Yamaha XVS1100 (L). Service Manual - part 4

 

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Yamaha XVS1100 (L). Service Manual - part 4

 

 

E

2-33

J Fasten the wire harness with a

band on the tool box plate.

K Fasten the wire harness to the

frame with a plastic locking tie.
Position the locking tie front of
the solder.

F Route the battery positive (+)

lead through the slit of the
battery box.

G Clamp the igniter unit lead to

the frame with a holder.

H To the rear fender.

I Route the fuel tank breather

hose under the fuel filter and
connect it (fuel tank side-roll
over valve side) with a joint.
Position the end of clip outside.

B Route the rear brake switch

lead under the master cylinder
reservoir hose.

C Position the band end of right

side bracket.

D Position the steel band end to

forward.

E Position the steel band end to

right side.

CABLE ROUTING

SPEC

E

2-34

P Route the igniter lead through

the igniter plate hole to the wire
harness.

Q Clamp the taillight lead with

mud guard clamp.

R Clamp the taillight lead with a

holder on the mud guard.

L Route wire harness outside of

the guide on the frame.

M Clamp the clutch cable and

starter cable with a holder.
Position the end of holder down
side.

N Route the throttle position

sensor lead and carburetor
heater lead left side of the
tappet cover.

O To the wire harness.

CABLE ROUTING

SPEC

E

1

Throttle cable

2

Starter cable

3

Clutch cable

4

Handlebar switch lead (left)

5

Headlight lead

6

Brake hose

A Route the handlebar switch

lead (right) rear side of the
throttle cable.

2-35

CABLE ROUTING

SPEC

 

INSP

ADJ

 

3

INSP

ADJ

CHAPTER 3

PERIODIC INSPECTIONS AND ADJUSTMENTS

INTRODUCTION

3-1

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

PERIODIC MAINTENANCE / LUBRICATION INTERVALS

3-1

. . . . . . . . . . . 

FUEL TANK AND SEATS

3-3

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

REMOVAL

3-4

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

INSTALLATION

3-4

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

ENGINE

3-5

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

ADJUSTING THE VALVE CLEARANCE

3-5

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

SYNCHRONIZING THE CARBURETORS

3-8

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

ADJUSTING THE ENGINE IDLING SPEED

3-10

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

ADJUSTING THE THROTTLE CABLE FREE PLAY

3-11

. . . . . . . . . . . . . 

CHECKING THE SPARK PLUGS

3-12

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

CHECKING THE IGNITION TIMING

3-13

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

MEASURING THE COMPRESSION PRESSURE

3-14

. . . . . . . . . . . . . . . 

CHECKING THE ENGINE OIL LEVEL

3-16

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

CHANGING THE ENGINE OIL

3-17

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

ADJUSTING THE CLUTCH CABLE FREE PLAY

3-18

. . . . . . . . . . . . . . . . 

CLEANING THE AIR FILTER ELEMENT

3-19

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

CHECKING THE CARBURETOR JOINT AND INTAKE

MANIFOLD

3-20

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

CHECKING THE BREATHER HOSE

3-20

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

CHECKING THE EXHAUST SYSTEM

3-21

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

CHASSIS

3-22

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

ADJUSTING THE FRONT BRAKE

3-22

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

ADJUSTING THE REAR BRAKE

3-23

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

CHECKING THE BRAKE FLUID LEVEL

3-24

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

ADJUSTING THE REAR BRAKE LIGHT SWITCH

3-25

. . . . . . . . . . . . . . . 

CHECKING THE BRAKE HOSES

3-25

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

BLEEDING THE HYDRAULIC BRAKE SYSTEM

3-26

. . . . . . . . . . . . . . . . 

ADJUSTING THE SHIFT PEDAL

3-27

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

CHECKING THE FINAL DRIVE OIL LEVEL

3-28

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

CHANGING THE FINAL DRIVE OIL

3-28

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

CHECKING AND ADJUSTING THE STEERING HEAD

3-29

. . . . . . . . . . 

