Index Manuals Yamaha XVS1100 (L). Service Manual

Yamaha XVS1100 (L). Service Manual - part 1

NOTE:

CAUTION:

EB001000

NOTICE

This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and
their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual,
so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha mo-
torcycles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair.
Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe and
unfit for use.

Yamaha Motor Company, Ltd.is continually striving to improve all its models. Modifications and signifi-
cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.

Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!

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.

A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

EB002000

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)

1st title

This is the title of the chapter with its symbol in the upper right corner of each page.

2nd title

This title indicates the section of the chapter and only appears on the first page of each

section. It is located in the upper right corner of the page.

3rd title

This title indicates a sub-section that is followed by step-by-step procedures accompa-

nied by corresponding illustrations.

EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each re-
moval and disassembly section.

1. An easy-to-see exploded diagram

is provided for removal and disassembly jobs.

2. Numbers

are given in the order of the jobs in the exploded diagram. A number that is enclosed by

a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks

. The meanings of the symbol marks are given on the next page.

4. A job instruction chart

accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

5. For jobs requiring more information, the step-by-step format supplements

are given in addition to

the exploded diagram and the job instruction chart.

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols

are printed on the

top right of each page and indicate the subject of
each chapter.

General information

Specifications

Periodic inspections and adjustments

Engine

Cooling system

Carburetion

Chassis

Electrical

Troubleshooting

Illustrated symbols

are used to identify

the specifications appearing in the text.

Can be serviced with engine mounted

Filling fluid

Lubricant

Special tool

Torque

Wear limit, clearance

Engine speed

Ω

, V, A

Illustrated symbols

in the exploded dia-

grams indicate the types of lubricants and lu-
brication points.

Apply engine oil

Apply gear oil

Apply molybdenum disulfide oil

Apply wheel bearing grease

Apply lightweight lithium-soap base grease

Apply molybdenum disulfide grease

Illustrated symbols

in the exploded dia-

grams indicate where to apply locking agent

and when to install new parts

Apply locking agent (LOCTITE

)

Replace

E004000

INSP

ADJ

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTION AND
ADJUSTMENTS

ENGINE OVERHAUL

CARBURETION

CHASSIS

ELECTRICAL

TROUBLESHOOTING

GEN

INFO

SPEC

ENG

CARB

CHAS

ELEC

TRBL

SHTG

CHAPTER TITLES

GEN

INFO

CHAPTER 1.

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

1-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE IDENTIFICATION NUMBER

1-1

. . . . . . . . . . . . . . . . . . . . . . . . .

MODEL LABEL

1-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IMPORTANT INFORMATION

1-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREPARATION FOR REMOVAL PROCEDURES

1-2

. . . . . . . . . . . . . . .

REPLACEMENT PARTS

1-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GASKETS, OIL SEALS AND O-RINGS

1-2

. . . . . . . . . . . . . . . . . . . . . . . .

LOCK WASHERS/ PLATES AND COTTER PINS

1-3

. . . . . . . . . . . . . . . .

BEARINGS AND OIL SEALS

1-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCLIPS

1-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING OF CONNECTIONS

1-4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS

1-5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

MOTORCYCLE IDENTIFICATION

GEN

INFO

EB100000

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

EB100010

VEHICLE IDENTIFICATION NUMBER
The vehicle identification number

is stamped

into the right side of the steering head.

MODEL LABEL
The model label

is affixed to the frame. This

information will be needed to order spare parts.

1-2

IMPORTANT INFORMATION

GEN

INFO

EB101000

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL PROCE-
DURES
1. Remove all dirt, mud, dust and foreign mate-

rial before removal and disassembly.

2. Use proper tools and cleaning equipment.

Refer to the “SPECIAL TOOLS” section.

3. When disassembling the machine, always

keep mated parts together. This includes
gears, cylinders, pistons and other parts that
have been “mated” through normal wear.
Mated parts must always be reused or re-
placed as an assembly.

4. During machine disassembly, clean all parts

and place them in trays in the order of disas-
sembly. This will speed up assembly and al-
low for the correct installation of all parts.

5. Keep all parts away from any source of fire.

EB101010

REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all re-

placements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.

EB101020

GASKETS, OIL SEALS AND O-RINGS
1. Replace all gaskets, seals and O-rings when

overhauling the engine. All gasket surfaces,
oil seal lips and O-rings must be cleaned.

2. Properly oil all mating parts and bearings

during reassembly. Apply grease to the oil
seal lips.

1-3

IMPORTANT INFORMATION

GEN

INFO

CAUTION:

EB101030

LOCK WASHERS/ PLATES AND COTTER
PINS
1. Replace all lock washers / plates

and cot-

ter pins after removal. Bend lock tabs along
the bolt or nut flats after the bolt or nut has
been tightened to specification.

EB101040

BEARINGS AND OIL SEALS
1. Install bearings and oil seals so that the

manufacturer’s marks or numbers are vis-
ible. When installing oil seals, apply a light
coating of lightweight lithium base grease to
the seal lips. Oil bearings liberally when
installing, if appropriate.

Oil seal

Do not use compressed air to spin the bear-
ings dry. This will damage the bearing sur-
faces.

Bearing

EB101050

CIRCLIPS
1. Check all circlips carefully before reassemb-

ly. Always replace piston pin clips after one
use. Replace distorted circlips. When instal-
ling a circlip

, make sure that the sharp-

edged corner

is positioned opposite the

thrust

it receives. See sectional view.

