Yamaha XVS1100 (L). Service Manual

4-42

CLUTCH

ENG

NOTE:

EAS00278

REMOVING THE CLUTCH
1. Straighten the lock washer tab.
2. Loosen:

clutch boss nut

While holding the clutch boss

with the clutch

holding tool

, loosen the clutch boss nut.

Clutch holding tool

90890-04086

3. Remove:

clutch boss nut

lock washer

clutch boss

There is a built-in damper between the clutch
boss

and the clutch plate

. It is not neces-

sary to remove the wire circlip

and disas-

semble the built-in damper unless there is seri-
ous clutch chattering.

EAS00281

CHECKING THE FRICTION PLATES
The following procedure applies to all of the fric-
tion plates.
1. Check:

friction plate
Damage / wear

Replace the friction plates

as a set.

2. Measure:

friction plate thickness
Out of specification

Replace the friction

plates as a set.

Measure the friction plate at four places.

Friction plate thickness

2.9

3.1 mm

<Limit>: 2.8 mm

4-43

CLUTCH

ENG

NOTE:

EAS00286

CHECKING THE PRESSURE PLATE
1. Check:

pressure plate
Cracks / damage

Replace.

bearing
Damage / wear

Replace.

EAS00285

CHECKING THE CLUTCH BOSS
1. Check:

clutch boss splines
Damage / pitting / wear

Replace the clutch

boss.

Pitting on the clutch boss splines will cause er-
ratic clutch operation.

EAS00288

CHECKING THE CLUTCH PUSH RODS
1. Check:

short clutch push rod

long clutch push rod

Cracks / damage / wear

Replace the de-

fective part(-s).

2. Measure:

long clutch push rod bending limit
Out of specification

Replace the long

clutch push rod.

Long clutch push rod bending
limit

0.5 mm

4-44

CLUTCH

ENG

NOTE:

EAS00281

CHECKING THE CLUTCH PLATES
The following procedure applies to all of the
clutch plates.
1. Check:

clutch plate
Damage

Replace the clutch plates as a

set.

2. Measure:

clutch plate warpage
(with a surface plate and thickness gauge

)

Out of specification

Replace the clutch

plates as a set.

Clutch plate warpage limit

Less than 0.1 mm

EAS00283

CHECKING THE CLUTCH SPRING AND
CLUTCH SPRING SEAT PLATE
1. Check:

clutch spring plate
Damage

Replace.

2. Check:

clutch spring plate seat
Damage

Replace.

3. Measure:

clutch spring free height
Out of specificatrion

Replace the clutch

spring

Clutch spring free height

7.2 mm
<Limit>: 6.5 mm

EAS00284

CHECKING THE CLUTCH HOUSING
1. Check:

clutch housing dogs
Damage / pitting / wear

Deburr the clutch

housing dogs or replace the clutch housing.

Pitting on the clutch housing dogs will cause er-
ratic clutch operation.

4-45

CLUTCH

ENG

NOTE:

70 Nm (7.0 m

kg)

NOTE:

EAS00295

INSTALLING THE CLUTCH
1. Install:

clutch housing

If the wire circlip

has been removed, care-

fully install a new one as shown.

2. Tighten:

lock washer

New

clutch boss nut

While holding the clutch boss with the clutch
holding tool

, tighten the clutch boss nut.

Clutch holding tool

90890-04086

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

the nut.

4. Lubricate:

long clutch push rod

short clutch push rod
(with the recommended lubricant)

Recommended lubricant

Lithium soap base grease

5. Lubricate:

friction plates

clutch plates
(with the recommended lubricant)

Recommended lubricant

Engine oil

6. Install:

friction plates

clutch plates

long clutch push rod

short clutch push rod

bearing

washer

CLUTCH

ENG

4-46

NOTE:

Make sure that the semicircular slot

in the

friction plate is aligned with the mark

on the

clutch housing.

7. Install:

clutch pressure plate

clutch spring plate seat

clutch spring

clutch spring plate

clutch spring bolts

Tighten the clutch spring bolts in stages and in a
crisscross pattern.

