Yamaha Royal Star Tour Deluxe XVZ13CTTC Manual

LIT-11616-18-02 4XY-28197-E1
XVZ13CTT(C)
SUPPLEMENTARY
SERVICE MANUAL

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
XVZ13CTT(C). For complete service information procedures it is necessary to use this Supplemen-
tary Service Manual together with the following manual.
XVZ13TFL/XVZ13TFLC SERVICE MANUAL: LIT-11616-12-60 (4XY-28197-E0)
XVZ13CTT(C)
SUPPLEMENTARY
SERVICE MANUAL
©2004 by Yamaha Motor Corporation, U.S.A.
First edition, March 2004
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
LIT-11616-18-02

EAS00003
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-
ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in
one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard
to performance and emissions. Proper service with the correct tools is necessary to ensure that the
vehicle will operate as designed. If there is any question about a service procedure, it is imperative
that you contact a Yamaha dealer for any service information changes that apply to this model. This
policy is intended to provide the customer with the most satisfaction from his vehicle and to conform
to federal environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-
ers and will appear in future editions of this manual where applicable.
NOTE:
@
• This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
• Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person checking or repairing the
motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:

EAS00007
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are
laid out with the individual steps in sequential order.
1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter.
Refer to “SYMBOLS”.
2Each chapter is divided into sections. The current section title is shown at the top of each page,
except in chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s)
appears.
3Sub-section titles appear in smaller print than the section title.
4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8Jobs requiring more information (such as special tools and technical data) are described sequen-
tially.
7
5
214
6
8
3

EAS00008
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1to 9indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Engine
5Cooling system
6Carburetor(s)
7Chassis
8Electrical system
9Troubleshooting
Symbols 0to Gindicate the following.
0Serviceable with engine mounted
AFilling fluid
BLubricant
CSpecial tool
DTightening torque
EWear limit, clearance
FEngine speed
GElectrical data
Symbols Hto Min the exploded diagrams
indicate the types of lubricants and lubrication
points.
HEngine oil
IGear oil
JMolybdenum disulfide oil
KWheel bearing grease
LLithium-soap-based grease
MMolybdenum disulfide grease
Symbols Nto Oin the exploded diagrams
indicate the following.
NApply locking agent (LOCTITE®)
OReplace the part
12
34
56
78
90
AB
CD
EFG
HIJ
KLM
NO
GEN
INFO
SPEC
CHK
ADJ ENG
COOL CARB
CHAS
–+
ELEC
TRBL
SHTG
T
R
.
.
EGM
BLS M
LT
New

CONTENTS
SPECIFICATIONS ............................................................................................1
GENERAL SPECIFICATIONS ..................................................................1
MAINTENANCE SPECIFICATIONS .........................................................3
ENGINE ................................................................................................3
CHASSIS ..............................................................................................4
ELECTRICAL ........................................................................................6
CABLE ROUTING .....................................................................................7
PERIODIC CHECKS AND ADJUSTMENTS ..................................................29
INTRODUCTION .....................................................................................29
PERIODIC MAINTENANCE CHART
FOR THE EMISSION CONTROL SYSTEM ...........................................29
GENERAL MAINTENANCE AND LUBRICATION CHART .....................29
RIDER AND PASSENGER SEATS ........................................................32
WINDSHIELD AND FUEL TANK ............................................................33
BACKREST AND SIDECASES ...............................................................34
CHASSIS .................................................................................................35
CHECKING AND ADJUSTING THE STEERING HEAD .....................35
ELECTRICAL SYSTEM ..........................................................................37
ADJUSTING THE HEADLIGHT BEAM ...............................................37
ELECTRICAL SYSTEM ..................................................................................38
CHECKING THE SWITCHES .................................................................38
IGNITION SYSTEM .................................................................................40
CIRCUIT DIAGRAM ............................................................................40
TROUBLESHOOTING ........................................................................41
ELECTRIC STARTING SYSTEM ............................................................46
CIRCUIT DIAGRAM ............................................................................46
LIGHTING SYSTEM ................................................................................47
CIRCUIT DIAGRAM ............................................................................47
SIGNALING SYSTEM .............................................................................48
CIRCUIT DIAGRAM ............................................................................48
CHECKING THE SIGNALING SYSTEM .............................................50
COOLING SYSTEM ................................................................................54
CIRCUIT DIAGRAM ............................................................................54
TROUBLESHOOTING ........................................................................55
FUEL PUMP SYSTEM ............................................................................58
CIRCUIT DIAGRAM ............................................................................58
TROUBLESHOOTING ........................................................................59
CARBURETOR HEATING SYSTEM ......................................................61
CIRCUIT DIAGRAM ............................................................................61
TROUBLESHOOTING ........................................................................62

