Yamaha XVS1100 (L). Service Manual - part 7

3-43

CHECKING THE FUSES

INSP

ADJ

CAUTION:

NOTE:

EAS00181

CHECKING THE FUSES
The following procedure applies to all of the
fuses.

To avoid a short circuit, always turn the main
switch to “OFF” when checking or replacing
a fuse.

1. Remove:

rider’s seat

ignitor plate
Refer to “FUEL TANK AND SEATS”.

tool box cover 

1

2. Check:

fuse

a. Connect the pocket tester to the fuse and

check it for continuity.

Set the pocket tester selector to “

Ω

 

 

 1”.

Pocket tester

90890-03112

b. If the pocket tester indicates “

∞

”, replace the

fuse.

3. Replace:

blown fuse

a. Turn off the ignition.
b. Install a new fuse of the correct amperage

rating.

c. Turn on the switches to verify if the electrical

circuit is operational.

d. If the fuse immediately blows again, check

the electrical circuit.

Fuses

Amperage rating

Quantity

Main

30A

1

Headlight

15A

1

Carburetor
heater

15A

1

Signals

10A

1

Ignition

10A

1

Back up

5A

1

Reserve

30A

1

Reserve

15A

1

Reserve

10A

1

Reserve

5A

1

CHECKING THE FUSES/

REPLACING THE HEADLIGHT BULB

INSP

ADJ

3-44

WARNING

WARNING

Never use a fuse with an amperage rating
other than that specified. Improvising or us-
ing a fuse with the wrong amperage rating
may cause extensive damage to the electri-
cal system, cause the lighting and ignition
systems to malfunction and could possibly
cause a fire.

4. Install:

tool box cover

ignitor plate

rider’s seat

EAS00182

REPLACING THE HEADLIGHT BULB
1. Disconnect:

connectors 

1

2. Remove

headlight bulb cover 

2

3. Remove:

headlight bulb holder 

1

4. Remove:

headlight bulb 

2

Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.

5. Install:

headlight bulb (New)
Secure the new headlight bulb with the head-
light bulb holder.

3-45

REPLACING THE HEADLIGHT BULB/

ADJUSTING THE HEADLIGHT BEAM

INSP

ADJ

CAUTION:

a

b

a

b

Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.

5. Install:

headlight bulb holder

6. Install:

headlight bulb cover

7. Connect:

leads

EAS00184

ADJUSTING THE HEADLIGHT BEAM
1. Adjust:

headlight beam (vertically)

a. Turn the adjusting screw 

1

 in direction 

a

 or

b

.

Direction  

Headlight beam is raised.

Direction  

Headlight beam is
lowered.

2. Adjust:

headlight beam (horizontally)

a. Turn the adjusting knob 

2

 in direction 

a

 or

b

.

Direction  

Headlight beam moves to
the right.

Direction  

Headlight beam moves to
the left.

 

ENG

 

4

ENG

CHAPTER 4

ENGINE

ENGINE REMOVAL

4-1

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

MUFFLERS, BRAKE PEDAL AND SIDE COVER

4-1

. . . . . . . . . . . . . . . 

LEADS, SHIFT PEDAL AND CLUTCH CABLE

4-3

. . . . . . . . . . . . . . . . . . 

ENGINE MOUNTING BOLTS

4-4

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

INSTALLING THE ENGINE

4-5

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

CYLINDER HEADS

4-6

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

REAR CYLINDER HEAD

4-6

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

FRONT CYLINDER HEAD

4-8

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

REMOVING THE CYLINDER HEADS

4-10

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

CHECKING THE CYLINDER HEADS

4-12

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

CHECKING THE TIMING CHAIN TENSIONER

4-13

. . . . . . . . . . . . . . . . . 

INSTALLING THE CYLINDER HEADS

4-13

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

ROCKER ARMS AND CAMSHAFT

4-16

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

REMOVING THE ROCKER ARMS AND CAMSHAFT

4-17

. . . . . . . . . . . . 

CHECKING THE CAMSHAFTS

4-17

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

CHECKING THE ROCKER ARMS AND ROCKER ARM
SHAFTRS

4-18

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

INSTALLING THE CAMSHAFT AND ROCKER ARMS

4-19

. . . . . . . . . . . 

