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XVS13AWC
Yamaha XVS13AWC - User Manual
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Y
amaha Service Manual
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2
Table of Contents
Main Page
Table of Contents
8
How to Use this Manual
5
Symbols
6
1 General Information
10
Identification
11
Vehicle Identification Number
11
Model Label
11
Features
12
Outline of the Fi System
12
Fi System
13
Instrument Functions
14
Important Information
16
Preparation for Removal and Disassembly
16
Replacement Parts
16
Gaskets, Oil Seals and O-Rings
16
Lock Washers/Plates and Cotter Pins
16
Bearings and Oil Seals
17
Circlips
17
Checking the Connections
18
Special Tools
19
Specifications
26
General Specifications
27
Engine Specifications
28
Chassis Specifications
35
Electrical Specifications
38
Tightening Torques
41
General Tightening Torque Specifications
41
Engine Tightening Torques
42
Chassis Tightening Torques
46
Lubrication Points and Lubricant Types
50
Engine
50
Chassis
51
Lubrication System Chart and Diagrams
53
Engine Oil Lubrication Chart
53
Lubrication Diagrams
55
Cooling System Diagrams
63
Cable Routing
69
Periodic Checks and Adjustments
90
Periodic Maintenance
93
General Maintenance and Lubrication Chart
93
Introduction
93
Periodic Maintenance Chart for the Emission Control System
93
Engine
96
Adjusting the Valve Clearance
96
Synchronizing the Throttle Bodies
98
Adjusting the Throttle Cable Free Play
100
Checking the Spark Plugs
101
Checking the Ignition Timing
101
Measuring the Compression Pressure
102
Checking the Engine Oil Level
103
Changing the Engine Oil
104
Adjusting the Clutch Lever Free Play
105
Replacing the Air Filter Element
106
Checking the Intake Manifold Joints
107
Checking the Fuel Line
107
Checking the Crankcase Breather Hose
107
Checking the Exhaust System
108
CHECKING the CANISTER (California Only)
108
Checking the Coolant Level
108
Checking the Cooling System
109
Changing the Coolant
109
Chassis
112
Adjusting the Front Brake Lever Free Play
112
Adjusting the Rear Disc Brake
112
Checking the Brake Fluid Level
113
Checking the Front Brake Pads
113
Checking the Rear Brake Pads
113
Checking the Front Brake Hoses
114
Checking the Rear Brake Hoses
114
Adjusting the Rear Brake Light Switch
114
Bleeding the Hydraulic Brake System
114
Adjusting the Shift Pedal
116
Adjusting the Drive Belt Slack
116
Checking and Adjusting the Steering Head
118
Checking the Front Fork
119
Adjusting the Rear Shock Absorber Assembly
119
Checking the Tires
120
Checking the Wheels
121
Checking and Lubricating the Cables
121
Lubricating the Levers
122
Lubricating the Pedal
122
Lubricating the Sidestand
122
Lubricating the Rear Suspension
122
Chassis
126
General Chassis
129
Front Wheel
137
Removing the Front Wheel
139
Disassembling the Front Wheel
139
Checking the Front Wheel
139
Assembling the Front Wheel
140
Adjusting the Front Wheel Static Balance
140
Installing the Front Wheel (Front Brake Disc)
141
Rear Wheel
143
Removing the Rear Wheel (Disc)
148
Disassembling the Rear Wheel
148
Checking the Rear Wheel
148
Checking the Rear Brake Caliper Bracket
148
Checking the Rear Wheel Drive Hub
148
Checking and Replacing the Rear Wheel Pulley
148
Assembling the Rear Wheel
149
Adjusting the Rear Wheel Static Balance
149
Installing the Rear Wheel (Rear Brake Disc)
149
Front Brake
150
Introduction
155
Checking the Front Brake Discs
155
Replacing the Front Brake Pads
156
Removing the Front Brake Calipers
157
Disassembling the Front Brake Calipers
157
Checking the Front Brake Calipers
157
Assembling the Front Brake Calipers
158
Installing the Front Brake Calipers
158
Removing the Front Brake Master Cylinder
159
Checking the Front Brake Master Cylinder
159
Assembling the Front Brake Master Cylinder