CRUISE CONTROL SYSTEM ................................................................66
CIRCUIT DIAGRAM ............................................................................66
INSTRUMENT AND CONTROL FUNCTIONS ...................................68
CHECKING THE CRUISE CONTROL SYSTEM ................................70
SELF-DIAGNOSIS FUNCTION
OF THE CRUISE CONTROL SYSTEM ..............................................72
SELF-DIAGNOSIS ..................................................................................75
XVZ13CTT(C) WIRING DIAGRAM

–1 –
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard
Model code: 1D61 (for USA)
1D62 (for California)
1D63 (for CDN)
2C41 (for Oceania)
Dimensions:
Overall length 2,505 mm (98.6 in)
Overall width 1,010 mm (39.8 in)
(for USA, California, and CDN)
995 mm (39.2 in) (for Oceania)
Overall height 1,525 mm (60.0 in)
Seat height 740 mm (29.1 in)
Wheelbase 1,715 mm (67.5 in)
Ground clearance 150 mm (5.91 in)
Minimum turning radius 3,500 mm (137.8 in)
Basic weight:
Dry weight 357 kg (787 lb)
With oil and a full fuel tank 383 kg (844 lb)
Fuel:
Type Unleaded gasoline only
(for USA, California, and Oceania)
Regular unleaded gasoline only (for CDN)
Fuel tank capacity 20.0 L (4.40 Imp gal, 5.28 US gal)
Fuel reserve amount 3.9 L (0.86 Imp gal, 1.03 US gal)
Carburetor:
Type ×quantity BDSR32 ×4
Manufacturer MIKUNI
Chassis:
Frame type Double cradle
Caster angle 28.83°
Trail 131.0 mm (5.16 in)
Tire:
Type Tubeless
Size front 150/80-16M/C 71H
rear 150/90B15M/C 74H
Manufacturer front BRIDGESTONE
rear BRIDGESTONE
Type front G705G
rear G702G
GENERAL SPECIFICATIONS

–2 –
SPEC
GENERAL SPECIFICATIONS
Bulb wattage ×quantity:
Headlight 12 V 60 W/55 W ×1
Auxiliary light 12 V 4 W ×1 (for Oceania)
Tail/brake light 12 V 8 W/27 W ×1
(for USA, California, and CDN)
12 V 5 W/21 W ×1 (for Oceania)
Front turn signal/position light 12 V 23 W/8 W ×2
(for USA, California, and CDN)
Front turn signal light 12 V 21 W ×2 (for Oceania)
Rear turn signal light 12 V 21 W ×2
Meter light LED
Indicator light
Neutral indicator light LED
Turn signal indicator light LED
High beam indicator light LED
Oil level warning light LED
Coolant temperature warning light LED
Engine trouble warning light LED
Overdrive indicator right LED
Cruise control “SET”indicator light LED
Cruise control “ON”indicator light LED
Item Standard

