Yamaha XVS1100 (L). Service Manual

6-7

FRONT WHEEL AND BRAKE DISCS

CHAS

NOTE:

59 Nm (5.9 m

kg)

20 Nm (2.0 m

kg)

CAUTION:

40 Nm (4.0 m

kg)

WARNING

EAS00544

INSTALLING THE FRONT WHEEL
The following procedure applies to both brake
discs.
1. Lubricate:

wheel axle

oil seallips

Recommended lubricant

Lithium soap base grease

2. Install:

front wheel assembly

The arrow mark

on the tire must point in the

direction of the wheel.

3. Tighten:

wheel axle

wheel axle pinch bolt

Before tightening the wheel axle nut, push
down hard on the handlebar several times and
check if the front fork rebounds smoothly.

4. Install:

brake caliper

Make sure that the brake hose is routed
properly.

6-8

FRONT WHEEL AND BRAKE DISCS

CHAS

NOTE:

EAS00549

ADJUSTING THE FRONT WHEEL STATIC
BALANCE

After replacing the tire, wheel or both, the front
wheel static balance shourd be adjusted.

Adjust the front wheel static balance with the
brake discs installed.

1. Remove:

balancing weight (-s)

Place the front wheel on a suitable balancing
stand.

2. Find:

front wheel’s heavy spot

a. Spin the front wheel.
b. When the front wheel stops, put an “X

” mark

at the bottom of the wheel.

c. Turn the front wheel 90

so that the “X

” mark

is positioned as shown.

d. Release the front wheel.
e. When the wheel stops, put an “X

” mark at

the bottom of the wheel.

f. Repeat steps (b) through (d) several times

until all the marks come to rest at the same
spot.

g. The spot where all the marks come to rest is

the front wheel’s heavy spot “X”.

3. Adjust:

front wheel static balance

a. Install a balancing weight

onto the rimex-

actly opposite the heavy spot “X”.

Start with the lightest weight.

b. Turn the front wheel 90

so that the heavy

spot is positioned as shown.

c. If the heavy spot does not stay in that posi-

tion, install a heavier weight.

d. Repeat steps (b) and (c) until the front wheel

is balanced.

6-10

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4

Removing the muffler and brake
caliper
Muffler
Muffler stay
Brake hose holder
Brake caliper

1
1
1
1

Remove the parts in the order listed.

Refer to “REMOVING THE REAR WHEEL”.
For installation, reverse the removal
procedure.

40 Nm (4.0m

kg)

25 Nm (2.5m

kg)

20 Nm (2.0m

kg)

30 Nm (3.0m

kg)

20 Nm (2.0m

kg)

REAR WHEEL AND BRAKE DISC

CHAS

REAR WHEEL AND BRAKE DISC

MUFFLER AND BRAKE CALIPER

6-11

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5
6
7

Removing the rear wheel

Final gear oil

Fuel tank and seats

Rear fender assembly
Brake caliper bracket bolt
Bolts
Rear axle nut / washer
Rear axle end nuts / axle holder
Rear wheel assembly
Washer
Collar

1
4

1 / 1
2 / 1

1
1
1

Remove the parts in the order listed.

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

Drain
Refer to “FINAL GEAR OIL REPLACE-
MENT” in CHAPTER 3.
Refer to “FUEL TANK AND SEATS” in
CHAPTER 3.
Loosen

For installation, reverse the removal
procedure.

Refer to “REMOVING / INSTAL-
LING THE REAR WHEEL”.

WARNING

40 Nm (4.0m

kg)

23 Nm (2.3m

kg)

23 Nm (2.3m

kg)

90 Nm (9.0m

kg)

107 Nm (10.7m

kg)

REAR WHEEL AND BRAKE DISC

CHAS

REAR WHEEL

6-12

REAR WHEEL AND BRAKE DISC

CHAS

Order

Job name / Part name

Q’ty

Remarks

Rear wheel disassembly
Disassembling the rear wheel
Lock washers
Clutch hub
Dampers
O-rings
Oil seal
Bearing
Spacer
Bearing

2
1
6
2
1
1
1
1

Remove the parts in the order listed.

For assembly, reverse the disassembly
procedure.

