Yamaha XVS1100 (L). Service Manual

Order

Job name / Part name

Q’ty

Remarks

12
13
14

Collapsible collar
Middle driven shaft

Oil seal
Bearing
Bearing

1
1

For installation, reverse the removal
procedure.

Refer to “ASSEMBLING THE MIDDLE
DRIVEN SHAFT ASSEMBLY”.

Refer to “INSTALLING THE MIDDLE
GEAR ASSEMBLY AND ADJUSTING
THE BACKLASH”.

MIDDLE GEAR

ENG

4-74

4-75

MIDDLE GEAR

ENG

NOTE:

REMOVING THE MIDDLE DRIVE SHAFT AS-
SEMBLY
1. Remove:

bearing retainer

middle drive shaft assembly

a. Straighten the thread on the bearing retainer.
b. Attach the bearing retainer wrench

Bearing retainer wrench:

90890-04137

c. Remove the bearing retainer and middle

drive shaft assembly.

DISASSEMBLING THE MIDDLE DRIVE
SHAFT ASSEMBLY
1. Remove:

spring retainers

While compressing the spring with a damper
spring compressor

, remove the spring re-

tainers.

Damper spring compressor

90890-04090

2. Straighten the thread on the middle drive

shaft nut.

3. Remove:

middle drive shaft nut

bearing

middle drive shaft

a. Attach the middle drive shaft holder

onto

the middle drive shaft as shown.

Middle drive shaft holder

90890-04055

b. Secure the middle drive shaft holder in a

vice.

c. Loosen the middle drive shaft nut with the

middle drive shaft nut wrench

Middle drive shaft nut wrench

90890-04138

d. Remove the middle drive shaft nut and bear-

ing.

4-76

MIDDLE GEAR

ENG

NOTE:

REMOVING THE MIDDLE DRIVEN SHAFT
ASSEMBLY
1. Remove:

universal joint

a. Remove the circlips

b. Place the universal joint in a press.
c. With a pipe of the proper diameter positioned

beneath the universal joint driven yoke as
shown, press the bearing into the pipe.

It may be necessary to lightly tap the universal
joint driven yoke.

d. Repeat the above steps to remove the oppo-

site side’s bearing.

e. Separate the universal joint yokes.

2. Loosen:

middle driven shaft nut

While holding the universal joint driven yoke

with the universal joint holder

, loosen the

middle driven shaft nut.

Universal joint holder

90890-04062

EAS00438

CHECKING THE MIDDLE DRIVE SHAFT AS-
SEMBLY
1. Check:

damper cam surface
Scratches/wear

Replace the damper cam.

2. Check:

spring
Cracks / damage

Replace.

EAS00439

CHECKING THE MIDDLE DRIVEN SHAFT
ASSEMBLY
1. Check:

middle drive gear

middle driven gear

Galling / pitting / wear

Replace the middle

driven shaft assembly.

2. Check:

bearings
Damage / pitting

Replace the middle drive

shaft bearing housing assembly.

4-77

MIDDLE GEAR

ENG

110 Nm (11.0 m

kg)

NOTE:

3. Check:

O-ring

oil seal
Damage

Replace the defective part(-s).

4. Check:

universal joint movement
Rough movement

Replace the universal

joint.

EAS00441

ASSEMBLING THE MIDDLE DRIVE SHAFT
ASSEMBLY
1. Tighten:

middle drive shaft nut

Set the torque wrench at a right angle to the
middle drive shaft nut wrench

Lock the threads on the middle drive shaft nut
by staking them with a center punch.

Middle drive shaft nut wrench

90890-04138

Middle drive shaft holder

90890-04055

2. Install:

spring retainers

While compress the spring with the damper
spring compressor

, and then install the

spring retainers.

Damper spring compressor

90890-04090

4-78

MIDDLE GEAR

ENG

NOTE:

WARNING

NOTE:

25 Nm (2.5 m

kg)

ASSEMBLING THE MIDDLE DRIVEN SHAFT
ASSEMBLY

The following points are critical when assem-
bling the middle gears:

The collapsible collar must be replaced when-
ever the middle driven shaft assembly is re-
moved from the middle driven shaft bearing
housing.