Clutch spring bolt

8 Nm (0.8 m

kg)

4-47

10 Nm (1.0 m

kg)

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5

Removing the startor coil
Engine oil

Left side cover
AC magneto lead / pickup lead /
sidestand switch lead
Footrest / shift pedal
Sidestand
Clutch adjusting cover / clutch cable
Left crankcase cover
Dowel pins
Gasket
Stator coil
Pickup coil

1
2
1
1
1

Remove the parts in the order listed
Refer to “ENGINE OIL REPLACEMENT”
in CHAPTER 3.

For installation, reverse the removal
procedure.

Refer to “ENGINE REMOVAL”.

10 Nm (1.0 m

kg)

7 Nm (0.7 m

kg)

GENERATOR AND STARTER CLUTCH

ENG

GENERATOR AND STARTER CLUTCH

STATOR COIL AND PICKUP COIL

4-48

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5
6
7
8
9

Removing the generator and starter
clutch.
Rotor
Dowel pins
Springs
Woodruff key
Shaft
Starter idler gear
Circlip
Starter clutch drive gear
Starter clutch assembly

1
6
6
1
1
1
1
1
1

Remove the parts in the order listed

For installation, reverse the removal
procedure.

Refer to “REMOVING / INSTALLING
THE GENERATOR.”

Refer to “INSTALLING THE
GENERATOR.”

175 Nm (17.5 m

kg)

12 Nm (1.2 m

kg)

GENERATOR AND STARTER CLUTCH

ENG

GENERATOR AND STARTER CLUTCH

4-49

GENERATOR AND STARTER CLUTCH

ENG

NOTE:

EAS00347

REMOVING THE GENERATOR
1. Remove:

camshaft sprocket cover

tappet covers
Refer to “REAR CYLINDER HEAD.”

2. Align:

“T” mark

(with the stationary pointer

)

a. Temporarily install the AC magneto 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 the “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. Remove:

generator rotor nut

washer

While holding the generator rotor

with the

sheave holder

, loosen the generator rotor

nut.

Do not allow the sheave holder to touch the
projection on the generator rotor.

Sheave holder

90890-01701

4. Remove:

generator rotor

(with the flywheel puller set

and adapter

)

woodruff key

4-50

GENERATOR AND STARTER CLUTCH

ENG

NOTE:

Remove the rotor by pushing back the rotor,
the flywheel puller

and the adapter

Install the flywheel puller bolts and tighten the
center bolt, making sure that the tool body
stays parallel to the rotor. If necessary, one
holding bolt may be backed out slightly for re-
alignment of the tool.

When rotor is removed, the dowel pins and
springs are scatter and dropping down. Do not
missing them.

Sheave holder:

90890-01701

Flywheel puller:

90890-01362

Adapter:

90890-04131

EAS00349

CHECKING THE STARTER CLUTCH
1. Check:

starter clutch idle gear

starter clutch drive gear

Burrs / chips / roughness / wear

Replace

the defective part(-s).

2. Check:

starter clutch operation

a. When turning the starter clutch drive gear

counter clockwise

, the starter clutch and

the starter clutch drive gear should engage.
If the starter clutch drive gear and starter
clutch do not engage, the starter clutch is
faulty and must be replaced.

b. When turning the starter clutch drive gear

clockwise

, it should turn freely.

If the starter clutch drive gear does not turn
freely, the starter clutch is faulty and must be
replaced.

4-51

GENERATOR AND STARTER CLUTCH

ENG

NOTE:

175 Nm (17.5 m

kg)

NOTE:

INSTALLING THE GENERATOR
1. Install:

starter clutch assembly

Align the hole

on the starter clutch housing

with the hole

on the rotor.

Starter clutch bolt:

12 Nm (1.2 m

kg)

LOCTITE



2. Install:

timing drive gear

springs

dowel pins

Align the punch mark

on the timing drive

gear with the key slide

Push the projections

on the timing drive

gear into the space

3. Install:

rotor assembly

Insert the suitable pin

into the hole of timing

chain drive gear sprocket and match the gear
teeth.

Align the punch mark

on the timing drive

gear

the punch mark

on the timing chain

drive gear sprocket and the key position

shown.

When installing the rotor, make sure the wood-
ruff key is properly seated in the key way of the
crankshaft.

4. Tighten:

nut (rotor)

Tighten the rotor nut

while holding the mag-

neto rotor with a sheave holder

Sheave holder:

90890-01701

4-52

GENERATOR AND STARTER CLUTCH

ENG

4. Check:

TDC on the compression stroke
If the marks do not align

Adjust.

a. Align the “T” mark

with the stationary

pointer

on the left crankcase cover.

b. When the “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.

