Yamaha XVS1100 (L). Service Manual

2-1

GENERAL SPECIFICATIONS

SPEC

Temp.

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item

Standard

Model code:

XVS1100: 5EL1 (For Europe)

5EL2 (For D, A, FIN)
5EL3 (For Australia)

Dimensions:

Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius

2,405 mm
895 mm
1,095 mm
690 mm
1,640 mm
145 mm
3,200 mm

Basic weight:

With oil and a full fuel tank

274 kg (5EL2 : 275kg)

Engine:

Engine type
Cylinder arrangement
Displacement
Bore

stroke

Compression ratio
Compression pressure (STD)
Starting system

Air cooled 4-stroke, SOHC
V-type 2-cylinder
1.063 L
95

75mm

8.3 : 1
1,000 kPa (10 kg / cm

, 10 bar) at 400 r / min

Electric starter

Lubrication system:

Wet sump

Oil type or grade:

Engine oil

API standard:

“SE” or higher grade

ACEA standard:

G4 or G5

Final gear oil:

SAE80API “GL-4” Hypoid Gear Oil

Oil quantity:

Engine oil

Periodic oil change
With oil filter replacement
Total amount

Final gear case oil

Total amount

3.0 L
3.1 L
3.6 L

0.2 L

Air filter:

Dry type element

Fuel:

Type
Fuel tank capacity
Fuel reserve amount

Regular unleaded gasoline
17 L
4.5 L

2-2

GENERAL SPECIFICATIONS

SPEC

Item

Standard

Carburetor:

Type / quantity
Manufacturer

BSR37/ 2
MIKUNI

Spark plug:

Type
Manufacturer
Spark plug gap

BPR7ES/ W22EPR–U
NGK/ DENSO
0.7

0.8 mm

Clutch type:

Wet, multiple-disc

Transmission:

Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Transmission type
Operation
Gear ratio

1st
2nd
3rd
4th
5th

Spur gear
78 / 47 (1.660)
Shaft drive
44 / 47

19 / 18

32 / 11 (2.875)

Constant mesh 5-speed
Left foot operation
40 / 17 (2.353)
40 / 24 (1.667)
36 / 28 (1.286)
32 / 31 (1.032)
29 / 34 (0.853)

Chassis:

Frame type
Caster angle
Trail

Double cradle
33

136 mm

Tire:

Type
Size

front
rear

Manufacturer

front
rear

Type

front
rear

With tube
110 / 90-18 61S
170 / 80-15M / C 77S
BRIDGESTONE/ DUNLOP
BRIDGESTONE/ DUNLOP
EXEDRA L309 / K555F
EXEDRA G546 / K555

Maximum load-except motorcycle:

201 kg (5EL2 : 200kg)

Tire pressure (cold tire):

90 kg (0

198 lb) load *

front
rear

90 kg (198 lb)

Maximum load *

front
rear

200 kPa (2.00 kg / cm

)

225 kPa (2.25 kg / cm

)

225 kPa (2.25 kg / cm

)

250 kPa (2.50 kg / cm

)

* Load is the total weight of the cargo, rider,
passenger and accessories.

Brake:

Front brake

type
operation

Rear brake

type
operation

Dual disc brake
Right hand operation
Single disc brake
Right foot operation

2-3

GENERAL SPECIFICATIONS

SPEC

Item

Standard

Suspension:

Front suspension
Rear suspension

Telescopic fork
Swingarm (link suspension)

Shock absorber:

Front shock absorber
Rear shock absorber

Coil spring / Oil damper
Coil spring / Gas-oil damper

Wheel travel:

Front wheel travel
Rear wheel travel

140 mm
113 mm

Electrical:

Ignition system
Generator system
Battery type
Battery capacity

T.C.I. (digital)
A.C. magneto
GT14B-4
12 V 12 AH

Headlight type:

Quartz bulb (halogen)

Bulb wattage

quantity:

Headlight
Auxiliary light
Tail / brake light
Turn signal
Licence light
Meter light
Neutral indicator light
High beam indicator light
Turn indicator light
Oil level caution light
Engine warning light

12 V 60 W / 55 W

12 V 4 W

12 V 5 W / 21 W

12 V 21 W

12 V 5 W

14 V 1.4 W

12 V 1.7 W

2-4

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Item

Standard

Limit

Cylinder head:

