Yamaha XVS1100 (L). Service Manual

4-10

CYLINDER HEADS

ENG

NOTE:

EAS00226

REMOVING THE CYLINDER HEADS
Rear cylinder head
1. Remove:

camshaft sprocket cover

tappet covers

2. Align:

“T” mark

(with the stationary pointer

)

a. Temporarily install the left crankcase cover

without the pickup coil and stator coil.

b. Turn the crankshaft clockwise.
c. Align the “T” mark

with the stationary

pointer

on the crankcase cover (left) when

the rear piston is at TDC on the compression
stroke.

d. Check that the rear piston is at TDC in the

compression stroke.

e. The rear piston is at TDC on the compression

stroke when there is clearance at both of the
rocker arms. If there is no clearance then turn
the crankshaft clockwise one full turn.

f. When to “T” mark is aligned with the station-

ary pointer the punch mark

on the cam-

shaft sprocket should be aligned with the sta-
tionary pointer

on the cylinder head.

3. Loosen:

bolt (camshaft sprocket)

Use the sheave holder

to hold the rotor.

Sheave holder:

90890-01701

4-11

CYLINDER HEADS

ENG

NOTE:

4. Remove:

timing chain tensioner

gasket

5. Remove:

bolt (camshaft sprocket)

camshaft sprocket

To prevent the timing chain from falling into the
crankcase fasten a wire to it.

6. Remove:

cylinder head

Loosen the bolts and nuts in the proper se-
quence.

Follow the numerical order shown in the il-
lustration. Loosen each bolt 1 / 4 of a turn at a
time until all of the bolts are loose.

Front cylinder head

When removing the front cylinder head, repeat
the rear cylinder head removal procedures.
However, note the following points.

1. Align:

“I” mark
(with the stationary pointer)

Removal steps:

Turn the crankshaft clockwise 290

Align the “I” mark

with the stationary pointer

on the crankcase cover (left) when the front

piston is at TDC on the compression stroke.

When the “I” mark is aligned with the stationary
pointer the punch mark

on the camshaft

sprocket should be aligned with the stationary
pointer

on the cylinder head.

The front piston is at TDC on the compression
stroke when there is clearance at both of the
rocker arms.

4-12

CYLINDER HEADS

ENG

NOTE:

EAS00228

CHECKING THE CYLINDER HEADS
The following procedure applies to all of the cyl-
inder heads.
1. Eliminate:

combustion chamber carbon deposits
(with a rounded scraper)

Do not use a sharp instrument to avoid damag-
ing or scratching:

spark plug threads

valve seats

2. Check:

cylinder head
Damage / scratches

Replace.

3. Measure:

cylinder head warpage
Out of specification

Resurface the cylin-

der head.

Cylinder head warpage

Less than 0.03 mm

a. Place a straightedge

and a thickness

gauge

across the cylinder head.

b. Measure the warpage.
c. If the limited is exceeded, resurface the cylin-

der head as follows.

d. Place 400 – 600 grit wet sandpaper on the

surface plate and resurface the cylinder
head using a figure-eight sanding pattern.

To ensure an even surface, rotate the cylinder
head several times.

4-13

CYLINDER HEADS

ENG

NOTE:

50 Nm (5.0 m

kg)

35 Nm (3.5 m

kg)

20 Nm (2.0 m

kg)

NOTE:

EB401430

CHECKING THE TIMING CHAIN TENSIONER
1. Check:

timing chain tensioner
Cracks / damage / rough movement

Re-

place.

a. Lightly press the timing chain tensioner rod

into the timing chain tensioner housing by
hand.

While pressing the timing chain tensioner rod,
wind it clockwise with a thin screwdriver

until

it stops.

b. Remove the screwdriver and slowly release

the timing chain tensioner rod.

c. Make sure that the timing chain tensioner rod

comes out of the timing chain tensioner
housing smoothly. If there is rough move-
ment, replace the timing chain tensioner.