4-53

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5
6

Removing the shift shaft and stopper
lever.
Engine oil

Left crankcase cover
Rotor assembly
Shift shaft
Circlip
Torsion spring (stopper lever)
Stopper lever
Circlip
Torsion spring (shift shaft)

1
1
1
1
1
1

Remove the parts in the order listed.

Refer to “ENGINE OIL REPLACEMENT”
in CHAPTER 3.

For installation, reverse the removal
procedure.

Refer to “INSTALLING THE SHIFT
SHAFT”.

Refer to “GENERATOR AND STARTER
CLUTCH”.

SHIFT SHAFT

ENG

SHIFT SHAFT

4-54

SHIFT SHAFT

ENG

NOTE:

EAS00328

CHECKING THE SHIFT SHAFT
1. Check:

shift shaft

shift lever

Bends / damage / wear

Replace.

shift lever spring

Damage / wear

Replace.

EB408410

CHECKING THE STOPPER LEVER
1. Check:

stopper lever
Bends / damage

Replace.

Roller turns roughly

Replace the stopper

lever.

EAS00331

INSTALLING THE SHIFT SHAFT
1. Install:

stopper lever

stopper lever spring

shift shaft lever

Hook the ends of the stopper lever spring onto
the stopper lever and the crankcase boss.

Mesh the stopper lever with the shift drum seg-
ment assembly.

4-55

Order

Job name / Part name

Q’ty

Remarks

1
2

3
4
5

Removing the oil pump
Rotor assembly

Crankcase cover (right)
Driven gear cover
Driven gear (oil pump) / Oil pump drive
chain
Oil pump assembly
O-rings / dowel pin
Oil delivery pipe

1 / 1

2 / 1

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

For installation, reverse the removal
procedure.

12 Nm (1.2 m

kg)

7 Nm (0.7 m

kg)

10 Nm (1.0 m

kg)

OIL PUMP

ENG

OIL PUMP

4-56

OIL PUMP

ENG

Order

Job name / Part name

Q’ty

Remarks

Disassembling the oil pump
Oil pump cover
Oil pump body
Oil pump rotor (inner)
Oil pump rotor (outer)
Pin
Oil pump body
Oil pump rotor (inner)
Oil pump rotor (outer)
Pin
Dowel pins
Oil pump shaft
Washer
Circlip
Oil strainer

1
1
1
1
1
1
1
1
1
2
1
1
1
1

Disassembly the parts in the order listed.

For assembly, reverse the disassembly
procedure.

Refer to “ASSEMBLING THE OIL
PUMP”.

1
2
3
4
5
6
7
8
9

Refer to “ASSEMBLING THE OIL
PUMP”.

10 Nm (1.0 m

kg)

4-57

OIL PUMP

ENG

EAS00364

CHECKING THE OIL PUMP
1. Check:

oil pump driven gear

oil pump body

oil pump driven gear cover
Cracks / damage / wear

Replace the de-

fective part(-s).

2. Measure:

inner-rotor-to-outer-rotor-tip clearance

outer-rotor-to-oil-pump-body-side clearance

oil-pump-body-to-inner-rotor-and-outer-ro-
tor clearance

Out of specification

Replace the oil pump.

1 Inner rotor

2 Outer rotor

3 Oil pump body

Inner-rotor-to-outer-rotor-tip
clearance

0.03

0.09 mm

<Limit>: 0.15 mm

Outer-rotor-to-oil-pump-body-side
clearance

0.03

0.08 mm

<Limit>: 0.15 mm

Oil-pump-body-to-inner-rotor and
outer-rotor clealance

0.03

0.08 mm

<Limit>: 0.15 mm

EAS00367

CHECKING THE OIL DELIVERY PIPES
The following procedure applies to all of the oil
delivery pipes.
1. Check:

oil delivery pipes

Damage

Replace.

Obstruction

Wash and blow out with com-

pressed air.

EAS00368

CHECKING THE OIL STRAINER
1. Check:

oil strainer

Damage

Replace.

Contaminants

Clean with engine oil.

Yamaha XVS1100 (L). Service Manual - part 10