VALVES AND VALVE SPRINGS

4-21

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

REMOVING THE VALVES

4-22

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

CHECKING THE VALVES AND VALVE GUIDES

4-22

. . . . . . . . . . . . . . . . 

CHECKING THE VALVE SEATS

4-24

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

CHECKING THE VALVE SPRINGS

4-26

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

INSTALLING THE VALVES

4-26

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

CYLINDERS AND PISTONS

4-28

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

REMOVING THE CYLINDERS AND PISTONS

4-29

. . . . . . . . . . . . . . . . . 

CHECKING THE CYLINDERS AND PISTONS

4-29

. . . . . . . . . . . . . . . . . . 

CHECKING THE PISTON RINGS

4-31

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

CHECKING THE PISTON PINS

4-32

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

INSTALLING THE PISTONS AND CYLINDERS

4-32

. . . . . . . . . . . . . . . . . 

TIMING GEARS

4-34

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

REMOVING THE TIMING DRIVE GEARS

4-35

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

CHECKING THE TIMING CHAINS, CAMSHAFT
SPROCKETS AND TIMING GUIDS

4-35

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

CHECKING THE PRIMARY DRIVE

4-36

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

INSTALLING THE TIMING DRIVE GEARS

4-36

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

ENG

CLUCTH

4-38

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

RIGHT CRANKCASE COVER

4-38

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

CLUTCH ASSEMBLY

4-40

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

REMOVING THE CLUTCH

4-42

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

CHECKING THE FRICTION PLATES

4-42

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

CHECKING THE PRESSURE PLATE

4-43

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

CHECKING THE CLUTCH BOSS

4-43

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

CHECKING THE CLUTCH PUSH RODS

4-43

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

CHECKING THE CLUTCH PLATES

4-44

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

CHECKING THE CLUTCH SPRING AND CLUTCH SPRING

SEAT PLATE

4-44

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

CHECKING THE CLUTCH HOUSING

4-44

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

INSTALLING THE CLUTCH

4-45

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

GENERATOR AND STARTER CLUTCH

4-47

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

STATOR COIL AND PICKUP COIL

4-47

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

GENERATOR AND STARTER CLUTCH

4-48

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

REMOVING THE GENERATOR

4-49

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

CHECKING THE STARTER CLUTCH

4-50

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

INSTALLING THE GENERATOR

4-51

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

SHIFT SHAFT

4-53

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

CHECKING THE SHIFT SHAFT

4-54

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

CHECKING THE STOPPER LEVER

4-54

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

INSTALLING THE SHIFT SHAFT

4-54

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

OIL PUMP

4-55

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

CHECKING THE OIL PUMP

4-57

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

CHECKING THE OIL DELIVERY PIPES

4-57

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

CHECKING THE OIL STRAINER

4-57

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

INSTALLING THE OIL PUMP

4-58

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

CRANKSHAFT AND CONNECTING RODS

4-59

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

CRANKCASE

4-59

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

CRANKSHAFT AND CONNECTING RODS

4-60

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

DISASSEMBLING THE CRANKCASE

4-61

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

REMOVING THE CRANKSHAFT ASSEMBLY

4-62

. . . . . . . . . . . . . . . . . . 

REMOVING THE CONNECTING RODS

4-62

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

CHECKING THE CRANKSHAFT AND CONNECTING RODS

4-62

. . . . 

CHECKING THE BEARING AND OIL SEALS

4-65

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

INSTALLING THE CRANKSHAFT

4-65

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

ASSEMBLING THE CRANKCASE

4-66

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

TRANSMISSION

4-68

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

CHECKING THE SHIFT FORKS

4-69

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

CHECKING THE SHIFT DRUM ASSEMBLY

4-69

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

CHECKING THE TRANSMISSION

4-70

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

INSTALLING THE TRANSMISSION

4-71

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

ENG

MIDDLE GEAR

4-72

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

MIDDLE DRIVE PINION GEAR

4-72

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

MIDDLE DRIVEN PINION GEAR

4-73

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

REMOVING THE MIDDLE DRIVE SHAFT ASSEMBLY

4-75

. . . . . . . . . . 

DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY

4-75

. . . . . 

REMOVING THE MIDDLE DRIVEN SHAFT ASSEMBLY

4-76

. . . . . . . . . 

