm 1 4 Shift rod 1 5 Left rider footrest assembly 1 6 Rear brake light switch 1 7 Horn connector 2 Disconnect 8 Horn 1 9 Right rider footrest assembly 1 10 Front cylinder left cover 1 11 Front cylinder right cover 1 12 Rear cylinder left cover 1 13 Rear cylinder right cover 1 T R 64 Nm 6 4 m kg 46 ft Ib T R 64 Nm 6 4 m kg 46 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 56 Nm 5 6 m kg...

Page 284: ...and and drive pulley housing for XVS13AA C XVS13CTA C Order Job Parts to remove Q ty Remarks T R 64 Nm 6 4 m kg 46 ft Ib T R 64 Nm 6 4 m kg 46 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 56 Nm 5 6 m kg 40 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LT T R 8 Nm 0 8 m kg 5 8 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib LT T R 8 Nm 0 8 m kg 5 8 ft Ib 1 2 12 13 15 16 17 14 6 9 7 8 3 4 5 10 11 5 ...

Page 285: ...1 4 Shift rod 1 5 Left rider footrest assembly 1 6 Rear brake light switch 1 7 Horn connector 1 Disconnect 8 Horn 1 9 Right rider footrest assembly 1 10 Front cylinder left cover 1 11 Front cylinder right cover 1 12 Rear cylinder left cover 1 13 Rear cylinder right cover 1 LT LT 3 1 4 7 Nm 0 7 m kg 5 1 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 56 Nm 5 6 m kg 40 ft Ib T R 16...

Page 286: ... pulley housing for XVS13CA C Order Job Parts to remove Q ty Remarks LT LT 3 1 4 7 Nm 0 7 m kg 5 1 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 56 Nm 5 6 m kg 40 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 2 5 14 17 15 12 13 11 9 6 7 8 5 16 LT LT LT LT 10 48 Nm 4 8 m kg 35 ft Ib T R 48 Nm 4 8 m kg 35...

Page 287: ...side bolts then the exhaust side bolts to specification EAS3D81018 INSTALLING THE SHIFT ARM 1 Install Shift arm 1 TIP Align the I mark a in the shift shaft with the punch mark b in the shift arm 2 Adjust Shift rod length Refer to ADJUSTING THE SHIFT PEDAL on page 3 24 T R Cylinder cover bolt 8 Nm 0 8 m kg 5 8 ft lb T R Shift arm bolt for XVS13AA C XVS13CTA C 10 Nm 1 0 m kg 7 2 ft lb Shift arm bolt...

Page 288: ...ssembly Refer to THROTTLE BODIES on page 7 9 Rectifier regulator cover Refer to SWINGARM on page 4 93 1 Oil level switch coupler 1 Disconnect 2 Spark plug cap 2 Disconnect 3 Crankcase breather hose 1 4 Stator coil coupler 1 Disconnect 5 Crankshaft position sensor coupler 1 Disconnect 6 Speed sensor coupler 1 Disconnect 7 Starter motor lead 1 Disconnect 8 Clutch cable 1 Disconnect For installation ...

Page 289: ...ar upper side 1 9 Engine mounting nut rear lower side 1 10 Engine mounting bolt rear lower side 1 11 Engine bracket bolt rear upper side 2 12 Engine bracket rear upper side 1 13 Engine bracket bolt rear lower side 2 14 Engine bracket rear lower side 1 15 Engine mounting bolt front left upper side 2 LT LT LT LT LT LT LT LT LT LT 7 Nm 0 7 m kg 5 1 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 48 Nm 4 8 m kg...

Page 290: ... down tube and engine for XVS13AA C XVS13CTA C Order Job Parts to remove Q ty Remarks LT LT LT LT LT LT LT LT LT LT 7 Nm 0 7 m kg 5 1 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib T R 88 Nm 8 8 m kg 64 ft Ib T R 88 Nm 8 8 m kg 64 ft Ib T R 88 Nm 8 8 m kg 64 ft Ib T R 1 5 4 3 2 17 10 8 7 9 12 14 16 1...

Page 291: ...t lower side 1 8 Engine mounting bolt front lower side 1 9 Engine bracket bolt front lower side 2 10 Engine bracket front lower side 1 11 Engine mounting nut rear upper side 1 12 Engine mounting bolt rear upper side 1 13 Engine bracket nut rear upper side 2 14 Engine bracket bolt rear upper side 2 15 Engine bracket rear upper side 2 LT LT LT 4 1 18 19 16 11 15 15 20 9 9 7 10 2 4 4 3 5 5 6 6 22 21 ...

Page 292: ...t center side 1 For installation reverse the removal proce dure Removing the down tube and engine for XVS13CA C Order Job Parts to remove Q ty Remarks LT LT LT 4 1 18 19 16 11 15 15 20 9 9 7 10 2 4 4 3 5 5 6 6 22 21 14 12 14 8 17 7 Nm 0 7 m kg 5 1 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib T R 88 Nm 8 8 m kg 64 ft Ib T R 88 Nm 8 8 m kg 64 ft Ib T R 88...

Page 293: ...front lower side 17 Engine mounting nut front lower side 18 TIP Apply locking agent LOCTITE to the threads of the engine mounting bolts front right upper side engine bracket bolts rear lower side engine bracket bolts rear upper side down tube bolts front side and down tube bolts rear side Do not tighten the bolts and nuts 3 Tighten Engine bracket bolts rear lower side 7 Engine bracket bolts rear u...

Page 294: ...Engine mounting bolt front lower side 15 Engine mounting nut front lower side 16 Engine brackets front upper side 17 Engine bracket bolts front upper side M10 18 Engine bracket nuts front upper side M10 19 Engine bracket bolt front upper side M12 20 Engine bracket nut front upper side M12 21 TIP Apply locking agent LOCTITE to the threads of the engine bracket bolts rear lower side Do not tighten t...

Page 295: ... 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 T R Engine mounting nut rear lower side 88 Nm 8 8 m kg 64 ft lb Engine mounting nut rear upper side 88 Nm 8 8 m kg 64 ft lb Engine mounting nut front lower side 88 Nm 8 8 m kg 64 ft lb Engine bracket nut front upper side M12 88 Nm...

Page 296: ...nder head cover bolt 6 l 45 mm 1 77 in 8 Rear cylinder head cover bolt 1 l 45 mm 1 77 in 9 Rear cylinder head cover bolt 2 l 55 mm 2 17 in 10 Rear cylinder head cover bolt 2 l 30 mm 1 18 in 11 Rear cylinder head cover bracket 1 12 Front cylinder head cover 1 13 Rear cylinder head cover 1 14 Cylinder head cover gasket 2 1 10 8 7 10 9 11 9 7 7 1 13 14 15 15 1 5 4 2 6 2 3 3 1 5 12 14 15 15 New New Ne...

Page 297: ...ts to remove Q ty Remarks 1 10 8 7 10 9 11 9 7 7 1 13 14 15 15 1 5 4 2 6 2 3 3 1 5 12 14 15 15 New New New New New New T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib New New LS LS LS LS LS LS 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R FWD ...

Page 298: ...over holder 1 8 Rear cylinder head cover bolt 7 l 45 mm 1 77 in 9 Rear cylinder head cover bolt 2 l 55 mm 2 17 in 10 Rear cylinder head cover bolt 2 l 30 mm 1 18 in 11 Rear cylinder head cover bracket 1 12 Front cylinder head cover 1 13 Rear cylinder head cover 1 14 Cylinder head cover gasket 2 15 Dowel pin 4 For installation reverse the removal proce dure 1 10 8 8 10 9 11 9 8 8 1 13 14 15 15 1 5 ...

Page 299: ... 1 8 Front cylinder timing chain tensioner housing gasket 1 9 Camshaft sprocket 2 10 Rear cylinder camshaft assembly 1 11 Front cylinder camshaft assembly 1 For installation reverse the removal proce dure FWD T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib E E T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 10 Nm 1 0 m...

Page 300: ...alve clearance adjusting screw 4 3 Intake rocker arm shaft 1 4 Exhaust rocker arm shaft 1 5 Intake rocker arm 1 6 Exhaust rocker arm 1 7 Circlip 1 8 Front cylinder camshaft 1 9 Rear cylinder camshaft 1 10 Camshaft carrier 1 For installation reverse the removal proce dure EX IN EX IN E E M T R 14 Nm 1 4 m kg 10 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib M New 1 1 2 2 3 5 8 9 7 4 6 2 10 1 2 1 ...

Page 301: ...I mark c on the camshaft sprocket with the arrow mark d on the front cylinder camshaft carrier 2 Remove Front cylinder timing chain tensioner 1 TIP Never remove a timing chain tensioner when the engine is mounted 3 Remove Front cylinder camshaft sprocket TIP While holding the camshaft sprocket with the rotor holding tool 1 loosen the camshaft sprocket bolts 2 To prevent the timing chain from falli...

Page 302: ... tensioner Rear cylinder camshaft sprocket Rear cylinder camshaft assembly TIP Never remove a timing chain tensioner when the engine is mounted Remove the parts using the same procedure as for the front cylinder camshaft assembly EAS3D81034 REMOVING THE ROCKER ARMS AND CAMSHAFTS The following procedure applies to all of the rocker arms and camshafts 1 Remove Intake rocker arm shaft Exhaust rocker ...

Page 303: ...plies to all of the rocker arms and rocker arm shafts 1 Check Rocker arm Rocker arm roller Damage wear Replace 2 Check Rocker arm shaft Blue discoloration excessive wear pit ting scratches Replace or check the lubri cation system 3 Measure Rocker arm inside diameter Out of specification Replace Camshaft lobe dimensions Intake A 42 988 43 088 mm 1 6924 1 6964 in Limit 42 888 mm 1 6885 in Intake B 3...

Page 304: ...chain tensioner clips Damage wear Replace the as a set 3 Assemble Timing chain tensioner TIP Prior to installing the timing chain tensioner rod drain the engine oil from the timing chain ten sioner housing a Install the timing chain tensioner outer spring timing chain tensioner clip 2 1 and clip 1 2 TIP Be sure to face the ends of timing chain tension er clip 2 1 in the direction shown in the illu...

Page 305: ...INSTALLING THE CAMSHAFTS AND ROCKER ARMS The following procedure applies to all of the rocker arms and camshafts 1 Lubricate Camshaft 2 Install Camshaft 1 Circlip 2 TIP Position the camshaft as shown in the illustra tion so that the camshaft lobes will not catch on the camshaft carrier during installation Position the opening between the ends of the circlip in the 90 range a shown in the illustra ...

Page 306: ...stroke align the TDC mark a on the generator rotor with the slot b in the generator cover c Install the timing chain 1 onto the front cylin der camshaft sprocket 2 then install the camshaft sprocket onto the camshaft and then finger tighten the camshaft sprocket bolts 3 NOTICE ECA13740 Do not turn the crankshaft when installing the camshaft s to avoid damage or improper valve timing TIP To positio...