CHECKING THE FRONT FORK

3-31

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

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY

3-31

. . . . . . 

CHECKING THE TIRES

3-32

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

CHECKING AND TIGHTENING THE SPOKES

3-35

. . . . . . . . . . . . . . . . . 

CHECKING AND LUBRICATING THE CABLES

3-36

. . . . . . . . . . . . . . . . . 

LUBRICATING THE LEVERS AND PEDALS

3-36

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

LUBRICATING THE SIDESTAND

3-36

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

LUBRICATING THE REAR SUSPENSION

3-36

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

INSP

ADJ

ELECTRICAL SYSTEM

3-37

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

CHECKING AND CHARGING THE BATTERY

3-37

. . . . . . . . . . . . . . . . . . 

CHECKING THE FUSES

3-43

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

REPLACING THE HEADLIGHT BULB

3-44

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

ADJUSTING THE HEADLIGHT BEAM

3-45

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

3-1

INTRODUCTION/PERIODIC MAINTENANCE/

LUBRICATION INTERVALS

INSP

ADJ

EB300000

PERIODIC INSPECTIONS AND ADJUSTMENTS

INTRODUCTION

This chapter includes all information necessary to perform recommended inspections and adjust-
ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera-
tion and a longer service life. The need for costly overhaul work will be greatly reduced. This informa-
tion applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All
service technicians should be familiar with this entire chapter.

EB301000

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

EVERY

NO.

ITEM

CHECKS AND MAINTENANCE JOBS

Initial

(1,000 km)

6,000 km

or

6 months

(whichever

comes first)

12,000 km

or

12 months

(whichever

comes first)

1

*

Fuel line (manual cock)

Check fuel hoses for cracks or damage.

Replace if necessary.

2

*

Fuel filter

Check condition.

Replace if necessary.

3

Spark plugs

Check condition.

Clean, regap or replace if necessary.

4

*

Valves (arm SOHC)

Check valve clearance.

Adjust if necessary.

5

Air filter

Clean or replace if necessary.

6

Clutch

Check operation.

Adjust or replace cable.

7

*

Front brake (disc)

Check operation, fluid level and vehicle for fluid leakage.
(See NOTE.)

Correct accordingly.

Repalce brake pads if necessary.

8

*

Rear brake (disc)

Check operation, fluid level and vehicle for fluid leakage.
(See NOTE.)

Correct accordingly.

Replace brake pads if necessary.

9

*

Wheels (spoke)

Check balance, runout, spoke tightness and for damage.

Tighten spokes and rebalance, replace if necessary.

10 *

Tires (EUR)

Check tread depth and for damage.

Replace if necessary.

Check air pressure.

Correct if necessary.

11 *

Wheel bearings

Check bearing for looseness or damage.

Replace if necessary.

12 *

Swingarm (no nipple)

Check swingarm pivoting point for play.

Correct if necessary.

Lubricate with molybdenum disulfide grease every
24,000 km or 24 months (whichever comes first).

13 *

Steering bearings

Check bearing play and steering for roughness.

Correct accordingly.

Lubricate with lithium soap base grease every 24,000
km or 24 months (whichever comes first).

14 *

Chassis fasteners

Make sure that all nuts, bolts and screws are properly
tightened.

Tighten if necessary.

15

Sidestand

Check operation.

Lubricate and repair if necessary.

16 *

Sidestand switch

Check operation.

Replace if necessary.

3-2

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

INSP

ADJ

NOTE:

EVERY

NO.

ITEM

CHECKS AND MAINTENANCE JOBS

Initial

(1,000 km)

6,000 km

or

6 months

(whichever

comes first)

12,000 km

or

12 months

(whichever

comes first)

17 *

Front fork

Check operation and for oil leakage.

Correct accordingly.

