OWNER’S MANUAL XVZ13CTT(C) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2004.03-0.
U1D610E0.
U1D610E0.book Page 1 Monday, March 15, 2004 4:00 PM INTRODUCTION EAU10080 Congratulations on your purchase of the Yamaha Royal Star™ Series. This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle.
U1D610E0.book Page 1 Monday, March 15, 2004 4:00 PM IMPORTANT MANUAL INFORMATION EAU10130 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
U1D610E0.book Page 2 Monday, March 15, 2004 4:00 PM IMPORTANT MANUAL INFORMATION AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.
U1D610E0.book Page 3 Monday, March 15, 2004 4:00 PM IMPORTANT MANUAL INFORMATION EAU10192 AFFIX DEALER LABEL HERE XVZ13CTT(C) OWNER’S MANUAL ©2004 by Yamaha Motor Corporation, U.S.A. 1st edition, February 2004 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan.
U1D610E0.book Page 1 Monday, March 15, 2004 4:00 PM TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 Location of important labels ...........1-5 DESCRIPTION ..................................2-1 Left view ..........................................2-1 Right view ........................................2-2 Controls and instruments ................2-3 INSTRUMENT AND CONTROL FUNCTIONS .......................................3-1 Main switch/steering lock ................
U1D610E0.book Page 2 Monday, March 15, 2004 4:00 PM TABLE OF CONTENTS Checking and lubricating the sidestand ...................................6-29 Checking the front fork .................6-29 Checking the steering ...................6-30 Checking the wheel bearings .......6-31 Battery ..........................................6-31 Replacing the fuses ......................6-32 Replacing the headlight bulb ........6-34 Replacing a turn signal light bulb or the tail/brake light bulb ..........
U1D610E0.book Page 1 Monday, March 15, 2004 4:00 PM SAFETY INFORMATION EAU10250 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: ● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION.
U1D610E0.book Page 2 Monday, March 15, 2004 4:00 PM SAFETY INFORMATION 1 ● ● wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). • Always obey the speed limit and never travel faster than warranted by road and traffic conditions. • Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control.
U1D610E0.book Page 3 Monday, March 15, 2004 4:00 PM SAFETY INFORMATION Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of 201 kg (443 lb). When loading within this weight limit, keep the following in mind: ● Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability.
U1D610E0.book Page 4 Monday, March 15, 2004 4:00 PM SAFETY INFORMATION 1 Gasoline and exhaust gas ● GASOLINE IS HIGHLY FLAMMABLE: • Always turn the engine off when refueling. • Take care not to spill any gasoline on the engine or exhaust system when refueling. • Never refuel while smoking or in the vicinity of an open flame. ● Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time.
U1D610E0.book Page 5 Monday, March 15, 2004 4:00 PM SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.
U1D610E0.book Page 6 Monday, March 15, 2004 4:00 PM SAFETY INFORMATION 1 1 2 CAUTION Cleaning with alkaline or acid cleaner, gasoline or solvent will damage windshield. Use neutral detergent.
U1D610E0.book Page 1 Monday, March 15, 2004 4:00 PM DESCRIPTION EAU10410 Left view 2 1. 2. 3. 4. 5. 6. 7. 8. 9. Sidecase (page 3-16) 10.Tail/brake light (page 6-35) 11.
U1D610E0.book Page 2 Monday, March 15, 2004 4:00 PM DESCRIPTION EAU10420 Right view 2 1. 2. 3. 4. 5. 6. 7. 8. 9. Windshield (page 3-15) 10.Headlight (page 6-34) 11.Front turn signal/position lights (page 6-35) 12.Fuse box 1 (page 6-32) 13.Brake pedal (page 3-8) 14.Rider footrest 15.
U1D610E0.book Page 3 Monday, March 15, 2004 4:00 PM DESCRIPTION EAU10430 Controls and instruments 2 1. 2. 3. 4. 5. 6. 7.