CHECKING THE MIDDLE DRIVE SHAFT ASSEMBLY

4-76

. . . . . . . . . . . 

CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY

4-76

. . . . . . . . . 

ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY

4-77

. . . . . . . . 

ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY

4-78

. . . . . . . 

INSTALLING THE MIDDLE GEAR ASSEMBLY AND
ADJUSTING THE BACKLASH

4-78

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

INSTALLING THE UNIVERSAL JOINT

4-80

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

ALIGNING THE MIDDLE GEAR

4-81

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

4-1

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5
6

Removing the muffler, brake pedal
and side cover

Fuel tank

Air filter case assembly
Carburetor assembly
Muffler assembly
Cover (emblem)
Reservoir tank
Exhaust pipes
Rear brake switch lead
Footrest / brake pedal

1
1
1
2
1

1 / 1

Remove the parts in the order listed.

Stand the motorcycle on a level surface.

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

Refer & “FUEL TANK AND SEATS” in
Chapter 3.

Disconnect

Refer to “CARBURETOR” in Chapter 5.

WARNING

23 Nm (2.3 m

kg)

64 Nm (6.4 m

kg)

25 Nm (2.5 m

kg)

20 Nm (2.0 m

kg)

20 Nm (2.0 m

kg)

10 Nm (1.0 m

kg)

ENGINE REMOVAL

ENG

ENGINE

ENGINE REMOVAL

MUFFLERS, BRAKE PEDAL AND SIDE COVER

4-2

ENGINE REMOVAL

ENG

Order

Job name / Part name

Q’ty

Remarks

7
8
9

10

11

12
13

Rear brake master cylinder / bracket
Battery cover
Battery leads

Right side cover
Starter motor
Cylinder head covers
Spark plug caps

1 / 1

1
2

1
1
4
4

Disconnect

First, disconnect the negative lead, then
disconnect the positive lead.

Disconnect

For installation, reverse the removal
procedure

NOTE:

23 Nm (2.3 m

kg)

64 Nm (6.4 m

kg)

25 Nm (2.5 m

kg)

20 Nm (2.0 m

kg)

20 Nm (2.0 m

kg)

10 Nm (1.0 m

kg)

4-3

Order

Job name / Part name

Q’ty

Remarks

1
2
3

4
5
6
7
8
9

10

11

Removing the leads, shift pedal and
clutch cable
Tool box cover
Left side cover
AC magneto lead / pickup lead / side
stand switch lead / speed sensor lead
Neutral switch lead
Footrest/shift pedal
Sidestand
Clutch adjusting cover
Clutch cable
Speed sensor
Fuel tank fitting knobs
Steering head side covers

1
1

1/1/1

1

1 / 1

1
1
1
1
2
2

Remove the parts in the order listed.

Disconnect

Disconnect
Refer to “INSTALLING THE ENGINE”.

Disconnect

For installation, reverse the removal
procedure.

64 Nm (6.4 m

kg)

64 Nm (6.4 m

kg)

ENGINE REMOVAL

ENG

LEADS, SHIFT PEDL AND CLUTCH CABLE

4-4

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5
6
7
8
9

Engine mounting bolt removal

Left crankcase cover

Tool box

Horn
Engine ground lead connector
Engine stay (front-lower)
Down tube
Engine bracket bolts
Engine mount bolts (rear upper)
Engine mount bolt (rear lower)
Engine stays (rear upper / lower)
Engine assembly

1
1
1
1
4
2
1

1 / 1

1

Remove the parts in the order below.
Place a suitable stand under the frame and
engine.
Refer to “GENERATOR AND STARTER
CLUTCH”
Refer to “REAR SHOCK ABSORBER
AND SWINGARM” in Chapter 6.

For installation, reverse the removal
procedure.

Refer to “INSTALLING THE ENGINE”.

48 Nm (4.8 m

kg)

48 Nm (4.8 m

kg)

48 Nm (4.8 m

kg)

74 Nm (7.4 m

kg)

ENGINE REMOVAL

ENG

ENGINE MOUNTING BOLTS

4-5

ENGINE

ENG

NOTE:

EAS00192

INSTALLING THE ENGINE
1. Tighten the bolts in the following order.

