Yamaha XVS1100 (L). Service Manual

4-26

VALVE AND VALVE SPRINGS

ENG

EAS00241

CHECKING THE VALVE SPRINGS
The following procedure applies to all of the
valve springs.
1. Measure:

valve spring free length

Out of specification

Replace the valve

spring.

Valve spring free length (intake
and exhaust)

44.6 mm
<Limit>: 43.5 mm

2. Measure:

compressed spring force

Out of specification

Replace the valve

spring.

b Installed length

Compressed spring force

Intake and exhaust spring
160.7 N (16.4 kg) at 40 mm

3. Measure:

valve spring tilt

Out of specification

Replace the valve

spring.

Spring tilt limit

Intake and exhaust valve spring

2.5

/ 1.9 mm

EAS00245

INSTALLING THE VALVES
The following procedure applies to all of the
valves and related components.
1. Deburr:

valve stem end
(with an oil stone)

2. Lubricate:

valve stem

oil seal

New

(with the recommended lubricant)

Recommended lubricant

Molybdenum disulfide oil

3. Install:

valve

lower spring seat

oil seal

New

valve spring

upper spring seat
(into the cylinder head)

4-27

VALVE AND VALVE SPRINGS

ENG

NOTE:

CAUTION:

Install the valve spring with the larger pitch

facing up.

b Smaller pitch

4. Install:

valve cotters

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

Valve spring compressor

90890-04019

5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.

Hitting the valve tip with excessive force
could damage the valve.

4-28

Remove the parts in the order listed.
Refer to “CYLINDER HEADS”.
The “5EL” mark should face towards the
cylinder head.

For installation, reverse the removal
procedure.

Order

Job name / Part name

Q’ty

Remarks

2
3
4
5
6
7
8

Removing the cylinders and pistons
Cylinder heads
Timing chain guide

Cylinder
Dowel pins
Cylinder gasket
Piston pin clips
Piston pin
Piston
Piston ring set

1
2
1
2
1
1
1

Refer to “INSTALLING THE PISTONS
AND CYLINDERS”.

10 Nm (1.0 m

kg)

Refer to “REMOVING / INSTALLING
THE CYLINDERS AND PISTONS”.

CYLINDERS AND PISTONS

ENG

CYLINDERS AND PISTONS

4-29

CYLINDERS AND PISTONS

ENG

CAUTION:

NOTE:

EAS00254

REMOVING THE PISTONS
The following procedure applies to all of the pis-
tons.
1. Remove:

piston pin clip

piston pin

piston

Do not use a hammer to drive the piston pin
out.

Before removing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the piston pin clip from falling into the crank-
case.

For reference during installation, put an identi-
fication mark on each piston crown.

Before removing the piston pin, deburr the pis-
ton pin clip’s groove and the piston’s pin bore
area. If both areas are deburred and the piston
pin is still difficult to remove, remove it with the
piston pin puller

Piston pin puller

90890-01304

2. Remove:

top ring

2nd ring

oil ring

When removing a piston ring, open the end gap
with your fingers and lift the other side of the ring
over the piston crown.

EB404405

CHECKING THE CYLINDERS AND PISTONS
The following procedure applies to all of the cyl-
inders and pistons.
1. Check:

piston wall

cylinder wall
Vertical scratches

Rebore or replace the

cylinder, and replace the piston and piston
rings as a set.

4-30

CYLINDER AND PISTONS

ENG

NOTE:

X + Y

C =

2. Measure:

piston-to-cylinder clearance

a. Measure cylinder bore “C” with the cylinder

bore gauge.

a 40 mm from the top of the cylinder

Measure cylinder bore “C” by taking side-to-
side and front-to-back measurements of the cyl-
inder. Then, find the average of the measure-
ments.

Standard

Wear

limit

Cylinder

bore C:

95.00

95.01 mm

95.1 mm

b. If out of specification, rebore or replace the

cylinder, and replace the piston and piston
rings as a set.

c. Measure piston skirt diameter “P” with the

micrometer.

b 5 mm from the bottom edge of the piston.

Piston size P

Standard

94.960

94.975 mm

d. If out of specification, replace the piston and

piston rings as a set.

e. Calculate the piston-to-cylinder clearance

with the following formula.

Piston-to-cylinder clearance =

Cylinder bore “C” –
Piston skirt diameter “P”

Piston-to-cylinder clearance

0.025

0.050 mm

<Limit>: 0.15 mm

f. If out of specification, replace the cylinder, and

replace the piston and piston rings as a set.

