Yamaha XVS1100 (L). Service Manual

6-71

REAR SHOCK ABSORBER AND SWINGARM

CHAS

2. Install:

relay arm

left connecting arm

right connecting arm

Rear-shock-absorber-assembly
lower nut

48 Nm (4.8 m

kg)

Connecting arm nuts

48 Nm (4.8 m

kg)

Relay-arm-to-frame-nut

48 Nm (4.8 m

kg)

3. Install:

rear shock absorber
Reter to “INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY”.

4. Install:

rear wheel
Refer to “REAR WHEEL AND BRAKE
DISC”.

6-72

SHAFT DRIVE

CHAS

NOTE:

SHAFT DRIVE

EAS00715

TROUBLESHOOTING
The following conditions may indicate damaged shaft drive components:

Symptoms

Possible causes

1. A pronounced hesitation or jerky movement

during acceleration, deceleration, or sus-
tained speeds. (not to be confused with engine
surging or transmissionrelated
movements.)

2. A rolling “rumble” noticeable at low speeds, a

high-pitched whine, or a “clunk” from a shaft
drive component or vicinity of the shaft drive.

3. The shaft drive is locked up or no power is

transmitted from the engine to the rear wheel

A. Bearing damage
B. Improper gear lash
C.Damaged gear teeth
D.Broken drive shaft
E. Broken gear teeth
F. Seizure due to lack of lubrication
G.Small foreign objects lodged between moving

parts

Causes A, B and C may be extremely difficult to diagnose. The symptoms are quite subtle and difficult
to distinguish from normal operating noises. If there is reason to believe these components are dam-
aged, remove them for individual inspection.

6-73

SHAFT DRIVE

CHAS

WARNING

Inspection notes
1. Investigate any unusual noises.

The following noises may indicate a me-
chanical defect:
a. A rolling “rumble” during coasting, accelera-

tion, or deceleration, (increases with the rear
wheel speed, but does not increase with
higher engine or transmission speeds).
Diagnosis: Possible wheel bearing damage.

b. A whining noise that varies with acceleration

and deceleration.
Diagnosis: Possible incorrect reassembly or
too little gear lash.

Insufficient gear lash is extremely destruc-
tive to the gear teeth. If a test ride, following
reassembly, indicates these symptoms,
stop riding immediately to minimize gear
damage.

c. A slight “clunk” evident at low speed opera-

tion. (not to be confused with normal motor-
cycle operation)
Diagnosis: Possible broken gear teeth

Stop riding immediately if broken gear teeth
are suspected. This condition could result
in the shaft drive assembly locking up, caus-
ing a loss of control and possible injury to
the rider.

6-74

YES

Place the motorcycle on a suitable stand so
that the front wheel is elevated and then spin
the front wheel. Is the wheel bearing dam-
aged?

Place the motorcycle on a suitable stand so
that the rear wheel is elevated and then spin
the rear wheel. Is the wheel bearing dam-
aged?

Replace the wheel bearing.
Refer to “FRONT WHEEL AND BRAKE
DISC”.

Rear wheel bearings and shaft drive bearings
are probably not damaged.
Repeat the test or remove and check the
components.

Remove the rear wheel. Is the wheel bearing
damaged?

Replace the rear wheel bearing.
Refer to “REAR WHEEL AND BRAKE DISC”.

Remove and inspect the drive shaft compo-
nents.

SHAFT DRIVE

CHAS

EAS00716

Troubleshooting chart
When causes A and B shown in the chart at the beginning of the “TROUBLESHOOTING” section exist,
check the following points:

6-75

SHAFT DRIVE

CHAS

NOTE:

EAS00717

CHECKING THE FINAL DRIVE OIL FOR
CONTAMINATION AND INSPECTING THE
SHAFT DRIVE FOR LEAKS
1. Drain:

final drive oil
(from the final drive housing)
Refer to “CHARGING THE FINAL DRIVE
OIL” in chapter 3.

2. Check:

final drive oil
Large amount of metal particles

Check for

bearing seizure.

