Content .. 4 5 6 7 ..

Yamaha XVS1100 (L). Service Manual - part 6

3-27

BLEEDING THE HYDRAULIC BRAKE SYSTEM/

ADJUSTING THE SHIFT PEDAL

INSP

ADJ

WARNING

NOTE:

h. Tighten the bleed screw and then release the

brake lever or brake pedal.

i. Repeat steps (e) to (h) until all of the air

bubbles have disappeared from the brake
fluid in the plastic hose.

j. Tighten the bleed screw to specification.

Bleed screw

6 Nm (0.6 m

kg)

k. Fill the reservoir to the proper level.

Refer to “CHECKING THE BRAKE FLUID
LEVEL”.

After bleeding the hydraulic brake system,
check the brake operation.

EAS00137

ADJUSTING THE SHIFT PEDAL

The shift pedal position is determined by the ad-
justing bolt length

1. Measure:

adjusting the length

Incorrect

Adjust.

Adjusting bolt length

114.7 mm

2. Adjust:

adjusting bolt length

a. Loosen both locknuts

b. Turn the adjusting bolt

in direction

to obtain the correct shift pedal position.

Direction

shift pedal is raised.

Direction

shift pedal is lowered.

3-28

CHECKING THE FINAL DRIVE OIL LEVEL/

CHANGING THE FINAL DRIVE OIL

INSP

ADJ

NOTE:

23 Nm (2.3 m

kg)

23 Nm (2.3 m

kg)

EAS00144

CHECKING THE FINAL DRIVE 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. Remove:

final drive housing oil filler bolt

3. Check:

final drive oil level
The final drive oil level should be to the bot-
tom brim

of the filler hole.

Below the bottom brim

Add the recom-

mended final drive oil to the proper level.

Recommended final drive oil

SAE 80 hypoid gear oil graded
“GL-4”, “GL-5” or “GL-6”
or
multi-purpose SAE 80W90
hypoid gear oil

4. Install:

final drive housing oil filler bolt

EAS00145

CHANGING THE FINAL DRIVE OIL
1. Place a container under the final drive hous-

ing.

2. Remove:

final drive housing oil filler bolt

final drive housing oil drain bolt

Completely drain the final drive housing of its
oil.

3. Check:

final drive housing oil drain bolt gasket
Damage

Replace.

4. Install:

final drive housing oil drain bolt

5. Fill:

final drive housing
(with the specified amount of the recom-
mended final drive oil)

3-29

CHANGING THE FINAL DRIVE OIL/

CHECKING AND ADJUSTING THE STEERING HEAD

INSP

ADJ

WARNING

NOTE:

Quantity

0.2 L

Refer to “CHECKING THE FINAL DRIVE OIL
LEVEL”.

EAS00146

CHECKING AND ADJUSTING THE STEER-
ING HEAD
1. Stand the motorcycle on a level surface.

Securely support the motorcycle so that
there is no danger of it falling over.

Place the motorcycle on a suitable stand so that
the front wheel is elevated.

2. Check:

steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Looseness or binding

Adjust the steering

head.

3. Remove:

upper bracket pinch bolt

steering stem nut

upper bracket

4. Adjust:

steering head

a. Remove the lock washr

, the upper ring nut

, and the rubber washer

CHECKING AND ADJUSTING THE STEERING HEAD

INSP

ADJ

3-30

NOTE:

WARNING

NOTE:

110 Nm (11.0 m

kg)

20 Nm (2.0 m

kg)

b. Loosen the lower ring nut

and then tighten

it to specification with a ring nut wrench

Set the torque wrench at a right angle to the ring
nut wrench.

Ring nut wrench

90890-01403

Lower ring nut (initial tightening
torque)

52 Nm (5.2 m

kg)

c. Loosen the lower ring nut

completely, then

tighten it to specification.

Do not overtighten the lower ring nut.

