Yamaha XVS1100 (L). Service Manual

4-58

OIL PUMP

ENG

10 Nm (1.0 m

kg)

CAUTION:

NOTE:

EAS00376

ASSEMBLING THE OIL PUMP
1. Assemble:

oil pump

After tightening the bolts, make sure that the
oil pump turns smoothly.

Align the pin

with the slots

on the inner ro-

tor.

4-59

Order

Job name / Part name

Q’ty

Remarks

1
2
3

5
6

Removing the crankshaft assembly
Engine assembly
Cylinder head
Cylinder and piston
Clutch assembly
AC magneto and starter clutch

Shift shaft
Oil pump assembly
Oil level gauge
Neutral switch
Shift shaft stopper plate

Crankcase (right)

Dowel pins
Relief valve

1
1
1

3
1

Remove the parts in the order listed.
Refer to “ENGINE REMOVAL”.
Refer to “CYLINDER HEADS”.
Refer to “CYLINDERS AND PISTONS”.
Refer to “CLUTCH”.
Refer to “GENERATOR AND STARTER
CLUTCH”.
Refer to “SHIFT SHAFT”.
Refer to “OIL PUMP”.

Refer to “ASSEMBLING THE
CRANKCASE”.
Refer to “DISASSEMBLING/ASSEMBLING
THE CRANKCASE”.

For installation, reverse the removal
procedure.

38.5 Nm (3.85 m

kg)

20 Nm (2.0 m

kg)

10 Nm (1.0 m

kg)

CRANKSHAFT AND CONNECTING RODS

ENG

CRANKSHAFT AND CONNECTING RODS

CRANKCASE

Order

Job name / Part name

Q’ty

Remarks

2
3
4
5
6
7
8

Removing the crankshaft and
connecting rod
Crankshaft assembly

Oil pump drive sprocket
Bearing
Nuts (connecting rod caps)
Connecting rod bolts
Connecting rods
Connecting rod caps
Plain bearings

1
1
4
4
2
2
4

Remove the parts in the order listed.

Refer to “REMOVING / INSTALLING
THE CRANKSHAFT”.

For installation, reverse the removal
procedure.

Refer to “INSTALLING THE
CRANKSHAFT”.

48 Nm (4.8 m

kg)

Refer to “REMOVING THE CONNECTING
RODS/ INSTALLING THE
CRANKSHAFT”.

CRANKSHAFT AND CONNECTING RODS

ENG

4-60

CRANKSHAFT AND CONNECTING RODS

4-61

CRANKSHAFT AND CONNECTING RODS

ENG

NOTE:

CAUTION:

EAS00386

DISASSEMBLING THE CRANKCASE
1. Remove:

crankcase bolts

Loosen each bolt 1 / 4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.

Loosen the bolts in decreasing numerical or-
der (refer to the numbers in the illustration.)

A Right crankcase

B Left crankcase

2. Remove:

right crankcase

For this removal, slits

in the crankcase can

be use as shown.

Use a soft hammer to tap on one side of the
crankcase. Tap only on reinforced portions
of the crankcase. Do not tap on the crank-
case mating surfaces. Work slowly and
carefully. Make sure that the crankcase
halves separate evenly.

4-62

CRANKSHAFT AND CONNECTING RODS

ENG

NOTE:

EB412111

REMOVING THE CRANKSHAFT
1. Remove:

crankshaft assembly

Remove the crankshaft assembly with the
crankcase separating tool

Make sure that the crankcase separating tool
is centered over the crankshaft assembly.

Crankcase separating tool

90890-01135

EB412121

REMOVING THE CONNECTING RODS
1. Remove:

connecting rods

big end bearings

Identify the position of each big end bearing so
that it can be reinstalled in its original place.

EB413404

CHECKING THE CRANKSHAFT AND CON-
NECTING RODS
1. Measure:

crankshaft runout
Out of specification

Replace the crank-

shaft.

Crankshaft runout

Less than 0.02 mm

2. Check:

crankshaft journal surfaces

crankshaft pin surfaces

bearing surfaces
Scratches / wear

Replace the crankshaft.

3. Measure:

crankshaft-pin-to-big-end-bearing clear-
ance
Out of specification

Replace the big end

bearings.

Crankshaft-pin-to-big-end-bearing
clearance

0.044

0.073 mm

The following procedure applies to all of the
connecting rods.

4-63

CRANKSHAFT AND CONNECTING RODS

ENG

CAUTION:

NOTE:

CAUTION:

Do not interchange the big end bearings and
connecting rods. To obtain the correct
crankshaft-pin-to-big-end-bearing clearance
and prevent engine damage, the big end
bearings must be installed in their original
positions.

a. Clean the big end bearings, crankshaft pins,

and the inside of the connecting rod halves.

b. Install the big end upper bearing into the con-

necting rod and the big end lower bearing
into the connecting rod cap.