Warp limit

SSS

0.03 mm

Cylinder:

Bore size
Measuring point

95.00

95.01 mm

40 mm

95.1 mm

SSS

Camshaft:

Drive method
Cam cap inside diameter
Camshaft outside diameter
Shaft-to-cap clearance
Cam dimensions

Intake

“A”
“B”

“C”

Exhaust

“A”
“B”
“C”

Camshaft runout limit

Chain drive (left & right)
25.000

25.021 mm

24.96

24.98 mm

0.020

0.061 mm

39.112

39.212 mm

#1: 32.093

32.193 mm

#2: 32.127

32.227 mm

7.162 mm
39.145

39.245 mm

32.200

32.300 mm

7.195 mm

SSS

39.012 mm
#1: 31.993 mm
#2: 32.027 mm
7.0 1 2 mm
39.045 mm
32.100 mm
7.045 mm
0.03 mm

2-5

Margin Thickness

Head Dia

Face width

Seat Width

MAINTENANCE SPECIFICATIONS

SPEC

Item

Standard

Limit

Timing chain:

Timing chain type / No. of links
Timing chain adjustment method

SILENT CHAIN / 98L
Automatic

SSS

Rocker arm / rocker arm shaft:

Bearing inside diameter
Shaft outside diameter
Arm-to-shaft clearance

14.000 mm

14.018 mm

13.985 mm

13.991 mm

0.009 mm

0.033 mm

14.036 mm
13.95 mm
0.086 mm

Valve, valve seat, valve guide:

Valve clearance (cold)

IN
EX

0.07

0.12 mm

0.12

0.17 mm

SSS

Valve dimensions:

“A” head diameter

IN
EX

“B” face width

IN
EX

“C” seat width

IN
EX

“D” margin thickness

IN
EX

Stem outside diameter

IN
EX

Guide inside diameter

IN
EX

Stem-to-guide clearance

IN
EX

47.0

47.2 mm

39.0

39.2 mm

2.1 mm
2.1 mm
1.2

1.4 mm

1.2

1.4 mm

1.1

1.5 mm

1.1

1.5 mm

7.975

7.990 mm

7.960

7.975 mm

8.000

8.012 mm

8.000

8.012 mm

0.010

0.037 mm

0.025

0.052 mm

SSS

1.8 mm
1.8 mm
0.8 mm
0.8 mm

SSS

0.08 mm
0.10 mm

2-6

MAINTENANCE SPECIFICATIONS

SPEC

Item

Standard

Limit

Stem runout limit

Valve seat width

IN
EX

SSS

1.2

1.4 mm

1.2

1.4 mm

0.03 mm

2.0 mm
2.0 mm

Valve spring:

Free length

IN
EX

Set length (valve closed)

IN
EX

Compressed pressure

(installed) EX
Tilt limit

IN
EX

Direction of winding
(top view)

IN
EX

44.6 mm
44.6 mm
40 mm
40 mm
160.7 N (16.4 kg)
160.7 N (16.4 kg)

SSS

Clockwise
Clockwise

43.5 mm
43.5 mm

SSS

2.5

/ 1.9mm

2.5

/ 1.9mm

SSS

Piston:

Piston to cylinder clearance
Piston size “D”

Measuring point “H”
Piston off-set

0.025

0.050 mm

94.960

94.975 mm

5 mm
0 mm

0.15 mm

SSS

2-7

MAINTENANCE SPECIFICATIONS

SPEC

Item

Standard

Limit

Piston pin bore inside diameter
Piston pin outside diameter

22.004

22.015 mm

21.991

22.000 mm

SSS

Piston rings:

Top ring:

Type
Dimensions (B

End gap (installed)
Side clearance (installed)

2nd ring:

Type
Dimensions (B

End gap (installed)
Side clearance

Oil ring:

Dimensions (B

End gap (installed)

Plain
1.5

3.8 mm

0.3

0.5 mm

0.04

0.08 mm

Taper
1.2

3.8 mm

0.30

0.45 mm

0.03

0.07 mm

2.5

3.4 mm

0.2

0.7 mm

SSS

0.8 mm
0.1 mm

SSS

0.8 mm
0.1 mm

SSS

Connecting rod:

Oil clearance
Color code (corresponding size)

0.044

0.073 mm

Blue

Black

Brown

Green

Yellow

SSS

Crankshaft:

Crank width “A”
Runout limit “C”
Big end side clearance “D”

101.95

102.00 mm

SSS

0.320

0.474 mm

SSS

0.02 mm

SSS

2-8

MAINTENANCE SPECIFICATIONS

SPEC

Item

Standard

Limit

Clutch:

Friction plate thickness

Quantity

Clutch plate thickness

Quantity

Clutch plate thickness

Quantity

Clutch spring free length

Quantity

Clutch housing thrust clearance
Clutch housing radial clearance
Clutch release method
Push rod bending limit

2.9

3.1 mm

8
2.5

2.7 mm

1
1.9

2.1 mm

7
7.2 mm
1
0.05

0.40 mm

0.010

0.044 mm

Inner push, screw push

SSS

2.8 mm

SSS

0.1 mm

SSS

0.1 mm

6.5 mm

SSS

0.5 mm

Transmission:

Main axle deflection limit
Drive axle deflection limit

SSS

0.08 mm
0.08 mm

Shifter:

Shifter type

Guide bar

SSS

Carburetor:

I. D. mark
Main jet

(M.J)

Main air jet

(M.A.J)

Jet needle

(J.N)

Needle jet

(N.J)

Pilot air jet

(P.A.J.1)
(P.A.J.2)

Pilot outlet

(P.O)

Pilot jet

(P.J)

Bypass 1

(B.P.1)

Bypass 2

(B.P.2)

Bypass 3

(B.P.3)

Pilot screw

(P.S)

Valve seat size

(V.S)

Starter jet

(G.S.1)

Starter jet

(G.S.2)

Throttle valve size

(Th.V)

Fuel level

(F.L)

Engine idle speed
Intake vacuum
Engine oil temperature

5EL1 00
#1: #110, #2: #112.5
#55
#1: 5DL39-53-3 / 5, #2: 5DL40-53-3 / 5
P-0M
#63.8
#145
1.0
#17.5
0.8
0.8
0.8
3
1.2
#42.5
0.8
#125
4

5 mm

950

1,050 r / min

34.7

37.3 kPa (260

280 mmHg)

SSS

Fuel pump:

Type
Model / manufacturer
Consumption amperage

<max>

Output pressure

Electrical type
UC-Z6M / MITSUBISHI
0.8 A
12 kPa (0.12 kg / cm

)

SSS

2-9

MAINTENANCE SPECIFICATIONS

SPEC

Item

Standard

Limit

Lubrication system:

Oil filter type
Oil pump type
Tip clearance “A” or “B”
Side clearance
Relief valve operating pressure

Paper type
Trochoid type
0.03

0.09 mm

0.03

0.08 mm

450

550 kPa (4.5

5.5 kg / cm

)

SSS

0.15 mm
0.15 mm

SSS

Shaft drive:

Middle gear backlash
Final gear backlash

0.1

0.2 mm

0.1

0.2 mm

SSS

2-12

MAINTENANCE SPECIFICATIONS

SPEC

Tightening torques

Part to be tightened

Part name

Thread

size

Q’ty

Tightening

torque

Remarks

size

Cylinder head
Cylinder head
Plate
Cylinder head cover
Cylinder head (exhaust pipe)
Rocker arm shaft
Camshaft sprocket cover
Tappet cover
Rocker arm shaft (oil passage)
Stopper plate (camshaft)
Spark plug
Cylinder
Lower cylinder head cover
Upper cylinder head cover
Connecting rod
Rotor
Valve adjusting locknut
Camshaft sprocket
Timing chain tensioner
Timing chain tentioner cap
Timing chain guide
Oil pump
Oil strainer cover
Oil filter cover
Oil pump gear
Oil pump cap
Oil deliuery pipe (cylinder head)

(crankcase)

Drain bolt
Carburetor cover
Air filter case stay
Air filter case assembly
Exhaust pipe joint and cylinder head
Exhaust pipe joint and muffler
assembly
Muffler
Crankcase (cylinder)
Crankcase (cylinder)
Crankcase
Crankcase
Bearing retainer (middle drive pinion
gear)
Crankcase cover (left)
Crankcase cover (right)
Clamp
One-way clutch
Primary drive gear

