Yamaha XVS13AW 2006 User manual

SERVICE MANUAL
XVS13AW(C)
XVS13CTW(C)
LIT-11616-20-42 3D8-28197-10

EAS20050
XVS13AW(C)/XVS13CTW(C)
SERVICE MANUAL
©2006 by Yamaha Motor Corporation, U.S.A.
First edition, August 2006
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-11616-20-42

EAS20070
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. 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 vehi-
cle 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 vehi-
cle 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 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.
NOTE:
• This Service Manual contains information regarding periodic maintenance to the emission control sys-
tem. Please read this material carefully.
• Designs and specifications are subject to change without notice.
EAS20080
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 vehicle operator, a bystander or a person checking or repairing the ve-
hicle.
A CAUTION indicates special precautions that must be taken to avoid dam-
age to the vehicle.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:

EAS20090
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.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-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 chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
3
4
5
6
1
2
7

EAS20100
SYMBOLS
The following symbols are used in this manual
for easier understanding.
NOTE:
The following symbols are not relevant to every
vehicle.
GM
E
BLS M
91011
12 13 14
15 16
LT New
T
R
.
123
456
78
1. Serviceable with engine mounted
2. Filling fluid
3. Lubricant
4. Special tool
5. Tightening torque
6. Wear limit, clearance
7. Engine speed
8. Electrical data
9. Engine oil
10.Gear oil
11.Molybdenum-disulfide oil
12.Wheel-bearing grease
13.Lithium-soap-based grease
14.Molybdenum-disulfide grease
15.Apply locking agent (LOCTITE®)
16.Replace the part

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

1
GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1
VEHICLE IDENTIFICATION NUMBER..................................................... 1-1
MODEL LABEL ......................................................................................... 1-1
FEATURES ..................................................................................................... 1-2
OUTLINE OF THE FI SYSTEM................................................................. 1-2
FI SYSTEM ............................................................................................... 1-3
INSTRUMENT FUNCTIONS..................................................................... 1-4
IMPORTANT INFORMATION ......................................................................... 1-6
PREPARATION FOR REMOVAL AND DISASSEMBLY .......................... 1-6
REPLACEMENT PARTS .......................................................................... 1-6
GASKETS, OIL SEALS AND O-RINGS.................................................... 1-6
LOCK WASHERS/PLATES AND COTTER PINS..................................... 1-6
BEARINGS AND OIL SEALS.................................................................... 1-7
CIRCLIPS.................................................................................................. 1-7
CHECKING THE CONNECTIONS.................................................................. 1-8
SPECIAL TOOLS............................................................................................ 1-9

IDENTIFICATION
1-1
EAS20130
IDENTIFICATION
EAS20140
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

FEATURES
1-2
EAS20170
FEATURES
EAS3D81037
OUTLINE OF THE FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum
air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In
the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion
chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the
respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating con-
ditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter the
fuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-
fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the en-
gine.
As the requirements for the engine to deliver more 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 microprocessor that regulates the fuel injection volume according to
the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response,
better fuel economy, and reduced exhaust emissions.
1 2 3 4 5 6 7 8 9 10 11 12 13 14
15161718819
1. Air temperature sensor
2. Engine trouble warning light
3. Front cylinder intake air pressure sensor
4. Rear cylinder intake air pressure sensor
5. Rear cylinder ignition coil
6. Front cylinder ignition coil
7. Throttle position sensor
8. Spark plug
9. Speed sensor
10.Lean angle sensor
11.Relay unit (fuel pump relay)
12.Fuel pump
13.ECU (engine control unit)
14.O2sensor
15.Rear cylinder injector
16.ISC (idle speed control) unit
17.Crankshaft position sensor
18.Front cylinder injector
19.Coolant temperature sensor

