Yamaha XVS1100 (L). Service Manual - part 13

5-6

CARBURETOR

CARB

CAUTION:

NOTE:

NOTE:

EB600042

ASSEMBLING THE CARBURETORS
The following procedure applies to both of the
carburetors.

Before assembling the carburetors, wash
all of the parts in a petroleum-based sol-
vent.

Always use a new gasket.

1. Install:

coasting enricher diaphragm

coasting enricher spring

coasting enricher cover

Align the holes 

a

 on the coasting enricher dia-

phragm with the projections 

b

 in the carbure-

tor body.

When installing the coasting enricher, position
the throttle connecting arm 

1

 as shown.

2. Install:

connecting bolts

After installing the connecting bolts, check that
the throttle cable lever and starter plunger link
operate smoothly.

EB600051

INSTALLING THE CARBURETORS
1. Adjust:

carburetor synchronization
Refer to “SYNCHRONIZING THE CARBU-
RETORS” in chapter 3.

2. Adjust:

engine idling speed

Engine idling speed

950 

 1,050 r / min

Refer to “ADJUSTING THE ENGINE IDLING
SPEED” in chapter 3.

3. Adjust:

throttle cable free play

Throttle cable free play
(at the flange of the throttle grip)

4 

 6 mm

Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.

5-7

CARBURETOR

CARB

NOTE:

EB600063

MEASURING AND ADJUSTING THE FUEL
LEVEL
1. Measure:

fuel level 

a

Out of specification 

 Adjust.

Fuel level (above the line on
the float chamber)

4 

 5 mm

a. Stand the motorcycle on a level surface.
b. Place the motorcycle on a suitable stand to

ensure that the motorcycle is standing
straight up.

c. Install the fuel level gauge 

1

 to the fuel drain

pipe 

2

.

Fuel level gauge

90890-01312

d. Loosen the fuel drain screw 

3

.

e. Hold the fuel level gauge vertically next to the

upper face of the float chamber 

4

.

f. Measure the fuel level 

a

.

Fuel level readings should be equal on both
sides of the carburetor assembly.

2. Adjust:

fuel level

a. Remove the carburetor assembly.
b. Check the needle valve seat and needle

valve.

c. If either is worn, replace them as a set.
d. If both are fine, adjust the float level by slight-

ly bending the float tang 

1

.

e. Install the carburetor assembly.
f. Measure the fuel level again.
g. Repeat steps (a) to (f) until the fuel level is

within specification.

5-8

CARBURETOR

CARB

NOTE:

EB600071

CHECKING AND ADJUSTING THE
THROTTLE POSITION SENSOR

S

Before adjusting the throttle position sensor,
the engine idling speed should be properly ad-
justed.

1. Inspect:

S

throttle position sensor

a. Disconnect the throttle position sensor cou-

pler.

b. Connect the pocket tester (

Ω

 

 

 1k) to the

throttle position sensor.

Tester positive lead 

 blue 

1

Tester negative lead 

 black 

2

c. Check the throttle position sensor resistance

“R1”.
Out of specification 

 Replace the throttle

position sensor.

Throttle position sensor
resistance “R1”

4 

X

 6 k

Ω

 at 20

_

C (68

_

F)

(blue – black)

d. Connect the pocket tester (

Ω

 

 

 1k) to the

throttle position sensor.

Tester positive lead 

 yellow 

3

Tester negative lead 

 black 

2

e. While slowly opening the throttle, check that

the throttle position sensor resistance “R2” is
within the specified range.
Out of specification 

 Replace the throttle

position sensor.

Throttle position sensor
resistance “R2”

0.56 

X

 0.84 k

Ω

 to 3.01 

X

4.51 k

Ω 

at 20

_

C (68

_

F)

(yellow – black)

2. Adjust:

S

throttle position sensor angle

a. Loosen the throttle position sensor screws

1

.

b. Turn the throttle position sensor in direction

a

 or 

b

 until the specified closed-throttle re-

sistance is indicated on the pocket tester.

5-9

CARBURETOR

CARB

NOTE:

Closed-throttle resistance 
0.56 

 0.84 k

Ω

 at 20

°

C

(yellow – black)

c. Tighten the throttle position sensor screws.