U1D610E0.book Page 1 Monday, March 15, 2004 4:00 PM INSTRUMENT AND CONTROL FUNCTIONS EAU10460 Main switch/steering lock EAU10690 LOCK The steering is locked, and all electrical systems are off. The key can be removed. To unlock the steering To lock the steering 3 1. Push. 2. Turn. The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below.
U1D610E0.book Page 2 Monday, March 15, 2004 4:00 PM INSTRUMENT AND CONTROL FUNCTIONS EAU35140 ACC (Accessory) The auxiliary DC terminals can be used in this position. Therefore, do not use the accessory position for an extended period of time, otherwise the battery may discharge. The key cannot be removed. EAU11001 Indicator and warning lights EAU11080 High beam indicator light “ ” This indicator light comes on when the high beam of the headlight is switched on. EAU11120 1. 2. 3. 4. 5. 6. 7. 8.
U1D610E0.book Page 3 Monday, March 15, 2004 4:00 PM INSTRUMENT AND CONTROL FUNCTIONS 3 EAU11440 EAU11480 Coolant temperature warning light “ ” This warning light comes on when the engine overheats. When this occurs, stop the engine immediately and allow the engine to cool. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical circuit.
U1D610E0.
U1D610E0.book Page 5 Monday, March 15, 2004 4:00 PM INSTRUMENT AND CONTROL FUNCTIONS EAU35161 Cruise control system This model is equipped with a cruise control system designed to maintain a set traveling speed. 3 Activating and setting the cruise control system The cruise control system can only be activated when riding in 4th or 5th gear at speeds between 50 km/h (30 mi/h) and 130 km/h (80 mi/h). To activate and set the cruise control system: 1.
U1D610E0.book Page 6 Monday, March 15, 2004 4:00 PM INSTRUMENT AND CONTROL FUNCTIONS is increased by more than 8 km/h (5 mi/h), the cruise control system will be deactivated until the traveling speed is within 8 km/h (5 mi/h) of the set speed. Deactivating the cruise control system Applying the front or rear brake or disengaging the clutch will automatically deactivate the cruise control system. Push the “CANCEL” switch to manually deactivate the cruise control system.
U1D610E0.book Page 7 Monday, March 15, 2004 4:00 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12400 Dimmer switch “ / ” Set this switch to “ ” for the high beam and to “ ” for the low beam. EAU12500 Horn switch “ ” Press this switch to sound the horn. EAU12820 Clutch lever EAU12660 EAU12430 3 Turn signal switch “ / ” To signal a right-hand turn, push this switch to “ ”. To signal a left-hand turn, push this switch to “ ”. When released, the switch returns to the center position.
U1D610E0.book Page 8 Monday, March 15, 2004 4:00 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12880 Shift pedal EAU12890 Brake lever EAU12941 Brake pedal 3 1. Shift pedal 1. Brake lever 1. Brake pedal The shift pedal is located on the left side of the engine and is used in combination with the clutch lever when shifting the gears of the 5-speed constant-mesh transmission equipped on this motorcycle. The brake lever is located at the right handlebar grip.
U1D610E0.book Page 9 Monday, March 15, 2004 4:00 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13120 Fuel tank cap EAU13210 NOTE: The fuel tank cap cannot be installed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked. Fuel EWA10130 WARNING 3 Make sure that the fuel tank cap is properly installed before riding. 1. Fuel tank cap lock cover 2. Unlock. 3. “ ” mark 1. Fuel tank filler tube 2.
U1D610E0.book Page 10 Monday, March 15, 2004 4:00 PM INSTRUMENT AND CONTROL FUNCTIONS ECA10070 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EAU13300 Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: 20.0 L (5.28 US gal) (4.40 Imp.gal) Fuel reserve amount: 3.9 L (1.03 US gal) (0.86 Imp.gal) knocking (or pinging) occurs, use a gasoline of a different brand or premium unleaded fuel.
