engine YAMAHA XVZ1300TF 2001 Owner's Manual

OPERATION AND IMPORTANT RIDING POINTS
6-6
6
EAU00457
Parking When parking, stop the engine, re-
move the key from the main switch,
and then turn the fuel cock lever to
“OFF”.
EW000058
WARNING
@ l
Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.
l
Do not park on a slope or on
soft ground, otherwise the
motorcycle may overturn.
@
E_5jc.book Page 6 Monday, January 22, 2001 12:12 PM

7
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 7-1
Periodic maintenance and lubrication chart ......... 7-3
Removing and installing cowlings and panels ..... 7-6
Checking the spark plugs .................................. 7-11
Engine oil and oil filter cartridge ........................ 7-12
Final gear oil ...................................................... 7-15
Checking the coolant level ................................. 7-15
Cleaning the air filter elements .......................... 7-17
Adjusting the carburetors ................................... 7-19
Adjusting the engine idling speed ...................... 7-20
Adjusting the throttle cable free play .................. 7-21
Adjusting the valve clearance ............................ 7-21
Tires ................................................................... 7-21
Cast wheels ....................................................... 7-24
Clutch lever free play ......................................... 7-25
Adjusting the brake lever free play ..................... 7-25
Adjusting the brake pedal position ..................... 7-26
Adjusting the rear brake light switch .................. 7-26Checking the front and rear brake pads ............ 7-27
Checking the brake and clutch fluid levels ........ 7-28
Changing the brake and clutch fluids ................ 7-29
Checking and lubricating the brake and
shift pedals ...................................................... 7-29
Checking and lubricating the brake and
clutch levers .................................................... 7-30
Checking and lubricating the sidestand ............ 7-30
Checking the front fork ...................................... 7-31
Checking the steering ....................................... 7-31
Battery ............................................................... 7-32
Replacing the fuses .......................................... 7-33
Replacing the headlight bulb ............................. 7-35
Replacing a turn signal light bulb or the
tail/brake light bulb .......................................... 7-36
Replacing the license plate light bulb ................ 7-37
Troubleshooting ................................................. 7-37
Troubleshooting charts ...................................... 7-38
E_5jc.book Page 1 Monday, January 22, 2001 12:12 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
7-4
7
10
*Wheels• Check runout and for damage.ÖÖÖÖ
11*Tires• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.ÖÖÖÖ
12*Wheel bearings• Check bearing for looseness or damage.ÖÖÖÖ
13*Swingarm• Check operation and for excessive play.ÖÖÖÖ
• Lubricate with lithium-soap-based grease. Every 50,000 km
14*Steering bearings• Check bearing play and steering for roughness.ÖÖÖÖÖ
• Lubricate with lithium-soap-based grease. Every 50,000 km
15*Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.ÖÖÖÖ Ö
16 Sidestand• Check operation.
• Lubricate.ÖÖÖÖ Ö
17*Sidestand switch• Check operation.ÖÖÖÖÖ Ö
18*Front fork• Check operation and for oil leakage.ÖÖÖÖ
19*Shock absorber
assembly• Check operation and shock absorber for oil leakage.ÖÖÖÖ
20*Rear suspension relay
arm and connecting arm
pivoting points• Check operation.ÖÖÖÖ
• Lubricate with lithium-soap-based grease.ÖÖ
21*Carburetors• Check starter (choke) operation.
• Adjust engine idling speed and synchronization.ÖÖÖÖÖ Ö
22 Engine oil• Change.ÖÖÖÖÖ Ö
23 Engine oil filter cartridge• Replace.ÖÖÖ
24*Cooling system• Check coolant level and vehicle for coolant leakage.ÖÖÖÖ Ö
• Change. Every 3 years NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
E_5jc.book Page 4 Monday, January 22, 2001 12:12 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
7-11
7
EAU01880
Checking the spark plugs The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal col-
or when the motorcycle is ridden nor-
mally), and all spark plugs installed in
the engine should have the same color.
If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
NOTE:@ If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible. @
a. Spark plug gap
Specified spark plug:
DPR8EA-9 (NGK) or
X24EPR-U9 (DENSO)
Spark plug gap:
0.8–0.9 mm
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf)
E_5jc.book Page 11 Monday, January 22, 2001 12:12 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
7-12
7
EAU01703
Engine oil and oil filter
cartridge The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. @2. Start the engine, warm it up for
several minutes, and then turn it
off.3. Wait a few minutes until the oil set-
tles, and then check the oil level
through the check window located
at the bottom-right side of the
crankcase.