Remove the pocket tester leads and connect
the throttle position sensor coupler.

5-10

VEIW 1

VEIW 2

AIR INDUCTION SYSTEM (AIS)

CARB

EB601000

AIR INDUCTION SYSTEM (AIS)

AIR INDUTION
This system burns the unburned exhaust gases
by injecting fresh air (secondary air) at the ex-
haust port. This is to reduce the output of the hy-
drocarbons.
When there is negative pressure around the ex-
haust port, the reed valve opens and the sec-
ondary air flows into the exhaust port.
The required temperature for burning the un-
burned exhaust gases is approximately 600

_

 to

700

_

C.

AIR CUT-OFF VALVE
The air cut-off valve is operated by intake gas
pressure through the diaphragm. Normally, this
valve is opened in order to allow fresh air to flow
into the exhaust port.
When the throttle is rapidly closed, negative
pressure is generated and the valve closes in
order to prevent after-burning.
VIEW 1. (NO FLOW)

When decelerating (the throttle closes), the 
valve will close.

VIEW 2. (FLOW)

During normal operation the valve is open.

A

From the air filter

B

To the cylinder heads

C

To the carburetor joint

1

Reed valve

5-11

Reed valve
Air filter
Orifice
Carburetor joint (near cylinder)
To the front cylinder head
To the rear cylinder head
To the orifice
To the carburetor joint (rear cylinder)
To the AIS valve

1
2
3

A
B

4

C
D
E

AIR INDUCTION SYSTEM (AIS)

CARB

NOTE:

AIR INDUCTION SYSTEM INSPECTION
1. Inspect:

hose connections
Poor connections 

 Properly connect.

hoses

reed valves

air cut-off valve

air filter
Cracks / damage 

 Replace.

Clogged 

 Clean.

The orifice 

3

 should be installed with the arrow

mark facing the AIS valve side.

CARB

 

CHAS

 

6

CHAS

CHAPTER 6

CHASSIS

FRONT WHEEL AND BRAKE DISCS

6-1

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

REMOVING THE FRONT WHEEL

6-3

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

CHECKING THE FRONT WHEEL

6-3

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

CHECKING THE BRAKE DISCS

6-5

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

INSTALLING THE FRONT WHEEL

6-7

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

ADJUSTING THE FRONT WHEEL STATIC BALANCE

6-8

. . . . . . . . . . 

REAR WHEEL AND BRAKE DISC

6-10

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

MUFFLER AND BRAKE CALIPER

6-10

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

REAR WHEEL

6-11

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

REMOVING THE REAR WHEEL

6-13

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

CHECKING THE REAR WHEEL

6-13

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

CHECKING THE REAR WHEEL DRIVE HUB

6-14

. . . . . . . . . . . . . . . . . . 

INSTALLING THE REAR WHEEL

6-14

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

ADJUSTING THE REAR WHEEL STATIC BALANCE

6-15

. . . . . . . . . . . . 

FRONT AND REAR BRAKES

6-16

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

FRONT BRAKE PADS

6-16

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

REAR BRAKE PADS

6-17

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

REPLACING THE FRONT BRAKE PADS

6-18

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

REPLACING THE REAR BRAKE PADS

6-20

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

FRONT BRAKE MASTER CYLINDER

6-22

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

REAR BRAKE MASTER CYLINDER

6-24

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

REMOVING THE FRONT BRAKE MASTER CYLINDER

6-26

. . . . . . . . . 

REMOVING THE REAR BRAKE MASTER CYLINDER

6-26

. . . . . . . . . . 

CHECKING THE FRONT AND REAR BRAKE MASTER

CYLINDER

6-27

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

INSTALLING THE FRONT BRAKE MASTER CYLINDER

6-28

. . . . . . . . 

INSTALLING THE REAR BRAKE MASTER CYLINDER

6-30

. . . . . . . . . . 

FRONT BRAKE CALIPERS

6-32

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

REAR BRAKE CALIPER

6-34

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

REMOVING THE FRONT BRAKE CALIPERS

6-36

. . . . . . . . . . . . . . . . . . 