U1D610E0.book Page 11 Monday, March 15, 2004 4:00 PM INSTRUMENT AND CONTROL FUNCTIONS ON This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the fuel cock lever to this position if you run out of fuel while riding. When this occurs, refuel as soon as possible and be sure to turn the fuel cock lever back to “ON”! EAU13600 Starter (choke) knob “ ” 3 1. Pointed end positioned over “ON” 1.
U1D610E0.book Page 12 Monday, March 15, 2004 4:00 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13780 Locking the steering with a padlock EAU35170 Rider seat To remove the rider seat Remove the bolts, and then pull the rider seat up. 3 1. Projection 2. Seat holder In addition to the main switch/steering lock, there are brackets on the right side of the steering head pipe for locking the steering with a padlock.
U1D610E0.book Page 13 Monday, March 15, 2004 4:00 PM INSTRUMENT AND CONTROL FUNCTIONS EAU35791 Passenger backrest To remove the backrest 1. Push the lever on each side of the backrest downward. 3 1. Locked position To install the backrest Place the backrest in the original position, then pull it backward until it stops and the levers snap locking it into place. 1. Backrest lever 2. Push the backrest forward until it stops, then lift it upward and remove it by pulling it to the rear as shown.
U1D610E0.book Page 14 Monday, March 15, 2004 4:00 PM INSTRUMENT AND CONTROL FUNCTIONS EAU35180 EWA11040 Helmet holder WARNING A helmet holding cable is provided in the left sidecase to secure a helmet to the helmet holder. To secure a helmet to the helmet holder 1. To open the helmet holder, insert the key into the helmet holder lock, and then turn the key as shown. Never ride with a helmet attached to a helmet holder, since the helmet may hit objects, causing loss of control and possibly an accident.
U1D610E0.book Page 15 Monday, March 15, 2004 4:00 PM INSTRUMENT AND CONTROL FUNCTIONS EAU35221 Windshield To remove the windshield 1. Push the lever on each side of the windshield forward. To install the windshield 1. Place the windshield in the original position as shown. 3 1. Windshield lever 2. Push the lever on each side of the windshield backward onto its fastener to lock it into place. 2. To remove the windshield, pull it upward as shown.
U1D610E0.book Page 16 Monday, March 15, 2004 4:00 PM INSTRUMENT AND CONTROL FUNCTIONS EAU35210 Sidecases EWA12520 WARNING Improper loading or overloading can cause loss of control and possibly an accident or personal injury. See pages 1-5 and 6-21 for important loading and tire pressure information. ● Always securely close the sidecases before riding. ● Distribute weight evenly on each side of the motorcycle. ● Do not exceed the load limit of 9 kg (20 lb) for each sidecase.
U1D610E0.book Page 17 Monday, March 15, 2004 4:00 PM INSTRUMENT AND CONTROL FUNCTIONS EAU14651 Adjusting the front fork This front fork is equipped with air valves for adjusting the spring rate. EWA10180 WARNING 3 Always adjust both fork legs equally, otherwise poor handling and loss of stability may result. Adjust the spring rate as follows. 1. Place the vehicle on the sidestand. NOTE: When checking and adjusting the air pressure, there should be no weight on the vehicle. 2.
U1D610E0.book Page 18 Monday, March 15, 2004 4:00 PM INSTRUMENT AND CONTROL FUNCTIONS EAU15300 Spring rate: Minimum (soft): Air pressure = 0 kPa (0 psi) (0 kgf/cm²) Standard: Air pressure = 0 kPa (0 psi) (0 kgf/cm²) Maximum (hard): Air pressure = 400 kPa (57 psi) (4.0 kgf/cm²) 1. Shock absorber assembly air valve cap 3. Check the air pressure with the air pressure gauge included in the owner’s tool kit. 4.
U1D610E0.book Page 19 Monday, March 15, 2004 4:00 PM INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer repair it if it does not function properly. 3 EAU15311 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. ● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled.
U1D610E0.book Page 20 Monday, March 15, 2004 4:00 PM INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is turned on. 3. Turn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? YES NOTE: This check is most reliable if performed with a warmed-up engine. NO The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer.