159
Installing the Front Brake Master Cylinder
160
Rear Brake
162
Introduction
168
Checking the Rear Brake Disc
168
Replacing the Rear Brake Pads
168
Removing the Rear Brake Caliper
169
Disassembling the Rear Brake Caliper
169
Checking the Rear Brake Caliper
170
Assembling the Rear Brake Caliper
170
Installing the Rear Brake Caliper
170
Removing the Rear Brake Master Cylinder
171
Checking the Rear Brake Master Cylinder
171
Assembling the Rear Brake Master Cylinder
172
Installing the Rear Brake Master Cylinder
172
Handlebar
175
Removing the Handlebar
175
Checking the Handlebar
175
Installing the Handlebar
175
Front Fork
178
Removing the Front Fork Legs
182
Disassembling the Front Fork Legs
182
Checking the Front Fork Legs
183
Assembling the Front Fork Legs
183
Installing the Front Fork Legs
185
Steering Head
187
Removing the Lower Bracket
189
Checking the Steering Head
189
Installing the Steering Head
189
Rear Shock Absorber Assembly
191
Handling the Rear Shock Absorber
193
Disposing of a Rear Shock Absorber
193
Removing the Rear Shock Absorber Assembly
193
Checking the Rear Shock Absorber Assembly
193
Checking the Connecting Arm and Relay Arm
194
Installing the Relay Arm
194
Installing the Rear Shock Absorber Assembly
194
Swingarm
196
Removing the Swingarm
198
Checking the Swingarm
198
Installing the Swingarm
198
Belt Drive
200
Removing the Drive Belt and Drive Pulley
201
Checking the Drive Belt
201
Installing the Drive Belt and Drive Pulley
201
Engine
204
Engine Removal
207
Installing the Exhaust Pipe Cover Screw Clamps
208
Installing the Cylinder Covers
211
Installing the Shift Arm
211
Installing the Engine
216
Camshafts
218
Removing the Camshaft Assemblies
221
Removing the Rocker Arms and Camshafts
222
Checking the Camshafts
223
Checking the Camshaft Sprockets
223
Checking the Rocker Arms and Rocker Arm Shafts
223
Checking the Timing Chain Tensioners
224
Installing the Camshafts and Rocker Arms
225
Installing the Camshaft Assemblies
226
Installing the Cylinder Head Covers
229
Cylinder Heads
230
Removing the Cylinder Heads
231
Checking the Cylinder Heads
231
Installing the Cylinder Heads
231
Valves and Valve Springs
234
Removing the Valves
234
Checking the Valves and Valve Guides
234
Checking the Valve Seats
236
Checking the Valve Springs
237
Installing the Valves
238
Cylinders and Pistons
240
Removing the Pistons
241
Checking the Cylinders and Pistons
241
Checking the Piston Rings
242
Checking the Piston Pins
243
Installing the Pistons and Cylinders
244
Generator and Starter Clutch
246
Removing the Generator
249
Removing the Starter Clutch
249
Checking the Starter Clutch
249
Checking the Torque Limiter
250
Installing the Starter Clutch
250
Installing the Generator
250
Clutch
252
Removing the Clutch
257
Removing the Primary Drive Gear
257
Checking the Friction Plates
257
Checking the Clutch Plates
258
Checking the Clutch Spring Plate
258
Checking the Clutch Housing
258
Checking the Clutch Boss
258
Checking the Pressure Plate
259
Checking the Primary Drive Gear
259
Checking the Primary Driven Gear
259
Checking the Pull Lever Shaft and Pull Rod
259
Checking the Oil/Water Pump Drive Sprocket and Oil/Water Pump Drive Chain
259
Installing the Primary Drive Gear
259
Installing the Clutch
260
Shift Shaft
263
Checking the Shift Shaft
264
Checking the Stopper Lever
264
Installing the Shift Shaft
264
Balancer Gears
265
Checking the Right Balancer Gears
267
Checking the Left Balancer Gears
267
Installing the Right Balancer Gears
267
Installing the Left Balancer Gears
267
Electric Starter
268
Checking the Starter Motor
270
Assembling the Starter Motor
271
Crankcase
272
Disassembling the Crankcase
276
Checking the Crankcase
276
Checking the Bearings and Oil Seal
276
Checking the Oil Delivery Pipes and Coolant Delivery Pipe