A small amount of metal particles in the final
drive oil is normal.

3. Check:

shaft drive housing
(for oil leaks)

a. Thoroughly clean the entire motorcycle and

then completely dry it.

b. Apply a leak-locating compound or dry pow-

der spray to the shaft drive.

c. Test ride the motorcycle long enough to lo-

cate a leak.
Oil leak

Repair or replace the faulty

part(-s).

1 Oil seal

2 O-ring

3 Forward

What may appear to be an oil leak on a new or
fairly new motorcycle, may result from the ap-
plication of a rust preventive coating or exces-
sive seal lubrication.

Always clean the motorcycle and recheck the
area where the leak is thought to originate
from.

6-76

1.5 mm

11 mm

100 mm

25 mm

14 mm

SHAFT DRIVE

CHAS

NOTE:

EAS00719

MEASURING THE RING GEAR BACKLASH
1. Secure the final drive assembly in a vise.
2. Remove:

final drive oil drain bolt

3. Drain:

final drive oil
(from the final drive assembly)

4. Measure:

ring gear backlash
Out of specification

Adjust.

Ring gear backlash

0.1

0.2 mm

a. Install a bolt

of the specified size, into the

final drive oil filler hole.

b. Finger tighten the bolt until it stops the ring

gear from moving.

Do not overtighten the bolt.

c. Install the final gear backlash band

and

dial gauge

Final gear backlash band

90890-01230

Dial-gauge-plunger contact point: 54.5 mm

d. Gently rotate the gear coupling from engage-

ment to engagement.

e. Record the reading on the dial gauge.
f. Remove the dial gauge, special tool, and

bolt.

6-77

SHAFT DRIVE

CHAS

NOTE:

g. Rotate the final drive pinion gear 90

h. Reinstall the bolt, special tool, and dial

gauge.

i. Repeat steps (d) to (h) three more times (for

a total of four measurements).

j. If any of the readings are over specification,

adjust the ring gear backlash.

EAS00720

ADJUSTING THE RING GEAR BACKLASH
1. Remove:

ring gear bearing housing nuts

ring gear bearing housing bolts

Working in a crisscross pattern, loosen each nut
1 / 4 of a turn. After all of the nuts are fully loos-
ened, remove them and the bolts.

2. Remove:

ring gear bearing housing

ring gear

thrust washer

ring gear shim(-s)

3. Adjust:

ring gear backlash

a. Use the following chart to select the suitable

shim(-s) and thrust washer.

Thinner shim

Ring gear backlash is
increased.

Thicker shim

Ring gear backlash is
decreased.

6-78

SHAFT DRIVE

CHAS

Rig gear shims

Thickness (mm)

0.25, 0.30, 0.40

Thrust washers

Thickness (mm)

1.2, 1.4, 1.6, 1.8, 2.0

b. If it is necessary to increase the ring gear

backlash by more than 0.2 mm, reduce the
thrust washer thickness by 0.2 mm for every
0.2 mm increase of ring gear shim thickness.

c. If it is necessary to reduce the ring gear back-

lash by more than 0.2 mm, increase the
thrust washer thickness by 0.2 mm for every
0.2 mm decrease of ring gear shim thick-
ness.

6-79

Order

Job name / Part name

Q’ty

Remarks

1
2
3

Removing the final drive assembly
and drive shaft.

Rear wheel assembly

Collar
Drive shaft assembly
Final drive pinion gear assembly

Final gear assembly

1
1
1

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

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

Refer to “REAR WHEEL AND BRAKE
DISC”.

Refer to “DISASSEMBLING THE FINAL
DRIVE ASSEMBLY/ ALIGNING THE
FINAL DRIVE PINION GEAR AND RING
GEAR”.

For installation, reverse the removal
procedure.