1
2
3
4
5
6
7
8

62 Nm (6.2m

kg)

6-13

REAR WHEEL AND BRAKE DISC

CHAS

WARNING

NOTE:

EAS00562

REMOVING THE REAR 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 rear wheel is elevated.

2. Remove:

rear gear case fitting bolts

3. Remove:

brake caliper

brake caliper bracket bolt

Do not depress the brake pedai when removing
the brake caliper.

4. Remove:

wheel axle nut

washer

5. Remove:

rear axle end nut

6. Remove:

rear axle holder

7. Remove:

rear wheel

EAS00566

CHECKING THE REAR WHEEL
1. Check:

wheel axle

rear wheel

wheel bearings

oil seals
Refer to “FRONT WHEEL AND BRAKE
DISCS”.

2. Check:

tire
Damage / wear

Replace.

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

3. Check:

spokes
Refer to “FRONT WHEEL AND BRAKE
DISCS”.

4. Measure:

rear wheel radial runout

rear wheel lateral runout
Refer to “FRONT WHEEL AND BRAKE
DISCS”.

6-14

REAR WHEEL AND BRAKE DISC

CHAS

NOTE:

EAS00567

CHECKING THE REAR WHEEL DRIVE HUB
1. Check:

rear wheel drive hub
Cracks / damage

Replace.

rear wheel drive hub dampers
Damage / wear

Replace.

EAS00572

INSTALLING THE REAR WHEEL
1. Lubricate:

drive shaft splines

Recommended lubricant

Molydenum disulfide grease

2. Lubricate:

wheel axle

wheel bearings

oil seal lips

Recommended lubricant

Lithium soap base grease

2. Install:

rear wheel assembly

a. Install the rear wheel assembly

with the

rear brake caliper bracket

and hold the

bracket to keep the specified position.

b. After installation of the rear axle shaft

slide the wheel assembly to forward direc-
tion.

c. To make sure the caliper bracket mounts on

the swingarm and then, fix the holder of swin-
garm temporally.

The holder should installed with the punch mark

facing upper.

d. Tighten the rear gear housing bolts, with spe-

cified tightening torque.

Rear gear housing bolt

90 Nm (9.0 m

kg)

e. Tighten the nut of rear axle shaft with speci-

fied torque.

Wheel axle nut

107 Nm (10.7 m

kg)

6-15

REAR WHEEL AND BRAKE DISC

CHAS

NOTE:

f. Tighten the rear axle holder with specified

torque.

Rear axle end nut

23 Nm (2.3 m

kg)

g. Tighten the rear brake caliper bracket bolt

with specified tightening torque.

Brake caliper bracket bolt

40 Nm (4.0 m

kg)

h. Install the rear brake caliper on the bracket

and tighten the bolts with specified tightening
torque.

Brake caliper bolt

40 Nm (4.0 m

kg)

EAS00575

ADJUSTING THE REAR WHEEL STATIC
BALANCE

After replacing the tire, wheel or both, the rear
wheel static balance should be adjusted.

Adjust the rear wheel static balance with the
brake disc and rear wheel drive hub installed.

1. Adjust:

rear wheel static balance
Refer to “FRONT WHEEL AND BRAKE
CISCS”.

6-16

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4

Removing the front brake pads
Retaining bolt
Brake caliper
Brake pads
Pad spring

1
1
2
1

Remove the parts in the order listed.

For installation, reverse the removal
procedure.

Refer to “REPLACING THE FRONT
BRAKE PADS”.

23 Nm (2.3 m

kg)

FRONT AND REAR BRAKES

CHAS

FRONT AND REAR BRAKES

FRONT BRAKE PADS

6-17

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5
7
6

Removing the rear brake pads
Muffler
Muffler stay
Brake hose holder
Caliper
Cover
Clips
Pad pins
Pad spring
Brake pads

1
1
1
2
2
1
2

Remove the parts in the order listed.

For installation, reverse the removal
procedure.

Refer to “REPLACING THE REAR
BRAKE PADS”.

Refer to “REAR WHEEL AND BRAKE
DISC”.

