Yamaha XVS1100 (L). Service Manual

3-11

ADJUSTING THE ENGINE IDLING SPEED/

ADJUSTING THE THROTTLE CABLE FREE PLAY

INSP

ADJ

NOTE:

6. Adjust:

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

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

6 mm

EAS00058

ADJUSTING THE THROTTLE CABLE FREE
PLAY

Prior to adjusting the throttle cable free play, the
engine idling speed should be adjusted.

1. Check:

throttle cable free play

Out of specification

Adjust.

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

6 mm

2. Remove:

rider’s seat

fuel tank
Refer to “FUEL TANK AND SEATS”.

3. Adjust:

throttle cable free play

When the motorcycle is accelerating, the accel-
erator cable

is pulled.

Carburetor side
a. Loosen the locknut

on the accelerator cable.

b. Turn the adjusting nut

in direction

until the specified throttle cable free play is
obtained.

Direction

Throttle cable free play
is decreased.

Direction

Throttle cable free play
is increased.

c. Tighten the locknuts.

If the specified throttle cable free play cannot be
obtained on the carburetor side of the cable, use
the adjusting nut on the handlebar side.

3-12

ADJUSTING THE THROTTLE CABLE FREE PLAY/

CHECKING THE SPARK PLUGS

INSP

ADJ

WARNING

CAUTION:

Handlebar side
a. Loosen the locknut

b. Turn the adjusting nut

in direction

until the specified throttle cable free play is
obtained.

Direction

Throttle cable free play is
increased.

Direction

Throttle cable free play is
decreased.

c. Tighten the locknut.

After adjusting the throttle cable free play,
turn the handlebar to the right and to the left
to ensure that this does not cause the en-
gine idling speed to change.

EAS00059

CHECKING THE SPARK PLUGS
The following procedure applies to all of the
spark plugs.
1. Remove:

cylinder head covers

2. Disconnect:

spark plug cap

3. Remove:

spark plug

Before removing the spark plugs, blow away
any dirt accumulated in the spark plug wells
with compressed air to prevent it from fal-
ling into the cylinders.

4. Check:

spark plug type
Incorrect

Change.

Spark plug type (manufacturer)
BPR7ES (NGK)
W22EPR-U (DENSO)

5. Check:

electrode

Damage / wear

Replace the spark plug.

insulator

Abnormal color

Replace the spark plug.

Normal color is a medium-to-light tan color.

6. Clean:

spark plug
(with a spark plug cleaner or wire brush)

3-13

CHECKING THE SPARK PLUGS/

CHECKING THE IGNITION TIMING

INSP

ADJ

20 Nm (2.0 m

kg)

NOTE:

7. Measure:

spark plug gap

(with a wire gauge)
Out of specification

Regap.

Spark plug gap

0.7

0.8 mm

8. Install:

spark plug

Before installing the spark plug, clean the spark
plug and gasket surface.

9. Connect:

spark plug cap

EAS00064

CHECKING THE IGNITION TIMING

Prior to checking the ignition timing, check the
wiring connections of the entire ignition system.
Make sure that all connections are tight and free
of corrosion.

1. Remove:

timing plug

2. Install:

timing light

engine tachometer

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

Timing light:

90890-03141

Engine tachometer:

90890-03113

3-14

CHECKING THE IGNITION TIMING/

MEASURING THE COMPRESSION PRESSURE

INSP

ADJ

NOTE:

3. Check:

ignition timing

a. Start the engine, warm it up for several min-

utes, and then let it run at the specified en-
gine idling speed.

Engine idling speed:

950

1,050 r / min

b. Check that the stationary pointer

is within

the firing range

on the generator rotor.

Incorrect firing range

Check the ignition

system.

The ignition timing is not adjustable.

4. Install:

timing plug

EAS00065

MEASURING THE COMPRESSION PRES-
SURE
The following procedure applies to all of the cyl-
inders.

Insufficient compression pressure will result in a
loss of performance.

1. Check:

valve clearance
Out of specification

Adjust.

Refer to “ADJUSTING THE VALVE CLEAR-
ANCE”.

2. Start the engine, warm it up for several min-

utes, and then turn it off.