FEATURES
1-3
EAS3D81038
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm², 46.1 psi). Accordingly,
when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing
the fuel to be injected into the intake manifold only during the time the passage remains open. There-
fore, the longer the length of time the fuel injector is energized (injection duration), the greater the vol-
ume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized
(injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled 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 O2sensor 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 that is required by the engine can be supplied at all times
in accordance with the driving conditions.
Illustration is for reference only.
15
A
1
2
3
C
12
13
14
B
9
11
4
8
7
65
Front
Rear
10
1. Fuel pump
2. Fuel injector
3. Ignition coil
4. ECU (engine control unit)
5. Air temperature sensor
6. Lean angle sensor
7. ISC (idle speed control) unit
8. Throttle position sensor
9. O2sensor
10.Coolant temperature sensor
11.Catalytic converter
12.Crankshaft position sensor
13.Intake air pressure sensor
14.Throttle body
15.Air filter case
A. Fuel system
B. Air system
C. Control system

FEATURES
1-4
EAS3D81033
INSTRUMENT FUNCTIONS
Multi-function meter unit
WARNING
EWA3D81011
Be sure to stop the vehicle before making
any setting changes to the multi-function
meter unit.
The multi-function meter unit is equipped with
the following:
• a speedometer (which shows the riding speed)
• an odometer (which shows the total distance
traveled)
• two tripmeters (which show the distance trav-
eled since they were last set to zero)
• a fuel reserve tripmeter (which shows the dis-
tance traveled on the fuel reserve)
•aclock
• a self-diagnosis device
• a brightness control mode
NOTE:
Be sure to turn the key to “ON” before using the
“SELECT” switch “ / ” and “RESET” switch,
except for setting the brightness control mode.
Speedometer
The speedometer shows the riding speed.
When the key is turned to “ON”, the speedome-
ter needle will sweep once across the speed
range and then return to zero in order to test the
electrical circuit.
Odometer, tripmeter, and fuel reserve trip-
meter modes
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
NOTE:
Push the “ ” side of the “SELECT” switch to
switch the display in the reverse order.
If the fuel level warning light comes on, the
odometer display will automatically change to
the fuel reserve tripmeter mode “F-TRIP” and
start counting the distance traveled from that
point. In that case, push the “ ” side of the “SE-
LECT” switch to switch the display between the
various tripmeter, odometer, and clock modes in
the following order:
F-TRIP →TRIP 1 →TRIP 2 →Clock →ODO →
F-TRIP
1. Speedometer
2. Odometer/tripmeter/fuel reserve
tripmeter/clock
1. “SELECT” switch “ / ”
2. “RESET” switch
12
SELECT
RESET
1
2
1. Speedometer
1. Odometer/tripmeter/fuel reserve
tripmeter/clock
1
1

FEATURES
1-5
NOTE:
Push the “ ” side of the “SELECT” switch to
switch the display in the reverse order.
To reset a tripmeter, select it by pushing the “ ”
or “ ” side of the “SELECT” switch, and then
push the “RESET” switch for at least one sec-
ond. If you do not reset the fuel reserve tripmeter
manually, it will reset itself automatically, and the
display will return to the prior mode after refuel-
ing and traveling 5 km (3 mi).
Clock mode
Push the “RESET” switch for less than one sec-
ond to display the clock for five seconds, regard-
less of the currently selected display mode.
To set the clock:
1. Push the “ ” or “ ” side of the “SELECT”
switch to change the display to the clock
mode.
2. Push the “ ” side of the “SELECT” switch
and the “RESET” switch together for at least
two seconds.
3. When the hour digits start flashing, push the
“ ” or “ ” side of the “SELECT” switch to
set the hours.
4. Push the “RESET” switch, and the minute
digits 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 defective, the engine
trouble warning light will come on, and then the
odometer/tripmeter/clock display will indicate a
two-digit error code (e.g., 12, 13, 14).
If the odometer/tripmeter/clock display indicates
any error codes, note the code number, and
then check the vehicle. Refer to “FUEL INJEC-
TION SYSTEM” on page 8-31.
CAUTION:
ECA3D81016
If the display indicates an error code, the ve-
hicle should be checked as soon as possible
in order to avoid engine damage.
Brightness control mode
This function allows you to adjust the brightness
of the speedometer panel to suit the outside
lighting conditions.
To set the brightness:
1. Turn the key to “OFF”.
2. Push and hold the “ ” side of the “SELECT”
switch.
3. Turn the key to “ON”, and then release the
“SELECT” switch after five seconds or more.
4. Push the “ ” or “ ” side of the “SELECT”
switch to select the desired brightness level.
5. Push the “RESET” switch to confirm the se-
lected brightness level. The display will return
to the odometer, tripmeter or clock mode.
1. Clock
1
1. Speedometer panel
2. Brightness level
1
2