WARNING

23 Nm (2.3 m

kg)

23 Nm (2.3 m

kg)

42 Nm (4.2 m

kg)

115 Nm (11.5 m

kg)

130 Nm (13.0 m

kg)

SHAFT DRIVE

CHAS

FINAL DRIVE ASSEMBLY AND DRIVE SHAFT

6-80

SHAFT DRIVE

CHAS

Order

Job name / Part name

Q’ty

Remarks

Disassembling the final gear.
Bolts (bearing housing)
Nuts (bearing housing)

Bearing housing / O-ring
Ring gear
Shim (s)
Thrust washer

2
6

1 / 1

1
1
1

Disassemble the parts in the order listed.

Working in a crisscross pattern, loosen
each bolt and nut 1 / 4 of a turn. After all
the bolts and nuts are loosened, remove
them.

For assembly, reverse the disassembly
procedure.

NOTE:

1
2

3
4
5
6

23 Nm (2.3 m

kg)

40 Nm (4.0 m

kg)

FINAL GEAR

6-81

SHAFT DRIVE

CHAS

NOTE:

CAUTION:

WARNING

CAUTION:

EAS00724

DISASSEMBLING THE FINAL DRIVE AS-
SEMBLY
1. Remove:

ring gear bearing housing nuts

ring gear bearing housing bolts

Working in a crisscross pattern, loosen each
bolts and nuts 1 / 4 of a turn. After all of the bolts
and nuts are fully loosened, and remove them.

2. Remove:

self-locking nut

gear coupling
(with the special tool

)

Coupling gear / middle shaft tool

90890-01229

3. Remove:

bearing retainer

(with the special tool

)

Bearing retainer wrench

90890-04077

The bearing retainer has left-hand threads.
To loosen the bearing retainer, turn it clock-
wise.

4. Remove:

final drive pinion gear
(with the special tools)

Crankshaft installer bolt
adapter

90890-01277

Armature shock puller

90890-01290

Weight

90890-01291

Always use new bearings.

The final drive pinion gear should only be re-
moved if ring gear replacement is neces-
sary.

6-82

SHAFT DRIVE

CHAS

NOTE:

EAS06725

REMOVING AND INSTALLING THE RING
GEAR BEARINGS
1. Remove:

collar

oil seal

bearing

(with an appropriate press tool

and an ap-

propriate support for the final drive housing)

2. Check:

bearing
Damage

Replace.

3. Remove:

bearing

a. Heat the final gear case to approximately

150

C (302

F).

b. Remove the bearing outer races with an ap-

propriately shaped punch

c. Remove the inner race from the final drive

pinion gear.

The removal of the final drive pinion gear bear-
ing is a difficult procedure and is rarely neces-
sary.

4. Install:

bearing (New)

a. Heat the final gear case to approximately

150

C (302

F).

b. Install the bearing outer races with a socket

or appropriate tool that matches the diameter
of the races.

c. Install the inner race onto the final drive pin-

ion gear.

6-83

SHAFT DRIVE

CHAS

NOTE:

5. Install:

collar

oil seal

New

bearing
(with an appropriate press tool

and press)

The bearing can be reused, but Yamaha recom-
mends installing a new one.

EAS00726

ALIGNING THE FINAL DRIVE PINION GEAR
AND RING GEAR

Aligning the final drive pinion gear and ring gear
is necessary when any of the following parts are
replaced:

Final drive housing

Any bearing

1. Select:

final drive pinion gear shim(-s)

ring gear shim(-s)

a. Position the final drive pinion gear and the

ring gear with shims

and

. Calculate the

respective thicknesses from information
marked on the final drive housing and the
drive pinion gear.

1 Final drive pinion gear shim

2 Ring gear shim

3 Thrust washer

b. To find final drive pinion gear shim thickness

“A” use the following formula:

Final drive pinion gear shim thickness
A = (84 +

/ 100) –

6-84

SHAFT DRIVE

CHAS

Final drive pinion gear shim

Thickness (mm)

0.30, 0.40, 0.50

Where:
a = a numeral (positive or negative) on the ring
gear, to be divided by 100 and added to “84”
b = a numeral on the final drive housing.
Example:
If the final drive pinion gear is marked “+ 01” and
the final drive housing is marked “83.50”:
A = (84 + 1 / 100) – (83.50)
= (84 + 0.01) – (83.50)
= 84.01 – 83.50
= 0.51
Therefore, the calculated final drive pinion gear
shim thickness is 0.51 mm.
Shim sizes are supplied in the following thick-
nesses.