Page 307: ...k a on the front cylinder timing chain tensioner should face up Push the end of the front cylinder timing chain guide intake side 3 to release the timing chain tensioner rod 6 Install Rear cylinder camshaft assembly 1 TIP Be sure to install the camshaft assembly without a punch mark onto the rear cylinder 7 Tighten Rear cylinder camshaft assembly bolts TIP Tighten the bolts in the proper sequence ...

Page 308: ...shaft carrier The rear cylinder camshaft assembly does not have a punch mark Be sure to install the cam shaft assembly without a punch mark onto the rear cylinder When installing the rear cylinder camshaft sprocket be sure to keep the timing chain as tight as possible on the intake side d Remove the wire from the timing chain 9 Tighten Rear cylinder camshaft sprocket bolts 1 TIP While holding the ...

Page 309: ...in Bolts 5 l 55 mm 2 17 in EAS27D1023 INSTALLING THE CYLINDER HEAD COVERS for XVS13CA C 1 Install Rear cylinder head cover Rear cylinder head cover bracket 1 Bolts 2 l 30 mm 1 18 in Bolts 3 l 45 mm 1 77 in Bolts 4 l 55 mm 2 17 in T R Rear cylinder head cover bolt 2 3 5 10 Nm 1 0 m kg 7 2 ft lb Rear cylinder head cover bolt 4 12 Nm 1 2 m kg 8 7 ft lb A Intake side 2 a 1 New 3 A B 5 3 4 3 2 1 3 5 2 ...

Page 310: ...er head cover bracket 1 Front cylinder head cover holder 2 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 T R Front cylinder head cover bolt 10 Nm 1 0 m kg 7 2 ft lb A Intake side B Exhaust side 4 5 3 4 6 3 6 1 A B 2 ...

Page 311: ... check bolt 2 2 Front cylinder head 1 3 Rear cylinder head 1 4 Cylinder head gasket 2 5 Dowel pin 4 For installation reverse the removal proce dure T R 15 Nm 1 5 m kg 11 ft Ib T R 15 Nm 1 5 m kg 11 ft Ib T R 65 Nm 6 5 m kg 47 ft Ib T R 65 Nm 6 5 m kg 47 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib FWD 2 1 4 4 3 5 1 5 New New 4 4 New E E New E E E E ...

Page 312: ...g Spark plug bore threads Valve seats 2 Check Cylinder heads Damage scratches Replace 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylinder head as follows d Place 400 600 grit wet sandpaper on a sur face plate and resurface th...

Page 313: ...e oil Tighten the cylinder head nuts and bolts in the proper tightening sequence as shown and torque them in two stages T R 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 A Front cylinder head B Rear cylinder head 3 2 4 6 5 1 A 6 5 1 3 2 4 B ...

Page 314: ...ure applies to both cyl inders Cylinder heads Refer to CYLINDER HEADS on page 5 32 1 Valve cotter 8 2 Upper spring seat 4 3 Valve spring 4 4 Intake valve 2 5 Exhaust valve 2 6 Valve stem seal 4 7 Lower spring seat 4 8 Valve guide 4 For installation reverse the removal proce dure New New New New M M M M M M E E 1 1 2 2 6 6 3 3 7 7 7 7 8 8 8 8 1 1 2 2 6 6 3 3 4 5 ...

Page 315: ... cotters TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 3 Remove Upper spring seat 1 Valve spring 2 Valve 3 Valve stem seal 4 Lower spring seat 5 TIP Identify the position of each part very carefully so that it can be reinstalled in its original place EAS24290 CHECKING THE VALVES AND VALVE GUIDES The foll...

Page 316: ...tem to valve guide clearance TIP After replacing the valve guide reface the valve seat 3 Eliminate Carbon deposits from the valve face and valve seat Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clear ance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 0039 in Valve guide position 14 5 14 9 mm 0 571 0 587 i...

Page 317: ...m the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head a Apply Mechanic s blueing dye Dykem b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat width TIP Whe...

Page 318: ...h be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b onto the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear i...

Page 319: ...tem seal 2 with the recommended lubricant 3 Lubricate Valve stem end with the recommended lubricant 4 Install Lower spring seat 1 Installed compression spring force intake 171 00 197 00 N 17 44 20 09 kgf 38 44 44 29 lbf Installed compression spring force exhaust 171 00 197 00 N 17 44 20 09 kgf 38 44 44 29 lbf Installed length intake 35 00 mm 1 38 in Installed length exhaust 35 00 mm 1 38 in b Inst...

Page 320: ...he valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 6 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damage the valve b Smaller pitch Valve spring compressor 90890 04019 YM 04019 Valve spring compressor atta...

Page 321: ...NDER HEADS on page 5 32 1 Timing chain guide 2 2 Front cylinder 1 3 Rear cylinder 1 4 Front cylinder gasket 1 5 Rear cylinder gasket 1 6 Dowel pin 4 7 Circlip 4 8 Piston pin 2 9 Piston 2 10 Top ring 2 11 2nd ring 2 12 Oil ring 2 For installation reverse the removal proce dure New New New New New New E E E FWD 1 2 4 6 6 3 5 6 10 11 12 7 9 9 7 7 7 8 8 1 10 11 12 ...

Page 322: ...n the end gap with your fingers and lift the other side of the ring over the piston crown EAS24410 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cyl inders and pistons 1 Check Piston wall Cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure the cylinder bo...

Page 323: ...ing side clearance Out of specification Replace the piston and piston rings as a set TIP Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder TIP Level the piston ring in the cylinder with the pis ton crown Piston Diameter D 99 955 99 970 mm 3 9352 3 9358 in b 8 mm 0 31 in from the bottom...

Page 324: ... b Out of specification Replace the piston 4 Calculate Piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set a 10 mm 0 39 in Piston ring Top ring End gap installed 0 20 0 35 mm 0 0079 0 0138 in Limit 0 60 mm 0 0236 in 2nd ring End gap installed 0 45 0 60 mm 0 0177 0 0236 in Limit 0 95 mm 0 0374 in Oil ring End gap installed 0 20 0 70 mm 0 0079 0 02...

Page 325: ... front side of the cylinder Before installing the piston pin clips cover the crankcase opening with a clean rag to prevent the clips from falling into the crankcase Install the piston pin clips so that the clip ends are 3 mm 0 12 in b or more from the cutout in the piston Reinstall each piston into its original cylinder 3 Lubricate Piston Piston rings Cylinder with the recommended lubricant 4 Offs...

Page 326: ... AND PISTONS 5 47 6 Install Cylinder 1 TIP 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 1 ...

Page 327: ... page 7 1 Drive pulley cover Refer to BELT DRIVE on page 4 99 Left rider footrest assembly Sidestand Refer to ENGINE REMOVAL on page 5 1 1 Stator coil coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Damper cover 1 4 Generator cover 1 5 Generator cover gasket 1 6 Dowel pin 2 7 Crankshaft position sensor stator assembly lead holder 1 8 Crankshaft position sensor 1 7 8 6 6 5 ...

Page 328: ...tor coil 1 For installation reverse the removal proce dure Removing the stator coil Order Job Parts to remove Q ty Remarks 7 8 6 6 5 9 2 1 3 4 6 12 New New LS LS New LS New E LT LT LT 10 Nm 1 0 m kg 7 2 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib T R ...

Page 329: ... Q ty Remarks 1 Generator rotor 1 2 Starter clutch 1 3 Woodruff key 1 4 Starter clutch gear 1 5 Torque limiter 1 6 Starter clutch idle gear shaft 1 7 Starter clutch idle gear 1 For installation reverse the removal proce dure 6 LT 1 6 7 5 4 3 2 T R 24 Nm 2 4 m kg 17 ft Ib T R 90 Nm 9 0 m kg 65 ft Ib E E E E E ...

Page 330: ...the starter clutch Make sure the flywheel puller is centered over the generator rotor EAS24560 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts Starter clutch TIP While holding the generator rotor 1 with the sheave holder 2 loosen the starter clutch bolts EAS24570 CHECKING THE STARTER CLUTCH 1 Check Starter clutch rollers Damage wear Replace 2 Check Starter clutch idle gear Starter clutch...

Page 331: ...IP While holding the generator rotor 1 with the sheave holder 2 tighten the starter clutch bolts EAS24500 INSTALLING THE GENERATOR 1 Install Generator rotor Washer Generator rotor bolt TIP Clean the tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure the woodruff key is properly seated in the key way of the crankshaft Lubricate the generator ...

Page 332: ...GENERATOR AND STARTER CLUTCH 5 53 3 Apply Sealant onto the crankshaft position sensor stator assembly lead grommet Yamaha bond No 1215 90890 85505 Three Bond No 1215 ...

Page 333: ...1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 12 1 Clutch cable holder 1 2 Clutch cable 1 Disconnect 3 Pull lever 1 4 Pull lever spring 1 5 Damper cover 1 6 Clutch cover 1 7 Clutch cover gasket 1 8 Dowel pin 2 For installation reverse the removal proce dure New 1 2 3 4 5 6 7 8 8 6 8 New 4 Nm 0 4 m kg 2 9 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R ...

Page 334: ... Removing the pull lever shaft Order Job Parts to remove Q ty Remarks 1 Circlip 1 2 Pull lever shaft 1 3 Oil seal 1 4 Bearing 1 5 Bearing 1 For installation reverse the removal proce dure LS New E 4 5 2 New 1 3 LS ...

Page 335: ...n 7 Clutch plate 7 8 Friction plate 2 7 Inside diameter 124 mm 4 88 in 9 Clutch boss nut 1 10 Conical spring washer 1 11 Wire circlip 1 12 Clutch plate 1 13 Friction plate 3 1 Inside diameter 135 mm 5 31 in 14 Clutch damper spring 1 15 Clutch damper spring seat 1 16 Clutch boss 1 17 Thrust washer 1 1 E 7 8 6 19 18 17 16 15 14 13 12 11 10 9 1 4 5 New New E LS 22 21 20 E E E 2 6 3 E 8 Nm 0 8 m kg 5 ...

Page 336: ... pump drive sprocket 1 22 Thrust washer 2 1 For installation reverse the removal proce dure Removing the clutch Order Job Parts to remove Q ty Remarks E 7 8 6 19 18 17 16 15 14 13 12 11 10 9 1 4 5 New New E LS 22 21 20 E E E 2 6 3 E 8 Nm 0 8 m kg 5 8 ft Ib T R 125 Nm 12 5 m kg 90 ft lb T R ...