–3 –
SPEC
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
Tightening torques
Item Standard Limit
Carburetor:
I.D.mark 4XY1 20 (for USA and CDN)
4XY2 30 (for California)
5JC1 10 (for Oceania)
----
----
----
Main jet (M.J) #1, 2 : #122.5 #3 : #117.5 #4 : #120 ----
Main air jet (M.A.J) #110 ----
Jet needle (J.N) 5DL38-54-1 (for USA, California, and
CDN)
5DL41-54-3 (for Oceania)
----
----
Needle jet (N.J) P-0M ----
Pilot air jet (P.A.J.1) #85 ----
Pilot outlet (P.O) 1.1 ----
Pilot jet (P.J) #15 ----
Bypass 1 (B.P.1) 0.8 ----
Bypass 2 (B.P.2) 0.8 ----
Bypass 3 (B.P.3) 0.8 ----
Valve seat size (V.S) 1.5 ----
Starter jet (G.S.1) #35 ----
Starter jet (G.S.2) 0.5 ----
Throttle valve size (Th. V) #110 ----
Fuel level (F.L) 13.1 ~ 14.1 mm (0.52 ~ 0.56 in) ----
Engine idle speed 950 ~ 1,050 r/min ----
Intake vacuum 37 kPa (280 mmHg, 11.0 inHg) ----
Fuel pump:
Type Electrical type ----
Model/manufacturer 1D6/MITSUBISHI ----
Consumption amperage <max> 1 A ----
Output pressure 15 ~ 20 kPa (0.15 ~ 0.20 kgf/cm2, 2.1 ~
2.8 psi)
----
Item Fastener Thread size Q’ty Tightening torque Remarks
Nm m ·kg ft ·lb
Heat protector plate Bolt M6 ×1.0 2 10 1.0 7.2
Air induction box cover Screw M5 4 3 0.3 2.2
Air filter case duct Screw M5 4 3 0.3 2.2
Air filter case cover Screw M5 10 3 0.3 2.2
Air filter element Screw M5 4 3 0.3 2.2
Air filter assembly Bolt M6 ×1.0 4 7 0.7 5.1
Middle gear case cover Bolt M6 ×1.0 1 10 1.0 7.2
Final gear case and swingarm Nut M10 ×1.25 4 42 4.2 30
Ignition coil bracket Bolt M6 ×1.0 2 10 1.0 7.2

–4 –
SPEC
MAINTENANCE SPECIFICATIONS
CHASSIS
Tightening torque
Item Standard Limit
Front suspension:
Front fork travel 140 mm (5.51 in) ----
Fork spring free length 570 mm (22.44 in) 558.6 mm
(21.99 in)
Spring rate (K1) 8.83 N/mm (0.9 kgf/mm, 50.4 lb/in) ----
Spring stroke (K1) 0 ~ 140 mm (0.00 ~ 5.51 in) ----
Optional spring No ----
Oil capacity 553 cm3(19.5 Imp oz, 18.7 US oz) ----
Oil level 117 mm (4.61 in) ----
Oil grade Yamaha fork oil 5WT (for USA, California,
and CDN)
----
Fork oil 5 W or equivalent (for Oceania) ----
Enclosed gas/air pressure 0 kPa (0 kgf/cm2, 0 psi) ----
(Minimum ~ Maximum) 0 ~ 50 kPa (0 ~ 0.5 kgf/cm2, 0 ~ 7.1 psi) ----
Rear suspension:
Shock absorber travel 45 mm (1.77 in) ----
Spring free length 184.5 mm (7.26 in) 180.8 mm
(7.12 in)
Fitting length 165.5 mm (6.52 in) ----
Spring rate (K1) 147 N/mm (14.99 kgf/mm, 839.4 lb/in) ----
Spring stroke (K1) 0 ~ 45 mm (0.00 ~ 1.97 in) ----
Optional spring No ----
Enclosed gas/air pressure 0 kPa (0 kg/cm2, 0 psi) ----
(Minimum ~ Maximum) 0 ~ 490 kPa (0 ~ 4.9 kgf/cm2, 0 ~ 69.7 psi) ----
Front wheel:
Type Cast wheel ----
Rim size 16 M/C ×MT3.50 ----
Rim material Aluminum ----
Rim runout limit radial ---- 1 mm
(0.04 in)
lateral ---- 0.5 mm
(0.02 in)
Part to be tightened Thread
size
Tightening torque Remarks
Nm m ·kg ft ·lb
Engine bracket and down tube M10 45 4.5 32
Muffler bracket (left and right) and frame M8 16 1.6 11
Muffler bracket (left and right) and muffler M10 30 3.0 22
M8 30 3.0 22
License plate bracket and rear fender M6 7 0.7 5.1
Rear turn signal light bracket and rear fender M6 7 0.7 5.1
Top cover bracket and fuel tank M6 7 0.7 5.1