3. Disconnect:

spark plug cap

4. Remove:

spark plug

3-15

MEASURING THE COMPRESSION PRESSURE

INSP

ADJ

CAUTION:

WARNING

NOTE:

Before removing the spark plugs, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug wells to prevent it
from falling into the cylinders.

5. Install:

compression gauge

Compression gauge set:

90890-03081

6. Measure:

compression pressure
Above the maximum pressure

Inspect the

cylinder head, valve surfaces, and piston
crown for carbon deposits.
Below the minimum pressure

Squirt a few

drops of oil into the affected cylinder and
measure again.

Refer to the following table.

Compression pressure

(with oil applied in the cylinder)

Reading

Diagnosis

Higher than
without oil

Piston wear or damage

Repair.

Same as
without oil

Piston ring(-s), valves, cylin-
der head gasket or piston
possibly defective

Repair.

Compression pressure (at sea
level)

Standard:

1,000 kPa (10 kg/cm

, 10 bar)

Minimum:

900 kPa (9 kg/cm

, 9 bar)

Maximum:

1,100 kPa (11 kg/cm

, 11 bar)

a. Turn the main switch to “ON”.
b. With the throttle wide open, crank the engine

until the reading on the compression gauge
stabilized.

To prevent sparking, ground all spark plug
leads before cranking the engine.

The difference in compression pressure be-
tween cylinders should not exceed 100 kPa (1
kg / cm

, 1 bar).

3-16

MEASURING THE COMPRESSION PRESSURE/

CHECKING THE ENGINE OIL LEVEL

INSP

ADJ

20 Nm (2.0 m

kg)

NOTE:

CAUTION:

7. Install:

spark plug

8. Connect:

spark plug cap

EAS00069

CHECKING THE ENGINE OIL LEVEL
1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.

Make sure that the motorcycle is upright.

2. Let the engine idle for a few minutes.

3. Check:

engine oil level
The engine oil level should be between the
minimum level marks

and maximum level

marks

Below the minimum level mark

Add the

recommended engine oil to the proper level.

Recommended engine oil

Refer to the chart for the
engine oil grade which is best
suited for certain atmospheric
temperatures.
API standard

SE or higher grade

ACEA standard

G4 or G5

Engine oil also lubricates the clutch and
the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives or use engine
oils with a grade of CD

or higher and do

not use oils labeled “ENERGY CONSERV-
ING II”

or higher.

Do not allow foreign materials to enter the
crankcase.

3-17

CHECKING THE ENGINE OIL LEVEL/

CHANGING THE ENGINE OIL

INSP

ADJ

NOTE:

WARNING

43 Nm (4.3 m

kg)

4. Start the engine, warm it up for several min-

utes, and then turn it off.

5. Check the engine oil level again.

Before checking the engine oil level, wait a few
minutes until the oil has settled.

EAS00075

CHANGING THE ENGINE OIL
1. Start the engine, warm it up for several min-

utes, and then turn it off.

2. Place a container under the engine oil drain

bolt.

3. Remove:

engine oil filler cap

o-ring

engine oil drain bolt

gasket

4. Drain:

engine oil
(completely from the crankcase)

5. If the oil filter element is also to be replaced,

perform the following procedure.

Oil filter element replacement should be
made cold exhaust pipe and muffler, at room
temperature.

a. Remove the muffler

, rear brake reservoir

tank

, element cover

and exhaust pipe

(front cylinder)

b. Remove the oil filter element cover plate

element cover

and oil filter element

c. Check the O-ring

and replace it if it is

cracked or damaged.

d. Install the new oil filter element and the ele-

ment cover.

Oil filter element cover bolt

10 Nm (1.0 m

kg)

e. Install the exhaust pipe (front cylinder), ele-

ment cover plate, rear brake reservoir tank
and muffler.
Refer to “ENGINE” in chapter 4.

6. Check:

engine oil drain bolt gasket
Damage

Replace.

7. Install:

gasket

engine oil drain bolt

8. Fill:

crankcase
(with the specified amount of the recom-
mended engine oil)

3-18

CHANGING THE ENGINE OIL/

ADJUSTING THE CLUTCH CABLE FREE PLAY

INSP

ADJ

NOTE:

Quantity

Total amount

3.6 L

Without oil filter element
replacement

3.0 L

With oil filter element
replacement

3.1 L

9. Install:

o-ring

engine oil filter cap

10. Start the engine, warm it up for several min-

utes, and then turn it off.