276
Checking the Timing Chains
276
Checking the Oil/Water Pump Driven Sprocket
276
Checking the Oil Nozzles
276
Installing the Bearing Retainers
277
Assembling the Crankcase
277
Oil Pump
279
Checking the Oil Pump
280
Checking the Relief Valve
280
Checking the Oil Strainer
281
Assembling the Oil Pump
281
Installing the Oil/Water Pump Assembly
281
Crankshaft
282
Removing the Connecting Rods
283
Checking the Crankshaft and Connecting Rods
283
Installing the Connecting Rods
285
Installing the Crankshaft Assembly
286
Transmission
290
Checking the Shift Forks
291
Checking the Shift Drum Assembly
291
Checking the Transmission
291
Assembling the Main Axle and Drive Axle
292
Installing the Shift Forks and Shift Drum Assembly
292
Cooling System
294
Radiator
296
Checking the Radiator
297
Installing the Radiator
297
Thermostat
298
Checking the Thermostat
300
Installing the Thermostat Assembly
300
Water Pump
301
Disassembling the Water Pump
303
Checking the Water Pump
303
Assembling the Water Pump
303
Fuel System
306
Fuel Tank
307
Checking the Fuel Cock
311
Checking the Fuel Cock Operation
311
Checking the Fuel Pump Body
311
Checking the Rollover Valve
311
Removing the Fuel Pump
311
Removing the Fuel Tank
311
Installing the Fuel Pump
312
Installing the Fuel Tank Hoses
312
Throttle Bodies
314
Checking the Injectors
317
Checking the Throttle Bodies
317
Checking the Fuel Pressure
317
Adjusting the Throttle Position Sensor
317
Installing the Intake Manifold Assembly
318
Electrical System
320
Ignition System
323
Circuit Diagram
323
Engine Stopping Due to Sidestand Operation
325
Troubleshooting
326
Electric Starting System
329
Circuit Diagram
329
Starting Circuit Cut-Off System Operation
331
Troubleshooting
333
Charging System
335
Circuit Diagram
335
Troubleshooting
337
Lighting System
339
Circuit Diagram
339
Troubleshooting
341
Signaling System
343
Circuit Diagram
343
Troubleshooting
345
Cooling System
349
Circuit Diagram
349
Troubleshooting
351
Fuel Injection System
353
Circuit Diagram
353
Ecu Self-Diagnostic Function
355
Self-Diagnostic Function Table
356
Troubleshooting Method
358
Diagnostic Mode
359
Troubleshooting Details
365
Fuel Pump System
385
Circuit Diagram
385
Troubleshooting
387
Electrical Components
389
Checking the Switches
393
Checking the Bulbs and Bulb Sockets
396
Checking the Fuses
397
Checking and Charging the Battery
397
Checking the Relays
401
Checking the Turn Signal Relay
402
Checking the Diodes
403
Checking the Ignition Spark Gap
404
Checking the Spark Plug Caps
405
Checking the Ignition Coils
405
Checking the Crankshaft Position Sensor
406
Checking the Lean Angle Sensor
406
Checking the Starter Motor Operation
407
Checking the Stator Coil
407
Checking the Rectifier/Regulator
407
Checking the Horn
408
Checking the Oil Level Switch
408
Checking the Fuel Sender
409
Checking the Fuel Level Warning Light
409
Checking the Oil Level Warning Light
410
Checking the Speed Sensor
410
Checking the Radiator Fan Motor
410
Checking the Coolant Temperature Sensor
410
Checking the Throttle Position Sensor
411
Specifications
411
Checking the Air Temperature Sensor
412
Troubleshooting
414
General Information
414
General Information
415
Incorrect Engine Idling Speed
415
Starting Failures
415
Troubleshooting
415
Faulty Clutch
416
Faulty Gear Shifting
416
Jumps out of Gear
416
Poor Medium-And-High-Speed Performance
416
Shift Pedal Does Not Move
416
Faulty Front Fork Legs
417
Overcooling
417
Overheating
417
Poor Braking Performance
417
Unstable Handling
417
Faulty Lighting or Signaling System
418
Wiring Diagram
420
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Yamaha XVS13AWC Specifications
General
Brand
Yamaha
Model
XVS13AWC
Category
Motorcycle
Language
English
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