Page 337: ...n Down tube Refer to ENGINE REMOVAL on page 5 1 Generator cover Refer to GENERATOR AND STARTER CLUTCH on page 5 48 1 Primary drive gear cover 1 2 Primary drive gear cover gasket 1 3 Dowel pin 3 4 Primary drive gear nut 1 5 Lock washer 1 6 Spacer 1 7 Primary drive gear 1 For installation reverse the removal proce dure New New New E LT New LS 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R...

Page 338: ...RY DRIVE GEAR 1 Straighten the lock washer tab 2 Remove Primary drive gear nut 1 Lock washer 2 TIP While holding the generator rotor 3 with the sheave holder 4 loosen the primary drive gear nut Do not allow the sheave holder to touch the projection on the generator rotor EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check Friction plate Dama...

Page 339: ...asure Clutch spring free height Out of specification Replace the clutch spring plate EAS25150 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing TIP Pitting on the clutch housing dogs will cause er ratic clutch operation Friction plate 1 3 thickness 2 90 3 10 mm 0 114 0 122 in Wear limit 2 80 mm 0 1102 in Frictio...

Page 340: ...eplace 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 EAS25220 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1 Check Pull lever shaft pinion gear teeth 1 Pull rod teeth 2 Damage wear Replace the pull rod and pull lever shaft pinion gear as a set 2 Check Pull rod bearing Damage wear Replace EAS3D81028 CHE...

Page 341: ...sprocket with its projections a facing outward 2 Install Clutch housing 1 TIP Fit the projections a on the oil water pump drive sprocket into the grooves b in the clutch housing Lubricate the clutch housing bearing with en gine oil Make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly After installing the clutch housing make sure that the primary drive gear 2 and...

Page 342: ...n the tab of each friction plate 2 1 with the mark a on the clutch hous ing and align the cutout in the tab of friction plate 1 2 with the punch mark b on the hous ing 7 Install Clutch spring plate Clutch spring plate retainer TIP Tighten the clutch spring plate retainer bolts in stages and in a crisscross pattern 8 Install Pull lever spring 1 Pull lever 2 Washer Circlip TIP Make sure that the mar...

Page 343: ...CLUTCH 5 64 9 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 13 2 1 c b a ...

Page 344: ...E on page 4 99 Shift arm Refer to ENGINE REMOVAL on page 5 1 Primary drive gear cover Refer to CLUTCH on page 5 54 1 Shift shaft 1 2 Stopper lever spring 1 3 Circlip 1 4 Stopper lever 1 5 Collar 1 6 Shift shaft spring 1 7 Shift shaft spring stopper 1 For installation reverse the removal proce dure LS New E 7 LT 1 6 5 4 3 2 New E T R 22 Nm 2 2 m kg 16 ft Ib ...

Page 345: ...ughly Replace the stopper lever EAS25450 INSTALLING THE SHIFT SHAFT 1 Install Stopper lever 1 Stopper lever spring 2 Shift shaft 3 TIP Lubricate the oil seal lips with lithium soap based grease Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss 4 Mesh the stopper lever with the shift drum seg ment assembly Hook the end of the shift shaft spring onto the shift s...

Page 346: ... Order Job Parts to remove Q ty Remarks Primary drive gear Refer to CLUTCH on page 5 54 1 Straight key 1 2 Right balancer drive gear 1 3 Right balancer assembly 1 For installation reverse the removal proce dure R 12 Nm 1 2 m kg 8 7 ft Ib LT LT R 12 Nm 1 2 m kg 8 7 ft Ib LT E LT 2 1 3 ...

Page 347: ...ove Q ty Remarks Generator rotor Starter clutch idle gear Refer to GENERATOR AND STARTER CLUTCH on page 5 48 1 Left balancer drive gear 1 2 Left balancer assembly 1 For installation reverse the removal proce dure 1 2 T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib New E ...

Page 348: ...bly 2 Install Right balancer drive gear 1 Straight key 2 TIP Align the punch mark a in the right balancer driven gear with the punch mark b in the right balancer drive gear EAS3D81027 INSTALLING THE LEFT BALANCER GEARS 1 Install Left balancer assembly 2 Install Left balancer drive gear 1 TIP Align the punch mark a in the left balancer driven gear with the punch mark b in the left balancer drive ge...

Page 349: ...RIC STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks 1 Starter motor lead 1 Disconnect 2 Starter motor 1 For installation reverse the removal proce dure 1 2 10 Nm 1 0 m kg 7 2 ft Ib T R 5 Nm 0 5 m kg 3 6 ft Ib T R ...

Page 350: ...otor front cover 1 3 Oil seal 1 4 Bearing 1 5 Armature assembly 1 6 Starter motor yoke 1 7 Gasket 2 8 Starter motor rear cover 1 9 Brush assembly 1 10 O ring 1 For assembly reverse the disassembly pro cedure 1 2 3 4 7 6 5 8 9 10 7 E LS New New New New New New 5 Nm 0 5 m kg 3 6 ft Ib T R 11 Nm 1 1 m kg 8 0 ft Ib T R ...

Page 351: ...ces with the digital circuit tester b If any resistance is out of specification re place the starter motor 4 Measure Brush length a Out of specification Replace the brush as sembly 5 Measure Brush spring force Out of specification Replace the brush as sembly 6 Check Gear teeth Damage wear Replace the starter motor 7 Check Bearing Damage wear Replace the starter motor Mica undercut depth 0 70 mm 0 ...

Page 352: ...ING THE STARTER MOTOR 1 Install Starter motor yoke 1 Starter motor front cover 2 Starter motor rear cover 3 TIP Align the match marks a on the starter motor yoke with the match marks b on the starter mo tor front and rear covers 1 2 3 b b a ...

Page 353: ...iming chain 2 7 Coolant delivery pipe 1 8 Speed sensor 1 9 Spacer 1 10 Oil filter cartridge 1 11 Oil delivery pipe 2 1 1 5 6 2 3 9 4 7 10 11 12 18 17 4 9 5 6 8 13 14 16 15 New New New New New New New New New New New LS LS LS LS LS LS LT LT LT LT LT LT LT LT LT LT LT LT 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg...

Page 354: ... remove Q ty Remarks 1 5 6 2 3 9 4 7 10 11 12 18 17 4 9 5 6 8 13 14 16 15 New New New New New New New New New New New LS LS LS LS LS LS LT LT LT LT LT LT LT LT LT LT LT LT 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib T ...

Page 355: ...pipe 2 1 6 Oil baffle plate 2 1 7 Gasket 1 8 Right crankcase 1 For installation reverse the separating pro cedure 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 36 Nm 3 6 m kg 25 ft Ib T R LT LT LT LT LT LT New New New New New LS LS LT LS LS 1 5 2 3 19 7 3 4 5 6 8 ...

Page 356: ... page 5 80 Crankshaft Refer to CRANKSHAFT on page 5 83 Transmission Refer to TRANSMISSION on page 5 88 1 Bearing retainer 2 2 Oil seal 1 3 Bearing 7 4 Oil nozzle 2 For installation reverse the removal proce dure New LT LT LS LT LT E T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib LT E New LS E E New LS E 1 1 3 2 3 3 3 3 4 4 ...

Page 357: ...AL 1 Check Bearings Clean and lubricate the bearings then rotate the inner race with your finger Rough movement Replace Oil seals Damage wear Replace EAS25600 CHECKING THE OIL DELIVERY PIPES AND COOLANT DELIVERY PIPE The following procedure applies to all of the oil delivery pipes and joint pipe 1 Check Oil delivery pipe Joint pipe Damage Replace Obstruction Wash and blow out with com pressed air ...

Page 358: ...nkcase TIP Tap lightly on the left crankcase with a soft face hammer 4 Install Crankcase bolts M10 Crankcase bolts M6 TIP Apply locking agent LOCTITE to the threads of the bolts 2 Tighten each bolt 1 4 of a turn at a time in stag es and in a crisscross pattern M10 110 mm bolts 1 M6 120 mm bolts 2 M6 80 mm bolts 3 5 Apply Engine oil onto the crankshaft pin bearings and oil de livery holes 6 Check C...

Page 359: ...sembly 1 4 Dowel pin 2 5 Joint pipe 1 6 Oil pump housing 1 7 Bearing 1 8 Pin 2 9 Oil pump outer rotor 1 10 Oil pump inner rotor 1 11 Pin 1 12 Water pump housing 1 For installation reverse the removal proce dure T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib LS 8 8 6 9 10 11 12 7 4 5 1 2 3 New New New Ne...

Page 360: ...he defective part s EAS24970 CHECKING THE RELIEF VALVE 1 Check Relief valve body 1 Relief valve 2 Spring 3 Spring retainer 4 Damage wear Replace the defective part s EAS24990 CHECKING THE OIL STRAINER 1 Check Oil strainer 1 Damage Replace Contaminants Clean with solvent Inner rotor to outer rotor tip clearance Less than 0 12 mm 0 0047 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump housing clea...

Page 361: ... impeller shaft with the grooves a in the in ner rotor 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 81 EAS25020 INSTALLING THE OIL WATER PUMP ASSEMBLY 1 Install Oil water pump assembly NOTICE ECA3D81020 After tightening the bolts make sure the oil water pump assembly turns smoothly Recommended lubricant Engine oil T R Oil pump housing bolt 10 Nm 1 0 m kg 7 2 ft lb T R Oil wa...

Page 362: ...kcase Separate Refer to CRANKCASE on page 5 74 1 Crankshaft 1 2 Connecting rod cap 2 3 Big end lower bearing 2 4 Connecting rod 2 5 Big end upper bearing 2 For installation reverse the removal proce dure E E M M M M New New New E T R 1st 15 Nm 1 5 m kg 11 ft lb 2nd Specified angle 125 135 1 2 3 4 5 4 2 3 ...

Page 363: ... correct crankshaft pin to big end bearing clear ance and prevent engine damage the big end bearings must be installed in their origi nal positions a Clean the big end bearings crankshaft pin and the inside of the connecting rod halves b Install the big end upper bearing into the con necting rod and the big end lower bearing into the connecting rod cap TIP Align the projections a on the big end be...

Page 364: ...g end bearings 4 Select Big end bearings P1 P2 TIP The numbers a stamped into the crankshaft web and the numbers b on the connecting rods are used to determine the replacement big end bearing sizes P1 P2 refer to the bearings shown in the crank shaft illustration For example if the connecting rod P1 and the crankshaft web P numbers are 5 and 1 re spectively then the bearing size for P1 is 5 Measur...

Page 365: ...er surface with the recommended lubricant 3 Install Big end bearings Connecting rods Connecting rod caps onto the crankshaft pin TIP Align the projections a on the big end bear ings with the notches b in the connecting rods and connecting rod caps Be sure to reinstall each big end bearing in its original place Make sure the projection c on each connect ing rod faces towards the left side of the cr...