Align the projections

on the big end bearings

with the notches

in the connecting rod and

connecting rod cap.

c. Put a piece of Plastigauge



on the crank-

shaft pin.

d. Assemble the connecting rod halves.

Do not move the connecting rod or crankshaft
until the clearance measurement has been
completed.

Apply molybdenum disulfide grease onto the
bolts, threads, and nut seats.

Make sure that the “Y” mark

on the connect-

ing rod faces towards the left side of the crank-
shaft.

Make sure that the characters

on both the

connecting rod and connecting rod cap are
aligned.

e. Tighten the connecting rod nuts.

When tightening the connecting rod nuts,
be sure to use an F-type torque wrench.

Without pausing, tighten the connecting
rod nuts to the specified torque. Apply con-
tinuous torque between 4.3 and 4.8 m

kg.

Once you reach 4.3 m

kg, DO NOT STOP

TIGHTENING until the specified torque is
reached.
If the tightening is interrupted between 4.3
and 4.8 m

kg, loosen the connecting rod

nut to less than 4.3 m

kg and start again.

CRANKSHAFT AND CONNECTING RODS

ENG

4-64

NOTE:

Refer to “INSTALLING THE CONNECTING
RODS”.

Connecting rod nut

48 Nm (4.8 m

kg)

f. Remove the connecting rod and big end

bearings.
Refer to “REMOVING THE CONNECTING
RODS”.

g. Measure the compressed Plastigauge



width

on each crankshaft pin.

If the clearance is out of specification, select
replacement big end bearings.

4. Select:

big end bearings (P

)

The numbers

stamped into the crankshaft

web and the numbers

on the connecting

rods are used to determine the replacement
big end bearing sizes.

“P

” refer to the bearings shown in the

crankshaft illustration.

For example, if the connecting rod “P

” and the

crankshaft web “P

” numbers are “4” and “1” re-

spectively, then the bearing size for “P

” is:

Bearing size for “P

”:

“P

” (connecting rod) – “P

”

(crankshaft web) =
4 – 1 = 3 (brown)

Rear cylinder lower bearing / Front cylinder up-
per and lower bearing.

BEARING COLOR CODE

blue

black

brown

green

yellow

Rear cylinder upper bearing

BEARING COLOR CODE

black

brown

green

4-65

CRANKSHAFT AND CONNECTING RODS

ENG

NOTE:

48 Nm (4.8 m

kg)

NOTE:

EB412440

CHECKING THE BEARINGS AND OIL
SEALS
1. Check:

bearings
Clean and lubricate the bearings, then rotate
the inner race with your finger
Rough movement

Replace.

2. Check:

oil seals
Damage / wear

Replace.

INSTALLING THE CRANKSHAFT
3. Install:

connecting rod bearings

Align the projection

of the bearings with the

notches

in the connecting rod cap.

Install each bearing in its original place.

4. Install:

connecting rods

The stamped “Y” mark

on the connecting

rods should face towards the left side of the
crankcase.

Install each connecting rod in its original place.

5. Install:

connecting rod cap

Be sure that the characters

on the side of the

cap and connecting rod are aligned.

6. Tighten:

nuts (connecting rod cap)

Apply molybdenum disulfide grease to the rod
cap bolt threads and nut surfaces.

CRANKSHAFT AND CONNECTING RODS

ENG

4-66

CAUTION:

NOTE:

When tightening the nuts be sure to use an
F-type torque wrench.

Without pausing tighten to full torque
specification. Apply continuous torque be-
tween 4.3 and 4.8 m

kg. Once you reach 4.3

kg DO NOT STOP TIGHTENING until fi-

nal torque is reached. If the tightening is in-
terrupted between 4.3 and 4.8 m

kg, loosen

the nut to less than 4.3 m

kg and start

again.

7. Install:

crankshaft installing tool

Attach the spacer to the bearing inner race.

Crankshaft installer pot

90890-01274

Crankshaft installer bolt

90890-01275

Adapter

90890-04130

Spacer

90890-04060

8. Install:

crankshaft

Align the left connecting rod with the rear cylin-
der sleeve hole.

ASSEMBLING THE CRANKCASE
1. Apply:

engine oil
(onto the main journal bearings)

sealant
(onto the crankcase mating surfaces)

Yamaha Bond No. 1215:

90890-85505

4-67

CRANKSHAFT AND CONNECTING RODS

ENG

NOTE:

38.5Nm (3.85 m

kg)

10 Nm (1.0 m

kg)

NOTE:

2. Tighten:

crankcase bolts
(follow the proper tightening sequence)

The numbers embossed on the crankcase indi-
cate the crankcase tightening sequence.

(M10)

(M6)

Lubricate the bolt threads with engine oil.

Tighten the bolts in increasing numerical order.

30 mm

(Chromium

plated bolt)

55 mm

80 mm

M10

60 mm

M10

70 mm

M10

100 mm

:with engine ground lead

3. Install:

shift shaft stopper plate

Install the shift shaft stopper plate as shown.