NOTE:@ The engine oil should be between the
minimum and maximum level marks. @4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.To change the engine oil (with or
without oil filter cartridge replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
1. Engine oil filler cap
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PERIODIC MAINTENANCE AND MINOR REPAIR
7-13
73. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
NOTE:@ Skip steps 4–6 if the oil filter cartridge is
not being replaced. @
4. Remove the oil filter cartridge with
an oil filter wrench.NOTE:@ An oil filter wrench is available at a
Yamaha dealer. @5. Apply a thin coat of engine oil to
the O-ring of the new oil filter
cartridge.NOTE:@ Make sure that the O-ring is properly
seated. @
6. Install the new oil filter cartridge,
and then tighten it to the specified
torque with a torque wrench.
7. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
1. Engine oil drain bolt
1. Engine oil filter cartridge
1. Torque wrench
2. Oil filter wrench
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf)
E_5jc.book Page 13 Monday, January 22, 2001 12:12 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
7-14
7 8. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
EC000072
CAUTION:@ l
In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives with
the oil or use oils of a higher
grade than “CD”. In addition, do
not use oils labeled “ENERGY
CONSERVING II” or higher.
l
Make sure that no foreign mate-
rial enters the crankcase.
@9. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.NOTE:@ After the engine is started, the engine
oil level warning light should go off if the
oil level is sufficient. @
EC000067
CAUTION:@ If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha deal-
er check the vehicle. @10. Turn the engine off, and then
check the oil level and correct it if
necessary. Recommended engine oil:
See page 9-1.
Oil quantity:
Without oil filter cartridge
replacement:
3.5 L
With oil filter cartridge
replacement:
3.7 L
Total amount (dry engine):
4.3 L
E_5jc.book Page 14 Monday, January 22, 2001 12:12 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
7-15
7
EAU01220
Final gear oil The final gear case must be checked
for oil leakage before each ride. If any
leakage is found, have a Yamaha deal-
er check and repair the motorcycle. In
addition, have a Yamaha dealer
change the final gear oil at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU03974
Checking the coolant level The coolant level should be checked as
follows before each ride. In addition,
the coolant must be changed at the in-
tervals specified in the periodic mainte-
nance and lubrication chart.
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. Remove panel A. (See page 7-9
for panel removal and installation
procedures.)NOTE:_ l
The coolant level must be checked
on a cold engine since the level
varies with engine temperature.
l
Make sure that the motorcycle is
positioned straight up when
checking the coolant level. A slight
tilt to the side can result in a false
reading.
_
3. Check the coolant level in the
coolant reservoir.NOTE:_ The coolant should be between the
minimum and maximum level marks. _
1. Final gear oil filler bolt
2. Final gear oil drain bolt
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
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PERIODIC MAINTENANCE AND MINOR REPAIR
7-16
7 4. If the coolant is at or below the
minimum level mark, remove the
rider seat (See page 3-15 for rider
seat removal and installation pro-
cedures.), open the reservoir cap,
add coolant to the maximum level
mark, and then close the reservoir
cap and install the rider seat.
EC000080
CAUTION:_ l
If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
l
If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the cool-
ing system will not be protected
against frost and corrosion.
l
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.
_
EW000067
WARNING
_ Never attempt to remove the radia-
tor cap when the engine is hot. _5. Install the panel.
NOTE:_ l
The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.
l
If the engine overheats, see page
7-39 for further instructions.
_
1. Coolant reservoir cap
Coolant reservoir capacity:
0.84 L
E_5jc.book Page 16 Monday, January 22, 2001 12:12 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
7-19
77. Install the air filter element by fit-
ting the projection on the air filter
element into the holder in the air
filter case, then tightening the
screws.
EC000082*
CAUTION:@ l
Make sure that the air filter ele-
ment is properly seated in the
air filter case.
l
The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
pistons and/or cylinders may
become excessively worn.
@
8. Install the air filter case cover by
installing the bolts.
9. Install the air filter by pushing it
onto the air filter joint, then tighten-
ing the air filter joint clamp screw.
10. Install the air filter case by install-
ing the bolts.
11. Install the cowlings.NOTE:@ Make sure that the air filter case drain
hose is routed as shown. @
EAU00630
Adjusting the carburetors The carburetors are important parts of
the engine and require very sophisti-
cated adjustment. Therefore, most car-
buretor adjustments should be left to a
Yamaha dealer, who has the neces-
sary professional knowledge and expe-
rience. The adjustment described in
the following section, however, may be
serviced by the owner as part of routine
maintenance.
EC000095
CAUTION:_ The carburetors have been set and
extensively tested at the Yamaha
factory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-
mance of or damage to the engine. _
1. Air filter case drain hose
E_5jc.book Page 19 Monday, January 22, 2001 12:12 PM