– 5 –
SPEC
MAINTENANCE SPECIFICATIONS
NOTE:
1. First, tighten the lower ring nut approximately 52 Nm (5.2 m · kg, 37 ft · lb) by using the torque
wrench, then loosen the lower ring nut completely.
2. Retighten the lower ring nut to specification.
3. Turn the steering all the way in both directions several times, and then tighten the lower ring nut
to specification.
4. Repeat step (3) until the lower ring nut does not turn.
Rollover valve M5 4 0.4 2.9
Rider seat and frame M8 16 1.6 11
Passenger seat and frame M8 19 1.9 13
Rear wheel axle pinch bolt M8 23 2.3 17
Upper bracket and inner tube M6 18 1.8 13
Lower bracket and inner tube M8 23 2.3 17
Front fender and outer tube M8 30 3.0 22
Handlebar and grip end M6 8 0.8 5.8 LT
Windshield mount and windshield mount bracket M8 23 2.3 17 LT
Windshield mount and lower bracket M8 23 2.3 17 LT
Meter assembly and windshield mount bracket M6 7 0.7 5.1
Meter assembly and meter assembly bracket M6 10 1.0 7.2
Meter assembly bracket and upper bracket M6 10 1.0 7.2
Front turn signal light bracket and lower bracket M8 23 2.3 17
Front turn signal light assembly and front turn sig-
nal light bracket M6 5 0.5 3.6 LT
Headlight and headlight bracket M6 7 0.7 5.1
Rear brake hose holder and down tube M6 10 1.0 7.2
Rear brake hose holder and frame M6 10 1.0 7.2
Rear brake hose holder and swingarm M6 10 1.0 7.2
Footrest bracket and frame M10 52 5.2 37 LT
Sidecase frame and frame M8 23 2.3 17 LT
Backrest bracket mount and sidecase frame M8 23 2.3 17 LT
Helmet holder and sidecase bracket M6 7 0.7 5.1 LT
Sidecase guard and muffler bracket (left and right) M8 23 2.3 17
Sidecase guard and sidecase bracket M8 23 2.3 17
Sidecase and sidecase bracket M6 7 0.7 5.1
Sidecase and sidecase frame M6 7 0.7 5.1
Sidecase and muffler bracket (left and right) M6 7 0.7 5.1
Sidecase frame and muffler bracket (left and right) M8 25 2.5 18
Sidecase frame, muffler bracket (left and right),
and muffler bracket (center) M8 23 2.3 17
Muffler bracket (left and right) and muffler bracket
(center) M8 23 2.3 17
Sidecase bracket and frame M8 16 1.6 11
Backrest bracket and lock assembly M6 6 0.6 4.3 LT
Backrest and backrest bracket M6 10 1.0 7.2 LT
Lower ring nut (steering nut) M25 18 1.8 13 See NOTE
Part to be tightened Thread
size
Tightening torque Remarks
Nm m ·kg ft ·lb

–6 –
SPEC
MAINTENANCE SPECIFICATIONS
ELECTRICAL
Item Standard Limit
Fuel sender:
Model/manufacturer 1D6/NIPPON SEIKI ----
Resistance (Full) 9 ~ 11 Ωat 20 °C (68 °F) ----
(Empty) 213 ~ 219 Ωat 20 °C (68 °F) ----
Starting circuit cut-off relay:
Model/manufacturer G8R-30Y-U0/OMRON ----
Coil resistance 162 ~ 198 Ω----
Fuel pump relay:
Model/manufacturer G8R-30Y-U0/OMRON ----
Coil resistance 162 ~ 198 Ω----
Fuses (amperage ×quantity):
Main fuse 30 A ×1 ----
Headlight fuse 15 A ×1 ----
Signaling system fuse 15 A ×1 ----
Ignition fuse 10 A ×1 ----
Radiator fan fuse 10 A ×1 ----
Backup fuse (meter assembly) 10 A ×1 ----
Cruise control fuse 10 A ×1 ----
Carburetor heater fuse 15 A ×1 ----
Auxiliary DC jack fuse 5 A ×1 ----
Spare fuse 30 A ×1 ----
15 A ×1 ----
10 A ×2 ----
5 A ×1 ----