U1D610E0.book Page 21 Monday, March 15, 2004 4:00 PM INSTRUMENT AND CONTROL FUNCTIONS EAU35200 Auxiliary DC terminals EWA12530 WARNING To prevent electrical shock or shortcircuiting, make sure that the caps are installed when the auxiliary DC terminals are not being used. 3 1. Auxiliary DC terminal 12-V accessories connected to the auxiliary DC terminals under the rider seat can be used when the key is in the “ACC” or “ON” position.
U1D610E0.book Page 1 Monday, March 15, 2004 4:00 PM PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences.
U1D610E0.book Page 2 Monday, March 15, 2004 4:00 PM PRE-OPERATION CHECKS EAU15602 Pre-operation check list ITEM 4 CHECKS PAGE Fuel • Check fuel level in fuel tank. • Refuel if necessary. • Check fuel line for leakage. 3-9 Engine oil • Check oil level in engine. • If necessary, add recommended oil to specified level. • Check vehicle for oil leakage. 6-12 Final gear oil • Check vehicle for oil leakage. 6-15 Coolant • Check coolant level in reservoir.
U1D610E0.book Page 3 Monday, March 15, 2004 4:00 PM PRE-OPERATION CHECKS ITEM CHECKS Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check fluid level in reservoir. If necessary, add recommended fluid to specified level. Check hydraulic system for leakage. PAGE Clutch • • • • • Throttle grip • Make sure that operation is smooth. • Check cable free play. • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing.
U1D610E0.book Page 1 Monday, March 15, 2004 4:00 PM OPERATION AND IMPORTANT RIDING POINTS EAU15950 EWA10270 WARNING ● ● 5 ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. Never start the engine or operate it in a closed area for any length of time. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time.
U1D610E0.book Page 2 Monday, March 15, 2004 4:00 PM OPERATION AND IMPORTANT RIDING POINTS ● diately stop the engine, and then check the engine oil level and the vehicle for oil leakage. If necessary, add engine oil, and then check the warning light again. If the warning light does not come on when turning the key to “ON”, or if it does not go off after starting the engine with sufficient engine oil, have a Yamaha dealer check the electrical circuit.
U1D610E0.book Page 3 Monday, March 15, 2004 4:00 PM OPERATION AND IMPORTANT RIDING POINTS EAU16671 Shifting ECA10260 CAUTION: ● 5 1. Shift pedal 2. Neutral position Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc. The gear positions are shown in the illustration. ● Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances.
U1D610E0.book Page 4 Monday, March 15, 2004 4:00 PM OPERATION AND IMPORTANT RIDING POINTS 3. Shift the transmission into the neutral position when the motorcycle is almost completely stopped. The neutral indicator light should come on. EAU16720 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below.
U1D610E0.book Page 5 Monday, March 15, 2004 4:00 PM OPERATION AND IMPORTANT RIDING POINTS EAU17170 Parking When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to “OFF”. EWA10310 WARNING ● 5 ● Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them. Do not park on a slope or on soft ground, otherwise the vehicle may overturn.
U1D610E0.book Page 1 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17231 EAU17300 PERIODIC MAINTENANCE Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of motorcycle inspection, adjustment, and lubrication are explained on the following pages.
U1D610E0.book Page 2 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10340 WARNING Modifications not approved by Yamaha may cause loss of performance, excessive emissions, and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any changes.
U1D610E0.book Page 3 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17600 Periodic maintenance chart for the emission control system INITIAL No. ITEM ROUTINE 1 * Fuel line • Check fuel hoses for cracks or damage. • Replace if necessary. 2 * Fuel filter • Replace. 3 Spark plugs • Check condition. • Adjust gap and clean. • Replace every 8000 mi (13000 km) or 12 months. 4 * Valve clearance • Check and adjust valve clearance when engine is cold.
