Yamaha XVS1100 (L). Service Manual - part 3

 

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Yamaha XVS1100 (L). Service Manual - part 3

 

 

2-17

MAINTENANCE SPECIFICATIONS

SPEC

NOTE:

Part to be tightened

Thread

size

Tightening

torque

Remarks

g

size

Nm

m

S

kg

Passenger footrest and frame
Sidestand bracket and frame
Sidestand and sidestand bracket
Sidestand switch
Brake pedal / footrest and frame
Rear brake master cylinder and master cylinder
bracket
Master cylinder bracket and down tube
Footrest and frame
Front wheel axle
Front wheel axle pinch bolt
Brake caliper
Brake disc and front wheel
Caliper bleed screw
Rear wheel axle nut
Rear brake caliper and caliper bracket
Caliper bracket and swingarm
Brake hose union bolt
Caliper bleed screw
Clutch hub and damper
Final gear case stud bolt
Final gear case stud bolt
Bearing housing (final gear case)
Bearing housing (final gear case)
Drive pinion
Bearing retainer (final drive pinion gear)
Oil filter bolt (final gear)
Oil drain bolt (final gear)
Housing cover

M8

M10
M10

M5
M6
M8

M8

M10
M16

M8

M10

M8
M7

M16
M10
M10
M10

M8

M10
M10

M8
M8

M10
M14
M65
M14
M14
M10

26
64
56

4
7

23

23
64
59
20
40
23

6

107

40
40
30

6

62
18

9

23
40

130

115

23
23
42

2.6
6.4
5.6
0.4
0.7
2.3

2.3
6.4
5.9
2.0
4.0
2.3
0.6

10.7

4.0
4.0
3.0
0.6
6.2
1.8
0.9
2.3
4.0

13.0

11.5

2.3
2.3
4.2

LH thread

1. First, tighten the ring nut approximately 52 Nm (5.2 m

S

kg) by using the torque wrench, then

loosen the ring nut completely.

2. Retighten the ring nut to specification.

2-18

MAINTENANCE SPECIFICATIONS

SPEC

ELECTRICAL

Item

Standard

Limit

Voltage:

12 V

SSS

Ignition system:

Ignition timing (B.T.D.C.)
Advancer type

10

_

 at 1,000 r / min

Digital type

SSS

SSS

T.C.I.:

Pickup coil resistance / color
T.C.I. unit model / manufacturer

189 

X

 231 

 at 20

_

C/ Gray – Black

J4T101 / MITSUBISHI

SSS

SSS

Ignition coil:

Model / manufacturer
Primary winding resistance
Secondary winding resistance

F6T507 / MITSUBISHI
3.57 

X

 4.83 

 at 20

_

C

10.7 

X

 14.5 k

 at 20

_

C

SSS

SSS

SSS

Spark plug cap:

Type
Resistance

Resin type
10 k

SSS

SSS

Charging system:

Type
Model / manufacturer
Nominal output
Stator coil resistance / color

A.C. magneto
F4T654 / MITSUBISHI
14 V 350 W at 5,000 r / min
0.36 

X

 0.44 

 at 20

_

C/ White – White

SSS

SSS

SSS

SSS

Voltage regulator:

Type
Model / manufacturer
No load regulated voltage

Semi-conductor, short-circuit type
SH650D-11 / SHINDENGEN
14.1 

X

 14.9 V

SSS

SSS

SSS

Rectifier:

Model / manufacturer
Capacity
Withstand voltage

SH650D-11 / SHINDENGEN
18 A
200 V

SSS

SSS

SSS

Battery:

Specific gravity

1.320

SSS

Electric starter system:

Type
Starter motor:

Model / manufacturer
Output
Armature coil resistance
Brush overall length
Brush spring pressure
Commutator diameter
Mica undercut

Starter relay:

Model / manufacturer
Amperage rating

Constant mesh type

SM-13 / MITSUBA
0.6 kW
0.026 

X

 0.034 

 at 20

_

C

12.5 mm
7.65 

X

 10.01 N (780 

X

 1021 g)