Since the final drive pinion gear shims are only
available in 0.10 mm increments, round off to
the hundredths digit.

Hundredths

Rounded value

0, 1, 2, 3, 4

5, 6, 7, 8, 9

In the example above, the calculated final drive
pinion gear shim thickness is 0.51 mm. The
chart instructs you to round off the 1 to 0. Thus,
you should use a 0.50 mm final drive pinion gear
shim.
c. To find ring gear shim thickness “B”, use the

following formula:

Ring gear shim thickness

B =

– [(35.40 +

/ 100) +

]

Where:

= a numeral on the final drive housing.

= a numeral usually on the outside of the ring

gear bearing housing.

= a numeral (positive or negative) on the in-

side of the ring gear, to be divided by 100 and
added to “35.40”.

6-85

SHAFT DRIVE

CHAS

Ring gear shim

Thickness (mm)

0.30, 0.40, 0.50

115Nm (11.5 m

kg)

CAUTION:

= the ring gear bearing thickness constant

Ring gear bearing thickness“

”

13.00 mm

Example:
If the final drive housing is marked “45.51” the
ring gear bearing housing is marked “3.35” the
ring gear is marked “-05”, and “f” is 13.00:

B = 45.51 + 3.35 – [(35.40 – 5 / 100) + 13]

= 45.51 + 3.35 – [(35.40 – 0.05) + 13]
= 48.86 – [35.35 + 13]
= 48.86 – 48.35
= 0.51

Therefore, the calculated ring gear shim thick-
ness is 0.51 mm.
Shim sizes are supplied in the following thick-
ness.

Since the ring gear shims are only available in
0.10 mm increments, round off the hundredths
digit.

Hundredths

Rounded value

0, 1, 2, 3, 4

5, 6, 7, 8, 9

In the example above, the calculated final gear
shim thickness is 0.51 mm. The chart instructs
you to round off the 1 to 0. Thus, you should use
a 0.50 mm ring gear shim.

2. Install:

shim(s) (as calculated)

final drive pinion gear

bearing retainer
(with the bearing retainer wrench)

The bearing retainer has left-hand threads.
To tighten the bearing retainer, turn it coun-
terclockwise.

SHAFT DRIVE

CHAS

6-86

130 Nm (13.0 m

kg)

CAUTION:

NOTE:

Bearing retainer wrench

90890-04077

3. Install:

gear coupling

self-locking nut
(with the special tool

)

Coupling gear / middle shaft tool

90890-01229

Apply LOCTITE



to the self-locking nut.

4. Install:

ring gear bearing housing
(along with the ring gear, but without the
thrust washer)

5. Adjust:

ring gear backlash
Refer to “MEASURING THE RING GEAR
BACKLASH” and “ADJUSTING THE RING
GEAR BACKLASH”.

6. Measure:

ring-gear-to-thrust-washer clearance

a. Remove the ring gear bearing housing

(along with the ring gear).

b. Place four pieces of Plastigauge



between

the original thrust washer and the ring gear.

c. Install the ring gear bearing housing and

tighten the bolts, and nuts to specification.

Ring gear bearing housing bolt
(M10)

40 Nm (4.0 m

kg)

Ring gear bearing housing
nut (M8)

23 Nm (2.3 m

kg)

Do not turn the final drive pinion gear and ring
gear while measuring the ring-gear-to-thrust-
washer clearance with Plastigauge



d. Remove the ring gear bearing housing.
e. Measure the width of the flattened Plasti-

gauge



Ring-gear-to-thrust-washer
clearance

0.2 mm

f. If the ring-gear-to-thrust-washer clearance is

within specification, install the ring gear bear-
ing housing (along with the ring gear).

Yamaha XVS1100 (L). Service Manual - part 18