IMPORTANT INFORMATION
1-6
EAS20180
IMPORTANT INFORMATION
EAS20190
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning equip-
ment.
Refer to “SPECIAL TOOLS” on page 1-9.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “mat-
ed” through normal wear. Mated parts must
always be reused or replaced as an assem-
bly.
4. During disassembly, clean all of the parts and
place them in trays in the order of disassem-
bly. This will speed up assembly and allow for
the 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 and O-rings. All gasket surfac-
es, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
EAS20220
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
“1” and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs
along a flat of the bolt or nut.
1. Oil
2. Lip
3. Spring
4. Grease

IMPORTANT INFORMATION
1-7
EAS20230
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manu-
facturer’s marks or numbers are visible. When
installing oil seals “1”, lubricate the oil seal lips
with a light coat of lithium-soap-based grease.
Oil bearings liberally when installing, if appropri-
ate.
CAUTION:
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 opposite
the thrust “3” that the circlip receives.

CHECKING THE CONNECTIONS
1-8
EAS20250
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• Lead
• Coupler
• Connector
2. Check:
• Lead
• Coupler
• Connector
Moisture →Dry with an air blower.
Rust/stains →Connect and disconnect sev-
eral times.
3. Check:
• All connections
Loose connection →Connect properly.
NOTE:
If the pin “1” on the terminal is flattened, bend it
up.
4. Connect:
• Lead
• Coupler
• Connector
NOTE:
Make sure all connections are tight.
5. Check:
• Continuity
(with the pocket tester)
NOTE:
• 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 most part stores.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C

SPECIAL TOOLS
1-9
EAS20260
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
NOTE:
• 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
1-8, 5-64, 8-73,
8-74, 8-75,
8-79, 8-80,
8-81, 8-82,
8-83, 8-84,
8-85, 8-86,
8-87, 8-88,
8-89, 8-90
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
3-5, 3-6
Tappet adjusting tool
90890-04154
YM-04154
3-6
Vacuum gauge
90890-03094
Carburetor synchronizer
YU-44456
3-7
Timing light
90890-03141
Inductive clamp timing light
YU-03141
3-10
3
YU-44456

SPECIAL TOOLS
1-10
Compression gauge
90890-03081
Engine compression tester
YU-33223
3-11
Oil filter wrench
90890-01469
YM-01469
3-12
Belt tension gauge
90890-03170
Rear drive belt tension gauge
YM-03170
3-25
Steering nut wrench
90890-01403
Spanner wrench
YU-33975
3-26, 4-61
Damper rod holder
90890-01460
4-54, 4-56
T-handle
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
4-54, 4-56
Fork seal driver
90890-01442
Adjustable fork seal driver (36–46 mm)
YM-01442
4-56, 4-57
Rotor holding tool
90890-01235
Universal magneto & rotor holder
YU-01235
5-15, 5-21,
5-22
Slide hammer bolt
90890-01083
Slide hammer bolt 6 mm
YU-01083-1
5-16
Tool name/Tool No. Illustration Reference
pages
66.8

SPECIAL TOOLS
1-11
Weight
90890-01084
YU-01083-3
5-16
Valve spring compressor
90890-04019
YM-04019
5-28, 5-33
Valve spring compressor attachment
90890-01243
Valve spring compressor adapter (26 mm)
YM-01253-1
5-28, 5-33
Valve guide remover (ø6)
90890-04064
Valve guide remover (6.0 mm)
YM-04064-A
5-29
Valve guide installer (ø6)
90890-04065
Valve guide installer (6.0 mm)
YM-04065-A
5-29
Valve guide reamer (ø6)
90890-04066
Valve guide reamer (6.0 mm)
YM-04066
5-29
Tool name/Tool No. Illustration Reference
pages
YU-01083-3