Page 366: ...6 When a bolt is tightened more than the spec ified angle do not loosen and then retighten it Replace the bolt with a new one and perform the procedure again NOTICE ECA3D81012 Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angle EAS26210 INSTALLING THE CRANKSHAFT ASSEMBLY 1 Install Crankshaft assembly NOTICE ECA3D81013 To avoid s...

Page 367: ...s to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 74 1 Long shift fork guide bar 1 2 Short shift fork guide bar 1 3 Shift drum assembly 1 4 Shift fork 1 2 5 Shift fork 2 1 6 Main axle assembly 1 7 Drive axle assembly 1 For installation reverse the removal proce dure New LS E E E 2 4 5 1 3 6 4 7 ...

Page 368: ...rts to remove Q ty Remarks 1 Circlip 1 2 2nd pinion gear 1 3 Circlip 1 4 3rd 4th pinion gear 1 5 Circlip 1 6 Toothed washer 1 7 5th pinion gear 1 8 Collar 1 9 Main axle 1st pinion gear 1 For assembly reverse the disassembly pro cedure New New New M M 1 2 3 4 5 6 7 8 9 ...

Page 369: ...th wheel gear 1 5 Circlip 1 6 Toothed washer 1 7 4th wheel gear 1 8 Toothed spacer 1 9 Toothed lock washer 1 10 Toothed lock washer retainer 1 11 3rd wheel gear 1 12 Toothed spacer 1 13 Toothed washer 1 14 Circlip 1 15 Dog clutch 1 16 Circlip 1 17 Toothed washer 1 New New New M M M M M M M 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 ...

Page 370: ...ar 1 19 Collar 1 20 Drive axle 1 For assembly reverse the disassembly pro cedure Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks New New New M M M M M M M 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 ...

Page 371: ...h movement Replace the shift forks and shift fork guide bar as a set EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum grooves Damage scratches wear Replace the shift drum assembly Shift drum segment 1 Damage wear Replace the shift drum as sembly Shift drum bearing 2 Damage pitting Replace the shift drum as sembly EAS26300 CHECKING THE TRANSMISSION 1 Measure Main axle runout with a cent...

Page 372: ...the sides of a spline b with both axles aligned 2 Install Toothed lock washer retainer 1 Toothed lock washer 2 TIP With the toothed lock washer retainer 1 in the groove a in the drive axle align the projection c on the retainer with an axle spline b and then install the toothed lock washer 2 Be sure to align the projection on the toothed lock washer that is between the alignment marks e with the a...

Page 373: ...2 Check Transmission Rough movement Repair TIP 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 4 1 2 3 5 ...

Page 374: ...TRANSMISSION 5 95 ...

Page 375: ...NG 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: ...age 5 1 Fuel tank Refer to FUEL TANK on page 7 1 Side panels For XVS13CA C Refer to FUEL TANK on page 7 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 18 1 Coolant reservoir cover bracket 1 2 Coolant reservoir breather hose 1 3 Coolant reservoir hose 1 4 Coolant reservoir cap 1 5 Coolant reservoir 1 6 Radiator cap 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m k...

Page 377: ...diator outlet hose 1 13 Radiator outlet pipe 1 14 Radiator fan 1 For installation reverse the removal proce dure Removing the radiator Order Job Parts to remove Q ty Remarks T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib New New T R 2 Nm 0 2 m kg 1 4 ft Ib LS LT LT 4 3 2 1 5 10 8 11 14 12 13 9 7 7 6 3 A ...

Page 378: ...Coolant reservoir cover bracket TIP Make sure that the rear brake hose brake fluid reservoir hose coolant reservoir breather hose horn lead and rear brake light switch lead are routed properly Refer to CABLE ROUTING for XVS13AA C XVS13CTA C on page 2 55 and CABLE ROUTING for XVS13CA C on page 2 79 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COO...

Page 379: ... thermostat inlet hose 1 2 Front cylinder thermostat inlet pipe 1 3 Rear cylinder thermostat inlet hose 1 4 Rear cylinder thermostat inlet pipe 1 1 5 Coolant temperature sensor coupler 1 Disconnect 6 Coolant temperature sensor 1 7 Radiator filler pipe 1 8 Thermostat cover inlet hose 1 9 Thermostat bracket 1 10 Radiator inlet hose 1 LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T ...

Page 380: ...the removal proce dure Removing the thermostat for XVS13AA C XVS13CTA C Order Job Parts to remove Q ty Remarks LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib New New New New LS LS LS 5 1 2 3 6 4 7 10 11 12 14 13 9 8 ...

Page 381: ...t inlet hose 1 4 Rear cylinder thermostat inlet pipe 1 5 Coolant temperature sensor coupler 1 Disconnect 6 Coolant temperature sensor 1 7 Radiator filler pipe 1 8 Thermostat cover inlet hose 1 9 Radiator inlet hose 1 10 Thermostat bracket 1 11 Thermostat cover 1 12 Thermostat 1 New 7 8 9 11 12 10 6 5 1 3 2 4 13 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R ...

Page 382: ...or XVS13CA C Order Job Parts to remove Q ty Remarks New 7 8 9 11 12 10 6 5 1 3 2 4 13 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R LT LT New New New LS LS LS ...

Page 383: ...g or overcooling 2 Check Thermostat housing cover Thermostat housing Thermostat pipes Thermostat hoses Radiator inlet hose Radiator filler pipe Cracks damage wear Replace EAS26480 INSTALLING THE THERMOSTAT ASSEMBLY 1 Install Thermostat TIP Install the thermostat with its breather hole a facing up 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOL...

Page 384: ...kcase Separate Refer to CRANKCASE on page 5 74 Oil pump rotors Refer to OIL PUMP on page 5 80 1 Water pump housing cover 1 2 Pin 2 3 O ring 1 4 Impeller shaft 1 5 Rubber damper holder 1 6 Rubber damper 1 7 Water pump seal 1 8 Oil seal 1 9 Bearing 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib LS 5 New New New New New LS LS LS Ne...

Page 385: ...e the removal proce dure Removing the water pump Order Job Parts to remove Q ty Remarks T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib LS 5 New New New New New LS LS LS New LS 3 1 2 2 10 6 7 8 9 4 ...

Page 386: ...er pump housing cover Water pump housing Impeller shaft Cracks damage wear Replace 2 Check Bearing Rough movement Replace EAS26560 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 into the oil water pump housing TIP Before installing the oil seal apply tap water or coolant onto its outer surface Install the oil seal with a socket that matches its outside diameter 2 Install Water pump seal 1 NOTICE E...

Page 387: ...ure the rubber damper and rubber damper holder are flush with the impeller Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A Middle driven shaft bearing driv er 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 Yamaha bond No 1215 90890 85505 Three Bond No 1215 A Push down 4 Mechanical seal installer 5 Middle driven shaft bearing driver New New Impeller shaft ti...

Page 388: ...WATER PUMP 6 13 ...

Page 389: ...CHECKING THE ROLLOVER VALVE 7 7 INSTALLING THE FUEL PUMP 7 7 INSTALLING THE FUEL TANK HOSES for XVS13AA C XVS13CTA C 7 7 INSTALLING THE FUEL TANK BREATHER HOSE for XVS13CA C 7 8 THROTTLE BODIES 7 9 CHECKING THE INJECTORS 7 14 CHECKING THE THROTTLE BODIES 7 14 CHECKING THE FUEL PRESSURE 7 14 ADJUSTING THE THROTTLE POSITION SENSOR 7 14 INSTALLING THE INTAKE MANIFOLD ASSEMBLY 7 15 ...

Page 390: ... coupler 1 Disconnect 5 Fuel cock hose 1 TIP Before removing the fuel cock hose turn the fuel cock to OFF 6 Air vent hose 1 7 Fuel tank overflow hose 1 8 Fuel tank breather hose fuel tank to hose joint 1 9 Fuel tank 1 10 Fuel sender 1 11 Fuel cock 1 For installation reverse the removal proce dure T R 23 Nm 2 3 m kg 17 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib New T R 7 Nm 0 7 m...

Page 391: ...moving the fuel cock hose turn the fuel cock to OFF 4 Air vent hose 1 5 Fuel tank breather hose fuel tank to hose joint 1 6 Fuel tank 1 7 Collar 1 8 Grommet 1 9 Fuel tank bracket 1 10 Rubber damper 1 11 Fuel sender 1 12 Fuel cock 1 13 Right side panel 1 New New New New New New New 11 5 10 9 2 2 7 1 8 12 13 14 3 6 4 7 Nm 0 7 m kg 5 1 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T...

Page 392: ...e Removing the fuel tank for XVS13CA C Order Job Parts to remove Q ty Remarks New New New New New New New 11 5 10 9 2 2 7 1 8 12 13 14 3 6 4 7 Nm 0 7 m kg 5 1 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R T R 23 Nm 2 3 m kg 17 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib ...

Page 393: ...CHASSIS on page 4 1 Seat Sub fuel tank cover Battery box For XVS13CA C Refer to GENERAL CHASSIS on page 4 1 1 Fuel pump coupler 1 Disconnect 2 Fuel hose 1 Disconnect 3 Sub fuel tank 1 4 Fuel pump bracket 1 5 Fuel pump gasket 1 6 Fuel pump 1 For installation reverse the removal proce dure 4 5 6 3 1 2 New R 10 Nm 1 0 m kg 7 2 ft Ib 3 3 3 6 4 Nm 0 4 m kg 2 9 ft Ib T R ...

Page 394: ...alifornia only 2 Fuel tank breather hose rollover valve to canis ter 1 California only 3 Fuel tank breather hose 1 Except for California 4 Holder 1 For XVS13CA C 5 Holder 1 For XVS13CA C 6 Fuel tank breather hose hose joint to rollover valve 1 7 Rollover valve 1 8 Canister 1 California only 9 Canister breather hose 1 California only For installation reverse the removal proce dure 3 2 6 5 4 7 8 9 L...

Page 395: ...e fuel hose connector cover 1 on the end of the hose in the direction of the arrow shown press the two buttons 2 on the sides of the connector and then remove the hose Remove the fuel hose manually without using any tools Before removing the hose place a few rags in the area under where it will be removed 2 Remove Fuel pump NOTICE ECA3D81001 Do not drop the fuel pump or give it a strong shock EAS2...

Page 396: ...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 2 Install Fuel hose NOTICE ECA3D81002 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly...

Page 397: ...o hose joint 1 NOTICE ECA27D1001 Be sure to install the fuel tank breather hose fuel tank to hose joint correctly Otherwise the engine may not operate properly or other problem could occur TIP Connect the fuel tank breather hose fuel tank to hose joint to the fuel tank place the fuel tank in its original position and then connect the hose to the hose joint Make sure that the fuel tank breather hos...