Lower ring nut (final tightening
torque)

18 Nm (1.8 m

kg)

d. Check the steering head for looseness or

binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and inspect the upper and
lower bearings.
Refer to “STEERING HEAD AND HAN-
DLEBAR” in chapter 7.

e. Install the rubber washer

f. Install the upper ring nut

g. Finger tighten the upper ring nut

, then

align the slots of both ring nuts. If necessary,
hold the lower ring nut and tighten the upper
ring nut until their slots are aligned.

h. Install the lock washer

Make sure that the lock washer tabs

sit cor-

rectly in the ring nut slots

5. Install:

upper bracket

steering stem nut

upper bracket pinch bolt

3-31

CHECKING THE FRONT FORK/

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY

INSP

ADJ

WARNING

CAUTION:

EAS00149

CHECKING THE FRONT FORK
1. Stand the motorcycle on a level surface.

Securely support the motorcycle so that
there is no danger of it falling over.

2. Check:

inner tube
Damage / scratches

Replace.

oil seal
Oil leakage

Replace.

3. Hold the motorcycle upright and apply the

front brake.

4. Check:

operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Unsmooth operation

Repair.

Refer to “FRONT FORK” in chapter 7.

EAS00159

ADJUSTING THE REAR SHOCK ABSORB-
ER ASSEMBLY

Securely support the motorcycle so that
there is no danger of it falling over.

Never go beyond the maximum or minimum
adjustment positions.

1. Adjust:

spring preload

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/

CHECKING THE TIRES

INSP

ADJ

3-32

WARNING

Ring nut wrench

1HX-28135-00

a. Turn the adjusting knob

in direction

Direction

Spring preload is
increased
(suspension is harder).

Direction

Spring preload is
decreased
(suspension is softer).

Adjusting position

Standard: 3
Minimum: 1 (soft)
Maximum: 7 (hard)

EB304174

CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Measure:

tire pressure
Out of specification

Regulate.

The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.

The tire pressure and the suspension must
be adjusted according to the total weight
(including cargo, rider, passenger and ac-
cessories) and the anticipated riding
speed.

Operation of an overloaded motorcycle
could cause tire damage, an accident or an
injury.

NEVER OVERLOAD THE MOTORCYCLE.

3-33

CHECKING THE TIRES

INSP

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WARNING

Basic
weight: (with
oil and full
fuel tank)

274 kg

Maximum
load*:

201 kg

Cold tire
pressure:

Front

Rear

Up to 90 kg
load*

200 kPa
(2.00 kgf/cm

)

225 kPa
(2.25 kgf/cm

)

90 kg

maximum

load*

225 kPa
(2.25 kgf/cm

)

250 kPa
(2.50 kgf/cm

)

High speed
riding

225 kPa
(2.25 kgf/cm

)

250 kPa
(2,50 kgf/cm

)

total of cargo, rider, passenger and acces-
sories

It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.

2. Check:

tire surfaces
Damage / wear

Replace the tire.

Minimum tire tread depth

1.6 mm

1 Tire tread depth

2 Side wall

3 Wear indicator

Do not use a tubeless tire on a wheel de-
signed only for tube tires to avoid tire fail-
ure and personal injury from sudden defla-
tion.

When using a tube tire, be sure to install the
correct tube.

Always replace a new tube tire and a new
tube as a set.

To avoid pinching the tube, make sure that
the wheel rim band and tube are centered in
the wheel groove.

3-34

CHECKING THE TIRES

INSP

ADJ

WARNING

Patching a punctured tube is not recom-
mended. If it is absolutely necessary to do
so, use great care and replace the tube as
soon as possible with a good quality re-
placement.

Tube wheel

Tubeless wheel

Tube tire only

Tube or tubeless tire

After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. Then front and rear tires
should always be by the same manufactur-
er and of the same design. No guarantee
concerning handling characteristics can
be given if a tire combination other than
one approved by Yamaha is used on this
motorcycle.

Front tire:

Manufactur-
er

Type

Size

BRIDGE-
STONE

110/90-18 61S EXEDRA L309

DUNLOP

110/90-18 61S

K555F

Rear tire:

Manufactur-
er

Type

Size

BRIDGE-
STONE

170 / 80-15

M / C 77S

EXEDRA

G546

DUNLOP

170 / 80-15

M / C 77S

K555

New tires have a relatilvely low grip on the
road surface until they have been slightly
worn.
Therefor, approximately 100 km should be
traveled at normal speed before any high-
speed riding is done.