40 Nm (4.0 m

kg)

FRONT AND REAR BRAKES

CHAS

EAS00578

REAR BRAKE PADS

6-18

FRONT AND REAR BRAKES

CHAS

CAUTION:

NOTE:

EAS00579

Disc brake components rarely require dis-
assembly.
Therefore, always follow these preventive
measures:

Never disassemble brake components un-
less absolutely necessary.

If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly.

Never use solvents on internal brake com-
ponents.

Use only clean or new brake fluid for clean-
ing brake components.

Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt fluid immediately.

Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.

First aid for brake fluid entering the eyes:

Flush with water for 15 minutes and get im-
mediate medical attention.

EAS00582

REPLACING THE FRONT BRAKE PADS
The following procedure applies to both brake
calipers.

When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the brake caliper.

1. Remove:

brake hose holder

retaining bolt

6-19

FRONT AND REAR BRAKES

CHAS

NOTE:

23 Nm (2.3 m

kg)

2. Remove:

brake pads

(along with the brake pad shims)

3. Measure:

brake pad wear limit

Out of specification

Replace the brake

pads as a set.

Brake pad wear limit

0.8 mm

4. Install:

brake pad shims
(onto the brake pads)

brake pads

brake pad spring

Always install new brake pads, brake pad
shims, and a brake pad spring as a set.

a. Connect a clear plastic hose

tightly to the

bleed screw

. Put the other end of the hose

into an open container.

b. Loosen the bleed screw and push the brake

caliper pistons into the brake caliper with
your finger.

c. Tighten the bleed screw.

Bleed screw

6 Nm (0.6 m

kg)

d. Install new brake pad shims onto the new

brake pads.

e. Install new brake pads and a new brake pad

spring.

5. Install:

brake caliper

retaining bolt

6-20

FRONT AND REAR BRAKES

CHAS

NOTE:

6. Check:

brake fluid level
Below the minimum lever mark

Add the

recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.

7. Check:

brake lever operation
Soft or spongy feeling

Bleed the brake

system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.

EAS00583

REPLACING THE REAR BRAKE PADS

When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the brake caliper.

1. Remove:

brake hose holder

brake caliper

2. Remove:

brake pad cover

brake pad clips

brake pad pins

brake pad spring

3. Remove:

brake pads
(along with the brake pad shims)

4. Measure:

brake pad wear limit

Out of specification

Replace the brake

pads as a set.

Brake pad wear limit

0.5 mm

6-21

FRONT AND REAR BRAKES

CHAS

NOTE:

40 Nm (4.0 m

kg)

5. Install:

brake pad shims
(onto the brake pads)

brake pads

brake pad spring

Always install new brake pads, brake pad
shims, and a brake pad spring as a set.

a. Connect a clear plastic hose

tightly to the

bleed screw

. Put the other end of the hose

into an open container.

b. Loosen the bleed screw and push the brake

caliper pistons into the brake caliper with
your finger.

c. Tighten the bleed screw.

Bleed screw

6 Nm (0.6 m

kg)

d. Install new brake pad shims onto the new

brake pads.

e. Install new brake pads and a new brake pad

spring.

The longer tangs

on the brake pad spring

must point in the direction of disc rotation.

6. Install:

brake pad pins

brake pad clips

brake pad cover

brake caliper

7. Check:

brake fluid level
Below the minimum level mark

Add the

recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.

8. Check:

brake pedal operation
Soft or spongy feeling

Bleed the brake

system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.

6-22

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5
6
7
8

Removing the front brake master
cylinder.
Brake fluid
Rear view mirror (right)
Brake lever / compression spring
Front brake switch
Union bolt
Copper washers
Brake hose
Master cylinder bracket
Master cylinder

1 / 1

1
1
2
1
1
1

Remove the parts in the order listed.

Drain

For installation, reverse the removal
procedure.

Reter to “INSTALLING THE FRONT
BRAKE MASTER CYLINDER”.

10 Nm (1.0 m

kg)

30 Nm (3.0 m

kg)

Refer to “REMOVING/INSTALLING THE
FRONT BRAKE MASTER CYLINDER”.

FRONT AND REAR BRAKES

CHAS

FRONT BRAKE MASTER CYLINDER

Yamaha XVS1100 (L). Service Manual - part 14