Page 398: ...e For XVS13CA C Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Throttle position sensor coupler 1 Disconnect 2 Canister purge hose 1 California only Disconnect 3 Intake air pressure sensor hose 1 4 Throttle cable 2 Disconnect 5 ISC idle speed control unit coupler 1 Disconnect 6 Throttle body 1 NOTICE ECA3D81003 The throttle body should not be disas sembled 7 Gasket...

Page 399: ... Throttle position sensor 1 For installation reverse the removal proce dure Removing the throttle body and ISC idle speed control unit Order Job Parts to remove Q ty Remarks 2 3 7 5 4 1 6 8 4 New T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 400: ...ver bracket 1 2 Ignition coil bracket bolt 2 3 Front cylinder resonator hose 1 4 Rear cylinder resonator hose 1 5 Resonator hose joint 1 6 Fuel hose 1 Disconnect 7 Sub wire harness coupler 2 Disconnect 8 Intake manifold joint clamp screw 2 Loosen 9 Rear cylinder intake manifold joint 1 10 Intake manifold assembly 1 11 Front cylinder intake manifold joint 1 For installation reverse the removal proc...

Page 401: ...9 1 Front cylinder resonator hose 1 2 Rear cylinder resonator hose 1 3 Resonator hose joint 1 4 Fuel hose 1 Disconnect 5 Front cylinder injector coupler 1 Disconnect 6 Rear cylinder injector coupler 1 Disconnect 7 Intake manifold joint clamp screw 2 Loosen 8 Rear cylinder intake manifold joint 1 9 Intake manifold assembly 1 10 Front cylinder intake manifold joint 1 For installation reverse the rem...

Page 402: ...coupler 1 For XVS13AA C XVS13CTA C Disconnect 2 Rear cylinder injector coupler 1 For XVS13AA C XVS13CTA C Disconnect 3 Sub wire harness 1 For XVS13AA C XVS13CTA C 4 Injector 2 5 Fuel pipe 1 6 Intake manifold 1 For assembly reverse the disassembly pro cedure T R 10 Nm 1 0 m kg 7 2 ft Ib New New New New E E 4 6 4 4 2 1 3 5 ...

Page 403: ...ing the hoses c Connect the fuel pressure adapter 3 be tween the fuel hose 1 and fuel pump 2 d Connect the pressure gauge 4 to the fuel pressure adapter 3 e Start the engine f Measure the fuel pressure Faulty Replace the fuel pump EAS27030 ADJUSTING THE THROTTLE POSITION SENSOR TIP Before adjusting the throttle position sensor the engine idling speed should be properly adjusted 1 Check Throttle po...

Page 404: ... b Install the rear cylinder intake manifold joint 2 to the intake manifold assembly TIP Lubricate the rear cylinder intake manifold joint and intake manifold assembly mating surfaces with engine oil Make sure that the projection b on the rear cylinder intake manifold joint contacts the pro jection c on the intake manifold assembly c Install the intake manifold assembly TIP Lubricate the front cyl...

Page 405: ... XVS13CA C 8 23 TROUBLESHOOTING XVS13AA C XVS13CTA C 8 25 TROUBLESHOOTING XVS13CA C 8 27 SIGNALING SYSTEM 8 29 CIRCUIT DIAGRAM for XVS13AA C XVS13CTA C 8 29 CIRCUIT DIAGRAM for XVS13CA C 8 31 TROUBLESHOOTING 8 33 COOLING SYSTEM 8 39 CIRCUIT DIAGRAM for XVS13AA C XVS13CTA C 8 39 CIRCUIT DIAGRAM for XVS13CA C 8 41 TROUBLESHOOTING 8 43 FUEL INJECTION SYSTEM 8 45 CIRCUIT DIAGRAM for XVS13AA C XVS13CTA...

Page 406: ...THE LEAN ANGLE SENSOR 8 109 CHECKING THE STARTER MOTOR OPERATION 8 109 CHECKING THE STATOR COIL 8 110 CHECKING THE RECTIFIER REGULATOR 8 110 CHECKING THE OIL LEVEL SWITCH 8 110 CHECKING THE FUEL SENDER for XVS13AA C XVS13CTA C 8 111 CHECKING THE FUEL SENDER for XVS13CA C 8 111 CHECKING THE FUEL LEVEL WARNING LIGHT 8 112 CHECKING THE OIL LEVEL WARNING LIGHT 8 112 CHECKING THE SPEED SENSOR 8 112 CHE...

Page 407: ......

Page 408: ...K Ch L B Ch L G B Y B B BLACK BLACK G W DARK GREEN B L DARK GRAY GRAY A WIRE HARNESS SUB WIREHARNESS B WIRE HARNESS SUB WIREHARNESS C WIRE HARNESS Gy R L R Br W BLACK B L R W2 R W1 W Gy1 Y G L B L Lg W Gy W G R W Gy W Gy G B L ON OFF RESET L N R Br L Br Br Br R W R R Y Dg Dg B B C Ch Ch Dg Ch B Dg L B Ch L B Y B B B Y L R L B W Br Y B B Y L R Y L B Br Y B B G C C C B B C W3 B R R Br W B R B R B R ...

Page 409: ...ttery 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: ... W Gy G B L BLACK Ch Y R W Sb W Dg P B B Y G Y L G R G W BLACK Sb W P B R W Ch Dg Y B G Y G R G Y L W B Y B P B Y G Y Br BLUE Y L Y B Dg Ch Br W B2 Br2 Y R B Y G L B B R R W L W1 B Y Y G B B W P W Br ON OFF RESET L N R SELECT Br L Br Br2 Br R W R R Y1 Dg L Ch Ch Ch Ch L B Y B B L Y L B W Br Y B B L Y L Y B Br Y B W B G B B B B B B R R Br W B R B R B R1 R1 R W L1 R W1 R W R W2 B L L W Y B W O R P R...

Page 411: ...ttery 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: ...eventing the spark plugs from producing a spark However the engine continues to run under the following conditions The transmission is in gear the neutral switch is open and the sidestand is up the sidestand switch is closed The transmission is in neutral the neutral switch is closed and the sidestand is down the sidestand switch is open 1 4 5 10 11 9 7 2 6 3 8 1 Battery 2 Main fuse 3 Main switch ...

Page 413: ...ING THE BATTERY on page 8 100 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 9 Regap or replace the spark plug s 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 107 Ignition system is OK 5 Check the spark plug caps Refer to CHECKING THE SPARK PLUG CAPS on page 8 107 Replace the spark...

Page 414: ...tral switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 93 Replace the sidestand switch 12 Check the relay unit diode Refer to CHECKING THE DI ODES on page 8 105 Replace the relay unit 13 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 109 Replace the lean angle sensor 14 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM for...

Page 415: ...IGNITION SYSTEM 8 8 ...

Page 416: ...Y P G Y R R Y L Y B Y B G L B L B Dg L B GRAY GRAY BL BL BLACK Ch L B Ch L G B Y B B BLACK BLACK G W DARK GREEN B L Br W BLACK B L R W2 R W1 W Gy1 Y G L B L Lg ON OFF RESET L N R Br L Br Br Br R W R R Y B Dg L B Ch L B Y B B B YL R L B W Br Y B B YL R Y L B Br Y B B G C C B B C W3 B R R Br W B R B R B R R L W R W1 R W2 B L L W Y B W O R P Y R Y R L Y G L R Y G L G L L B P W B W Y G L R B Y P B R W...

Page 417: ... 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 ...

Page 418: ... L2 B R L W1 R L L1 L R R W L G L Y Sb B Y Sb W B Y B P B Y G Y Br BLUE Y L Y B Dg Ch Br W B2 Br2 Y R B Y G L B B R R W L W1 B Y Y G B B W P W Br ON OFF RESET L N R SELECT Br L Br Br2 Br R W R R Y1 Dg L Ch L B Y B B L Y L B W Br Y B B L Y L Y B Br Y B W B G B B B B B B R R Br W B R B R B R1 R1 R W L1 R W1 R W R W2 B L L W Y B W O R P W Y R L Y L B L B L B P W Y G B Y P B R W L W1 B R Y B R Y1 R Y2...

Page 419: ... 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 ...

Page 420: ... is pulled to the handlebar the clutch switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the star...

Page 421: ...EVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Relay unit starting circuit cut off relay 7 Relay unit diode 8 Clutch switch 9 Sidestand switch 10 Neutral switch 11 Diode 12 Starter relay 13 Start switch 14 Starter motor 15 Relay unit diode for XVS13CA C ...

Page 422: ...0 Clean the battery terminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 109 The starter motor is OK Perform the elec tric starting system troubleshooting start ing with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 72 Repair or replace the starter motor 5 Check the relay unit starti...

Page 423: ...o CHECKING THE SWITCHES on page 8 93 Replace the neutral switch 12 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 93 Replace the sidestand switch 13 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 93 Replace the clutch switch 14 Check the start switch Refer to CHECKING THE SWITCHES on page 8 93 Replace the right handlebar switch 15 Check the entire starting sy...

Page 424: ... L B Y B P W Y G Y P B B Y Y G B W B P W P B L R1 W Br W L R W G Y Y L Y B Y Y G L B L B B R W2 R W1 W Gy1 ON OFF RESET Br L Br Br Br R W R R Y Br B W3 B R R Br W B R B R B R R L W R W1 R W2 P W P B R W L W B R B L L W B Y Sb Sb B Sb W R1 B B B R R G W2 W1 W3 W2 R Br L B Br L L Y W1 Br W L R W G Y 1 2 3 4 5 6 7 8 9 10 12 13 15 20 21 22 23 49 69 70 71 72 73 60 61 62 63 64 65 74 11 ...

Page 425: ...CHARGING SYSTEM 8 18 1 AC magneto 2 Rectifier regulator 3 Main fuse 6 Battery ...

Page 426: ...eck the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 100 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 110 Replace the crankshaft position sen sor stator assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 110 Replace the rectifier regulator 5 Check the entire...

Page 427: ...CHARGING SYSTEM 8 20 ...

Page 428: ...CK Ch L B Ch L G B Y B B BLACK BLACK G W DARK GREEN B L DARK GRAY GRAY A WIRE HARNESS SUB WIREHARNESS B WIRE HARNESS SUB WIREHARNESS C WIRE HARNESS Gy R L R Br W BLACK B L R W2 R W1 W Gy1 Y G L B L Lg W Gy W G R W Gy W Gy G B L ON OFF RESET L N R Br L Br Br Br R W R R Y Dg Dg B B C Ch Ch Dg Ch B Dg L B Ch L B Y B B B Y L R L B W Br Y B B Y L R Y L B Br Y B B G C C C B B C W3 B R R Br W B R B R B R...

Page 429: ...h 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 71 Ignition fuse 72 Signaling system fuse 73 Taillight fuse ...