REMOVING THE REAR BRAKE CALIPER

6-36

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

CHECKING THE FRONT AND REAR BRAKE CALIPERS

6-37

. . . . . . . . 

INSTALLING THE FRONT BRAKE CALIPERS

6-38

. . . . . . . . . . . . . . . . . 

INSTALLING THE REAR BRAKE CALIPER

6-40

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

FRONT FORK

6-43

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

REMOVING THE FRONT FORK LEGS

6-46

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

DISASSEMBLY THE FRONT FORK LEGS

6-46

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

CHECKING THE FRONT FORK LEGS

6-47

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

ASSEMBLING THE FRONT FORK LEGS

6-48

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

INSTALLING THE FRONT FORK LEGS

6-51

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

CHAS

HANDLEBAR

6-52

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

REMOVING THE HANDLEBAR

6-54

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

CHECKING THE HANDLEBAR

6-54

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

INSTALLING THE HANDLEBAR

6-55

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

STEERING HEAD

6-58

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

REMOVING THE LOWER BRACKET

6-60

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

CHECKING THE STEERING HEAD

6-60

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

INSTALLING THE STEERING HEAD

6-61

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

REAR SHOCK ABSORBER AND SWINGARM

6-63

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

RIGHT SIDE COVER AND BATTERY BOX

6-63

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

LEFT SIDE COVER AND TOOL BOX

6-64

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

REAR SHOCK ABSORBER AND SWINGARM

6-65

. . . . . . . . . . . . . . . . . 

HANDLING THE REAR SHOCK ABSORBER AND GA6

CYLINDER

6-66

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

DISPOSING OF A REAR SHOCK ABSORBER AND GAS

CYLINDER

6-66

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

REMOVING THE REAR SHOCK ABSORBER

6-67

. . . . . . . . . . . . . . . . . . 

REMOVING THE SWINGARM

6-68

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

CHECKING THE REAR SHGOCK ABSORBER AND GAS

CYLINDER

6-69

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

CHECKING THE SWINGARM

6-69

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

INSTALLING THE REAR SHOCK ABSORBER

6-70

. . . . . . . . . . . . . . . . . 

INSTALLING THE SWINGARM

6-70

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

SHAFT DRIVE

6-72

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

TROUBLESHOOTING

6-72

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

CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND

INSPECTING THE SHAFT DRIVE FOR LEAKS

6-75

. . . . . . . . . . . . . 

MEASURING THE RING GEAR BACKLASH

6-76

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

ADJUSTING THE RING GEAR BACKLASH

6-77

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

FINAL DRIVE ASSEMBLY AND DRIVE SHAFT

6-79

. . . . . . . . . . . . . . . . . 

FINAL GEAR

6-80

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

DISASSEMBLING THE FINAL DRIVE ASSEMBLY

6-81

. . . . . . . . . . . . . . 

REMOVING AND INSTALLING THE RING GEAR BEARINGS

6-82

. . . . 

ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR

6-83

. . 

CHECKING THE DRIVE SHAFT

6-87

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

INSTALLING THE DRIVE SHAFT

6-87

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

6-1

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5
6

Removing the front wheel and brake
discs

Brake calipers
Front wheel axle pinch bolt
Front wheel axle
Front wheel assembly
Collars
Brake discs

2
1
1
1
2
2

Remove the parts in the order listed.
Stand the motorcycle on a level surface.

For installation, reverse the removal
procedure.

Refer to “INSTALLING THE FRONT
WHEEL”.

WARNING

Securely support the motorcycle so
there is no danger of it falling over.

59 Nm (5.9 m

kg)

20 Nm (2.0 m

kg)

40 Nm (4.0 m

kg)

23 Nm (2.3 m

kg)

Refer to “REMOVING / INSTALLING
THE FRONT WHEEL”.

FRONT WHEEL AND BRAKE DISCS

CHAS

CHASSIS

FRONT WHEEL AND BRAKE DISCS

FRONT WHEEL AND BRAKE DISCS

CHAS

Order

Job name / Part name

Q’ty

Remarks

Disassembling the front wheel
Oil seals
Bearings
Collar

2
2
1

Disassemble the parts in the order listed.

For assembly, reverse the disassembly
procedure.