U1D610E0.book Page 4 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32182 General maintenance and lubrication chart INITIAL No. 6 ITEM ROUTINE 1 * Air filter element • Clean with compressed air. • Replace if necessary. 2 * Clutch • Check operation and fluid leakage. • Correct if necessary.
U1D610E0.book Page 5 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE Swingarm pivot bearings • Check bearing assemblies for looseness. • Moderately repack with lithiumsoap-based grease. 10 * Steering bearings • Check bearing assemblies for looseness. • Moderately repack with lithiumsoap-based grease every 16000 mi (25000 km) or 24 months.
U1D610E0.book Page 6 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month 18 * Rear suspension link pivots • Apply lithium-soap-based grease lightly. 19 Engine oil • Change (warm engine before draining). √ 20 * Engine oil filter cartridge • Replace.
U1D610E0.book Page 7 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. EAU17660 NOTE: ● The air filter needs more frequent service if you are riding in unusually wet or dusty areas. ● Hydraulic brake and clutch systems • After disassembling the brake or clutch master cylinders, caliper cylinders or clutch release cylinder, always change the fluid.
U1D610E0.book Page 8 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU18711 Removing and installing cowlings and panels The cowlings and panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a cowling or panel needs to be removed and installed. 1. Cowling B 2. Panel B 3. Panel C 1. Cowling A 2. Bolt 3. Quick fastener screw EAU35841 Cowling A 6 1. Cowling A 2. Panel A To remove the cowling 1.
U1D610E0.book Page 9 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: Make sure that the projection fits into the grommet. 2. Install cowling A. EAU35860 Panels A and B 1. Grommet 2. Projection 3. Cowling A To remove one of the panels Remove the bolt, and then pull the panel off as shown. 1. Cowling B 2. Bolt NOTE: Make sure that the projection fits into the grommet. 6 EAU35850 Cowling B To remove the cowling 1. Remove cowling A. 2.
U1D610E0.book Page 10 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Panel B 2. Bolt 6 To install the panel Place the panel in the original position, and then install the bolt. EAU19332 Panel C To remove the panel 1. Remove the left passenger footrest by removing the bolts. 2. Remove the screw, and then pull the panel off as shown. 1. Panel C 2. Screw 3. Bolt To install the panel 1. Place the panel in the original position, and then install the screw. 2.
U1D610E0.book Page 11 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Check each spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. EAU19543 Checking the spark plugs The spark plugs are important engine components, which are easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plugs should be removed and checked in accordance with the periodic maintenance and lubrication chart.
U1D610E0.book Page 12 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR 2. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. 3. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque. EAU19671 Canister (for California only) The engine oil level should be checked before each ride.
U1D610E0.book Page 13 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: The engine oil should be between the minimum and maximum level marks. 1. Engine oil level check window 2. Maximum level mark 3. Minimum level mark 2. Place an oil pan under the engine to collect the used oil. 3. Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase. 4. Remove the oil filter cartridge with an oil filter wrench. 1. Engine oil filler cap 1. Oil filter wrench 4.
U1D610E0.book Page 14 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR Recommended engine oil: See page 8-1. Oil quantity: Without oil filter cartridge replacement: 3.50 L (3.70 US qt) (3.08 Imp.qt) With oil filter cartridge replacement: 3.70 L (3.91 US qt) (3.26 Imp.qt) ECA11620 1. O-ring NOTE: Make sure that the O-ring is properly seated. 6 6. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench.
U1D610E0.book Page 15 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU20022 NOTE: After the engine is started, the engine oil level warning light should go off if the oil level is sufficient. ECA10400 CAUTION: If the oil level warning light flickers or remains on, immediately turn the engine off and have a Yamaha dealer check the vehicle. 10. Turn the engine off, and then check the oil level and correct it if necessary.
U1D610E0.book Page 16 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR 2. Remove the oil filler bolt and drain bolt to drain the oil from the final gear case. 3. Install the final gear oil drain bolt, and then tighten it to the specified torque. 6. Check the final gear case for oil leakage. If oil is leaking, check for the cause. Tightening torque: Final gear oil drain bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) The coolant level should be checked before each ride.