EAS00234

INSTALLING THE CYLINDER HEADS
Rear cylinder head
1. Install:

dowel pins

gasket

The “5EL” mark on the gasket must face up side
of the cylinder.

2. Install:

nuts (cylinder head) (M12: 1 – 4)

cap nut (cylinder head) (M10: 5)

bolts (cylinder head) (M8: 6 – 7)

Tighten the bolts and nuts in the proper se-
quence.

Follow the numerical order shown in the il-
lustration. Tighten the bolts and nuts in two
stages.

4-14

CYLINDER HEADS

ENG

WARNING

NOTE:

3. Install:

camshaft sprocket

a. Temporarily install the rotor nut and left

crankcase cover without the pickup coil and
stator coil.

b. Turn the crankshaft clockwise.
c. Align the “T” mark

with the stationary

pointer

on the crankcase cover (left).

d. Install the camshaft sprocket with the timing

mark

facing out.

e. Turn the camshaft just enough to remove any

slack from the intake side of the timing chain.

f. Insert your finger into the hole and timing

chain tensioner hole and push the timing
chain guide inward.

g. While pushing the timing chain guide, be

sure that the timing mark

and the station-

ary pointer

are properly aligned at TDC.

4. Install:

timing chain tensioner

a. Lightly press the timing chain tensioner rod

into the timing chain tensioner housing by
hand.

b. While pressing the timing chain tensioner

rod, wind it clockwise with a thin screwdriver

until it stops.

c. With the screwdriver still inserted into the

timing chain tensioner, install the timing
chain tensioner

, and gasket.

Then, tighten the timing chain tensioner bolts

to the specified torque.

Always use a new gasket.

The “UP” mark on the timing chain tensioner
should face up.

Timing chain tensioner bolt

10 Nm (1.0 m

kg)

4-15

CYLINDER HEADS

ENG

55 Nm (5.5 m

kg)

NOTE:

d. Remove the screwdriver, make sure that the

timing chain tensioner rod releases, and
tighten the cap bolt to the specified torque.

Cap bolt

8 Nm (0.8 m

kg)

5. Install:

bolt (camshaft sprocket)

Be sure the projection on the camshaft sprock-
et plate is aligned with the hole in the sprocket.

Use the sheave holder

to hold the rotor.

Sheave holder:

90890-01701

6. Check:

alignment marks
If the marks do not align

Adjust.

7. Measure:

valve clearance
Out of specification

Adjust.

Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” in CHAPTER 3.

Front cylinder head

When installing the front cylinder head, repeat
the rear cylinder head installation procedure.
However, note the following points.

1. Install:

camshaft sprocket

a. Turn the crankshaft clockwise 290

b. Align the “I” mark

with the stationary point-

on the crankcase cover (left).

c. Install the camshaft sprocket with the timing

mark

facing out.

d. Turn the camshaft just enough to remove any

slack from the intake side of the timing chain.

e. Insert your finger into the hole and timing

chain tensioner hole and push the timing
chain guide inward.

f. While pushing the timing chain guide, be

sure that the timing mark

and the station-

ary pointer

are properly aligned at TDC.

4-16

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5
6
7
8

Removing the rocker arm and
camshaft
Cylinder heads
Stopper plate
Camshaft bushing
Camshaft / dowel pin
Union bolt / gasket
Rocker arm shafts
Rocker arms
Locknuts
Valve adjusters

1
1

1 / 1
1 / 1

2
2
2
2

Remove the parts in the order listed.

Refer to “CYLINDER HEAD”.

For installation, reverse the removal
procedure.

Refer to “REMOVING / INSTALLING THE
ROCKER ARM AND CAMSHAFT”.