11. Check:

engine
(for engine oil leaks)

12. Check:

engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.

EAS00078

ADJUSTING THE CLUTCH CABLE FREE
PLAY
1. Check:

clutch cable free play

Out of specification

Adjust.

Clutch cable free play (at the end
of the clutch lever)

10 mm

2. Adjust:

clutch cable free play

Handlebar side
a. Loosen the locknut

b. Turn the adjusting screw

in direction

until the specified clutch cable free play is

obtained.

Direction

Clutch cable free play is
increased.

Direction

Clutch cable free play is
decreased.

c. Tighten the locknut.

If the specified clutch cable free play cannot be
obtained as described above, perform the mech-
anism adjustment procedure described below.

3. Remove:

left side cover

clutch adjusting cover

3-19

ADJUSTING THE CLUTCH CABLE FREE PLAY/

CLEANING THE AIR FILTER ELEMENT

INSP

ADJ

4. Adjust:

clutch mechanism

Engine side
a. Loosen the locknut

b. Turn in the adjusting screw

until it is lightly

seated.

c. Turn the adjusting screw out 1 / 4 of a turn.
d. Tighten the locknut.
e. Check the clutch cable free play again and

ajust it if necessary.

EAS00086

CLEANING THE AIR FILTER ELEMENT
1. Remove:

air filter case cover

air filter element

2. Clean:

air filter element
Apply compressed air to the outer surface of
the air filter element.

3. Check:

air filter element
Damage

Replace.

4. Install:

air filter element

air filter case cover

CLEANING THE AIR FILTER ELEMENT /

CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD /

CHECKING THE BREATHER HOSE

INSP

ADJ

3-20

CAUTION:

NOTE:

CAUTION:

Never operate the engine without the air filter
element installed. Unfiltered air will cause
rapid wear of engine parts and may damage
the engine. Operating the engine without the
air filter element will also affect the carburetor
turning, leading to poor engine performance
and possible overheating.

When installing the air filter element into the air
filter case cover, be sure their sealing surfaces
are aligned to prevent any air leaks.

EAS00094

CHECKING THE CARBURETOR JOINT AND
INTAKE MANIFOLD
1. Check:

carburetor joint

Cracks / damage

Replace.

Refer to “CARBURETOR” in chapter 6.

EAS00098

CHECKING THE BREATHER HOSE
1. Remove:

cylinder head cover

2. Check:

cylinder head breather hose

Cracks / damage

Replace.

Loose connection

Connect properly.

Make sure that the cylinder head breather
hose is routed correctly.

3-21

CHECKING THE EXHAUST SYSTEM

INSP

ADJ

EAS00100

CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the ex-
haust pipes, mufflers and gaskets.
1. Check:

exhaust pipes

muffler

Cracks / damage

Replace.

gaskets

Exhaust gas leaks

Replace.

2. Check:

tightening torque

Exhaust pipe nut

20 Nm (2.0 m

kg)

Exhaust pipe and muffler bolt

20 Nm (2.0 m

kg)

Muffler and muffler bracket bolt

25 Nm (2.5 m

kg)

3-22

ADJUSTING THE FRONT BRAKE

INSP

ADJ

WARNING

CAUTION:

EAS00108

CHASSIS

ADJUSTING THE FRONT BRAKE
1. Check:

brake lever free play

Out of specification

Adjust.

Brake lever free play (at the end
of the brake lever)

8 mm

2. Adjust:

brake lever free play

a. Loosen the locknut

b. Turn the adjusting bolt

in direction

until the specified brake lever free play is ob-
tained.

Direction

Brake lever free play is
increased.

Direction

Brake lever free play is
decreased.

c. Tighten the locknut.

A soft or spongy feeling in the brake lever
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will consid-
erably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, inspect and, if nec-
essary, bleed the brake system.

After adjusting the brake lever free play,
make sure that there is no brake drag.

3-23

ADJUSTING THE REAR BRAKE

INSP

ADJ

WARNING

CAUTION:

EAS00110

ADJUSTING THE REAR BRAKE
1. Check:

brake pedal position
(distance

from the top of the rider footrest

to the top of the brake pedal)
Out of specification

Adjust.