–7 –
SPEC
CABLE ROUTING
CABLE ROUTING
1Throttle cables
2Front brake hose
3Right handlebar switch lead
4Front brake switch lead
5Meter assembly lead
6Clutch hose
7Left handlebar switch lead
8Wire harness
ÈFasten the right handlebar switch lead and front
brake switch lead at the white tape on each lead
with a plastic band. The end of the plastic band
should be facing downward.
ÉThe clutch hose should be fastened 20 ~ 30 mm
(0.79 ~ 1.18 in) from the end of the protector
around the hose.
Ê
É
Ë
ÌÌ
1
È3452
6
7
8

–8 –
SPEC
CABLE ROUTING
ÊFasten the left handlebar switch lead and clutch
hose with a plastic band. Fasten the left handle-
bar switch lead at the white tape. The end of the
plastic band should be facing downward.
ËFasten the clutch hose in front of the left handle-
bar switch lead as shown in the illustration. Fas-
ten the right handlebar switch lead in front of the
front brake switch lead in the same way.
ÌTo headlight
Ê
É
Ë
ÌÌ
1
È3452
6
7
8

–9 –
SPEC
CABLE ROUTING
1Clutch hose
2Fuel sender lead
3Throttle position sensor lead
4Carburetor heater lead
5Throttle cables
6Crankcase breather hose
7Sidestand switch lead
8Carburetor air vent hose
9Ignition coil #2
0Front brake hose
ALeft handlebar switch lead
BFront brake switch lead
CRight handlebar switch lead
DIgnition coil #4 lead
ERear brake switch
FRear brake fluid reservoir hose
GAir induction system vacuum hose (front side)
HWire harness
IRectifier/regulator
JFuel hose
E
D
A
B
F-F
C-C
À
À
À
×
C
B
AÚÛ
Ü
Ü
H
1
1
2
4
3
5
1
B
A
C
E
I
5
L
M
7
6
1
HKJ
ß
0Ö
2É
È
Ï
Ì
ÐÎ
Í
Ò
B
A
E
D
F
C
C
F
AA AB AC AD
AE
AE
AH AI AJ
AG
5
4
3
Ñ
Ó
Ë
Ê
8
ÔÒ
Õ
Ø
Þ
Ý
Á
G
F
AF
Ù
9
5
D

–10 –
SPEC
CABLE ROUTING
KFuel tank breather hose
LCoolant reservoir hose
MCarburetor drain hoses
È80 mm (3.15 in)
ÉAttach the fuel sender lead coupler to the
bracket on the front of the fuel tank.
ÊFasten the throttle cables with the holder.
ËFasten the throttle cable (accelerator cable) on
the inside of the cable holder.
ÌFasten the throttle cable (decelerator cable) on
the outside of the cable holder.
ÍMake sure that there is no slack in the sidestand
switch lead.
E
D
A
B
F-F
C-C
À
À
À
×
C
B
AÚÛ
Ü
Ü
H
1
1
2
4
3
5
1
B
A
C
E
I
5
L
M
7
6
1
HKJ
ß
0Ö
2É
È
Ï
Ì
ÐÎ
Í
Ò
B
A
E
D
F
C
C
F
AA AB AC AD
AE
AE
AH AI AJ
AG
5
4
3
Ñ
Ó
Ë
Ê
8
ÔÒ
Õ
Ø
Þ
Ý
Á
G
F
AF
Ù
9
5
D