U1D610E0.book Page 17 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● If water has been added to the coolant, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. EWA10380 WARNING 1. Coolant reservoir 2. Maximum level mark 3. Minimum level mark 4. If the coolant is at or below the minimum level mark, remove the rider seat (See page 3-12.
U1D610E0.book Page 18 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR The coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart. Have a Yamaha dealer change the coolant. EAU35191 Cleaning the air filter elements The air filter elements should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter elements more frequently if you are riding in unusually wet or dusty areas. 1.
U1D610E0.book Page 19 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR 7. Install the air filter element by fitting the projection on the air filter element into the holder in the air filter case, then tightening the screws. ECA10480 CAUTION: ● 1. Air filter element 2. Screw 6. Lightly tap the air filter element to remove most of the dust and dirt, and then blow the remaining dirt out with compressed air as shown. If the air filter element is damaged, replace it.
U1D610E0.book Page 20 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21270 Adjusting the carburetors The carburetors are important parts of the engine and emission control system, which require very sophisticated adjustment. Therefore, all carburetor adjustments should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. EAU21380 Adjusting the throttle cable free play 1.
U1D610E0.book Page 21 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32541 Tires To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified tires. Tire air pressure The tire air pressure should be checked and, if necessary, adjusted before each ride. EWA10500 WARNING ● ● The tire air pressure must be checked and adjusted on cold tires (i.e., when the temperature of the tires equals the ambient temperature).
U1D610E0.book Page 22 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR in it, or if the sidewall is cracked, contact a Yamaha dealer immediately and have the tire replaced. Minimum tire tread depth (front and rear): 1.0 mm (0.04 in) EWA10520 WARNING 6 It is dangerous to ride with a wornout tire. When a tire tread begins to show lines, have a Yamaha dealer replace the tire immediately. Brakes, tires and related wheel parts replacement should also be left to a Yamaha dealer.
U1D610E0.book Page 23 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22010 Tightening torques: Valve stem nut: 1.6 Nm (0.16 m·kgf, 1.16 ft·lbf) Valve stem locknut: 1.6 Nm (0.16 m·kgf, 1.16 ft·lbf) Accessories and replacement parts any consequences caused by the use of items which have not been approved by Yamaha. EWA10620 WARNING This motorcycle is not designed to pull a trailer or to be attached to a sidecar.
U1D610E0.book Page 24 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22071 Clutch lever free play EAU22092 Adjusting the brake lever free play EWA10630 WARNING ● ● 1. Clutch lever free play 6 Since this model is equipped with a hydraulic clutch, adjusting the clutch lever free play is not needed. However, it is necessary to check the clutch fluid level and check the hydraulic system for leakage before each ride.
U1D610E0.book Page 25 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR Adjusting the rear brake light switch Checking the front and rear brake pads indicator grooves have almost disappeared, have a Yamaha dealer replace the brake pads as a set. The rear brake light switch, which is activated by the brake pedal, is properly adjusted when the brake light comes on just before braking takes effect.
U1D610E0.book Page 26 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22660 Checking the brake and clutch fluid levels ● Clutch Front brake Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking or clutch performance. Recommended brake and clutch fluid: DOT 4 brake fluid 1. Minimum level mark 1. Minimum level mark 6 Rear brake 1.
U1D610E0.book Page 27 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR brake fluid level goes down suddenly, have a Yamaha dealer check the cause. EAU22750 EAU23090 Changing the brake and clutch fluids Checking and lubricating the cables Have a Yamaha dealer change the brake and clutch fluids at the intervals specified in the NOTE after the periodic maintenance and lubrication chart.
U1D610E0.book Page 28 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23110 Checking and lubricating the throttle grip and cable EAU23131 Checking and lubricating the brake and shift pedals The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart.
U1D610E0.book Page 29 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23140 Checking and lubricating the brake and clutch levers EAU23200 Checking and lubricating the sidestand EAU23271 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. To check the condition EWA10750 WARNING Securely support the vehicle so that there is no danger of it falling over.
