Yamaha XVZ13TF 1999 User manual

EAS00001
XVZ13TF (L)
SERVICE MANUAL
1999 by Yamaha Motor Co., Ltd.
First edition, January 1999
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd
is expressly prohibited.

NOTE:
CAUTION:
EAS00003 NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
andtheirqualifiedmechanics.Itisnotpossibletoincludealltheknowledgeofamechanicinonemanu-
al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
shouldhaveabasicunderstandingofmechanicsandthetechniquestorepairthesetypesofvehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-
hicle 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 in necessary to ensure that the ve-
hicle 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
isintendedto providethecustomerwiththe mostsatisfactionfromhis vehicleandtoconformwith fed-
eral environmental quality objectives.
YamahaMotorCompany,Ltd.iscontinuallystrivingtoimproveallitsmodels.Modificationsandsignifi-
cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
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 INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
FailuretofollowWARNINGinstructions couldresultinsevereinjury ordeathto
the motorcycle operator, a bystander or a person inspecting or repairing the
motorcycle.
ACAUTIONindicatesspecialprecautionsthatmustbetaken to avoid damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

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EAS00007 HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanationsofallinstallation,removal,disassembly, assembly, repair and inspection 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” on the following page.
2Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“Periodic Inspections and Adjustments”), where the sub-section title(-s) appear.
(In Chapter 3, “Periodic Inspection and Adjustments”, the sub-section title appears at the top of each
page, instead of the section title.)
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 (see “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.

22
1
3
5
7
9
2
4
8
6
24 25
2321
19 2018
16 1715
1413
11 12
10
GEN
INFO SPEC
ENG
CARB
ELECCHAS
COOL
CHK
ADJ
TRBL
SHTG
EAS00008
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols 1to 9indicate the subject of each
chapter.
1General information
2Specifications
3Periodic inspections and adjustments
4Engine
5Cooling system
6Carburetor(-s)
7Chassis
8Electrical system
9Troubleshooting
Symbols 10 to 17 indicate the following.
10 Serviceable with engine mounted
11 Filling fluid
12 Lubricant
13 Special tool
14 Tightening torque
15 Wear limit, clearance
16 Engine speed
17 Electrical data
Symbols 18 to 23 intheexplodeddiagramsindi-
cate the types of lubricants and lubrication
points.
18 Engine oil
19 Gear oil
20 Molybdenum disulfide oil
21 Wheel bearing grease
22 Lithium soap base grease
23 Molybdenum disulfide grease
Symbols 24 to 25 intheexplodeddiagramsindi-
cate the following:
24 Apply locking agent (LOCTITER)
25 Replace the part

GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTIONS AND
ADJUSTMENTS
ENGINE
COOLING SYSTEM
CARBURETORS
CHASSIS
ELECTRICAL SYSTEM
TROUBLESHOOTING
GEN
INFO 1
SPEC 2
3
ENG 4
COOL 5
CARB 6
CHAS 7
ELEC 8
TRBL
SHTG 9
CHK
ADJ
EAS00012 TABLE OF CONTENTS

GEN
INFO
1

GEN
INFO
CONTENTS
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . .
MODEL CODE 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FEATURES 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRUISE CONTROL 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIGITAL SPEEDOMETER 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUDIO SYSTEM 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPORTANT INFORMATION 1-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION FOR REMOVAL AND DISASSEMBLY 1-13. . . . . . . . . .
REPLACEMENT PARTS 1-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKETS, OIL SEALS AND O-RINGS 1-13. . . . . . . . . . . . . . . . . . . . . . . .
LOCK WASHERS/PLATES AND COTTER PINS 1-14. . . . . . . . . . . . . . . .
BEARINGS AND OIL SEALS 1-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCLIPS 1-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CONNECTIONS 1-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 1-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEN
INFO

1-1
MOTORCYCLE IDENTIFICATION GEN
INFO
EAS00014
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
Thevehicleidentificationnumber 1isstamped
into the right side of the steering head.
EAS00018
MODEL CODE
The model code label 1is affixed to the frame.
This information will be needed to order spare
parts.

1-2
FEATURES GEN
INFO
CAUTION:
3 “SET” indicator light
4 “RES” indicator light 5 Cruise control switch 6 “CANCEL” switch
EAS00019
FEATURES
CRUISE CONTROL
This motorcycle is equipped with cruise control which designed to maintain a set speed.
Givinga severeload likeusingasatrailer/tractorordrivingona steepslope couldremovethe
cruise control.
Do not set the cruise control while idling the rear tires for the preparation.
Do not disassemble the vacuum pump.
Never remove the cruise control actuator rubber cover. When putting it back, bolts or other
parts will be caught and the cruise control wire can be locked.
Donotremovetheaircleanercoverofthevacuumpumpinordernottocauseamalfunctionin
cancellation of the cruise control by dirt, trash etc.
Do not drive without holding the steering wheel whether the cruise control is ON or OFF.
1“CRUISE” switch
2“ON” indicator light
Cruise control switch functions
1“CRUISE” switch
Pushthisswitchto“ON”whenthecruisecontrolsystemispreset.The“ON”indicatorlightwillcomeon.
Once the switch is released it will return to the center (Hold) position.
To cancel the cruise control system, push the switch to “OFF” or main switch to the “OFF” position.
2“ON” indicator light
This indicator light comes on when the cruise control systems preset (when “ON” is selected by the
“CRUISE” switch).
3“SET” indicator light
This indicator light comes on when the motorcycle is operating at a set speed.
4“RES” indicator light
This light comes on when the set speed, which is cancelled by any steps, is memorized and when the
operating speed is in the range of approx. 50-130 km/h.
Iftheresumesystemisoperatedwhilethislightison,itcontinuesflashinguntilthespeedreturnstothat
memorized.
5Cruise control switch
This switch is capable of the following controls.
Refer to the “Operation chart” for details.
Set speed ride
Minute adjustment of set speed
Consecutive adjustment of set speed
“RESUME” system
6“CANCEL” switch
Push this switch to cancel the set speed ride in the cruise control system.