4-31

CYLINDER AND PISTONS

ENG

NOTE:

EB404410

CHECKING THE PISTON RINGS
1. Measure:

piston ring side clearance
Out of specification

Replace the piston

and piston rings as a set.

Before measuring the piston ring side clear-
ance, eliminate any carbon deposits from the
piston ring grooves and piston rings.

Piston ring side clearance

Top ring
0.04

0.08 mm

<Limit>: 0.1 mm
2nd ring
0.03

0.07 mm

<Limit>: 0.1 mm

2. Install:

piston ring
(into the cylinder)

Using the piston crown pash the ring into the cyl-
inder so that the ring will be at a right angle to the
cylinder bore.

a 40 mm from the top of the cylinder

3. Measure:

piston ring end gap
Out of specification

Replace the piston ring.

The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is exces-
sive, replace all three piston rings.

Piston ring end gap

Top ring

0.3

0.5 mm

<Limit>: 0.8 mm

2nd ring

0.3

0.45 mm

<Limit>: 0.8 mm

Oil ring

0.2

0.7 mm

4-32

CYLINDERS AND PISTONS

ENG

NOTE:

EAS00266

CHECKING THE PISTON PINS
The following procedure applies to all of the pis-
ton pins.
1. CHECK:

piston pin
Blue discoloration / grooves

Replace, then

inspect the lubrication system.

2. Measure:

piston pin outside diameter

Out of specification

Replace the piston pin.

Piston pin outside diameter

21.991

22.000 mm

3. Measure:

piston pin bore inside diameter

Out of specification

Replace the piston

Piston pin bore inside diameter

22.004

22.015 mm

4. Calculate:

piston-pin-to-piston clearance
Out of specification

Replace the piston pin.

Piston-pin-to-piston clearance =

Piston pin bore size

–

Piston pin outside diameter

Piston-pin-to-piston clearance

0.004

0.024 mm

EB404701

INSTALLING THE PISTONS AND CYLINDERS
The following procedure applies to all of the pis-
tons and cylinders.
1. Install:

oil ring expander

lower oil ring rail

upper oil ring rail

2nd ring

top ring

Be sure to install the piston rings so that the
manufacuturer’s marks or numbers face up.

4-33

CYLINDERS AND PISTONS

ENG

NOTE:

2. Install:

piston

piston pin

piston pin clip (New)

Apply engine oil onto the piston pin.

Make sure that the “EX” mark

on the piston

faces towards the exhaust side of the engine.

Before installing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the clip from falling into the crankcase.

3. Install:

gasket (New)

dowel pins

4. Lubricate:

piston

piston rings

cylinder
(with the recommended lubricant)

Recommended lubricant

Engine oil

5. Offset:

piston ring end gaps

a Top ring

b Lower oil ring rail

c Upper oil ring rail

d 2nd ring

6. Install:

cylinder

While compressing the piston rings with one
hand, install the cylinder with the other hand.

Pass the timing chain and timing chain guide
(exhaust side) through the timing chain cavity.

Cylinder bolt

10 Nm (1.0 m

kg)

4-34

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5
6

7
8
9

Removing the timing gears
Cylinder heads
Cylinders
Clutch assembly
Primary drive gear nut
Timing drive gear
Dowel pins
Springs
Timing chain drive gear shaft
Timing chain drive gear sprocket /
Timing chain
Primary drive gear
Straight key
Timing chain guide

1
1
6
6
1

1 / 1

1
1
1

Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
Refer to “CYLINDERS AND PISTONS”.
Refer to “CLUTCH”.

For installation, reverse the removal
procedure.

Refer to “REMOVING / INSTALLING
THE TIMING DRIVE GEARS”.

Refer to “INSTALLING THE TIMING
DRIVE GEARS”.

10 Nm (1.0 m

kg)

110 Nm (11.0 m

kg)

TIMING GEARS

ENG

TIMING GEARS

4-35

TIMING GEARS

ENG

NOTE:

REMOVING THE TIMING DRIVE GEAR
Front cylinder
1. Straighten the lock washer tab.
2. Remove:

primary drive gear nut

While holding the generator rotor with the
sheave holder, loosen the primary drive gear
nut.

3. Remove:

timing drive gear

dowel pins

springs

When removing the timing drive gear, the dowel
pins and springs are scatter and dropping down.
Do not missing them.

Rear cylinder

When removing the rear cylinder timing gear,
repeat the front cylinder timing gear removal
procedure. However, note the following points.

1. Remove:

rotor assembly

dowel pins

springs

timing drive gear
Refer to “GENERATOR AND STARTER
CLUTCH”.