U1D610E0.book Page 30 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23280 Checking the steering ECA10590 Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1. Place a stand under the engine to raise the front wheel off the ground.
U1D610E0.book Page 31 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23290 Checking the wheel bearings EAU23370 EWA10760 Battery WARNING The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. ● 1. Battery 2. Negative battery terminal 3.
U1D610E0.book Page 32 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF CHILDREN. To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories. 6 To store the battery 1.
U1D610E0.book Page 33 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. 2. 3. 4. Cruise control fuse Carburetor heater fuse Auxiliary DC terminal fuse Spare fuse Fuse box 2 is located behind panel B. (See page 6-8.) 1. 2. 3. 4. 5. 6. Backup fuse (for odometer and clock) Radiator fan fuse Headlight fuse Signaling system fuse Ignition fuse Spare fuse If a fuse is blown, replace it as follows. 1. Turn the key to “OFF” and turn off the electrical circuit in question. 2.
U1D610E0.book Page 34 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Turn the key to “ON” and turn on the electrical circuit in question to check if the device operates. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EAU23792 Replacing the headlight bulb This model is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. 1. Remove the headlight unit by removing the screws. 1. Headlight coupler 2.
U1D610E0.book Page 35 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10790 EAU24281 Replacing a turn signal light bulb or the tail/brake light bulb WARNING Headlight bulbs get very hot. Therefore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down. 4. Place a new headlight bulb into position, and then secure it with the bulb holder.
U1D610E0.book Page 36 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR 2. Remove the defective bulb by pushing it in and turning it counterclockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screws. ECA10680 CAUTION: Do not overtighten the screws, otherwise the lens may break.
U1D610E0.book Page 37 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25870 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting charts represent quick and easy procedures for checking these vital systems yourself.
U1D610E0.book Page 38 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25911 Troubleshooting charts Starting problems or poor engine performance EWA10840 WARNING Keep away open flames and do not smoke while checking or working on the fuel system. 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle. Check the fuel level in the fuel tank.
U1D610E0.book Page 39 Monday, March 15, 2004 4:00 PM PERIODIC MAINTENANCE AND MINOR REPAIR Engine overheating EWA10400 WARNING ● ● Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
U1D610E0.book Page 1 Monday, March 15, 2004 4:00 PM MOTORCYCLE CARE AND STORAGE EAU26120 Cleaning Frequent, thorough cleaning of your motorcycle not only enhances its appearance, but also improves its performance and extends its life. ECA10730 CAUTION: ● 7 ● Improper cleaning can damage the windshield, cowlings, panels and other plastic parts. Use only a soft, clean cloth or sponge with mild detergent and water to clean plastic.
U1D610E0.book Page 2 Monday, March 15, 2004 4:00 PM MOTORCYCLE CARE AND STORAGE or another high-quality windshield cleaner. Some cleaning compounds for plastics may leave scratches on the windshield. Before using such cleaners, test an area of the windshield which does not affect your visibility and which cannot be easily recognized. After cleaning the motorcycle Apply Yamaha Silicone Wax or another high-quality automotive-type wax on all painted and chrome-plated surfaces.
U1D610E0.book Page 3 Monday, March 15, 2004 4:00 PM MOTORCYCLE CARE AND STORAGE 6. If storing in a humid or salt-air atmosphere, coat all exposed metal surfaces with a light film of oil. Do not apply oil to any rubber parts or the seat cover. 7. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month. Do not store the battery in an excessively cold or warm place [less than 0 °C (30 °F) or more than 30 °C (90 °F)].