When performing this procedure for the first
time, be sure to have at least one extra collaps-
ible collar on hand.

1. Install:

bearing outer race
(into the middle driven shaft bearing hous-
ing)

Do not press the bearing outer race. During
installation, always press the bearing inner
race carefully.

2. Install:

middle driven shaft nut

Finger tighten the middle driven shaft mut.

INSTALLING THE MIDDLE GEAR AS-
SEMBLY AND ADJUSTING THE BACKLASH

When installing the middle gear assembly, be
sure to replace the following parts:
- collapsible collar

1. Install:

middle driven shaft assembly

4-79

MIDDLE GEAR

ENG

2. Install:

shim

middle drive shaft assembly

3. Install:

bearing retainer

Install steps:

Attach the bearing retainer wrench

Bearing retainer wrench:

90890-04137

Tighten the bearing retainer.

Bearing retainer:

110 Nm (11.0 m

kg)

Lock the threads on the bearing retainer by
staking them with a center punch.

4. Adjust:

middle gear backlash

Middle gear backlash:

0.1

0.2 mm

a. Install the universal joint holder

and

middle gear backlash band

as shown.

Universal joint holder

90890-04062

Middle gear backlash band

90890-01231

b. Make sure that the dial gauge plunger on the

middle gear backlash band as shown.

Dial-gauge-plunger contact point: 68.2 mm

c. Remove the middle driven pinion gear nut

and apply the LOCKTITE



on it.

d. Reinstall the middle driven pinion gear nut.
e. While measure the middle gear backlash,

tighten the middle driven pinion gear nut until
specific backlash.

4-80

MIDDLE GEAR

ENG

CAUTION:

NOTE:

Do not over tighten the middle driven pinion
gear nut. If over tighten the middle driven
pinion gear nut, replace the collapsible col-
lar and adjust the backlash.

f. Stake the middle driven pinion gear shaft

thread.

INSTALLING THE UNIVERSAL JOINT
4. Install:

universal joint driven yoke / cross joint

(into the universal joint drive yoke)

Do not hammer the universal joint drive
yoke or the collapsible collar may be dis-
torted. This will result in a change in the
standard spinning torque, requiring re-
placement of the collapsible collar and reas-
sembly of the middle driven shaft assembly.

2. Install:

bearings

(onto the universal joint driven yoke / cross
joint)

The needles can easily fall out of their races,
so check each bearing carefully. Slide the
universal joint driven yoke assembly back
and forth on the bearings. If a needle is out of
place, the yoke will not go all the way onto
the bearings.

3. Press each bearing into the universal joint

driven yoke assembly with a socket of the
proper size.

The bearings must be inserted far enough into
the universal joint driven yoke assembly so that
circlips

can be installed.

4-81

MIDDLE GEAR

ENG

NOTE:

EAS00452

ALIGNING THE MIDDLE GEAR

Aligning the middle gear is necessary when any
of the following parts are replaced:

Crankcase

Middle drive shaft

1. Select:

middle drive gear shim(-s)

Select the middle drive gear shim(-s)

by cal-

culating the middle drive gear shim thickness
and then measuring the middle gear backlash.

a. Position the middle drive gear with the ap-

propriate shim(-s)

that has had its respec-

tive thickness calculated from information
marked on the crankcase and the end of the
middle drive gear.

b. To find middle drive gear shim thickness

“A”, use the following formula.

Middle drive gear shim thickness

“A” =

–

=“43.00”

=a numeral on the upper crankcase near

the main bearing selection numbers and
which is added to the nominal size “42”
Example:

is 43.00

If the upper crankcase is marked “46”

is 42.46 (i.e., 42.00 + 0.46 =42.46)

“A” = 43.00 – 42.46 = 0.54
Round off to the hundredths digit and select
the appropriate shim(-s).

In the above example, the calculated number
is 0.54. The chart instructs you to round off
the 4 to 5. Thus, the shim thickness is 0.55
mm.

4-82

MIDDLE GEAR

ENG

Middle drive pinion gear shim:

Thickness (mm)

0.10, 0.15, 0.20

Hundredths

Rounded value

0, 1, 2

3, 4, 5, 6,

7, 8, 9

Shims are supplied in the following thickness.