3-35

CHECKING THE TIRES/

CHECKING AND TIGHTENING THE SPOKES

INSP

ADJ

NOTE:

3 Nm (0.3 m

kg)

NOTE:

For tires with a direction of rotation mark

Install the tire with the mark pointing in the
direction of wheel rotation.

Align the mark

with the valve installation

point.

EAS00169

CHECKING AND TIGHTENING THE SPOKES
The following procedure applies to all of the
spokes.
1. Check:

spoke

Bends / damage

Replace.

Loose

Tighten.

Tap the spokes with a screwdriver.

A tight spoke will emit a clear, ringing tone; a
loose spoke will sound flat.

2. Tighten:

spoke
(with a spoke wrench

)

Be sure to tighten the spokes before and after
break-in.

CHECKING AND LUBRICATING THE CABLES /

LUBRICATING THE LEVERS AND PEDALS / LUBRICATING

THE SIDESTAND / LUBRICATING THE REAR SUSPENSION

INSP

ADJ

3-36

WARNING

NOTE:

EAS00170

CHECKING AND LUBRICATING THE
CABLES
The following procedure applies to all of the
cable sheaths and cables.

Damaged cable sheaths may causes the
cable to corrode and interfere with its move-
ment. Replace damaged cable sheaths and
cables as soon as possible.

1. Check:

cable sheath
Damage

Replace.

2. Check:

cable operation
Unsmooth operation

Lubricate.

Recommended lubricant

Engine oil or a suitable cable
lubricant

Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit-
able lubing device.

EAS00171

LUBRICATING THE LEVERS AND PEDALS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers and pedals.

Recommended lubricant

Engine oil

EAS00172

LUBRICATING THE SIDESTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.

Recommended lubricant

Engine oil

EAS00174

LUBRICATING THE REAR SUSPENSION
Lubricate the pivoting point and metal-to-metal
moving parts of the rear suspension.

Recommended lubricant

Molybdenum disulfide grease

3-37

CHECKING AND CHARGING THE BATTERY

INSP

ADJ

WARNING

CAUTION:

EB305020

ELECTRICAL SYSTEM

CHECKING AND CHARGING THE BATTERY

Batteries generate explosive hydrogen gas
and contain electrolyte which is made of poi-
sonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:

Wear protective eye gear when handling or
working near batteries.

Charge batteries in a well-ventilated area.

Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).

DO NOT SMOKE when charging or han-
dling batteries.

KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.

Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.

First aid in case of bodily contact:
External

SKIN – Wash with water.

EYES – Flush with water for 15 minutes and
get immediate medical attention.

Internal
Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical atten-
tion.

This is a sealed battery. Never remove the
sealing caps because the balance between
cells will not be maintained and battery per-
formance will deteriorate.

Charging time, charging amperage and
charging voltage for a MF battery are differ-
ent from those of conventional batteries.
The MF battery should be charged as ex-
plained in the charging method illustra-
tions. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging
the battery.

CHECKING AND CHARGING THE BATTERY

INSP

ADJ

Volt meter

Relationship between open-circuit
voltage and charging time at 20

Open-circuit voltage

Charging time (Hours)

This varies depending on the temperature, the state of
charge in battery plates and the electro lyte level.

3-38

NOTE:

CAUTION:

NOTE:

Since MF batteries are sealed, it is not possible
to check the charge state of the battery by mea-
suring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
checked by measuring the voltage at the battery
terminals.

1. Remove:

battery cover

2. Disconnect:

battery leads
(from the battery terminals)

First, disconnect the negative lead

, then

the positive lead

3. Remove:

battery

4. Check:

battery charge

a. Connect a pocket tester to the battery termi-

nals.

Tester positive lead

battery positive
terminal

Tester negative lead

battery negative
terminal

The charge state of a MF battery can be
checked by measuring its open-circuit voltage
(i.e., the voltage when the positive terminal is
disconnected).

No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V.

b. Check the charge of the battery, as shown in

the charts and the following example.

Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20

30 %

5. Charge:

battery
(refer to the appropriate charging method il-
lustration)

3-39

Open-circuit voltage (V)

Condition of charge in battery (%)

Ambient
temperature 20

Open-circuit voltage (V)

Charging

Ambient temperature
20

Check the Open-circuit
voltage

Time (Minutes)

CHECKING AND CHARGING THE BATTERY

INSP

ADJ

WARNING

CAUTION:

Do not quick charge a battery.