1-3
FEATURES GEN
INFO
SET
CRUISE
SET
RES
ON (After1.4sec)
SET
RES
ON
SET
RES
ON
Flash
Out of range
Out of range
Mannual
acceleration cancel Rear brake
Clutch
SET Front brake
Resume
Cruise SW
ON
Operation chart
Opera-
tion
Speed
Indica-
tor
Cruise control function
1) The cruise control can only be activated when riding in 4th, 5th gear and traveling between the
speed of 50 and 130 km/h.
2) To operate the system, the “CRUISE” switch should be turned “ON”.
3) When push the cruise control switch to “SET”, the cruise control system will be set the set speed.
4) Bypushing(inshorterthan0.5seconds),thecontrolswitchinthedirectionofeither“ACC”or“DEC”,
the set speed can be changed in increments or decrements of approximately 1.6 km/h.
5) Ifthecontrolswitchisheldinthe“ACC” or “DEC” position (longer than 0.5 seconds), the speed can
be successively increased or decreased slowly.
6) Thecruisecontrolwillbedeactivatedifthefrontorrearbrakeisappliedoriftheclutchisdisengaged
or if the “CANCEL” switch is pushed.
7) After canceling, the speed is returned to the one set before the cancellation by pushing the control
switch once in the “RES” direction.
8) Auto cruise function is canceled;
a. In case of current speed drops 8 km/h less than the originally set speed.
b. In case of gear position is moved to gears other than of 4th, 5th.
c. In case of systems fines any faulty signal in the following systems.
Control unit
Actuator cable
Logical error in cut off signal
Error signal in speed sensor signal
Error signal in engine revolution
Cruise control switch lead (“SET”/“RES”)
9) When main switch is cut off once, “resume” is canceled.

1-4
FEATURES GEN
INFO
NOTE:
DIGITAL SPEEDOMETER
This speedometer is equipped with:
An odometer
Two trip odometers
A fuel reserve trip meter
A clock
Odometer and trip meter modes
1) Selecting a mode
Push the “SELECT” button to change between the odometer mode “ODO” and the trip odometer
modes “TRIP 1” and “TRIP 2” in the following order.
“ODO” “TRIP 1” “TRIP 2” “ODO”
If the fuel level indicator light comes on, the odometer display will automatically change to the fuel re-
serve trip meter mode “TRIP F” and start counting the distance traveled from that point.
Pushthe “SELECT” button tochange between the fuelreserve tripmeter, trip odometerand odometer
modes in the following order:
“TRIP F” “TRIP 1” “TRIP 2” “ODO” “TRIP F”
2) Resetting a meter
Toresetatripodometerto0.0,selectitbypushingthe“SELECT”buttonandpushthe“RESET”button.
To reset the fuel reserve trip meter, select it by pushing the “SELECT” button and push the “RESET”
button. The display will return to prior mode (“ODO”, “TRIP 1” or “TRIP 2”).
Ifyou do not reset thefuelreserve trip meter manually, it will automatically resetand retum to “TRIP 1”
after refueling and the motorcycle has traveled both 5km.
Ifthefuelreservetripmeterappears,andadifferentmodewasNOTselectedpriortoresettingthefuel
reserve trip meter, the display always returns to the “TRIP 1” mode.
If the fuel reserve trip meter appears, and a different mode was selected prior to resetting the fuel
reserve trip meter, the display automatically returns to the prior mode.

1-5
FEATURES GEN
INFO
NOTE:
Clock mode
To change the display to the clock mode, push both the “SELECT” and “RESET” buttons.
To change the display back to odometer mode, push the “RESET” button.
1) To set the clock
a. Push both the “SELECT” and “RESET” buttons for at least two seconds.
b. When the hour digits start flashing, push the “RESET” button to set the hours.
c. Push the “SELECT” button and the minute digits will start flashing.
d. Push the “RESET” button to set the minutes.
e. Push the “SELECT” button to start the clock.
After setting the clock, be sure to push the “SELECT” button before turning the main switch to “OFF”,
otherwise the clock will not be set.
AUDIO SYSTEM
1. POWERING ON/OFF THE AUDIO SYS-
TEM
Turning on/off the audio system
Turn the main switch to the “ACC” or “ON” posi-
tion.
To turn on the power for the audio system,
push the audio button “AUDIO”.
To turn off the audio system, push the audio
button “AUDIO” continuously for 1 second or
more.