U1D610E0.book Page 1 Monday, March 15, 2004 4:00 PM SPECIFICATIONS Dimensions: Overall length: 2505 mm (98.6 in) Overall width: 1010 mm (39.8 in) Overall height: 1525 mm (60.0 in) Seat height: 740 mm (29.1 in) Wheelbase: 1715 mm (67.5 in) Ground clearance: 150 mm (5.91 in) Minimum turning radius: 3500 mm (137.8 in) Weight: With oil and fuel: 383.0 kg (844 lb) Engine: Engine type: Liquid cooled 4-stroke, DOHC Cylinder arrangement: V-type 4-cylinder Displacement: 1294.0 cm³ (78.96 cu.in) Bore × stroke: 79.
U1D610E0.book Page 2 Monday, March 15, 2004 4:00 PM SPECIFICATIONS Transmission type: Constant mesh 5-speed Operation: Left foot operation Gear ratio: 1st: 43/17 (2.529) 2nd: 31/19 (1.632) 3rd: 30/25 (1.200) 4th: 24/25 (0.960) 5th: 22/28 (0.786) Chassis: Frame type: Double cradle Caster angle: 28.83 ° Trail: 131.0 mm (5.
U1D610E0.book Page 3 Monday, March 15, 2004 4:00 PM SPECIFICATIONS Voltage, capacity: 12 V, 18.0 Ah Headlight: Bulb type: Halogen bulb Bulb voltage, wattage x quantity: Headlight: 12 V, 60 W/55.0 W × 1 Tail/brake light: 12 V, 8.0/27.0 W × 1 Front turn signal/position light: 12 V, 23 W/8.0 W × 2 Rear turn signal light: 12 V, 21.
U1D610E0.book Page 1 Monday, March 15, 2004 4:00 PM CONSUMER INFORMATION EAU26351 Identification numbers EAU26381 EAU26400 Key identification number Vehicle identification number 1. Key identification number 1. Vehicle identification number The key identification number is stamped into the key tag. Record this number in the space provided and use it for reference when ordering a new key. The vehicle identification number is stamped into the steering head pipe.
U1D610E0.book Page 2 Monday, March 15, 2004 4:00 PM CONSUMER INFORMATION EAU26470 Model label 1. Model label The model label is affixed to the frame under the rider seat. (See page 3-12.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
U1D610E0.book Page 3 Monday, March 15, 2004 4:00 PM CONSUMER INFORMATION EAU26550 Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A.
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U1D610E0.book Page 5 Monday, March 15, 2004 4:00 PM CONSUMER INFORMATION EAU26631 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required. It is not acceptable proof of maintenance work.
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U1D610E0.book Page 7 Monday, March 15, 2004 4:00 PM CONSUMER INFORMATION EAU26693 YAMAHA MOTOR CORPORATION, U.S.A. ROYAL STAR™ SERIES LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants that each new Yamaha Royal Star Series motorcycle purchased from an authorized Yamaha motorcycle dealer in the continental United States will be free from defects in material or workmanship for the period of time stated herein, subject to certain stated limitations.
U1D610E0.book Page 8 Monday, March 15, 2004 4:00 PM CONSUMER INFORMATION WARRANTY QUESTIONS AND ANSWERS CUSTOMER SERVICE Q. What costs are my responsibility during the warranty period? A. The customer’s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damage, and oil, oil filters, air filters, spark plugs, and brake shoes or pads.
U1D610E0.book Page 1 Monday, March 15, 2004 4:00 PM INDEX A Engine oil and oil filter cartridge ........... 6-12 Engine, starting a warm.......................... 5-2 Engine stop switch.................................. 3-7 Engine trouble warning light ................... 3-3 Accessories and replacement parts...... 6-23 Air filter elements, cleaning................... 6-18 Auxiliary DC terminals........................... 3-21 B Battery...................................................
U1D610E0.book Page 2 Monday, March 15, 2004 4:00 PM INDEX Storage ................................................... 7-2 Supporting the motorcycle .................... 6-36 T Throttle cable free play, adjusting......... 6-20 Throttle grip and cable, checking and lubricating ........................................... 6-28 Tires...................................................... 6-21 Tool kit .................................................... 6-1 Troubleshooting....................................
OWNER’S MANUAL XVZ13CTT(C) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2004.03-0.