Shaft

1-4

CHECKING OF CONNECTIONS

GEN

INFO

NOTE:

EB801000

CHECKING OF CONNECTIONS

Check the connectors for stains, rust, moisture,
etc.
1. Disconnect:

Connector

2. Check:

Connector
Moisture

Dry each terminal with an air

blower.
Stains/ rust

Connect and disconnect the

terminals several times.

3. Check:

Connector leads
Looseness

Bend up the pin

and con-

nect the terminals.

4. Connect:

Connector terminals

The two terminals “click” together.

5. Check:

Continuity (using a pocket tester)

If there is no continuity, clean the terminals.

When checking the wire harness be sure to
perform steps 1 to 3.

As a quick remedy, use a contact revitalizer
available at most part stores.

Check the connector with a pocket tester as
shown.

1-5

SPECIAL TOOLS

GEN

INFO

EB102001

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or
improvised techniques. Special tools may differ by shape and part number from country to country. In
such a case, two types are provided.
When placing an order, refer to the list provided below to avoid any mistakes.

Tool No.

Tool name / How to use

Illustration

Weight

90890-01084

Bolt

90890-01085

Slide hammer bolt / weight

These tools are used to remove the rocker
arm shaft.

90890-01135

Crankcase separating tool

This tool is used to remove the crankshaft.

90890-01229

Coupling gear / Middle shaft tool

This tool is needed when removing or
installing the final pinion shaft nut.

Final gear

backlash band

90890-01230

Middle gear

backlash band

90890-01231

Final gear backlash band

This tool is needed when measuring final gear

/ middle gear backlash.

Installer pot

90890-01274

Bolt

90890-01275

Crankshaft installer pot / bolt / adapter / spacer

90890 01275

Adaptor

90890-04130

Spacer

90890-04060

These tools are used to install the crankshaft.

90890-01304

Piston pin puller

This tool is used to remove the piston pin.

90890-01312

Fuel level gauge

This gauge is used to measure the fuel level
in the float chamber.

1-6

SPECIAL TOOLS

GEN

INFO

Tool No.

Tool name / How to use

Illustration

T-handle

90890-01326

Holder

90890-01460

T-handle / damper rod holder

These tools are needed to loosen and tighten
the damper rod holding bolt.

Puller

90890-01362

Adapter

90890-04131

Flywheel puller / adapter

These tools are needed to remove the rotor.

Weight

90890-01367

Adapter

90890-01381

Fork seal driver weight / adapter

These tools are needed when installing the
slide metal, oil seal and dust seal into the fork.

Ring nut wrench

90890-01403

Exhaust nut

wrench

90890-01268

Ring nut wrench / ehaust and steering nut
wrench

This tool is needed to loosen and tighten the
steering stem ring nut.

90890-01701

Sheave holder

This tool is needed to hold the rotor when re-
moving or installing the rotor bolt.

90890-03081

Compression gauge set

These tools are needed to measure engine
compression.

90890-03094

Vacuum gauge

This gauge is needed for carburetor synchro-
nization.

90890-03112

Pocket tester

This instrument is needed for checking the
electrical system.

90890-03113

Engine tachometer

This tool is needed for observing engine r/min.

1-7

SPECIAL TOOLS

GEN

INFO

Tool No.

Tool name / How to use

Illustration

90890-03141

Timing light

This tool is necessary for checking ignition
timing.

90890-04014

Valve guide remover & installer

This tool is needed to remove and install the
valve guide.

90890-04019

Valve spring compressor

This tool is needed to remove and install the
valve assemblies.

Adapter

90890-01277

Shock puller

90890-01290

Weight

90890-01291

Crankshaft installer bolt adapter / armature
shock puller / weight

These tools are needed when removing the
final pinion shaft.

90890-04137

Bearing retainer wrench

This tool is needed when removing or instal-
ling the middle drive shaft assembly.

Wrench

90890-04138

Holder

90890-04055

Middle drive shaft nut wrench / Middle drive
shaft holder

These tools are needed when removing or
installing the middle drive shaft bearing.

90890-04062

Universal joint holder

This tool is needed when removing or instal-
ling the driven pinion gear nut.

90890-04077

Bearing retainer wrench

This tool is needed when removing or instal-
ling the final drive pinion gear assembly.

90890-04086

Clutch holding tool

This tool is needed to hold the clutch when re-
moving or installing the clutch boss nut.

1-8

SPECIAL TOOLS

GEN

INFO

Tool No.

Tool name / How to use

Illustration

90890-04090

Damper spring compressor

This tool is needed when removing or instal-
ling the damper spring.

90890-06754

Dynamic spark tester
Ignition checker

This instrument is necessary for checking the
ignition system components.

90890-85505

Yamaha bond No.1215

This sealant (bond) is used on crankcase mat-
ing surfaces, etc.

SPEC

CHAPTER 2.

SPECIFICATIONS

GENERAL SPECIFICATIONS

2-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE SPECIFICATIONS

2-4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE

2-4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS

2-14

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL

2-18

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL TORQUE SPECIFICATIONS

2-20

. . . . . . . . . . . . . . . . . . . . . . . . . .

CONVERSION TABLE

2-20

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION POINTS AND LUBRICANT TYPES

2-21

. . . . . . . . . . . . . . . .

ENGINE

2-21

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS

2-22

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION DIAGRAMS

2-23

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING

2-26

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Content .. 1 2 ..

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