Make sure that the battery breather hose
and battery vent are free of obstructions.

Never remove the MF battery sealing caps.

Do not use a high-rate battery charger.
They force a high-amperage current into
the battery quickly and can cause battery
overheating and battery plate damage.

If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.

When charging a battery, be sure to remove
it from the motorcycle. (If charging has to
be done with the battery mounted on the
motorcycle, disconnect the negative lead
from the battery terminal.)

To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.

Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.

Make sure that the battery charger lead
clips are in full contact with the battery ter-
minal and that they are not shorted. A cor-
roded battery charger lead clip may gener-
ate heat in the contact area and a weak clip
spring may cause sparks.

If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the bat-
tery cool before reconnecting it. Hot batter-
ies can explode!

As shown in the following illustration, the
open-circuit voltage of a MF battery stabi-
lizes about 30 minutes after charging has
been completed. Therefore, wait 30 min-
utes after charging is completed before
measuring the open-circuit voltage.

Measure the open-circuit
voltage prior to charging.

Connect a charger and
AMP meter to the battery
and start charging.

Make sure the current is
higher than the standard
charging current written on
the battery.

By turning the charging volt-
age adjust dial, set the charg-
ing voltage at 20

25 V.

Adjust the voltage so that cur-
rent is at standard charging
level.

Monitor the amperage for 3

5 minutes to check if the stan-
dard charging current is
reached.

Set the timer according to the
charging time suitable for the
open-circuit voltage.
Refer to “Battery condition
checking steps.”

If the current does
not exceed stan-
dard charging cur-
rent after 5 min-
utes, replace the
battery.

In case that charging requires more than 5 hours, it is advisable to
check the charging current after a lapse of 5 hours. If there is any
charge in the amperage, readjust the voltage to obtain the standard
charging current.

Measure the battery open-circuit voltage after having left the battery
unused for more than 30 minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.

YES

NOTE:

Voltage should be measured 30 min-
utes after the machine is stopped.

NOTE:

Set the charging voltage at 16

17 V.

(If the setting is lower, charging will be
insufficient. If too high, the battery will
be over-charged.)

Charger

AMP meter

CHECKING AND CHARGING THE BATTERY

INSP

ADJ

3-40

Charging method using a variable-current (voltage) type charger

3-41

Measure the open-circuit
voltage prior to charging.

Connect a charger and
AMP meter to the battery
and start charging.

NOTE:

Voltage should be measured 30 min-
utes after the machine is stopped.

Make sure the current is
higher than the standard
charging current written on
the battery.

Charge the battery until the battery’s
charging voltage is 15 V.

This type of battery charger cannot
charge the MF battery. A variable volt-
age charger is recommended.

Measure the battery open-circuit
voltage after having left the battery
unused for more than 30 minutes.
12.8 V or more --- Charging is com-
plete.
12.7 V or less --- Recharging is re-
quired.
Under 12.0 V --- Replace the battery.

NOTE:

Set the charging time at 20 hours (maxi-
mum).

YES

Charging method using a constant-current type charger
This type of battery charger cannot charge the MF battery.

Volt meter

Charger

AMP meter

CHECKING AND CHARGING THE BATTERY

INSP

ADJ

Charging method using a constant-voltage type charger

CHECKING AND CHARGING THE BATTERY

INSP

ADJ

3-42

CAUTION:

6. Check:

battery breather hose and battery vent
Obstruction

Clean.

Damage

Replace.

7. Install:

battery

When inspecting the battery, make sure
that the battery breather hose is properly
attached and routed correctly. If the battery
breather hose is positioned so as to allow
electrolyte or hydrogen gas from the bat-
tery to contact the frame, the motorcycle
and its finish may be damaged.

Make sure that the battery breather hose is
properly routed away from the drive chain
and from below the swingarm.

8. Connect:

battery leads
(to the battery terminals)

First, connect the positive lead

, then the

negative lead

9. Check:

battery terminals
Dirt

Clean with a wire brush.

Loose connection

Connect properly.

10. Lubricate:

battery terminals

Recommended lubricant

Dielectric grease

11. Install:

battery cover

Content .. 4 5 6 7 ..