Page 430: ... W Gy G B L BLACK Ch Y R W Sb W Dg P B B Y G Y L G R G W BLACK Sb W P B R W Ch Dg Y B G Y G R G Y L W B Y B P B Y G Y Br BLUE Y L Y B Dg Ch Br W B2 Br2 Y R B Y G L B B R R W L W1 B Y Y G B B W P W Br ON OFF RESET L N R SELECT Br L Br Br2 Br R W R R Y1 Dg L Ch Ch Ch Ch L B Y B B L Y L B W Br Y B B L Y L Y B Br Y B W B G B B B B B B R R Br W B R B R B R1 R1 R W L1 R W1 R W R W2 B L L W Y B W O R P R...

Page 431: ...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 71 Ignition fuse 73 Taillight fuse ...

Page 432: ... BULB SOCKETS on page 8 98 Replace the bulb s and bulb socket s 2 Check the fuses Main headlight signaling system ignition and taillight Refer to CHECKING THE FUS ES on page 8 99 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 100 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 ...

Page 433: ...STEM 8 26 NG OK 7 Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM for XVS13AA C XVS13CTA C on page 8 21 Properly connect or repair the lighting sys tem s wiring Replace the ECU or meter assembly ...

Page 434: ...D BULB SOCKETS on page 8 98 Replace the bulb s and bulb socket s 2 Check the fuses Main headlight ignition and tail light Refer to CHECKING THE FUS ES on page 8 99 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 100 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 93 Replace the ...

Page 435: ...M 8 28 NG OK 7 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM for XVS13CA C on page 8 23 Properly connect or repair the lighting sys tem wiring Replace the ECU or meter assembly or tail brake light ...

Page 436: ...ACK Ch L B Ch L G B Y B B BLACK BLACK G W DARK GREEN B L DARK GRAY GRAY A WIRE HARNESS SUB WIREHARNESS B WIRE HARNESS SUB WIREHARNESS C WIRE HARNESS Gy R L R Br W BLACK B L R W2 R W1 W Gy1 Y G L B L Lg W Gy W G R W Gy W Gy G B L ON OFF RESET L N R Br L Br Br Br R W R R Y Dg Dg B B C Ch Ch Dg Ch B Dg L B Ch L B Y B B B Y L R L B W Br Y B B Y L R Y L B Br Y B B G C C C B B C W3 B R R Br W B R B R B ...

Page 437: ...cator light 36 Multi function meter 38 Coolant temperature warning light 40 Turn signal indicator light 42 Oil level switch 43 Fuel sender 45 Horn 46 Turn signal relay 51 Turn signal switch 52 Horn switch 53 Rear right turn signal light 54 Rear left turn signal light 55 Front right turn signal position light 56 Front left turn signal position light 60 Front brake light switch 66 Tail brake light 6...

Page 438: ...y W Gy G B L BLACK Ch Y R W Sb W Dg P B B Y G Y L G R G W BLACK Sb W P B R W Ch Dg Y B G Y G R G Y L W B Y B P B Y G Y Br BLUE Y L Y B Dg Ch Br W B2 Br2 Y R B Y G L B B R R W L W1 B Y Y G B B W P W Br ON OFF RESET L N R SELECT Br L Br Br2 Br R W R R Y1 Dg L Ch Ch Ch Ch L B Y B B L Y L B W Br Y B B L Y L Y B Br Y B W B G B B B B B B R R Br W B R B R B R1 R1 R W L1 R W1 R W R W2 B L L W Y B W O R P ...

Page 439: ...cator light 36 Multi function meter 38 Coolant temperature warning light 40 Turn signal indicator light 42 Oil level switch 43 Fuel sender 45 Turn signal relay 50 Turn signal switch 51 Horn switch 52 Rear right turn signal light 53 Rear left turn signal light 54 Horn 55 Front right turn signal position light 56 Front left turn signal position light 60 Front brake light switch 66 Tail brake light 6...

Page 440: ...on and back up Refer to CHECKING THE FUS ES on page 8 99 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 100 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 93 Replace the main switch 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM for XVS13AA C XVS13CTA C ...

Page 441: ... page 8 31 Properly connect or repair the signaling system s wiring Replace the horn 1 Check the brake light bulb and socket Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 98 Replace the brake light bulb socket or both 2 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 93 Replace the front brake light switch 3 Check the rear brake light switch Refer to CHECKING T...

Page 442: ...ly connect or repair the signaling system wiring Replace the tail brake light 1 Check the turn signal light bulbs and sockets Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 98 Replace the turn signal light bulb s sock et s or both 2 Check the turn signal switch Refer to CHECKING THE SWITCHES on page 8 93 The turn signal switch is faulty Replace the left handlebar switch 3 Check the turn si...

Page 443: ...CTA C on page 8 29 and CIRCUIT DIA GRAM for XVS13CA C on page 8 31 Properly connect or repair the signaling system s wiring Replace the meter assembly 1 Check the oil level switch Refer to CHECKING THE OIL LEVEL SWITCH on page 8 110 Replace the oil level switch 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM for XVS13AA C XVS13CTA C on page 8 29 and CIRCUIT DIA GRAM for XVS13...

Page 444: ...ATURE SENSOR on page 8 113 Replace the coolant temperature sensor 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM for XVS13AA C XVS13CTA C on page 8 29 and CIRCUIT DIA GRAM for XVS13CA C on page 8 31 Properly connect or repair the signaling system s wiring Replace the ECU or meter assembly 1 Check the speed sensor Refer to CHECKING THE SPEED SENSOR on page 8 112 Replace the s...

Page 445: ...SIGNALING SYSTEM 8 38 ...

Page 446: ...K Ch L B Ch L G B Y B B BLACK BLACK G W DARK GREEN B L DARK GRAY GRAY A WIRE HARNESS SUB WIREHARNESS B WIRE HARNESS SUB WIREHARNESS C WIRE HARNESS Gy R L R Br W BLACK B L R W2 R W1 W Gy1 Y G L B L Lg W Gy W G R W Gy W Gy G B L ON OFF RESET L N R Br L Br Br Br R W R R Y Dg Dg B B C Ch Ch Dg Ch B Dg L B Ch L B Y B B B Y L R L B W Br Y B B Y L R Y L B Br Y B B G C C C B B C W3 B R R Br W B R B R B R ...

Page 447: ...OLING SYSTEM 8 40 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 ...

Page 448: ... W Gy G B L BLACK Ch Y R W Sb W Dg P B B Y G Y L G R G W BLACK Sb W P B R W Ch Dg Y B G Y G R G Y L W B Y B P B Y G Y Br BLUE Y L Y B Dg Ch Br W B2 Br2 Y R B Y G L B B R R W L W1 B Y Y G B B W P W Br ON OFF RESET L N R SELECT Br L Br Br2 Br R W R R Y1 Dg L Ch Ch Ch Ch L B Y B B L Y L B W Br Y B B L Y L Y B Br Y B W B G B B B B B B R R Br W B R B R B R1 R1 R W L1 R W1 R W R W2 B L L W Y B W O R P R...

Page 449: ...OLING SYSTEM 8 42 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 ...

Page 450: ...heck the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 100 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 93 Replace the main switch 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 113 Replace the radiator fan motor 5 Check the radiator fan motor relay Refer to CHECKING T...

Page 451: ... 7 Check the entire cooling system s wiring Refer to CIRCUIT DIAGRAM for XVS13AA C XVS13CTA C on page 8 39 and CIRCUIT DIA GRAM for XVS13CA C on page 8 41 Properly connect or repair the cooling sys tem s wiring Replace the ECU ...

Page 452: ...CK BLACK Ch L B Ch L G B Y B B BLACK BLACK G W DARK GREEN B L DARK GRAY GRAY A WIRE HARNESS SUB WIREHARNESS B WIRE HARNESS SUB WIREHARNESS C WIRE HARNESS Gy R L R Br W BLACK B L R W2 R W1 W Gy1 Y G L B L Lg W Gy W G R W Gy W Gy G B L ON OFF RESET L N R Br L Br Br Br R W R R Y Dg Dg B B C Ch Ch Dg Ch B Dg L B Ch L B Y B B B Y L R L B W Br Y B B Y L R Y L B Br Y B B G C C C B B C W3 B R R Br W B R B...

Page 453: ...n angle sensor 23 Coolant temperature sensor 24 Air temperature sensor 25 ECU engine control unit 26 Rear cylinder ignition coil 27 Front cylinder ignition coil 28 Spark plug 29 ISC idle speed control unit 30 Front cylinder injector 31 Rear cylinder injector 36 Multi function meter 37 Engine trouble warning light 44 O2 sensor 47 Headlight relay 50 Clutch switch 61 Select switch 62 Reset switch 63 ...

Page 454: ... Gy W Gy G B L BLACK Ch Y R W Sb W Dg P B B Y G Y L G R G W BLACK Sb W P B R W Ch Dg Y B G Y G R G Y L W B Y B P B Y G Y Br BLUE Y L Y B Dg Ch Br W B2 Br2 Y R B Y G L B B R R W L W1 B Y Y G B B W P W Br ON OFF RESET L N R SELECT Br L Br Br2 Br R W R R Y1 Dg L Ch Ch Ch Ch L B Y B B L Y L B W Br Y B B L Y L Y B Br Y B W B G B B B B B B R R Br W B R B R B R1 R1 R W L1 R W1 R W R W2 B L L W Y B W O R ...

Page 455: ...Lean angle sensor 23 Coolant temperature sensor 24 Air temperature sensor 25 ECU engine control unit 26 Rear cylinder ignition coil 27 Front cylinder ignition coil 28 Spark plug 29 ISC idle speed control unit 30 Front cylinder injector 31 Rear cylinder injector 36 Multi function meter 37 Engine trouble warning light 44 O2 sensor 46 Headlight relay 49 Clutch switch 61 Select switch 62 Reset switch ...

Page 456: ...dometer tripme ter fuel reserve tripmeter clock LCD Once a fault code has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel injection system operation The warning light flashes when any one of the conditions listed below is present and the start switch is pushed Checking the engine trouble warning light The engine trouble...

Page 457: ...s Fault code No Item Symptom Able un able to start Able un able to drive 12 Crankshaft position sensor No normal signals are received from the crankshaft position sen sor Unable Unable 13 Intake air pressure sensor open or short circuit Intake air pressure sensor open or short circuit detected Able Able 14 Intake air pressure sensor hose system Intake air pressure sensor hose system malfunction cl...

Page 458: ...r of faulty cylin ders 41 Lean angle sensor open or short circuit Lean angle sensor open or short circuit detected Unable Unable 42 Speed sensor No normal signals are received from the speed sensor Able Able Neutral switch Open or short circuit is detected in the neutral switch Clutch switch Open or short circuit is detected in the clutch switch 43 Fuel system voltage monitoring voltage The ECU is...

