Yamaha XVS1100 (L). Service Manual

6-55

HANDLEBAR

CHAS

WARNING

28 Nm (2.8 m

kg)

CAUTION:

NOTE:

a. Apply a light coat of rubber adhesive onto the

left end of the handlebar.

b. Slide the handlebar grip over the left end of

the handlebar.

c. Wipe off any excess rubber adhesive with a

clean rag.

Do not touch the handlebar grip until the
rubber adhesive has fully dried.

EAS00670

INSTALLING THE HANDLEBAR
1. Stand the motorcycle on a level surface.

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

2. Install:

handlebar

upper handlebar holders

First, tighten the bolts on the front side of
the handlebar holder, then on the rear side.

Turn the handlebar all the way to the left
and right. If there is any contact with the
fuel tank, adjust the handlebar position.

The upper handlebar holders should be
installed with the punch mark

facing forward

6-56

HANDLEBAR

CHAS

WARNING

NOTE:

Align the match marks

on the handlebar

with the upper surface of the lower handlebar
holders.

3. Install:

throttle grip

throttle cable

Make sure that the pin

on the throttle

cable housing is aligned with the hole

the handlebar.

4. Install:

master cylinder
Refer to “FRONT AND REAR BRAKES”.

5. Install:

clutch lever holder

Align the slit in the clutch lever holder with the
punch mark

in the handlebar.

6. Install:

left handlebar switch

Aligh the matching surface on the handlebar
switches with the punch mark

on the handle-

bar.

7. Install:

clutch cable

8. Connect:

clutch switch coupler

Apply a thin coat of lithium soap base grease
onto the end of the clutch cable.

6-57

HANDLEBAR

CHAS

9. Adjust:

clutch cable free play
Refer to “ADJUSTING THE CLUTCH
CABLE FREE PLAY” in chapter 3.

Clutch cable free play (at the end
of the clutch lever)

10 mm

10. Adjust:

throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.

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

6 mm

6-58

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5
6
7
8

Removing the lower bracket

Front fork legs
Handlebar
Headlight lens unit
Leads (in the headlight body)
Front turn signal light (left / right)
Headlight body
Brake hose joint holder
Upper bracket
Lock washer
Upper ring nut

1
–

1 / 1

1
1
1
1
1

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

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

Refer to “FRONT FORK”.
Refer to “HANDLEBAR”.

Disconnect

WARNING

7 Nm (0.7 m

kg)

1st

110 Nm (11.0 m

kg)

2nd

52 Nm (5.2 m

kg)

18 Nm (1.8 m

kg)

STEERING HEAD

CHAS

STEERING HEAD

6-59

Order

Job name / Part name

Q’ty

Remarks

12
13
14
15

Rubber washer
Lower ring nut
Bearing cover
Lower bracket
Bearing (upper)
Rubber seal
Bearing (lower)

1
1
1
1
1
1
1

For installaiton, reverse the removal
procedure.

7 Nm (0.7 m

kg)

1st

110 Nm (11.0 m

kg)

2nd

52 Nm (5.2 m

kg)

18 Nm (1.8 m

kg)

Refer to “REMOVING THE LOWER
BRACKET/ INSTALLING THE
STEERING HEAD”.

STEERING HEAD

CHAS

6-60

STEERING HEAD

CHAS

WARNING

NOTE:

WARNING

EAS00677

REMOVING THE LOWER BRACKET
1. Stand the motorcycle on a level surface.

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

2. Remove:

upper ring nut

lower ring nut

Hold the lower ring nut with the exhaust and
steering nut wrench, then remove the upper ring
nut with the ring nut wrench.

Exhaust and steering nut wrench

90890-01268

Ring nut wrench

90890-01403

Securely support the lower bracket so that
there is no danger of it falling.

EAS00681

CHECKING THE STEERING HEAD
1. Wash:

bearings

bearing races

Recommended cleaning solvent

Kerosine

2. Check

bearings

bearing races

Damage / pitting

Replace.

3. Replace:

bearings

bearing races

6-61

STEERING HEAD

CHAS

CAUTION:

NOTE:

a. Remove the bearing reces from the steering

head pipe with a long rod

and hammer.

b. Remove the bearing race from the lower

bracket with a floor chisel

and hammer.

c. Install a new rubber seal and new bearing re-

ces.

If the bearing race is not installed properly,
the steering head pipe could be damaged.

Always replace the bearings and bearing
races as a set.

Whenever the steering head is disassembled,
replace the rubber seal.

4. Check:

upper bracket

lower bracket
(along with the steering stem)
Bends / cracks / damage

Replace.

EAS00683

INSTALLING THE STEERING HEAD
1. Lubricate:

upper bearing

lower bearing

bearing races

Recommended lubricant

Lithium soap base grease

2. Install:

Lower ring nut

rubber washer

upper ring nut

lock washer

Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” in chapter 3.

3. Install:

upper bracket

steering stem nut

6-63

Order

Job name / Part name

Q’ty

Remarks

1
2
3

Removing the right side cover and
battery box.
Seats

Muffler assembly

Battery cover
Right side cover
Battery

Battery box

1
1
1

Remove the parts in the order listed.
Stand the motorcycle on a level surface.
Refer to “FUEL TANK AND SEATS” in
CHAPTER 3.
Refer to “REAR WHEEL AND BRAKE
DISC”.

Refer to “REMOVING / INSTALLING THE
REAR SHOCK ABSORBER ASSEMBLY”.

For installation, reverse the removal
procedure.

7 Nm (0.7 m

kg)

REAR SHOCK ABSORBER AND SWINGARM

CHAS

REAR SHOCK ABSORBER AND SWINGARM

RIGHT SIDE COVER AND BATTERY BOX

6-64

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5
6
7

Removing the left side cover and
tool box
Tool box cover
Left side cover
Owner’s tool kit
Connector’s
Fuel hose holder
Fuel hoses
Tool box

1
1
1
–
1
2
1

Remove the parts in order listed.

