2005-2009 Yamaha XVZ1300 Royal Star Tour Deluxe Motorcycle Service Manual

Description

This Official 2005-2009 Yamaha XVZ13 Royal Star Tour Deluxe Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for the 2005-2009 Yamaha Royal Star Tour Deluxe. 2006-2007 Royal Star Midnight Tour Deluxe, 2008-2009 Royal Star Tour Deluxe S motorcycles.

This is the same book used by the service department at your local Yamaha dealer. It has everything in it you need to know in order to repair and service your motorcycle.

2005, 2006, 2007, 2008, 2009

2005-2009 Yamaha XVZ13 Royal Star Tour Deluxe Service Manual Table Of Contents

General Information
Specifications
Periodic Checks And Adjustments
Engine
Cooling System
Carburetors
Chassis
Electrical System
Troubleshooting

2005-2009 Yamaha XVZ13 Royal Star Tour Deluxe Service Manual Index of Topics

Chapter 1: General Information
Motorcycle Identification
Vehicle Identification Number
Model Code
Features
Cruise Control
Digital Speedometer
Audio System And Cb Radio
Important Information
Preparation For Removal And Disassembly
Replacement Parts
Gaskets, Oil Seals And O-rings
Lock Washers/plates And Cotter Pins
Bearings And Oil Seals
Circlips
Checking The Connections
Special Tools

Chapter 2: Specifications General Specifications
Maintenance Specifications
Engine
Chassis
Electrical
Audio System And Cbradio Specifications
Conversion Table
General Tightening Torque Specifications
Lubrication Points And Lubricant Types
Engine
Chassis
Cooling System Diagrams
Lubrication Diagrams
Cable Routing

Chapter 3: Periodic Checks And Adjustments
Periodic Maintenance Chart For Emission Control System
General Maintenance And Lubrication Chart
Front Cowling
Removing The Front Cowling Cover
Installing The Front Cowling Cover
Rider And Passenger Seats
Fuel Tank
Saddlebags
Engine
Adjusting The Valve Clearance
Synchronizing The Carburetors
Adjusting The Engine Idling Speed
Adjusting The Throttle Cable Free Play
Checking The Spark Plugs
Checking The Ignition Timing
Measuring The Compression Pressure
Checking The Engine Oil Level
Changing The Engine Oil
Measuring The Engine Oil Pressure
Checking The Clutch Fluid Level
Bleeding The Hydraulic Clutch System
Cleaning The Air Filter Element
Checking The Carburetor Joints And Intake
Manifolds
Checking The Fuel Hoses And Fuel Filter
Checking The Crankcase Breather Hose
Checking The Exhaust System
Checking The Coolant Level
Checking The Cooling System
Changing The Coolant
Chassis
Adjusting The Rear Brake
Checking The Brake Fluid Level
Checking The Brake Pads
Adjusting The Rear Brake Light Switch
Checking The Brake Hoses
Bleeding The Hydraulic Brake System
Adjusting The Shift Pedal
Checking The Final Drive Oil Level
Checking The Final Drive Oil
Checking And Adjusting The Steering Head
Checking The Front Fork
Adjusting The Front And Rear Shock Absorber
Assembly
Checking The Tires
Checking The Wheels
Checking And Lubricating The Cables
Lubricating The Levers And Pedals
Lubricating The Sidestand
Lubricating The Rear Suspension
Electrical System
Checking And Charging The Battery
Checking The Fuses
Replacing The Headlight Bulb
Adjusting The Headlight Beam

Chapter 4: Engine
Engine Removal
Leads, Cables And Hoses
Radiator And Ais
Mufflers And Exhausts
Horn And Brake Pedal
Engine
Installing The Engine
Camshafts
Cylinder Head Covers
Camshafts
Removing The Camshafts
Checking The Camshafts
Checking The Timing Chains, Camshaft Sprockets,
And Timing Chain Guides
Checking The Timing Chain Tensioners
Installing The Camshafts
Cylinder Heads
Checking The Cylinder Heads
Installing The Cylinder Heads
Valves And Valve Springs
Removing The Valves
Checking The Valves And Valve Guides
Checking The Valve Seats
Checking The Valve Springs
Checking The Valve Lifters
Installing The Valves
Clutch
Clutch Master Cylinder
Checking The Clutch Master Cylinder
Assemblyng The Clutch Master Cylinder
Installing The Clutch Master Cylinder
Disassembling The Clutch Release Cylinder
Checking The Clutch Release Cylinder
Assembling The Clutch Release Cylinder
Installing The Clutch Release Cylinder
Cluch Cover
Cluch
Removing The Clutch
Checking The Friction Plates
Checking The Clutch Plates
Checking The Clutch Spring Plate
Checking The Clutch Housing
Checking The Clutch Boss
Checking The Pressure Plate
Checking The Clutch Push Rods
Installing The Clutch
Shift Shaft
Shift Shaft And Stopper Lever
Checking The Shift Shaft
Checking The Stopper Lever
Installing The Shift Shaft
Starter Clutch And Generator
Stator Coil
Starter Clutch And Generator
Removing The Generator
Checking The Starter Clutch
Installing The Generator
Oil Pan And Oil Pump
Removing The Oil Pan
Checking The Oil Pump
Checking The Relief Valve
Checking The Oil Gallery Pipes
Checking The Oil Strainer
Installing The Oil Gallery Pipes
Assembling The Oil Pump
Installing The Oil Pump
Installing The Oil Strainer
Installing The Oil Pan
Crankcase
Disassembling The Crankcase
Checking The Crankcase
Assembling The Crankcase
Crankshaft
Removing The Crankshaft Assembly
Checking The Crankshaft
Checking The Balancer Shaft
Installing The Crankshaft
Installing The Balancer Shaft
Connecting Rods And Pistons
Removing The Connecting Rods And Pistons
Checking The Cylinders And Pistons
Checking The Piston Rings
Checking The Piston Pins
Checking The Crankshaft And Connecting Rods Installing The Piston And Connecting Rods
Transmission
Checking The Bearings And Oil Seals
Checking The Shift Forks
Checking The Shift Drum Assembly
Checking The Transmission
Installing The Shift Forks
Installing The Transmission
Middle Gear
Disassembling The Middle Drive Shaft Assembly Disassembling The Middle Driven Shaft Assembly
Checking The Middle Drive Shaft Assembly
Checking The Middle Driven Shaft Assembly
Assembling The Middle Drive Shaft Assembly
Assembling The Middle Driven Shaft Assembly
Aligning The Middle Gear
Adjusting The Middle Gear Backlash