Brake pedal position (below the
top of the rider footrest)

81.8 mm

2. Adjust:

brake pedal position

a. Loosen the locknut

b. Turn the adjusting bolt

in direction

until the specified brake pedal position is ob-
tained.

Direction

Brake pedal is raised.

Direction

Brake pedal is lowered.

After adjusting the brake pedal position,
check that the end of the adjusting bolt

visible through the hole

c. Tighten the locknut

to specification.

Locknut

16 Nm (1.6 m

kg)

A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will consid-
erably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, inspect and, if nec-
essary, bleed the brake system.

After adjusting the brake pedal position,
make sure that there is no brake drag.

3. Adjust:

rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH”.

3-24

CHECKING THE BRAKE FLUID LEVEL

INSP

ADJ

NOTE:

WARNING

CAUTION:

NOTE:

EAS00115

CHECKING THE BRAKE FLUID LEVEL
1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.

Make sure that the motorcycle is upright.

2. Check;

brake fluid level
Below the minimum level mark

Add the

recommended brake fluid to the proper level.

Recommended brake fluid

DOT 4

A Front brake

B Rear brake

Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.

Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.

When refilling, be careful that water does
not enter the reservoir. Water will signifi-
cantly lower the boiling point of the brake
fluid and could cause vapor lock.

Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.

In order to ensure a correct reading of the brake
fluid level, make sure that the top of the reser-
voir is horizontal.

3-25

ADJUSTING THE REAR BRAKE LIGHT SWITCH/

CHECKING THE BRAKE HOSES

INSP

ADJ

NOTE:

EAS00128

ADJUSTING THE REAR BRAKE LIGHT
SWITCH

The rear brake light switch is operated by move-
ment of the brake pedal.
The rear brake light switch is properly adjusted
when the brake light comes on just before the
braking effect starts.

1. Check:

rear brake light operation timing
Incorrect

Adjust.

2. Adjust:

rear brake light operation timing

a. Hold the main body

of the rear brake light

switch so that it does not rotate and turn the
adjusting nut

in direction

until the

rear brake light comes on at the proper time.

Direction

Brake light comes on
sooner.

Direction

Brake light comes on
later.

EAS00131

CHECKING THE BRAKE HOSES
The following procedure applies to all of the
brake hoses and clamps.
1. Check:

brake hose
Cracks / damage / wear

Replace.

2. Check:

brake hose clamp
Loose connection

Tighten.

3. Hold the motorcycle upright and apply the

brake.

4. Check:

brake hose
Activate the brake several times.
Brake fluid leakage

Replace the damaged

hose.
Refer to “FRONT AND REAR BRAKES” in
chapter 7.

3-26

BLEEDING THE HYDRAULIC BRAKE SYSTEM

INSP

ADJ

WARNING

NOTE:

EAS00134

BLEEDING THE HYDRAULIC BRAKE SYS-
TEM

Bleed the hydraulic brake system whenever:

the system was disassembled,

a brake hose was loosened or removed,

the brake fluid level is very low,

brake operation is faulty.

Be careful not to spill any brake fluid or allow
the brake master cylinder reservoir or brake
fluid reservoir to overflow.

When bleeding the hydraulic brake system,
make sure that there is always enough brake
fluid before applying the brake. Ignoring this
precaution could allow air to enter the hydrau-
lic brake system, considerably lengthening the
bleeding procedure.

If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Repeat
the bleeding procedure when the tiny bubbles
in the hose have disappeared.

1. Stand the motorcycle on alevel surface.

Place the motorcycle on a suitable stand.

Make sure that the motorcycle is upright.

2. Bleed:

hydraulic brake system

a. Add the recommended brake fluid to the

proper level.

b. Install the diaphragm (brake master cylinder

reservoir or brake fluid reservoir).

c. Connect a clear plastic hose

tightly to the

bleed screw

A : Front

B : Rear

d. Place the other end of the hose into a con-

tainer.

e. Slowly apply the brake several times.
f. Fully squeeze the brake lever or fully de-

press the brake pedal and hold it in position.

g. Loosen the bleed screw.

This will release the tension and cause the
brake lever to contact the throttle grip or the
brake pedal to fully extend.

Yamaha XVS1100 (L). Service Manual - part 5