18 *

Rear shock absorber
assembly

Check operation and shock absorber for oil leakage.

Replace shock absorber assembly if necessary.

19 *

Carburetors (multi)

Check engine idlilng speed, synchronization and start-
er operation.

Adjust if necessary.

20

Engine oil

Check oil level and vehicle for oil leakage.

Correct if necessary.

Change. (Warm engine before draining.)

21 *

Engine oil filter
element

Replace.

22

Final gear oil

Check oil level and vehicle for oil leakage.

Change oil at initial 1,000 km and thereafter every
24,000 km or 24 months (whichever comes first).

* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

Hydraulic brake system
– When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check

the brake fluid level regularly and fill as required.

– Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
– Replace the brake hoses every four years or if cracked or damaged.

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4

5
6
7
8

Fuel tank and seats removal
Passenger seat
Seat bracket
Rider’s seat
Fuel hose

Ignitor plate
Mud guard
Meter lead couper
Fuel tank assembly

1
1
1
1

1
1
1
1

Remove the parts in the order below.

Set the fuel cock to “OFF” before dis-
connecting the fuel hose.

For installation, reverse the removal
procedure.

NOTE:

7 Nm (0.7m

kg)

23Nm (2.3m

kg)

7 Nm (0.7m

kg)

3-3

FUEL TANK AND SEATS

INSP

ADJ

FUEL TANK AND SEATS

3-4

FUEL TANK AND SEATS

INSP

ADJ

NOTE:

NOTE:

REMOVAL
1. Remove:

Ignitor plate

To remove the quick fastener, push its center in
with a screwdriver, then pull the fastener out.

INSTALLATION
1. Install:

Ignitor plate

To install the quick fastener, push its pin so that it
protrudes from the fastener head, then insert
the fastener into the cowling and push the pin 

a

in with a screwdriver. Make sure that the pin is
flush with the fastener’s head.

3-5

ADJUSTING THE VALVE CLEARANCE

INSP

ADJ

NOTE:

EAS00047

ENGINE

ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.

Valve clearance adjustment should be made
on a cold engine, at room temperature.

When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.

1. Remove:

rider’s seat

fuel tank
Refer to “FUEL TANK AND SEATS”.

2. Disconnect:

spark plug caps

3. Remove:

spark plugs

4. Remove:

air intake box 

1

5. Remove:

cylinder head cover (rear cylinder) 

1

cylinder head cover (front cylinder)

3-6

ADJUSTING THE VALVE CLEARANCE

INSP

ADJ

6. Remove:

tappet covers 

1

7. Remove:

camshaft sprocket cover (rear cylinder) 

1

camshaft sprocket cover (front cylinder)

8. Remove:

timing plug 

1

straight plug 

2

9. Measure:

valve clearance
Out of specification 

 Adjust.

Valve clearance (cold):
Intake valve:

0.07 

 0.12 mm

Exhaust valve:

0.12 

 0.17 mm

3-7

ADJUSTING THE VALVE CLEARANCE

INSP

ADJ

A

B

a

b

a. Turn the crankshaft counterclockwise.
b. When the piston is at TDC on the compres-

sion stroke, align either the camshaft sprock-
et plate hole 

a

 with the stationary pointer 

b

on the cylinder head. When the camshaft
sprocket plate hole or camshaft sprocket
punch mark is aligned with the stationary
pointer, the piston is at top dead center
(TDC).

c. Align the TDC mark 

c

 on the generator rotor

with the stationary pointer 

d

 on the crank-

case.

A Rear cylinder (“TI” mark)

B Front cylinder (“I” mark)

d. Measure the valve clearance with a thick-

ness gauge 

1

.

e. Turn the crankshaft crockwise 290

_

, and

then measure the front cylinder.

10. Adjust

S

valve clearance

a. Loosen the locknut 

1

.

b. Insert a thickness gauge between the end of

the adjusting screw and the valve tip.

c. Turn the adjusting screw 

2

 in direction 

a

 or

b

 until the specified valve clearance is ob-

tained.