Page 459: ...g sensors and actuators in the diagnostic mode Refer to Sensor operation table and Actuator op eration table If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunction is detected in the sensors and actuators check and repair the inner parts of the engine Fault code No Item Symptom Able un able to start Able un able to drive Er 1 ECU internal malf...

Page 460: ...stop switch to 6 Select the diagnostic code number corresponding to the fault code number by pressing the SE LECT and RESET switches TIP To decrease the selected diagnostic code number press the side of the SELECT switch Press the side of the SELECT switch for 1 second or longer to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number press the side of ...

Page 461: ...clock LCD 5 Set the engine stop switch to 6 Select the diagnostic code number corresponding to the fault code number by pressing the SE LECT and RESET switches TIP To decrease the selected diagnostic code number press the RESET switch Press the RESET switch for 1 second or longer to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number press the SELECT ...

Page 462: ...tle position sensor 01 19 A break or disconnection of the blue black lead of the ECU is detected Malfunction in wire harness ECU coupler Open or short circuit in wire harness Defective sidestand switch Malfunction in ECU 20 21 Coolant temperature sen sor open or short circuit detected Open or short circuit in wire harness Defective coolant temperature sensor Malfunction in ECU Improperly installed...

Page 463: ...angle sensor Malfunction in ECU 08 42 No normal signals are re ceived from the speed sen sor Open or short circuit is de tected in the neutral switch Open or short circuit is de tected in the clutch switch Open or short circuit in wire harness Defective speed sensor Malfunction in speed sensor Defective neutral switch Malfunction in the engine side of the neutral switch Defective clutch switch Imp...

Page 464: ...n or short circuit in wire harness Malfunction in meter Malfunction in ECU Er 4 Non registered data has been received from the meter Open or short circuit in wire harness Malfunction in meter Malfunction in ECU Fault code No Symptom Probable cause of malfunction Diagnostic code No Diag nostic code No Item Meter display Checking method 01 Throttle angle Fully closed position 14 20 Check with thrott...

Page 465: ... the bat tery voltage is lower per form recharging 20 Sidestand switch Set on off the sidestand switch with the transmis sion in gear Sidestand retracted ON Sidestand extended OFF 21 Neutral switch and clutch switch Shift the transmission squeeze the clutch lever and extend the sidestand Neutral ON In gear and clutch lever released OFF In gear clutch lever squeezed and sidestand retracted ON In ge...

Page 466: ...rent malfunction that have occurred since the history was last erased For example if there have been three malfunctions 03 is displayed To erase the history set the engine stop switch to 63 Malfunction code reinstate ment for fault code No 24 only No malfunction code 00 Malfunction code exists Fault code 24 If more than one code number is detected the dis play alternates every two seconds to show ...

Page 467: ...inder in jector five times at one sec ond intervals Illuminates the engine trou ble warning light Check the operating sound of the rear cylinder injector five times 50 Fuel pump relay Actuates the fuel pump relay five times at one second in tervals Illuminates the engine trou ble warning light The engine trouble warning light is OFF when the relay is ON and the engine trouble warning light is ON w...

Page 468: ...n opens it to the standby opening position when the engine is started This operation takes approxi mately 12 seconds until it is completed Illuminates the engine trou ble warning light The ISC unit vibrates when the ISC valve operates Diag nostic code No Item Actuation Checking method ...

Page 469: ...code No 12 Symptom No normal signals are received from the crankshaft posi tion sensor Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of crankshaft posi tion sensor Check for looseness or pinching Cranking the engine 2 Connections Crankshaft position sensor coupler Main wire harness ECU coupler Check the coupler for a...

Page 470: ... ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit between intake air pressure sensor cou pler and ECU coupler XVS13AA C XVS13CTA C black blue black blue pink white pink white ...

Page 471: ...e and let it idle for approxi mately 5 sec onds 2 Intake air pressure sensor malfunction at intermediate electrical potential Check and repair the connec tion Replace it if there is a malfunc tion 3 Connections Intake air pressure sensor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair...

Page 472: ...heck the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit between throttle position sensor coupler and ECU coupler blue blue yellow yellow black blue black blue 4 Throttle position sensor lead open cir cuit output voltage check Check for open circuit ...

Page 473: ... the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely If the transmis sion is in gear retracting the sidestand If the transmis sion is in neu tral reconnecting the wiring 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between ECU and blue black...

Page 474: ...nt temperature sensor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit between coolant temperature sensor coupler and ECU coupler black blue black blue gr...

Page 475: ...temperature sensor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit between air temperature sensor coupler and ECU coupler brown white brown white black b...

Page 476: ...green black blue black blue 4 Check fuel pressure Refer to CHECKING THE FUEL PRESSURE on page 7 14 5 Defective O2 sensor Replace if defective Fault code No 30 Symptom The vehicle has overturned Diagnostic code No 08 Lean angle sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 The vehicle has overturned Raise the vehicle upright Turning the main switch ...

Page 477: ...harness ECU coupler Check the connector and cou pler for any pins that may be pulled out Check the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between front cylinder ignition coil connector and ECU cou pler orange orange Between fro...

Page 478: ...ness ECU coupler Check the connector and cou pler for any pins that may be pulled out Check the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between rear cylinder ignition coil connector and ECU cou pler gray red gray red Between rea...

Page 479: ... Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3 8 A 3 ISC valve is not moving correctly Replace the throttle body as sembly B 1 Installed condition of ISC idle speed control unit Check for looseness or pinch ing Start the en gine and let it idle for approxi mately 10 sec onds B 2 Connections ISC idle speed control unit coupler Wire harness ECU coupler Check the coupler for any pins that...

Page 480: ... 2 Open or short circuit in wire harness and or injector sub wire harness for XVS13AA C XVS13CTA C Repair or replace if there is an open or short circuit Between rear cylinder injector coupler and ECU coupler gray gray white red blue Between front cylinder injector coupler and ECU coupler green green white red blue 3 Open or short circuit in wire harness for XVS13CA C Repair or replace if there is...

Page 481: ...r any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to ON 2 Open or short circuit in lead Repair or replace if there is an open or short circuit between lean angle sensor coupler and ECU coupler blue blue yellow green yellow green black blue black blue 3 Defective lean angle senso...

Page 482: ...ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and acti vating the speed sensor by operating the vehicle at 20 to 30 km h A 2 Open or short circuit in speed sensor lead Repair or replace if there is an open or short circuit Between speed sensor co...

Page 483: ...ky blue sky blue Between relay unit coupler and main switch blue yellow blue yellow Between main switch and ECU coupler blue black blue black B 3 Faulty shift drum neutral detection ar ea Replace if defective Refer to TRANSMISSION on page 5 88 B 4 Defective neutral switch Execute the diagnostic mode Code No 21 Replace if defective Refer to CHECKING THE SWITCHES on page 8 93 Fault code No 42 Sympto...

Page 484: ...cuit Between clutch switch coupler and relay unit coupler fuel pump relay black yellow black yellow blue yellow blue yellow Between relay unit coupler and main switch blue yellow blue yellow Between clutch switch coupler and ECU coupler black yellow black yellow C 4 Defective neutral switch Execute the diagnostic mode Code No 21 Replace if defective Refer to CHECKING THE SWITCHES on page 8 93 Faul...

Page 485: ...y and ECU coupler blue red blue red red blue red blue Between relay unit coupler fuel pump relay and starter relay coupler red red Between relay unit coupler fuel pump relay and right handlebar switch coupler black red black red 3 Malfunction or open circuit in relay unit fuel pump relay Execute the diagnostic mode Code No 09 and or 50 Replace if defective If there is no malfunction with the relay...

Page 486: ...nction in rectifier regulator Replace if defective Refer to CHARGING SYS TEM on page 8 17 3 Malfunction in AC magneto Replace if defective Refer to CHARGING SYS TEM on page 8 17 Fault code No 50 Symptom Faulty ECU memory When this malfunction is detected in the ECU the fault code number might not appear on the meter Diagnostic code No Order Item components and probable cause Check or maintenance j...

Page 487: ...lue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 2 Symptom No signals are received from the ECU within the specified duration Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness ECU coupler Meter assembly coupler Check the coupler for any pins that ma...

Page 488: ...lue yellow blue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 4 Symptom Non registered data has been received from the meter Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness ECU coupler Meter assembly coupler Check the coupler for any pins that may ...

Page 489: ...FUEL INJECTION SYSTEM 8 82 ...

Page 490: ...ACK Ch L B Ch L G B Y B B BLACK BLACK G W DARK GREEN B L DARK GRAY GRAY A WIRE HARNESS SUB WIREHARNESS B WIRE HARNESS SUB WIREHARNESS C WIRE HARNESS Gy R L R Br W BLACK B L R W2 R W1 W Gy1 Y G L B L Lg W Gy W G R W Gy W Gy G B L ON OFF RESET L N R Br L Br Br Br R W R R Y Dg Dg B B C Ch Ch Dg Ch B Dg L B Ch L B Y B B B Y L R L B W Br Y B B Y L R Y L B Br Y B B G C C C B B C W3 B R R Br W B R B R B ...

Page 491: ...FUEL PUMP SYSTEM 8 84 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 ...

Page 492: ...y W Gy G B L BLACK Ch Y R W Sb W Dg P B B Y G Y L G R G W BLACK Sb W P B R W Ch Dg Y B G Y G R G Y L W B Y B P B Y G Y Br BLUE Y L Y B Dg Ch Br W B2 Br2 Y R B Y G L B B R R W L W1 B Y Y G B B W P W Br ON OFF RESET L N R SELECT Br L Br Br2 Br R W R R Y1 Dg L Ch Ch Ch Ch L B Y B B L Y L B W Br Y B B L Y L Y B Br Y B W B G B B B B B B R R Br W B R B R B R1 R1 R W L1 R W1 R W R W2 B L L W Y B W O R P ...

Page 493: ...FUEL PUMP SYSTEM 8 86 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 ...

Page 494: ...9 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 100 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 93 Replace the main switch 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 93 The engine stop switch is faulty Replace the right handlebar switch 5 Check...

Page 495: ...7 Check the entire fuel pump sys tem s wiring Refer to CIRCUIT DIAGRAM for XVS13AA C XVS13CTA C on page 8 83 and CIRCUIT DIA GRAM for XVS13CA C on page 8 85 Properly connect or repair the fuel pump system s wiring Replace the ECU ...

Page 496: ...ELECTRICAL COMPONENTS 8 89 EAS27970 ELECTRICAL COMPONENTS 1 5 4 6 7 9 8 10 11 12 13 15 2 3 14 ...

Page 497: ...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 Coolant temperature sensor for XVS13CA C 9 ECU engine control unit 10 Turn signal relay 11 Speed sensor 12 Neutral switch 13 Oil level switch 14 Horn 15 Air temperature sensor ...