Nut
Nut

Bolt

Screw

Stud bolt

Union bolt

Bolt
Bolt
Bolt
Bolt

—

Bolt
Bolt

Screw

Nut
Nut
Nut

Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt

Union bolt
Union bolt

—

Bolt
Bolt
Bolt

Nut

Bolt

Stud bolt
Stud bolt

Bolt
Bolt
Bolt

Bolt
Bolt
Bolt
Bolt

Nut

M12
M10

M8
M6
M8

M16

M6
M6

M16

M14

M6
M6
M6
M9

M16

M10

M6
M6
M6
M6
M6
M6
M6
M6

M16
M10
M14

M5
M6
M5
M8
M8

M10
M12
M10
M10

M6
M8

M6
M6
M6
M6

M20

8
2
2
4
4
2
4
8
4
4
2
2
6
8
4
1
4
2
4
2
4
3
3
5
1
1
2
1
1
2
2
3
4
2

2
8
2
3

1
8
1

50
35
20

12.5
37.5

10
10
38
20
20
10
10

175

27
55
10

10
10
10
10
12
10
20
20
43

20
20

25
24
20

38.5

10
25

10
10
10
12

110

5.0
3.5
2.0
0.4

1.25
3.75

1.0
1.0
3.8
2.0
2.0
1.0
1.0
0.5
4.8

17.5

2.7
5.5
1.0
0.8
1.0
1.0
1.0
1.0
1.2
1.0
2.0
2.0
4.3
0.7
1.0
0.2
2.0
2.0

2.5
2.4
2.0

3.85

1.0
2.5

1.0
1.0
1.0
1.2

11.0

Use lock washer

2-13

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened

Part name

Thread

size

Q’ty

Tightening

torque

Remarks

size

Clutch spring
Clutch adjuster
Clutch boss
Push lever axle
Middle drive pinion gear
Bearing retainer (middle driven shaft)
Yoke (middle driven shaft)
Bearing housing (middle drive shaft)
Shift lever stopper

Guide bar stopper
Shift dram segment
Shift arm
Shift pedal adjuster

Stator coil
Pickup coil
Starter motor
Neutral switch
Ignition coil
Speed sensor

Bolt

Nut
Nut

Screw

Nut
Nut
Nut

Bolt
Bolt

Screw
Screw

Bolt

Nut

Screw
Screw

Bolt

—

Screw

Bolt

M6
M8

M20

M44
M88
M14

M8
M8

M6
M5
M6
M6

M6
M5
M6

M10

M5
M6

6
1
1
1
1
1
1
4
1

2
1
1
2

3
2
2
1
4
1

12
70
12

110
110

—

25
22

7
4

10
10

10
20

2.5

0.8
1.2
7.0
1.2

11.0
11.0

—

2.5
2.2

0.7
0.4
1.0
1.0

1.0
0.7
1.0
2.0

0.25

0.7

Use lock washer

Stake
Stake
Stake

Use lock washer

1 of 2 has LH

thread

2-14

MAINTENANCE SPECIFICATIONS

SPEC

CHASSIS

Item

Standard

Limit

Steering system:

Steering bearing type

Angular bearing

SSS

Front suspension:

Front fork travel
Fork spring free length
Fitting length
Collar length
Spring rate

(K1)
(K2)

Stroke

(K1)
(K2)

Optional spring
Oil capacity
Oil level
Oil grade

140 mm
356.9 mm
319.4 mm
183 mm
8.8 N / mm (0.9 kg / mm)
12.7 N / mm (1.3 kg / mm)
0

77.5 mm

77.5

140 mm

No
0.464 L
108 mm
Fork oil 10W or equivalent

SSS

350 mm

SSS

Rear suspension:

Shock absorber travel
Spring free length
Fitting length
Spring rate

(K1)

Stroke

(K1)

Optional spring

113 mm
179.5 mm
163 mm
117.7 N / mm (12 kg / mm)
0

50 mm

SSS

Swingarm:

Free play limit

end

SSS

0 mm

Front wheel:

Type
Rim size
Rim material
Rim runout limit

radial
lateral

Spoke wheel
18

2.15

Steel

SSS

1.0 mm
0.5 mm

Rear wheel:

Type
Rim size
Rim material
Rim runout limit

radial
lateral

Spoke wheel
15M / C

MT4.50

Steel

SSS

1.0 mm
0.5 mm

2-15

MAINTENANCE SPECIFICATIONS

SPEC

Item

Standard

Limit

Front brake:

Type
Disc outside diameter

thickness

Disc deflection limit
Pad thickness

inner

Pad thickness

outer

Master cylinder inside diameter
Caliper cylinder inside diameter
Caliper cylinder inside diameter
Brake fluid type

Dual disc
298

5 mm

SSS

6.2 mm
6.2 mm

14.0 mm
25.4 mm
30.1 mm
DOT 4

SSS

4.5 mm
0.15 mm
0.8 mm
0.8 mm

SSS

Rear brake:

Type
Disc outside diameter

thickeness

Disc deflection limit
Pad thickness

inner
outer

Master cylinder inside diameter
Caliper cylinder inside dimeter
Brake fluid type

Single disc
282

6 mm

SSS

5.55 mm
5.55 mm
12.7 mm
42.9 mm
DOT 4

SSS

5.5 mm
0.15 mm
0.5 mm
0.5 mm

SSS

Brake lever & brake pedal:

Brake lever free play (at lever end)
Brake pedal position
Brake pedal free play
Clutch lever free play (at lever end)

Throttle grip free play

8 mm

81.8 mm
0 mm
5

10 mm

6 mm

SSS

2-16

MAINTENANCE SPECIFICATIONS

SPEC

Tightening torques

Part to be tightened

Thread size

Tightening

torque

Remarks

Upper bracket and inner tube
Lower bracket and inner tube
Upper bracket and steering shaft
Ring nut (steering shaft)
Handlebar holder (lower) and upper bracket
Handlebar holder (lower) and handlebar
holder (upper)
Master cylinder (front brake)
Union bolt (brake hose)
Brake hose holder and lower bracket
Brake hose joint and brake pipe
Brake hose joint and brake hose holder
Front fender and outer tube
Headlight stay and lower bracket
Headlight stay and headlight
Front flasher light and lower bracket
Engine mounting:

Frame and stay (front - upper)
Frame and stay (front - lower)
Stay and engine (front - upper)
Stay and engine (front - lower)
Frame and engine (rear - upper)
Frame and engine (rear - lower)

Down tube and frame
lgnition coil and stay
Muffler stay and frame
Rear shock absorber and relay arm
Rear shock absorber and frame
Pivot shaft and swingarm
Relay arm and frame
Connecting arm and relay arm
Connecting arm and swingarm
Final gear case and swingarm
Swingarm end and holder
Fuel tank and fuel cock
Fuel tank bracket and frame
Rider’s seat
Passenger seat
Fuel tank and top cover
Licence bracket and rear fender stay
Rear fender and rear fender stay
Rear fender and tail / brake light
Rear fender stay and rear flasher light
Frame and rear fender
Side cover (left)
Battery cover
Side cover (right)
Starter relay and leads

M10
M22

—

M12

M10

M6
M8
M6
M6
M6

M10
M10
M12
M10
M10
M10
M10

M5
M8

M10
M10
M16
M10
M12
M12
M10

M8
M6
M8
M6
M6
M5
M6
M5
M6

M12

M8
M6
M6
M6
M6

20
30

110

18
32
28

10
30
10
19
10
10

7
8
7

48
48
74
48
48
48
48

30
48
40
90
48
48
48
90
23

7
7
4
7
4
6
7

7
7
7
7

2.0
3.0

11.0

1.8
3.2
2.8

1.0
3.0
1.0
1.9
1.0
1.0
0.7
0.8
0.7

4.8
4.8
7.4
4.8
4.8
4.8
4.8
0.4
3.0
4.8
4.0
9.0
4.8
4.8
4.8
9.0
2.3
0.7
2.3
0.7
0.7
0.4
0.7
0.4
0.6
0.7
2.6
0.7
0.7
0.7
0.7

See NOTE

Yamaha XVS1100 (L). Service Manual - part 2