4-68

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5
6
7
8

Transmission removal
Crankcase separation
Guide bar
Shift fork 1 “R”
Shift fork 2 “C”
Shift fork 3 “L”
Shift drum
Main axle assembly
Drive axle assembly
Middle driven gear

1
1
1
1
1
1
1
1

Remove the parts in the order listed.
Refer to “CRANKSHAFT”.

For installation, reverse the removal
procedure.

Refer to “INSTALLING THE
TRANSMISSION”.

TRANSMISSION

ENG

TRANSMISSION

4-69

TRANSMISSION

ENG

WARNING

EAS00421

CHECKING THE SHIFT FORKS
The following procedure applies to all of the shift
forks and related components.
1. Check:

shift fork cam follower

shift fork pawl

Bends / damage / scoring / wear

Replace

the shift fork.

2. Check:

shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends

Replace.

Do not attempt to straighten a bent shift fork
guide bar.

3. Check:

shift fork movement
(on the shift fork guide bar)
Rough movement

Replace the shift forks

and shift fork guide bar as a set.

EAS00422

CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:

shift drum grooves
Damage / scratches / wear

Replace the

shift drum.

shift drum segment

Damage / wear

Replace.

shift drum bearing

Damage / pitting

Replace.

4-70

TRANSMISSION

ENG

EAS00424

CHECKING THE TRANSMISSION
1. Measure:

main axle runout
(with a centering device and dial gauge)
Out of specification

Replace the main

axle.

Main axle runout limit

0.08 mm

2. Measure:

drive axle runout
(with a centering device and dial gauge)
Out of specification

Replace the drive

axle.

Drive axle runout limit

0.08 mm

3. Check:

transmission gears
Blue discoloration / pitting / wear

Replace

the defective gear(-s).

transmission gear dogs
Cracks / damage / rounded edges

Replace

the defective gear(-s).

4. Check:

transmission gear movement
Rough movement

Replace the defective

part(-s).

5. Check:

washers
Damage / bends / looseness

Replace.

6. Check:

bearings
Un smooth

Replace.

4-71

TRANSMISSION

ENG

NOTE:

WARNING

NOTE:

EAS00430

INSTALLING THE TRANSMISSION
1. Install:

shift drum assembly

Turn the shift drum assembly to the neutral posi-
tion.

2. Install:

main axle assembly

drive axle assembly

shift fork “L”

shift fork “C”

shift fork “R”

shift fork guide bars

The embossed marks on the shift forks should
face towards the right side of the engine and
be in the following sequence:
“R”, “C”, “L”.

When installing the middle drive gear

, align

the slit

on the guide bar with the middle drive

gear.

Always use new circlips.

3. Check:

transmission
Rough movement

Repair.

Oil each gear, shaft, and bearing thoroughly.

4-72

Order

Job name / Part name

Q’ty

Remarks

2
3
4
5
6
7
8
9

Removing the middle drive pinion
gear
Sepalate the crankcase

Bearing retainer

Spring retainers
Spring seat
Damper spring
Damper cams
Nut
Bearing
Shim(s)
Middle drive pinion shaft

2
1
1
2
1
1
1
1

Remove the parts in the order listed.

Refer to “CRANKSHAFT AND
CONNECTING ROD.”
Refer to “REMOVING THE MIDDLE
DRIVE SHAFT ASSEMBLY/ INSTALLING
THE MIDDLE GEAR ASSEMBLY AND
ADJUSTING THE BACKLASH”.

For installation, reverse the removal
procedure.

Refer to “DISASSEMBLING /
ASSEMBLING THE MIDDLE DRIVE
SHAFT ASSEMBLY”.

110 Nm (11.0 m

kg)

110 Nm (11.0 m

kg)

MIDDLE GEAR

ENG

MIDDLE GEAR

MIDDLE DRIVE PINION GEAR

4-73

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5

7
8
9

Removing the middle driven
pinion gear.
Bolts
Circlips
Bearings
Driven yoke
Nut

Drive yoke

Bearing housing / O-ring
Washers
Collar

3
2
2
1
1

1 / 1

3
1

Remove the parts in the order listed.

Refer to “REMOVING THE MIDDLE
DRIVEN SHAFT ASSEMBLY/ INSTALING
THE MIDDLE GEAR ASSEMBLY AND
ADJUSTING THE BACKLASH”.
Refer to “INSTALLING THE MIDDLE
GEAR ASSEMBLY AND ADJUSTING
THE BACKLASH”.

Refer to “REMOVING THE MIDDLE
DRIVEN SHAFT ASSEMBLY/
INSTALLING THE UNIVERSAL JOINT”.

MIDDLE GEAR

ENG

MIDDLE DRIVEN PINION GEAR

Yamaha XVS1100 (L). Service Manual - part 11