Direction 

Valve clearance is
decreased.

Direction 

Valve clearance is
increased.

d. Hold the adjusting screw to prevent it from

moving and tighten the locknut to specifica-
tion.

ADJUSTING THE VALVE CLEARANCE/

SYNCHRONIZING THE CARBURETORS

INSP

ADJ

3-8

NOTE:

10 Nm (1.0 m

kg)

10 Nm (1.0 m

kg)

20 Nm (2.0 m

kg)

NOTE:

NOTE:

Locknut:

27 Nm (2.7 m

kg)

e. Measure the valve clearance again.
f. If the valve clearance is still out of specifica-

tion, repeat all of the valve clearance adjust-
ment steps until the specified clearance is
obtained.

11. Install:

all removed parts

Install all removed parts in the reverse order of
their disassembly. Note the following points.

camshaft sprocket covers

tappet covers

spark plugs

EAS00051

SYNCHRONIZING THE CARBURETORS

Prior to synchronizing the carburetors, the valve
clearance and the engine idling speed should
be properly adjusted and the ignition timing
should be checked.

1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.

2. Remove:

rider’s seat

fuel tank
Refer to “FUEL TANK AND SEATS”.

3. Remove:

air duct 

1

4. Remove:

vacuum plugs 

1

3-9

SYNCHRONIZING THE CARBURETORS

INSP

ADJ

NOTE:

5. Install:

vacuum gauge 

1

engine tachometer 

2

(to the spark plug lead of cyl. #2)

Vacuum gauge:

90890-03094

Engine tachometer:

90890-03113

6. Start the engine and let it warm up for several

minutes.

7. Check:

engine idling speed
Out of specification 

 Adjust.

Refer to “ADJUSTING THE ENGINE IDLING
SPEED”.

Engine idling speed:

950 

 1,050 r / min

8. Adjust:

Carburetor synchronization

a. Synchronize carburetor #1 to carburetor #2

by turning the synchronizing screw 

1

 in ei-

ther direction until both gauges read the
same.

b. Rev the engine two or three times, each time

for less than a second, and check the syn-
chronization again.

Vacuum pressure at idle speed:

34.7 

 37.3 kPa (260 

 280 mmHg)

The difference between the two carburetors
should not exceed 1.33 kPa (10 mmHg).

9. Check:

engine idling speed
Out of specification 

 Adjust.

10. Stop the engine and remove the measuring

equipment.

11. Adjust:

throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.

SYNCHRONIZING THE CARBURETORS/

ADJUSTING THE ENGINE IDLING SPEED

INSP

ADJ

3-10

NOTE:

a

b

Throttle cable free play (at the
flange of the throttle grip)

 6 mm

12. Install:

vacuum plugs

air duct

fuel tank

seat

EAS00054

ADJUSTING THE ENGINE IDLING SPEED

Prior to adjusting the engine idling speed, the
carburetor synchronization should be adjusted
properly, the air filter should be clean, and the
engine should have adequate compression.

1. Start the engine and let it warm up for several

minutes.

2. Remove:

cylinder head cover 

1

3. Install:

engine tachometer
(to the spark plug lead of cyl. #1)

Engine tachometer:

90890-03113

4. Check:

engine idling speed
Out of specification 

 Adjust.

Engine idling speed:

950 

 1,050 r / min

5. Adjust:

engine idling speed

a. Turn the pilot screw 

1

 in until it is lightly

seated.

b. Turn the pilot screw out the specified number

of turns.

Pilot screw

3 turns out

c. Turn the throttle stop screw 

2

 in direction 

a

or 

b

 until the specified engine idling speed is

obtained.

Direction 

Engine idling speed is
increased.

Direction 

Engine idling speed is
decreased.

 

 

 

 

 

 

 

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