28 mm
0.7 mm

MS5F-421 / JIDECO
180 A

SSS

SSS

SSS

SSS

5 mm

SSS

27 mm

SSS

SSS

SSS

2-19

MAINTENANCE SPECIFICATIONS

SPEC

Item

Standard

Limit

Horn:

Type
Quantity
Model / manufacturer
Maximum amperage

Plane type
1
YF-12 / NIKKO
3 A

SSS

SSS

SSS

SSS

Flasher relay:

Type
Model / manufacturer
Self cancelling device
Flasher frequency
Wattage

Full transistor type
FE246BH/ DENSO
No
75 

X

 95 cycle / min

21 W 

 

 2 + 3.4W

SSS

SSS

SSS

SSS

SSS

Oil level gauge:

Model / manufacturer

5EL/ DENSO

SSS

Starting circuit cut-off relay

Model / manufacturer

G8R-30Y-B / OMRON

SSS

Fuel pump relay:

Model / manufacturer

G8R-30Y-B / OMRON

SSS

Circuit breaker:

Type
Amperage for individual circuit

MAIN
HEAD LIGHT
SIGNALS
IGNITION
BACK UP
Carburetor heater
Reserve
Reserve
Reserve
Reserve

Fuse

30 A 

 

 1

15 A 

 

 1

10 A 

 

 1

10 A 

 

 1

5 A 

 

 1

15 A 

 

 1

30 A 

 

 1

15 A 

 

 1

10 A 

 

 1

5 A 

 

 1

SSS

SSS

SSS

SSS

SSS

SSS

SSS

SSS

SSS

SSS

SSS

2-20

GENERAL TORQUE SPECIFICATIONS

/CONVERSION TABLE

SPEC

GENERAL TORQUE
SPECIFICATIONS

This chart specifies torque for standard fasten-
ers with standard I.S.O. pitch threads. Torque
specifications for special components or as-
semblies are provided for each chapter of this
manual. To avoid warpage, tighten multi-fasten-
er assemblies in a crisscross fashion, in pro-
gressive stages, until the specified torque is
reached. Unless otherwise specified, torque
specifications require clean, dry threads. Com-
ponents should be at room temperature.

A: Distance between flats
B: Outside thread diameter

10 mm

6 mm

6

0,6

12 mm

8 mm

15

1,5

14 mm

10 mm

30

3,0

19 mm

14 mm

85

8,5

22 mm

16 mm

130

13,0

17 mm

12 mm

55

5,5

A

(nut)

B

(Bolt)

General torque

specifications

Nm

m

S

kg

EAS00028

CONVERSION TABLE

All specification data in this manual are listed
in SI and METRIC UNITS.
Use this table to convert METRIC unit data to
IMPERIAL unit data.

Ex.

CONVERSION TABLE

EB202001

METRIC

MULTIPLIER

IMP

** mm

x

0.03937

=

** in

2 mm

x

0.03937

=

0.08 in

METRIC TO IMP

Known

Multiplier

Result

Torque

m

S

kg

m

S

kg

cm

S

kg

cm

S

kg

7.233
86.794
0.0723
0.8679

ft

S

lb

in

S

lb

ft

S

lb

in

S

lb

Weight

kg
g

2.205
0.03527

lb
oz

Distance

km / hr
km
m
m
cm
mm

0.6214
0.6214
3.281
1.094
0.3937
0.03937

mph
mi
ft
yd
in
in

Volume /
Capacity

cc (cm

3

)

cc (cm

3

)

lt (liter)
It (liter)

0.03527
0.06102
0.8799
0.2199

oz (IMP liq.)
cu

S

in

qt (IMP liq.)
gal (IMP liq.)

