2001 YAMAHA XVZ1300TF brake
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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
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PERIODIC MAINTENANCE AND MINOR REPAIR
7-3
7
EAU03685
Periodic maintenance and lubrication chart
NOTE:_ l
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
l
From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
l
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_CP-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line• Check fuel hoses for cracks or damage.ÖÖÖÖ Ö
2*Fuel filter• Check condition.ÖÖ
3 Spark plugs• Check condition.
• Clean and regap.ÖÖ
•Replace.ÖÖ
4*Valves• Check valve clearance.
• Adjust.Every 40,000 km
5 Air filter element• Clean.ÖÖ
•Replace.ÖÖ
6*Clutch• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 7-5.) ÖÖÖÖÖ
7*Front brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 7-5.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
8*Rear brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 7-5.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
9*Brake hoses• Check for cracks or damage.ÖÖÖÖ Ö
• Replace. (See NOTE on page 7-5.) Every 4 years
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PERIODIC MAINTENANCE AND MINOR REPAIR
7-5
7
EAU03892
NOTE:_ l
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
l
Hydraulic brake and clutch systems
• After disassembling the brake or clutch master cylinders, caliper cylinders or clutch release cylinder, always change
the fluid. Regularly check the brake and clutch fluid levels and fill the reservoirs as required.
• Replace the oil seals on the inner parts of the brake or clutch master cylinders, caliper cylinders and clutch release
cylinder every two years.
• Replace the brake and clutch hoses every four years or if cracked or damaged.
_25 Final gear oil• Check oil level and vehicle for oil leakage.ÖÖ Ö
• Change.ÖÖÖ
26
*Front and rear brake
switches• Check operation.ÖÖÖÖÖ Ö
27 Moving parts and cables• Lubricate.ÖÖÖÖ Ö
28*Lights, signals and
switches• Check operation.
• Adjust headlight beam.ÖÖÖÖÖ Ö NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
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PERIODIC MAINTENANCE AND MINOR REPAIR
7-23
7
EW000079
WARNING
_ l
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta-
bility and can lead to loss of
control.
l
The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
_
Tire information
This motorcycle is equipped with tube-
less tires, tire air valves and cast
wheels.
EW000132
WARNING
_ l
The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the motor-
cycle cannot be guaranteed.
l
After extensive tests, only the
tires listed below have been ap-
proved for this model by
Yamaha Motor Co., Ltd.
l
Always make sure that the valve
caps are securely installed to
prevent air pressure leakage.
l
Use only the tire valves and
valve cores listed below to
avoid tire deflation during a
ride.
_
1. Tire air valve
2. Tire air valve core
3. Tire air valve cap with seal
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PERIODIC MAINTENANCE AND MINOR REPAIR
7-25
7
EAU00695
Clutch lever free play Since this model is equipped with a hy-
draulic clutch, adjusting the clutch lever
free play is not needed. However, it is
necessary to check the clutch fluid lev-
el and check the hydraulic system for
leakage before each ride. If the clutch
lever free play does become exces-
sive, and shifting becomes rough or
clutch slippage occurs, causing poor
acceleration, there may be air in the
clutch system. If there is air in the hy-
draulic system, have a Yamaha dealer
bleed the system before operating the
motorcycle.
EAU00696
Adjusting the brake lever free
play The brake lever free play should mea-
sure 2–5 mm as shown. Periodically
check the brake lever free play and, if
necessary, adjust it as follows.
1. Loosen the locknut at the brake
lever.
2. To increase the brake lever free
play, turn the adjusting bolt in di-
rection
a. To decrease the brake
lever free play, turn the adjusting
bolt in direction
b.3. Tighten the locknut.
EW000099
WARNING
@ l
After adjusting the brake lever
free play, check the free play
and make sure that the brake is
working properly.
l
A soft or spongy feeling in the
brake lever can indicate the
presence of air in the hydraulic
system. If there is air in the hy-
draulic system, have a Yamaha
dealer bleed the system before
operating the motorcycle. Air in
the hydraulic system will dimin-
ish the braking performance,
which may result in loss of con-
trol and an accident.
@
a. Clutch lever free play
1. Locknut
2. Brake lever free play adjusting bolt
c. Brake lever free play
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PERIODIC MAINTENANCE AND MINOR REPAIR
7-26
7
EAU01746
Adjusting the brake pedal
position The top of the brake pedal should be
positioned approximately 100 mm
above the top of the footrest as shown.
Periodically check the brake pedal po-
sition and, if necessary, have a
Yamaha dealer adjust it.
EW000109
WARNING
@ A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the hydraulic system. If there
is air in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the motorcycle. Air in
the hydraulic system will diminish
the braking performance, which
may result in loss of control and an
accident. @
EAU01799
Adjusting the rear brake light
switch The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect.
Since the brake light switch is a compo-
nent of the cruise control system, it
must be adjusted by a Yamaha dealer,
who has the necessary professional
knowledge and experience.
a. Distance between brake pedal and footrest
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PERIODIC MAINTENANCE AND MINOR REPAIR
7-27
7
EAU00721
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU03938
Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear
indicator grooves have almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU03939
Rear brake pads
Each rear brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator groove. If a brake
pad has worn to the point that the wear
indicator groove has almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
1. Brake pad wear indicator groove (´ 3)Front
1. Brake pad wear indicator grooveRear
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PERIODIC MAINTENANCE AND MINOR REPAIR
7-28
7
EAU03914
Checking the brake and clutch
fluid levels Insufficient brake or clutch fluid may al-
low air to enter the brake or clutch sys-
tems, possibly causing them to
become ineffective.
Before riding, check that the brake and
clutch fluids are above the minimum
level marks and replenish if necessary.
A low brake or clutch fluid level may in-
dicate brake or clutch system leakage
and/or worn brake pads. If the brake or
clutch levels are low, be sure to check
the brake or clutch systems for leakage
and the brake pads for wear.Observe these precautions:
l
When checking the brake and
clutch fluid levels, make sure that
the top of each reservoir is level.
l
Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking or clutch
performance.
l
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking or clutch per-
formance.
l
Be careful that water does not en-
ter the brake or clutch fluid reser-
voir when refilling. Water will
significantly lower the boiling point
of the fluid and may result in vapor
lock.
l
Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.
l
As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
1. Minimum level markFront brake
1. Minimum level markRecommended brake and clutch
fluid: DOT 4 brake fluidRear brake
1. Minimum level markClutch
E_5jc.book Page 28 Monday, January 22, 2001 12:12 PM