EB401422

CHECKING THE TIMING CHAINS, CAMSHAFT
SPROCKETS, AND TIMING CHAIN GUIDES
The following procedure applies to all of the tim-
ing chains, camshaft sprockets, and timing
chain guides.
1. Check:

timing chain

Damage/sitffness

Replace the timing chain

and its respective camshaft sprockets as a set.

2. Check:

camshaft sprocket
Damage / wear

Replace the respective

camshaft sprockets and the respective tim-
ing chain as a set.

3. Check:

timing chain guide (exhaust side)

timing chain guide (intake side)

Damage / wear

Replace the defective

part(-s).

4-36

TIMING GEARS

ENG

NOTE:

10 Nm (1.0 m

kg)

NOTE:

EAS00292

CHECKING THE PRIMARY DRIVE
1. Check:

primary drive gear

primary driven gear
Damage / wear

Replace the primary drive

and primary driven gears as a set.
Excessive noise during operation

Re-

place the primary drive and primary driven
gears as a set.

2. Check:

primary-drive-gear-to-primary-driven-gear
free play
Free play exists

Replace the primary drive

and primary driven gears as a set.

INSTALLING THE TIMING DRIVE GEARS
1. Install:

timing chain
(onto the timing chain drive gear sprocket)

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

2. Install:

timing chain drive gear sprocket

timing chain drive gear shaft

Make sure that the “2” mark on the timing chain
drive gear sprocket is installed in the rear cylin-
der and the “3” mark on the timing chain drive
gear sprocket is installed in the front cylinder.

3. Install:

stopper plate

stopper plate bolt

Turn the timing chain drive gear shaft so that the
stopper plate fits correctly into the slot and then
fasten the stopper plate with the bolt.

4-37

NOTE:

TIMING GEARS

ENG

110 Nm (11.0 m

kg)

NOTE:

Front cylinder
1. Install:

(Front cylinder)

springs

dowel pins

timing drive gear

Insert the suitable pin

into the hole of timing

chain drive gear sprocket and match the gear
teeth.

Push the projections

on the timing drive

gear into the spaces

Align the punch mark

on the timing drive

gear, the punch mark

on the timing chain

drive gear sprocket and the key posision

shown.

2. Install:

claw washer

lock washer

New

primary drive gear nut

While holding the generator retor with the sheave
holder, tighten the primary drive gear nut.

3. Bend the lock washer tab along a flat side of

the nut.

Rear cylinder

When installing the rear cylinder timing gear, re-
peat the front cylinder timing gear installation
procedure. However, note the following points.

1. Install:

springs

dowel pins

timing drive gear

rotor assembly
Refer to “GENERATOR AND STARTER
CLUTCH”.

4-38

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5

Removing the right clutch cover

Engine oil

Muffler assembly
Exhaust pipes
Brake pedal / Footrest
Rear brake master cylinder / bracket
Oil filter cover plate
Oil filter cover
O-rings
Oil filter
Right crankcase cover

1
1
3
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 to “ENGINE OIL REPLACEMENT”
in CHAPTER 3.

Refer to “ENGINE REMOVAL”.

WARNING

New

10 Nm (1.0 m

kg)

CLUTCH

ENG

CLUTCH

RIGHT CRANKCASE COVER

4-39

Order

Job name / Part name

Q’ty

Remarks

6
7

Dowel pins
Crankcase cover gasket

2
1

For installation, reverse the removal
procedure.

New

10 Nm (1.0 m

kg)

CLUTCH

ENG

4-40

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5
6
7
8
9

12
13
14

Removing the clutch
Clutch spring bolts
Clutch spring plate
Clutch spring
Clutch spring seat
Clutch pressure plate
Bearing / shart clutch push rod
Friction plates
Clutch plates
Wire circlip
Clutch plate
Damper
Clutch damper plate
Nut / lock washer
Clutch boss

6
1
1
1
1

1 / 1

6
5
1
1
1
1

1 / 1

Remove the parts in the order listed.

Refer to “INSTALLING THE CLUTCH”.

Refer to “REMOVING / INSTALLING
THE CLUTCH.”

70 Nm (7.0 m

kg)

8 Nm (0.8 m

kg)

CLUTCH

ENG

CLUTCH ASSEMBLY

4-41

Order

Job name / Part name

Q’ty

Remarks

15
16
17

Thrust washer
Clutch housing
Long clutch push rod

1
1
1

For installation, reverse the removal
procedure.

70 Nm (7.0 m

kg)

8 Nm (0.8 m

kg)

CLUTCH

ENG

Yamaha XVS1100 (L). Service Manual - part 9