Chapter 5: Cooling System
Radiator
Checking The Radiator
Installing The Radiator
Thermostat
Thermostat Housing
Checking The Thermostat
Assembling The Thermostat
Installing The Thermostat
Water Pump
Disassembling The Water Pump
Checking The Water Pump
Assembling The Water Pump
Installing The Water Pump

Chapter 6: Carburetors
Carburetors
Checking The Carburetors
Assembling The Carburetors
Installing The Carburetors
Measuring And Adjusting The Fuel Level
Checking And Adjusting The Throttle Position
Sensor
Checking The Fuel Pump
Checking The Fuel Cock
Checking The Fuel Cock Operation
Air Induction System(ais)
Air Injection
Air Cut-off Valve
Air Induction System Diagrams
Checking The Air Induction System

Chapter 7: Chassis
Front Wheel And Brake Discs
Front Wheel
Removing The Front Wheel
Checking The Front Wheei
Checking The Brake Discs
Installing The Front Wheel
Adjusting The Front Wheel Static Balance
Rear Wheel And Brake Disc
Rear Fender
Rear Wheel And Brake Disc
Removing The Rear Wheel
Checking The Rear Wheel
Checking The Rear Wheel Drive Hub
Installing The Rear Wheel
Adjusting The Rear Wheel Static Balance
Front And Rear Brakes
Front Brake Pads
Rear Brake Pads
Replacing The Front Brake Pads
Replacing The Rear Brake Pads
Front Brake Master Cylinder
Rear Brake Master Cylinder
Removing The Front Brake Master Cylinder
Removing The Rear Brake Master Cylinder
Checking The Front And Rear Brake Master
Cylinders
Installing The Front Brake Master Cylinder
Installing The Rear Brake Master Cylinder
Front Brake Calipers
Rear Brake Calipers
Disassembling The Front Brake Calipers
Disassembling The Rear Brake Caliper
Checking The Front And Rear Brake Calipers
Installing The Front Brake Calipers
Installing The Rear Brake Caliper
Front Fork
Removing The Front Fork Legs
Disassembling The Front Fork Legs
Checking The Front Fork Legs
Assembling The Front Fork Legs
Installing The Front Fork Legs
Handlebar
Handlebar
Removing The Handlebar
Checking The Handlebar
Installing The Handlebar
Steering Head
Removing The Lower Bracket
Checking The Steering Head
Installing The Steering Head
Rear Shock Absorber Assembly
Removing The Rear Shock Absorber Assembly
Checking The Rear Shock Absorber Assembly
Installing The Rear Shock Absorber Assembly
Swingarm
Swingarm
Removing The Swingarm
Checking The Swingarm
Installing The Swingarm
Shaft Drive
Troubleshooting
Checking The Final Drive Oil For Contamination And Inspecting The Shaft Drive For Leaks
Final Drive Assembly And Drive Shaft
Final Drive Assembly And Drive Shaft
Measuring The Ring Gear Backlash
Adjusting The Ring Gear Backlash
Measuring The Ring-gear-to-stopper-bolt
Clearance
Adjusting The Ring-gear-to-stopper-bolt
Clearance
Final Drive
Final Drive Assembly
Disassembling The Final Drive Assembly
Removing And Installing The Ring Gear Bearings Aligning The Final Drive Pinion Gear And Ring
Gear
Checking The Drive Shaft
Installing The Drive Shaft

Chapter 8: Electrical System
Electrical Components
Switches
Checking Switch Continuity
Switch Continuity Inspection
Checking The Bulbs And Bulb Sockets
Types Of Bulbs
Checking The Condition Of The Bulbs
Checking The Condition Of The Bulb Sockets
Ignition System
Circuit Diagram
Troubleshooting
Electric Starting System
Circuit Diagram
Starting Circuit Cutoff System Operation
Troubleshooting
Starter Motor
Checking The Starter Motor
Assembling The Starter Motor
Installation
Charging System
Circuit Diagram
Troubleshooting
Lighting System
Circuit Diagram
Troubleshooting
Checking The Lighting System
Signal System
Circuit Diagram
Troubleshooting
Cooling System
Circuit Diagram
Troubleshooting
Fuel Pump System
Circuit Diagram
Fuel Pump Circuit Operation
Troubleshooting
Checking The Fuel Pump
Carburetor Heating System
Troubleshooting
Audio System
Audio System Circui Operation
Cruise Control System
Circuit Diagram
Cruise Control Circuit Operation
Cruise Control System Components
Troubleshooting
Checking The Cruise Control System
Self Diagnosis Function Of The Cruise Control System
Self-diagnosis
Engine Warning Light
Troubleshooting
Fuel Meter
Troubleshooting
“set”/“res” Indicator Light
Troubleshooting