37.5 Nm (3.75 m

kg)

20 Nm (2.0 m

kg)

27 Nm (2.7 m

kg)

ROCKER ARMS AND CAMSHAFT

ENG

ROCKER ARMS AND CAMSHAFT

4-17

ROCKER ARMS AND CAMSHAFT

ENG

NOTE:

EAS00202

REMOVING THE ROCKER ARMS AND CAM-
SHAFT
1. Remove:

rocker arm shafts (intake and exhaust)

rocker arms

Use a slide hammer

and weight

to remove

the rocker arm shafts.

Slide hammer bolt (M8):

90890-01085

Weight:

90890-01084

2. Remove:

camshaft bushing

camshaft

Screw a 10 mm bolt

into the threaded end of

the camshaft and pull out the camshaft.

EAS00205

CHECKING THE CAMSHAFTS
1. Check:

camshaft bushings
Damage / wear

Replace.

2. Check:

camshaft lobes
Blue discoloration / pitting / scratches

Re-

place the camshaft.

3. Measure:

camshaft lobe dimensions

and

Out of specification

Replace the cam-

shaft.

Camshaft lobe dimension limit

Intake

39.012 mm

#1: 31.993 mm
#2: 32.027 mm

Exhaust

39.045 mm

32.100 mm

4. Check:

camshaft oil passage
Obstruction

Blow out with compressed air.

4-18

ROCKER ARMS AND CAMSHAFTS

ENG

NOTE:

EB401410

CHECKING THE ROCKER ARMS AND
ROCKER ARM SHAFTS
The following procedure applies to all of the
rocker arms and rocker arm shafts.
1. Check:

rocker arm
Damage / wear

Replace.

rocker arm lobe

valve adjuster

Excessive wear

Replace.

2. Check:

rocker arm shaft
Blue discoloration / excessive wear / pit-
ting / scratches

Replace or check the lu-

brication system.

3. Measure:

rocker arm inside diameter

Out of specification

Replace.

Rocker arm inside diameter

14.036 mm

4. Measure:

rocker arm shaft outside diameter

Out of specification

Replace.

Rocker arm shaft outside diameter

13.95 mm

5. Calculate:

rocker-arm-to-rocker-arm-shaft clearance

Calculate the clearance by subtracting the rock-
er arm shaft outside diameter from the rocker
arm inside diameter.

Above 0.086 mm

Replace the defective

part(-s).

Rocker-arm-to-rocker-arm-shaft
clearance

0.009

0.033 mm

<Limit> : 0.086 mm

4-19

ROCKER ARMS AND CAMSHAFTS

ENG

NOTE:

EAS00220

INSTALLING THE CAMSHAFT AND ROCK-
ER ARMS
1. Lubricate:

camshaft

Recommended lubricant

Camshaft / Bushing

Molybdenum disulfide oil

2. Install:

camshaft

camshaft bushing

The dowel pin

on the end of the camshaft

must align with the timing mark

on the cylin-

der head.

Make sure that the No.1 camshaft

installed in the rear cylinder head and the No.2
camshaft

is installed in the front cylinder

head.

3. Install:

stopper plate

Stopper plate bolt

20 Nm (2.0 m

kg)

4. Lubricate:

rocker arm shafts

Recommended lubricant

Engine oil

4-21

Order

Job name / Part name

Q’ty

Remarks

2
3
4
5
6
7

Removing the valves and valve
springs.
Cylinder heads
Rocker arms and camshafts

Valve cotters

Valve spring retainers
Valve springs
Valve (intake)
Valve (exhaust)
Valve stem seals
Valve spring seats

2
2
1
1
2
2

Remove the parts in the order listed.

Refer to “CYLINDER HEADS”.
Refer to “ROCKER ARMS AND
CAMSHAFT”.
Refer to “REMOVING / INSTALLING
THE VALVES”.

For installation, reverse the removal
procedure.

Refer to “INSTALLING THE VALVES”.