Disconnect

For installation, reverse the removal
procedure.

7 Nm (0.7 m

kg)

REAR SHOCK ABSORBER AND SWINGARM

CHAS

LEFT SIDE COVER AND TOOL BOX

6-65

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5
6
7

Removing the rear shock absorber
and swingarm
Rear wheel

Connecting arm bolts
Connecting arms
Rear shock absorber lower bolt
Rear shock absorber
Relay arm
Pivot shaft
Swingarm

2
2
1
1
1
1
1

Remove the parts in order listed.

Refer to “REAR WHEEL AND BRAKE
DISC”.

For installation, reverse the removal
procedure.

40 Nm (4.0 m

kg)

48 Nm (4.8 m

kg)

48 Nm (4.8 m

kg)

90 Nm (9.0 m

kg)

48 Nm (4.8 m

kg)

Refer to “REMOVING / INSTALLING THE
REAR SHOCK ABSORBER ASSEMBLY”.

Refer to “REMOVING / INSTALLING THE
SWINGARM”.

REAR SHOCK ABSORBER AND SWINGARM

CHAS

REAR SHOCK ABSORBER AND SWINGARM

6-66

REAR SHOCK ABSORBER AND SWINGARM

CHAS

WARNING

EAS00687

HANDLING THE REAR SHOCK ABSORBER
AND GAS CYLINDER

This rear shock absorber and gas cylinder
contain highly compressed nitrogen gas.
Before handling the rear shock absorber or
gas cylinder, read and make sure you under-
stand the following information. The
manufacturer cannot be held responsible
for property damage or personal injury that
may result from improper handling of the
rear shock absorber and gas cylinder.

Do not tamper or attempt to open the rear
shock absorber or gas cylinder.

Do not subject the rear shock absorber or
gas cylinder to an open flame or any other
source of high heat. High heat can cause an
explosion due to excessive gas pressure.

Do not deform or damage the rear shock
absorber or gas cylinder in any way. If the
rear shock absorber, gas cylinder or both
are damaged, damping performance will
suffer.

EAS00689

DISPOSING OF A REAR SHOCK ABSORB-
ER AND GAS CYLINDER

a. Gas pressure must be released before dis-

posing of a rear shock absorber and gas cy-
linder.To release the gas pressure, drill a
2

3 mm hole through the gas cylinder at a

point 15 – 20 mm from its end as shown.

Wear eye protection to prevent eye damage
from released gas or metal chips.

6-67

REAR SHOCK ABSORBER AND SWINGARM

CHAS

WARNING

NOTE:

CAUTION:

NOTE:

EAS00694

REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
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. Disconnect:

battery leads
(from the battery terminals)

First, disconnect the negative lead

, then

the positive lead

3. Remove:

connecting arm bolt(swingarm side)

rear shock absorber assembly lower bolt

While removing the connecting arm bolt (swin-
garm side), hold the swingarm so that it does not
drop down.

4. Remove:

rear shock absorber upper bolt

rear shock absorber

6-68

REAR SHOCK ABSORBER AND SWINGARM

CHAS

WARNING

NOTE:

EAS00702

REMOVING THE SWINGARM
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 shock absorber

3. Check:

swingarm side play

swingarm vertical movement

a. Check the tightening torque of the swingarm

pivot bolts and locknut.

Locknut

90 Nm (9.0 m

kg)

b. Check the swingarm side play

by moving

the swingarm from side to side.

c. If the swingarm side play is out of specifica-

tion, check the spacers and bearings.

Swingarm side play (at the end
of the swingarm)

0 mm

d. Check the swingarm vertical movement

by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers and
bearings.

6-69

REAR SHOCK ABSORBER AND SWINGARM

CHAS

EAS00696

CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY AND GAS CYLINDER
1. Check:

rear shock absorber rod
Bends / damage

Replace the rear shock

absorber assembly.

rear shock absorber
Gas leaks / oil leaks

Replace the rear

shock absorber assembly.

spring
Damage / wear

Replace the rear shock ab-

sorber assembly.

gas cylinder
Damage / gas leaks

Replace.

bushings
Damage / wear

Replace.

dust seals
Damage / wear

Replace.

bolts
Bends / damage / wear

Replace.

EAS00708

CHECKING THE SWINGARM
1. Check:

swingarm
Bends / cracks / damage

Replace.

2. Check:

pivot shaft
Damage / wear

Replace.

3. Check:

collars

oilseals

bearings

Damage / wear

Replace.

6-70

REAR SHOCK ABSORBER AND SWINGARM

CHAS

NOTE:

CAUTION:

EAS00698

INSTALLING THE REAR SHOCK ABSORB-
ER ASSEMBLY
1. Install:

swingarm
Refer to “INSTALLING THE SWINGARM”.

2. Lubricate:

spacers

bearings

Recommended lubricant

Molybdenum disulfide grease

3. Install:

rear shock absorber assembly

Rear shock absorber assembly
upper nut

40 Nm (4.0 m

kg)

Rear shock absorber assembly
lower nut

48 Nm (4.8 m

kg)

Relay-arm-to-frame-nut

48 Nm (4.8 m

kg)

When installing the rear shock absorber as-
sembly, lift up the swingarm.

Install the connecting arm front bolt from the
right.

4. Connect:

battery leads
(to the battery terminals)

First, connect the positive lead

, then the

negative lead

EAS00712

INSTALLING THE SWINGARM

1. Lubricate:

bearings

spacers

oil seals

Recommended lubricant

Molybdenum disulfide grease

Yamaha XVS1100 (L). Service Manual - part 17