Page 498: ...ELECTRICAL COMPONENTS 8 91 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 ...

Page 499: ... 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 Starter relay 14 Fuel injection system fuse 15 Relay unit 16 Radiator fan motor relay 17 Headlight relay 18 Sidestand switch 19 Rear brake light switch 20 Radiator fan motor ...

Page 500: ...TA C B B 9 10 11 8 12 Y G P B R R ON OFF Ch Br W Dg B Y R L N R L Y B Y B B BLACK 13 7 RESET 5 4 6 2 3 1 Br L Br L L B L Y R Y BLACK L Y B Y R W B W L W P W Y G B Y P B B R B Y B B Y L Y B Dg Ch Br W BLUE BLACK B Y P G Y R R Y B Y Y G B W B P W P B R W B R Br L W L Y L B Br B ...

Page 501: ... 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 Clutch switch 13 Sidestand switch ...

Page 502: ...Y G Br B R R ON OFF Ch Br W Dg B Y R L N R L Y B Y B B BLACK 9 7 RESET 5 4 6 2 3 1 Br L Br L L B L Y L B BLACK L Y B Y R W B L W Y G B Y SELECT P W B Y B R B B BLACK B Y P Br G Y R L B B Y Y G B B W P W Br B R R W L W L Y L B Br B W BLUE Y L Y B Dg Ch Br W ...

Page 503: ... 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 Turn signal switch 13 Horn switch ...

Page 504: ... range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch posit...

Page 505: ...ollowing procedure applies to all of the bulbs 1 Remove Bulb WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down NOTICE ECA3D81021 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of the...

Page 506: ...use and check the continuity TIP Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit WARNING EWA13310 Never use a fuse wit...

Page 507: ... from those of conventional batteries The VRLA Valve Regulated Lead Acid battery should be charged according to the appropriate charging method If the battery is over charged the electrolyte level will drop con siderably Therefore take special care when charging the battery TIP Since VRLA Valve Regulated Lead Acid bat teries are sealed it is not possible to check the charge state of the battery by...

Page 508: ... contact with the battery terminal and that they are not shorted A corroded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process dis connect the battery charger and let the bat tery cool before reconnecting it Hot batteries can explode As shown in the following illust...

Page 509: ... should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the bat tery TIP If the current is lower than the standard charging current written on the battery this type of battery charger cannot charge the VRLA Valve Regu lated Lead Acid battery A v...

Page 510: ...pecification Replace Starter relay 1 Relay unit starting circuit cut off relay Recommended lubricant Dielectric grease Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe A For XVS13AA C XVS13CTA C B For XVS13CA C R B R 4 3 L w A 2 1 R B R 2 4 3 L R w B 1 Result Continuity between 3 and 4 ...

Page 511: ... 3 and 4 Sb W L G L Y Sb B Y L W R L L R R B R L 1 3 2 4 A 3 1 2 4 B R R W B 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe A For XVS13AA C XVS13CTA C B For XVS13CA C Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 R Y ...

Page 512: ...he turn signal relay terminal as shown b Turn the main switch to ON c Measure the turn signal relay output voltage EAS28050 CHECKING THE DIODES Relay unit diode 1 Check Relay unit diode Out of specification Replace TIP The pocket tester or the analog pocket tester readings are shown in the following table Turn signal relay input voltage DC 12 V Pocket tester 90890 03112 Analog pocket tester YU 031...

Page 513: ...ow 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe blue yellow 3 No continuity Positive tester probe blue yellow 3 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe sky blue white 4 No continuity Positive tester probe sky blue white 4 Negative tester probe sky blue 1 Continuity Positive tester pro...

Page 514: ...gap a e Crank the engine by pushing the start switch and gradually increase the spark gap un til a misfire occurs EAS28070 CHECKING THE SPARK PLUG CAPS The following procedure applies to all of the spark plug caps 1 Check Spark plug cap resistance Out of specification Replace a Remove the spark plug cap from the spark plug lead b Connect the pocket tester Ω 1k to the spark plug cap as shown Contin...

Page 515: ...secondary coil resistance EAS28120 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace the crank shaft position sensor stator assembly a Connect the pocket tester Ω 100 to the crankshaft position sensor coupler as shown Primary coil resistance 2 16 2 64 Ω Pocket test...

Page 516: ...Perform the electric starting system troubleshooting starting with step 4 Refer to TROUBLESHOOTING on page 8 15 a Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 WARNING EWA13810 A wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make...

Page 517: ... 5000 r min d Measure the charging voltage EAS3D81012 CHECKING THE OIL LEVEL SWITCH 1 Drain Engine oil 2 Remove Oil level switch from the crankcase 3 Check Oil level switch resistance Out of specification Replace the oil level switch a Connect the pocket tester Ω 100 to the oil level switch terminal as shown Stator coil resistance 0 112 0 168 Ω Pocket tester 90890 03112 Analog pocket tester YU 031...

Page 518: ...the fuel send er a Connect the pocket tester Ω 100 to the fuel sender coupler as shown b Move the fuel sender float to the empty fuel tank position 3 and to the full fuel tank posi tion 4 Pocket tester 90890 03112 Analog pocket tester YU 03112 C Minimum level position A Positive tester probe connector white 1 Negative tester probe body ground 2 Maximum level position B Positive tester probe connec...

Page 519: ...GHT 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 Warning light is OK Warning light does not come on Replace the meter assembly Warning light flashes ten times then goes off for 2 5 seconds in a repeated cycle malfunc tion detected in oil le...

Page 520: ...lant temperature sen sor to strong shocks If the coolant temper ature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 100 to the coolant temperature sensor as shown b Immerse the coolant temperature sensor 1 in a container filled with coolant 2 TIP Make sure the coolant temperature sensor ter minals do not get we...

Page 521: ... Intake air pressure sensor output voltage Out of specification Replace a Connect the pocket tester DC 20 V to the in take air pressure sensor coupler as shown b Set the main switch to ON c Measure the intake air pressure sensor out put voltage EAS28420 CHECKING THE AIR TEMPERATURE SENSOR 1 Remove Air temperature sensor WARNING EWA3D81003 Handle the air temperature sensor with special care Resista...

Page 522: ...ture sensor terminal as shown b Immerse the air temperature sensor 1 in a container filled with water 2 TIP Make sure that the air temperature sensor termi nals do not get wet c Place a thermometer 3 in the water d Slowly heat the water and then let it cool down to the specified temperature e Measure the air temperature sensor resis tance Air temperature sensor resis tance 290 390 Ω at 80 C 176 F ...

Page 523: ...DLING 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 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 ...

Page 524: ...hose Clogged rollover valve Deteriorated or contaminated fuel 2 Fuel pump Faulty fuel pump Faulty relay unit fuel pump relay 3 Fuel cock Clogged or damaged fuel hose 4 Throttle body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug g...

Page 525: ...AS28540 SHIFT PEDAL DOES NOT MOVE Shift shaft Improperly adjusted shift rod Bent shift shaft Shift drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly ret...

Page 526: ...ermostat stays open EAS28620 POOR BRAKING PERFORMANCE Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper kit Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS28650 FAULTY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or...

Page 527: ... tail brake light bulb for XVS13AA C XVS13CTA C Wrong tail brake light LED for XVS13CA C Too many electrical accessories Incorrect connection Burnt out tail brake light bulb for XVS13AA C XVS13CTA C Faulty tail brake light LED for XVS13CA C Tail brake light bulb burnt out Wrong tail brake light bulb for XVS13AA C XVS13CTA C Wrong tail brake light LED for XVS13CA C Faulty battery Incorrectly adjust...

Page 528: ...ay 48 Left handlebar switch 49 Dimmer switch 50 Clutch switch 51 Turn signal switch 52 Horn switch 53 Rear right turn signal light 54 Rear left turn signal light 55 Front right turn signal position light 56 Front left turn signal position light 57 Headlight 58 Accessory light OPTION 59 Right handlebar switch 60 Front brake light switch 61 Select switch 62 Reset switch 63 Engine stop switch 64 Star...

Page 529: ...Left handlebar switch 48 Dimmer switch 49 Clutch switch 50 Turn signal switch 51 Horn switch 52 Rear right turn signal light 53 Rear left turn signal light 54 Horn 55 Front right turn signal position light 56 Front left turn signal position light 57 Headlight 58 Accessory light OPTION 59 Right handlebar switch 60 Front brake light switch 61 Select switch 62 Reset switch 63 Engine stop switch 64 St...

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Page 532: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 533: ...ACK BLACK G W DARK GREEN B L DARK GRAY GRAY A WIRE HARNESS SUB WIREHARNESS B WIRE HARNESS SUB WIREHARNESS C WIRE HARNESS Gy R L R Br W BLACK B L R W2 R W1 W Gy1 Y G L B L Lg W Gy W G R W Gy W Gy G B L ON OFF RESET L N R Br L Br Br Br R W R R Y Dg Dg B B C Ch Ch Dg Ch B Dg L B Ch L B Y B B B YL R L B W Br Y B B YL R Y L B Br Y B B G C C C B B C W3 B R R Br W B R B R B R R L W R W1 R W2 B L L W Y B ...

Page 534: ... BLACK DARK GREEN A WIRE HARNESS SUB WIREHARNESS B WIRE HARNESS SUB WIREHARNESS C WIRE HARNESS BLACK TAIL BRAKE LIGHT WIRE HARNESS ON OFF RESET L N R C C C C C A B B B B A A A A A BLACK GRAY DARK GRAY 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 27 26 28 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 68 67 69 70 71 72 53 54 55 56 58 59 60 61 62 63 64 6...

Page 535: ...K Ch Y R W Sb W Dg P B B Y G Y L G R G W BLACK Sb W P B R W Ch Dg Y B G Y G R G Y L W B Y B P B Y G Y Br BLUE Y L Y B Dg Ch Br W B2 Br2 Y R B Y G L B B R R W L W1 B Y Y G B B W P W Br ON OFF RESET L N R SELECT Br L Br Br2 Br R W R R Y1 Dg L Ch Ch Ch Ch L B Y B B L Y L B W Br Y B B L Y L Y B Br Y B W B G B B B B B B R R Br W B R B R B R1 R1 R W L1 R W1 R W R W2 B L L W Y B W O R P R W L B Gy1 W Y G...

Page 536: ...S B WIRE HARNESS BLACK BLACK YELLOW YELLOW BLACK BLACK BLACK BLACK BLUE ON OFF RESET L N R SELECT TAIL BRAKE LIGHT WIRE HARNESS B B B A A A A A A B B BLUE BLACK BLACK DARK GRAY GRAY 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 27 26 28 28 29 31 30 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 68 67 69 70 71 72 52 53 55 54 56 58 59 60 61 62 63 64 65 66 57 73 11 ...

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