–11 –
SPEC
CABLE ROUTING
ÎFasten the sidestand switch lead with a plastic
locking tie. The end of the plastic locking tie
should be on the inside of the frame, facing
downward.
ÏWithin 5 mm (0.20 in)
ÐFasten the sidestand switch lead with the holder.
ÑFasten the sidestand switch lead with a plastic
locking tie. The end of the plastic locking tie
should be facing inward.
ÒTo under cover
ÓFasten the clutch pipe with the holder.
ÔPass the carburetor air vent hose through the
hose guide on the air filter case.
ÕPass a plastic locking tie through the hole in the
frame, and then fasten the clutch hose to the
frame with the tie. Place the end of the plastic
locking tie behind the fuel tank bracket.
ÖPass the front brake hose through the hose
guide.
×55 ~ 75°
E
D
A
B
F-F
C-C
À
À
À
×
C
B
AÚÛ
Ü
Ü
H
1
1
2
4
3
5
1
B
A
C
E
I
5
L
M
7
6
1
HKJ
ß
0Ö
2É
È
Ï
Ì
ÐÎ
Í
Ò
B
A
E
D
F
C
C
F
AA AB AC AD
AE
AE
AH AI AJ
AG
5
4
3
Ñ
Ó
Ë
Ê
8
ÔÒ
Õ
Ø
Þ
Ý
Á
G
F
AF
Ù
9
5
D

–12 –
SPEC
CABLE ROUTING
ØFasten the left handlebar switch lead, right han-
dlebar switch lead, front brake switch lead,
clutch hose, and throttle cables with a plastic
band. Fasten the left handlebar switch lead, right
handlebar switch lead, and front brake switch
lead at the white tape on each lead.
ÙPass the cables, hoses, and leads through the
opening in the upper right side panel and do not
pinch them with the panel.
ÚFasten the left handlebar switch lead, right han-
dlebar switch lead, and front brake switch lead
with the holder.
ÛFasten the wire harness, main switch lead, fuel
sender lead, right handlebar switch lead (water-
resistant coupler side), and front brake switch
lead with the holder. Fasten the protectors
around the leads and do not fasten the leads
themselves.
Ü5 ~ 10 mm (0.20 ~ 0.39 in)
E
D
A
B
F-F
C-C
À
À
À
×
C
B
AÚÛ
Ü
Ü
H
1
1
2
4
3
5
1
B
A
C
E
I
5
L
M
7
6
1
HKJ
ß
0Ö
2É
È
Ï
Ì
ÐÎ
Í
Ò
B
A
E
D
F
C
C
F
AA AB AC AD
AE
AE
AH AI AJ
AG
5
4
3
Ñ
Ó
Ë
Ê
8
ÔÒ
Õ
Ø
Þ
Ý
Á
G
F
AF
Ù
9
5
D

–13 –
SPEC
CABLE ROUTING
ÝFasten the wire harness, main switch lead, right
handlebar switch lead (water resistance coupler
side), fuel sender lead, front brake switch lead,
and ignition coil #4 lead with a plastic band. The
end of the plastic band should be facing down-
ward.
ÞFasten the wire harness, carburetor heater lead,
left handlebar switch lead, right handlebar switch
lead (regular coupler side), and throttle position
sensor lead with a plastic band. The end of the
plastic band should be facing downward.
ßPass a plastic locking tie through the hole in the
bracket, and then fasten the clutch pipe with the
tie. The end of the plastic locking tie should be
facing inward.
ÀTo under cover (right)
ÁFasten the ignition coil #2 leads with a plastic
locking tie to the frame cross pipe. Cut off the
end of the plastic locking tie.
Route the air induction system vacuum hose
(front side) to the outside of where the air filter
case joint crosses the frame.
AA
E
D
A
B
F-F
C-C
À
À
À
×
C
B
AÚÛ
Ü
Ü
H
1
1
2
4
3
5
1
B
A
C
E
I
5
L
M
7
6
1
HKJ
ß
0Ö
2É
È
Ï
Ì
ÐÎ
Í
Ò
B
A
E
D
F
C
C
F
AA AB AC AD
AE
AE
AH AI AJ
AG
5
4
3
Ñ
Ó
Ë
Ê
8
ÔÒ
Õ
Ø
Þ
Ý
Á
G
F
AF
Ù
9
5
D