CARB

CHAPTER 5

CARBURETION

CARBURETOR

5-1

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

CHECKING THE CARBURETORS

5-4

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

ASSEMBLING THE CARBURETORS

5-6

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

INSTALLING THE CARBURETORS

5-6

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

MEASURING AND ADJUSTING THE FUEL LEVEL

5-7

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

CHECKING AND ADJUSTING THE THROTTLE POSITION

SENSOR

5-8

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

AIR INDUCTION SYSTEM (AIS)

5-10

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

AIR INDUCTION

5-10

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

AIR CUT-OFF VALVE

5-10

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

AIR INDUCTION SYSTEM INSPECTION

5-11

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

5-1

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5
6
7
8
9

Removing the carburetors
Fuel tank

Air filter case assembly
Air ducts
Cylinder head breather hose
Air chamber
Cover
Throttle position sensor lead
Carburetor heater lead
Fuel hoses
Carburetor assembly
Starter cable
Throttle cables

1
3
1
1
1
1
1
2
1
1
2

Remove the parts in the order listed.
Refer to “FUEL TANK AND SEATS” in
CHAPTER 3.

Disconnect

Disconnect
Disconnect
Disconnect

After removing the carburetor assembly,
remove the starter cable and throttle
cables.

For installation, reverse the removal
procedure.

NOTE:

10 Nm (1.0 m

kg)

CARBURETOR

CARB

CARBURETION

CARBURETOR

5-2

Order

Job name / Part name

Q’ty

Remarks

Disassembling the carburetor.
Carburetor heater leads
Carburetor heaters
Float chamber / gasket
Float
Needle valve set
Main jet
Jet holder
Pilot jet
Starter jet
Jet needle set
Starter plunger set

2
2
1
1
1
1
1
1
1
1
1

Disassemble the parts in the order listed.

12V 30W

Refer to “CARBURETOR ASSEMBLY”.

1
2
3
4
5
6
7
8
9

CARBURETOR

CARB

5-3

Order

Job name / Part name

Q’ty

Remarks

Diaphragm set

Throttle position sensor

Pilot screw
Main air jet
Pilot air jet 1
Pilot air jet 2
Throttle stop screw set

1
1
1
1
1

Refer to “ASSEMBLING THE CARBURE
TORS”.
Refer to “CHECKING AND ADJUSTING
THE THROTTLE POSITION
SENSOR (TPS)”.

For assembly, reverse the disassembly
procedure.

CARBURETOR

CARB

5-4

CARBURETORS

CARB

EB600031

CHECKING THE CARBURETORS
The following procedure applies to all of the car-
buretors.
1. Check:

carburetor body

float chamber

jet housing
Cracks / damage

Replace.

2. Check:

fuel passages
Obstruction

Clean.

a. Wash the carburetor in a petroleumbased

solvent. Do not use any caustic-carburetor-
cleaning solution.

b. Blow out all of the passages and jets with

compressed air.

3. Check:

float chamber body
Dirt

Clean.

4. Check:

float chamber rubber gasket
Cracks / damage / wear

Replace.

5. Check:

float
Damage

Replace.

6. Check:

needle valve

needle valve seat

O-ring

Damage / obstruction / wear

Replace the

needle valve, needle valve seat and O-ring
as a set.

7. Check:

piston valve

Damage / scratches / wear

Replace.

rubber diaphragm

Cracks / tears

Replace.

5-5

CARBURETOR

CARB

8. Check:

vacuum chamber cover

piston valve spring

plastic cap

O-ring

spring

Cracks / damage

Replace.

9. Check:

jet needle

needle jet

main jet

pilot screw

pilot jet

main air jet

starter jet

Bends / damage / wear

Replace.

Obstruction

Clean.

Blow out the jets with compressed air.

10. Check:

piston valve movement
Insert the piston valve into the carburetor
body and move it up and down.
Tightness

Replace the piston valve.

11. Check.

fuel feed pipes

hose joint
Cracks / damage

Replace.

Obstruction

Clean.

Blow out the pipes with compressed air.

12. Check:

fuel feed hoses

fuel hoses
Cracks / damage / wear

Replace.

Obstruction

Clean.

Blow out the hoses with compressed air.

Yamaha XVS1100 (L). Service Manual - part 12