Miscella-
neous

kg / mm
kg / cm

2

Centigrade

55.997
14.2234
9/5 (

_

C) + 32

lb / in
psi (lb / in

2

)

Fahrenheit (

_

F)

2-21

LUBRICATION POINTS AND LUBRICANT TYPES

SPEC

EB203000

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE

Lubrication point

Symbol

Oil seal lips

O-ring

Bearing

Connecting rod bolt / nut

Connecting rod small end and big end

Crankshaft pin

Crankshaft journal / big end

Piston surface

Piston pin

Camshaft cam lobe / journal

Rocker arm shaft

Valve stem (IN, EX)

Valve stem end (IN, EX)

Timing chain drive gear shafts / sprokets

Oil pump rotor (inner / outer), housing

Idle gear surface

Starter idle gear

Starter idle gear shaft

Starter oneway cam

Middle drive gear

Primary driven gear

Push rod 1, 2

Transmission gear (wheel / pinion)

Shift cam

Shift fork / guide bar

Shift shaft assembly

Push rod ball

Push lever assembly

2-22

LUBRICATION POINTS AND LUBRICANT TYPES

SPEC

EB203010

CHASSIS

Lubrication point

Symbol

Steering head pipe (upper / lower), bearing

Steering head pipe, bearing cover lip

Steering head pipe, oil seal lip

Front wheel oil seal lip (right / left)

Rear wheel oil seal lip

Clutch hub fitting area

Rear brake pedal shaft

Shift pedal shaft

Sidestand bolt, sidestand sliding surface

Tube guide (throttle grip) inner surface

Brake lever pivot bolt, contact surface

Clutch lever pivot bolt, contact surface

Rear shock absorber (lower) oil seal lip

Swingarm pivot bearing inner surface

Swingarm pivot oil seal lip

Relay arm bearing, collar and oil seal

Drive shaft spline

Drive shaft dust cover

2-23

LUBRICATION DIAGRAMS

SPEC

4

Oil pump

5

Drive axle

6

Middle drive shaft

1

Rocker arm shaft (intake)

2

Rocker arm shaft (exhaust)

3

Oil filter

EB205000

LUBRICATION DIAGRAMS

2-24

4

Middle drive shaft

1

Oil pump

2

Releaf valve

3

Oil filter

LUBRICATION DIAGRAMS

SPEC

2-25

4

Middle drive shaft

5

Drive axle

6

Connecting rod big end

1

Camshaft

2

Crankshaft

3

Main axle

LUBRICATION DIAGRAMS

SPEC

2-26

CABLE ROUTING

SPEC

19

Fuel hose (carburetor-fuel pump)

20

Brake hose

21

Heat protector

22

Fuel breather hose (fuel tank-
roll over valve) (for California)

23

Speedometer lead

24

Wireharness

25

Purge hose (carburetor-solenoid
valve) (for California)

10

Alarm connector

11

Fuel pump lead

12

Speed sensor lead

13

Sidestand switch lead

14

Neutral switch lead

15

Pickup coil lead

16

AC magneto lead

17

Ventilation hose

18

Sensing hose (AIS-carburetor
joint)

1

Clutch cable

2

Starter cable

3

Handlebar switch lead (left)

4

Handlebar switch lead (right)

5

High tension code

6

Starter cable

7

Throttle cable

8

Fuel hose (fuel cock-fuel filter)

9

Fuse box

EB206000

CABLE ROUTING

2-27

F Push the wire harness inside

of the tool box plate.

G Route the sidestand lead

inside of engine cover.

H Position the all connectors

inside of the connector cover.

I Route the clutch cable through

the cable guide.

B Position the throttle cable and

starter cable as shown, and
clamp them with holder.

C Clamp the wire harness with

the hook of frame side.

D When installing the pipe of

throttle cables, press it inside.

E Connect the sensing hose

(carburetor joint-AIS side) with
a nozzle.

26

Purge hose (carburetor-solenoid
valve) (for California)

A Fasten the handlebar switch

leads (left and right) to the
handlebar with plastic locking
tie.

CABLE ROUTING

SPEC

27

2-28

M Fasten the AC magneto lead

and sidestand switch lead with a
plastic locking tie.

