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

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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.
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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:

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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

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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