1
2
3

6-2

6-3

FRONT WHEEL AND BRAKE DISCS

CHAS

WARNING

NOTE:

NOTE:

NOTE:

WARNING

EAS00521

REMOVING THE FRONT WHEEL
1. Stand the motorcycle on a level surface.

Securely support the motorcycle so that
there is no danger of it falling over.

Place the motorcycle on a suitable stand so that
the front wheel is elevated.

2. Remove:

brake calipers 

1

 (left and right)

Do not squeeze the brake lever when removing
the brake calipers.

3. Loosen:

pinch bolt (front wheel axle) 

1

front wheel axle 

2

4. Elevate:

front wheel

Place the motorcycle on a suitable stand so that
the front wheel is elevated.

EAS00526

CHECKING THE FRONT WHEEL
1. Check:

wheel axle
Roll the wheel axle on a flat surface.
Bends 

 Replace.

Do not attempt to straighten a bent wheel axle.

2. Check:

tire

front wheel
Damage / wear 

 Replace.

Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.

3. Check:

spokes
Bends / damage 

 Replace.

Loose 

 Tighten.

Tap the spokes with a screwdriver.

FRONT WHEEL AND BRAKE DISCS

CHAS

6-4

NOTE:

3 Nm (0.3m

kg)

NOTE:

WARNING

A tight spoke will emit a clear, ringing tone, a
loose spoke will sound flat.

4. Tighten:

spokes

After tightening the spokes, measure the front
wheel runout.

5. Measure:

front wheel radial runout 

1

front wheel lateral runout 

2

Over the specified limits 

 Replace.

Front wheel radial runout limit

1.0 mm

Front wheel lateral runout limit

0.5 mm

6. Check:

collars
Damage / wear 

 Replace.

New tires have a relatively low grip on the
road surface until they have been slightly
worn.
Therefore, approximately 100 km should
be traveled at normal speed before any
highspeed riding is done.

7. Check

wheel bearings
Front wheel turns roughly or is loose 

 Re-

place the wheel bearings.

oil seals
Damage / wear 

 Replace.

8. Replace:

wheel bearings (New)

oil seals (New)

6-5

FRONT WHEEL AND BRAKE DISCS

CHAS

NOTE:

CAUTION:

NOTE:

a. Clean the outside of the front wheel hub.
b. Remove the oil seals 

1

 with a flat-head

screwdriver.

To prevent damaging the wheel, place a rag be-
tween the screwdriver and the wheel surface.

c. Remove the wheel bearings with a general

bearing puller 

2

.

d. Install the new wheel bearings and oil seals

in the reverse order of disassembly.

Do not contact the wheel bearing center race

4

 or balls 

5

. Contact should be made only

with the outer race 

6

.

Use a socket 

3

 that matches the diameter of

the wheel bearing outer race and oil seal.

EAS00531

CHECKING THE BRAKE DISCS
The following procedure applies to all of the
brake discs.
1. Check:

brake disc
Damage / galling 

 Replace.

2. Measure:

brake disc deflection 

1

Out of specification 

 Correct the brake disc

deflection or replace the brake disc.

Brake disc deflection limit
(maximum)

Front: 0.15 mm
Rear: 0.15 mm

a. Place the motorcycle on a suitable stand so

that the wheel is elevated.

b. Before measuring the front brake disc deflec-

tion, turn the handlebar to the left or right to
ensure that the front wheel is stationary.

FRONT WHEEL AND BRAKE DISCS

CHAS

6-6

NOTE:

c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against

the brake disc surface.

e. Measure the deflection 2 – 3 mm below the

edge of the brake disc.

3. Measure:

brake disc thickness 

1

Measure the brake disc thickness at a few
different locations.
Out of specification 

 Replace.

Brake disc thickness limit
(minimum)

Front: 4.5 mm
Rear: 5.5 mm

4. Adjust:

brake disc deflection

a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.

Tighten the brake disc bolts in stages and in a
crisscross pattern.

Brake disc bolt

23 Nm (2.3 m

kg)

LOCTITE



d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment

steps until the brake disc deflection is within
specification.

f. If the brake disc deflection cannot be brought

within specification, replace the brake disc.