1-6
FEATURES GEN
INFO
2. CASSETTE DESK OPERATION
The cassette tape deck has the following func-
tions.
Song search
Change tape play direction
Dolby noise reduction
Blank tape skip
a. Turn the main switch to the “ACC” or “ON”
position and push the “AUDIO”button to turn
on the power.
b. Insertacassettetapeintothecassettedeck.
c. If a tape is aleady loaded in the cassette
deck, push the “AUDIO” button until “PLAY”
appears.
The tape will start playing.
d. Turn the volume control knob to set the vol-
ume level. The volume level can be set from
0 to 30.
Track searching
To search for a song on the tape, push the up-
down switch 1for less than one second. The
“APC” (auto program control) indicator will ap-
pear in the display.
Pushthewitchonce for each song to be skipped.
Pushingtheswitchindirection“n”will search in
the forward direction.
Pushingtheswitchindirection“o”will search in
the reserve direction.
Whensearchinginthe forwarddirection,thenum-
ber of song that are being skipped will appear.
(i.e., “1”, meaning one track is being skipped)
Whensearchingthereversedirection,thenum-
ber of song that are being skipped will appear
alongwithaminussignbeforethenumber.(i.e.,
“-1”, meaning one song is being skipped)
The maxmum number of songs that can be
skipped in either direction is 9.
To stop a searching operation, push the up-
down button in the opposite direction that it was
originally pushed.

1-7
FEATURES GEN
INFO
Reserving tape play direction
Push the up-down button 1in either direction
for more than one second to reverse tape play.
When the tape is playing the forward direction,
the “F” indicator will appear.
When the tape is playing in the reverse direc-
tion, the “R” indicator will appear.
Dolby noise reduction
The Dolby noise reduction can be turned on or
off by pushing the “EJECT” button for at least
two seconds.
When the noise reduction is on, the “BNR” indi-
cator appears in the display.
Ejecting the cassette tape
Push the “EJECT” button to eject the tape from
the cassette dack.
Blank skipping
When there is a blank portion on the cassette
tape the “BLS” indicator light will come on and
the cassette deck automatically fast forwards
the tape to the next track.

1-8
FEATURES GEN
INFO
TAPE FM1 FM2 FM3
AUX. CD(option) AM


3. RADIO OPERATION
The radio has the following functions.
Switching the receiving band
Switching the receiving station
Automatic tuning (Seek)
Manual tuning
Programing preset stations in memory
Automatic writing of stations in memory (Auto
store operation)
Switching the receiving bands
This radio system has 3 bands for FM and 1
bandforAM.Selectabandbypushing the “AU-
DIO” button for less than 1 second.
The display will change as follows.
Automatic tuning (Seek operation)
Push the up-down switch 1in either direction
and hold it for as least 1 second.
The tuner will automatically stop at the first sta-
tion that has a strong enough radio wave.
Manually turning
When a radio wave is too weak to be picked up
automatically, it can be selected manually as
follows.
Push the “SELECT” button until “RADIO” sta-
tion appears.
Push the up-down switch 1for less than 1 se-
cond in either direction and the ferequency will
changein0.1 MHz stepsforFMandin 9kHzfor
AM.
Presetting station in memory
Station can be preset either automatically or
manually. 6 stations can be set for each band.
Preset station either manually or automatically
by the following procedure.
a. Select the station desired to be preset.
b. Push the “SELECT” button for as least 2 se-
condsunitltheradiofrequencyandthechan-
nel “Ch” start flashing.

1-9
FEATURES GEN
INFO
NOTE:
c. Push the up-down switch 1in either direc-
tiontoselectthechannelnumbertobesetfor
the current station. (Ch1, Ch2, Ch3, Ch4,
Ch5 and Ch6)
d. Press the “SELECT” button to programing
the channel in memory.
Repeat this procedure for the remaining sta-
tions desired to be preset in the memory.
Stations can be also be automatically preset by
the following procedure.
a. Pushthe “SELECT”buttonuntiltheradiofre-
quency and the channel “Ch” start flashing.
b. Push the up-down button in either direction
for at least 1 second to automatically tune in
a station.
c. When the desired station is found, push the
up-down switch for less than one second to
select the channel number to be set for that
station.
d. Pushthe“SELECT”buttontoprogramingthe
channels in memory.
e. Repeat this procedure for the remaining sta-
tions desived to be preset in memory.
Programingpresetstationsinmemoryauto-
matically
Settingupto6channelscanbemadebythefol-
lowing procedure.
Stations will be starting from the station preset
at chanel 6.
It is recommended to use this function only in
areas with strong radio frequencies.
a. Pushthe “SELECT”buttonuntiltheradiofre-
quency and the channel “Ch” start flashing.
b. Push the up-down switch 1in either direc-
tion to select channel “A”.
c. Press the “SELECT” button to start the ran-
dom channel selection and the tuner will au-
tomatically write the channels in memory.