VALVES AND VALVE SPRINGS

ENG

VALVES AND VALVE SPRINGS

4-22

VALVE AND VALVE SPRINGS

ENG

NOTE:

EAS00237

REMOVING THE VALVES
The following procedure applies to all of the
valves and related components.

Before removing the internal parts of the cylin-
der head (e.g., valves, valve springs, valve
seats), make sure that the valves properly seal.

1. Check:

valve sealing
Leakage at the valve seat

Check the valve

face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”.

a. Pour a clean solvent

into the intake and

exhaust ports.

b. Check that the valves properly seal.

There should be no leakage at the valve seat

2. Remove:

valve cotters

Remove the valve cotters by compressing the
valve spring with the valve spring compressor

Valve spring compressor

90890-04019

EAS00239

CHECKING THE VALVES AND VALVE GUIDES
The following procedure applies to all of the
valve and valve guides.
1. Measure:

valve-stem-to-valve-guide clearance

Valve-stem-to-valve-guide clearance =

Valve guide inside diameter

–

Valve stem diameter

4-23

VALVE AND VALVE SPRINGS

ENG

NOTE:

Out of specification

Replace the valve

guide.

Valve-stem-to-valve-guide
clearance
Intake 0.010

0.037 mm

<Limit>: 0.08 mm

Exhaust 0.025

0.052 mm

<Limit>: 0.10 mm

2. Replace.

valve guide

To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100

C (212

K) in an oven.

a. Remove the valve guide with a valve guide

remover

b. Install the new valve guide with a valve guide

installer

and valve guide remover

c. After installing the valve guide, bore the

valve guide with a valve guide reamer

obtain the proper valve-stem-to-valve-guide
clearance.

After replacing the valve guide, reface the valve
seat.

Valve guide remover and installer
(8 mm)

90890-04014

3. Eliminate:

carbon deposits
(from the valve face and valve seat)

4. Check:

valve face
Pitting/ wear

Grind the valve face.

valve stem end
Mushroom shape or diameter larger than the
body of the valve stem

Replace the valve.

4-24

VALVE AND VALVE SPRINGS

ENG

NOTE:

5. Measure:

valve margin thickness

Out of specification

Replace the valve.

Valve margin thickness limit

0.8 mm

6. Measure:

valve stem runout
Out of specification

Replace the valve.

When installing a new valve, always replace
the valve guide.

If the valve is removed or replaced, always re-
place the valve stem seal.

Valve stem runout

0.03 mm

EAS00240

CHECKING THE VALVE SEATS
The following procedure applies to all of the
valves and valve seats.
1. Eliminate:

carbon deposits
(from the valve face and valve seat)

2. Check:

valve seat
Pitting/ wear

Replace the cylinder head.

3. Measure:

valve seat width

Out of specification

Replace the cylinder

head.

Valve seat width limit

Intake: 1.8 mm
Exhaust: 1.8 mm

a. Apply Mechanic’s blueing dye (Dykem)

onto the valve face.

b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and

onto the valve seat to make a clear pattern.

d. Measure the valve seat width. Where the

valve seat and valve face contacted one
another, the blueing will have been removed.

4-25

VALVE AND VALVE SPRINGS

ENG

NOTE:

CAUTION:

NOTE:

4. Lap:

valve face

valve seat

After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.

a. Apply a coarse lapping compound to the

valve face.

Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.

b. Apply molybdenum disulfide oil onto the

valve stem.

c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve

seat are evenly polished, then clean off all of
the lapping compound.

For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth be-
tween your hand.

e. Apply a fine lapping compound to the valve

face and repeat the above steps.

f. After every lapping procedure, be sure to

clean off all of the lapping compound from
the valve face and valve seat.

g. Apply Mechanic’s blueing dye (Dykem) onto

the valve face.

h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and

onto the valve seat to make a clear impres-
sion.

j. Measure the valve seat width again. If the

valve seat width is out of specification, reface
and lap the valve seat.

Yamaha XVS1100 (L). Service Manual - part 8