Bolt 

1

:

48 Nm (4.8 m

kg)

Bolt 

2

:

48 Nm (4.8 m

kg)

Bolt 

3

:

48 Nm (4.8 m

kg)

Bolt 

4

:

48 Nm (4.8 m

kg)

Bolt 

5

:

48 Nm (4.8 m

kg)

2. Install:

shift arm 

1

Align the punch mark 

a

 in the shift shaft with

the slot in the shift arm.

Adjust the adjusting bolt length 

b

.

Refer to “ADJUSTING THE SHIFT PEDAL” in
chapter 3.

Shift arm bolt

10Nm (1.0m

kg)

Adjusting bolt length

114.7mm

4-6

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5
6
7

Cylinder head removal
Engine assembly
Left crankcase cover

Tappet cover (exhaust) / O-ring
Tappet cover (intake) / O-ring
Exhaust pipe joint / gasket
Carburetor joint / O-ring
Oil delivery pipes
Camshaft sprocket cover / O-ring
Camshaft sprocket bolt

1 / 1
1 / 1
1 / 1
1 / 1

2

1 / 1

1

Remove the parts in the order listed.
Refer to “ENGINE REMOVAL”.
Refer to “GENERATOR AND STARTER
CLUTCH”.

Refer to “INSTALLING THE CYLINDER
HEADS”.

35 Nm (3.5 m

kg)

10 Nm (1.0 m

kg)

20 Nm (2.0 m

kg)

10 Nm (1.0 m

kg)

55 Nm (5.5 m

kg)

20 Nm (2.0 m

kg)

50 Nm (5.0 m

kg)

20 Nm (2.0 m

kg)

CYLINDER HEADS

ENG

CYLINDER HEADS

REAR CYLINDER HEAD

4-7

Order

Job name / Part name

Q’ty

Remarks

8
9

10

11

12

Timing chain tensioner / gasket
Camshaft sprocket
Cylinder head
Dowel pins
Cylinder head gasket

1 / 1

1
1
2
1

For installation, reverse the removal
procedure.

Refer to “REMOVING / INSTALLING THE
CYLINDER HEADS”.

Refer to “INSTALLING THE CYLINDER
HEADS”.

20 Nm (2.0 m

kg)

50 Nm (5.0 m

kg)

35 Nm (3.5 m

kg)

10 Nm (1.0 m

kg)

20 Nm (2.0 m

kg)

10 Nm (1.0 m

kg)

55 Nm (5.5 m

kg)

20 Nm (2.0 m

kg)

CYLINDER HEADS

ENG

4-8

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5
6

Cylinder head removal
Engine assembly
Oil delivery pipes
Right crankcase cover
Tappet cover (exhaust) / O-ring
Tappet cover (intake) / O-ring
Carburetor joint / O-ring
Camshaft sprocket cover / O-ring
Baffle plate / O-ring
Camshaft sprocket bolt

1 / 1
1 / 1
1 / 1
1 / 1
1 / 1

1

Remove the parts in the order listed.
Refer to “ENGINE REMOVAL”.
Refer to “REAR CYLINDER HEAD”.
Refer to “CLUTCH”.

Refer to “INSTALLING THE CYLINDER
HEADS”.

New

10 Nm (1.0 m

kg)

10 Nm (1.0 m

kg)

10 Nm (1.0 m

kg)

10 Nm (1.0 m

kg)

20 Nm (2.0 m

kg)

50 Nm (5.0 m

kg)

55 Nm (5.5 m

kg)

35 Nm (3.5 m

kg)

CYLINDER HEADS

ENG

FRONT CYLINDER HEAD

4-9

Order

Job name / Part name

Q’ty

Remarks

7
8
9

10

11

12

Timing chain tensioner / gasket
Camshaft sprocket plate
Camshaft sprocket
Cylinder head
Dowel pins
Cylinder head gasket

1 / 1

1
1
1
2
1

For installationreverse the removal
procedure.

Refer to “REMOVING / INSTALLING
THE CYLINDER HEADS”.

Refer to “INSTALLING THE CYLINDER
HEADS”.

New

10 Nm (1.0 m

kg)

10 Nm (1.0 m

kg)

10 Nm (1.0 m

kg)

10 Nm (1.0 m

kg)

20 Nm (2.0 m

kg)

50 Nm (5.0 m

kg)

55 Nm (5.5 m

kg)

35 Nm (3.5 m

kg)

CYLINDER HEADS

ENG