N Fasten the alarm lead with a

plastic band on the lid.

J Fasten the handlebar switch

leads (left and right) under the
handle crown with a plastic
band.
Set the band at four notches,
and install it no slacking.

K Route the each hoses through

the frame guide and do not
pinch it.

L When installing the fitting plate,

do not pinch the each hoses
and wire harness.

CABLE ROUTING

SPEC

E

2-29

23

Handlebar switch lead (left)

24

Throttle position sensor lead

25

Carburetor heater lead

26

Thermo switch lead

27

Starting circuit cutoff relay

28

Down tube

29

High tension code

30

Purge hose (carburetor-
solenoid valve) (for California)

31

Carburetor heater lead

32

Oil level switch lead

12

Ignition coil

13

Master cylinder reservoir hose

14

Breather hose

15

Air filter drain hose

16

Battery negative (–) lead

17

Rear brake switch lead

18

Rear brake hose

19

Carburetor heater connector

20

Rectifier / regulator

21

Main switch lead

22

Flasher relay

1

Battery

2

Battery positive (+) lead

3

Starter motor positive (+) lead

4

Speedometer lead

5

Fuel hose (carburetor-fuel pump)

6

High tension code

7

Main switch lead

8

Throttle cable

9

Brake hose

10

Handlebar switch lead (right)

11

Headlight lead

CABLE ROUTING

SPEC

E

2-30

H Fasten the rear brake switch

lead and master cylinder
reservoir hose to the down
tube with a plastic locking tie.

I Fasten the wire harness,

starter motor positive (+) lead
and battery negative (–) lead to
the frame with a plastic locking tie.

J Route the rectifier / regulator

lead and carburetor heater lead
through inside of battery box
hole to outside it and connect
them.

D Connect the purge hose

(carburetor side-solenoid valve
side) with joint. (for California)

E Route the front turn signal light

lead and headlight lead through
the rear of headlight body hole.

F Connect the ignition coil lead at

red tape to the right side.

G Fasten the rear brake switch 

lead to the brake switch bracket 
with a plastic locking tie.

A Clamp the battery positive (+)

lead to the battery with battery
band.

B Connect the battery negative

(–) lead connector and push it
into the space between battery
box and battery.

C Route the rectifier / regulator

lead, wire harness and starter
motor positive (+) lead through
the outside of frame bracket
and fasten them to the frame
with a plastic locking tie.

CABLE ROUTING

SPEC

E

2-31

K To rear brake caliper

L Clamp the handlebar switch

lead (right) and main switch
lead to the frame with a holder.

M Arrange the throttle position

sensor connector, carburetor
heater connector and thermo
switch connector between the
starting circuit cutoff relay and
high tension code.

N Fasten the rear brake switch

to the down tube with a plastic
locking tie.

CABLE ROUTING

SPEC

E

2-32

20

Starter cable

21

Fuel hose (fuel cock-fuel filter)

22

Carburetor heater lead

23

Thermo switch lead

24

Igniter unit

25

Taillight lead

26

Throttle position sensor lead

27

Fuel filter

28

Igniter unit lead

29

Frame

30

Wire harness

A Clamp the throttle cables with

the holder.

11

Battery negative (–) lead
connector

12

Battery

13

Battery positive (+) lead

14

Taillight lead

15

Starter relay

16

Starter motor positive (+) lead

17

Speedometer lead connector

18

Fuel tank breather hose
(fuel tank-roll over valve) (for
California)

19

Ventilation hose

1

Brake hose

2

Throttle cable

3

Master cylinder reservoir hose

4

High tension code

5

Purge hose (carburetor-solenoid
valve) (for California)

6

Rear brake switch lead

7

Brake hose

8

Sensing hose (AIS-carburetor
joint)

9

Fuel hose (carburetor-fuel
pump)

10

Battery negative (–) lead

CABLE ROUTING

SPEC

 

 

 

 

 

 

 

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