Yamaha XVS1100 (L). Service Manual - part 19

6-87

SHAFT DRIVE

CHAS

Thrust washer

Thickness (mm)

1.2, 1.4, 1.6, 1.8, 2.0

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

out of specification, select the correct thrust
washer as follows.

h. Select the suitable thrust washer from the fol-

lowing chart.

i. Repeat the measurement steps until the

ring-gear-to-thrust-washer clearance is with-
in the specified limits.

Ring-gear-to-thrust-washer
clearance

0.2 mm

EAS00727

CHECKING THE DRIVE SHAFT
1. Check:

drive shaft splines
Damage / wear 

 Replace the drive shaft.

EAS00728

INSTALLING THE DRIVE SHAFT
1. Lubricate:

drive shaft splines

Recommended lubricant

Molybdenum disulfide grease

2. Apply:

sealant
(onto both final drive housing mating sur-
faces)

Yamaha bond No. 1215

90890-85505

3. Install:

drive shaft
(to the final drive pinion gear)

6-88

SHAFT DRIVE

CHAS

42 Nm (4.3 m

kg)

4. Tighten:

final bearing housing nuts

5. Install:

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

 

ELEC

 

7

–

+

ELEC

CHAPTER 7

ELECTRICAL

ELECTRICAL COMPONENTS

7-1

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

SWITCHES

7-2

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

CHECKING SWITCH CONTINUITY

7-2

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

CHECKING THE SWITCHES

7-3

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

CHECKING THE BULBS AND BULB SOCKETS

7-5

. . . . . . . . . . . . . . . . . . 

TYPES OF BULBS

7-5

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

CHECKING THE CONDITION OF THE BULBS

7-5

. . . . . . . . . . . . . . . . . 

CHECKING THE CONDITION OF THE BULB SOCKETS

7-7

. . . . . . . . 

IGNITION SYSTEM

7-8

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

CIRCUIT DIAGRAM

7-8

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

TROUBLESHOOTING

7-9

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

ELECTRIC STARTING SYSTEM

7-13

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

CIRCUIT DIAGRAM

7-13

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

STARTING CIRCUIT OPERATION

7-14

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

TROUBLESHOOTING

7-15

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

STARTER MOTOR

7-19

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

CHARGING SYSTEM

7-23

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

CIRCUIT DIAGRAM

7-23

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

TROUBLESHOOTING

7-24

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

LIGHTING SYSTEM

7-26

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

CIRCUIT DIAGRAM

7-26

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

TROUBLESHOOTING

7-27

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

CHECKING THE LIGHTING SYSTEM

7-28

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

SIGNAL SYSTEM

7-31

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

CIRCUIT DIAGRAM

7-31

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

TROUBLESHOOTING

7-33

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

CHECKING THE SIGNALING SYSTEM

7-34

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

FUEL PUMP SYSTEM

7-39

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

CIRCUIT DIAGRAM

7-39

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

FUEL PUMP CIRCUIT OPERATION

7-40

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

TROUBLESHOOTING

7-41

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

FUEL PUMP TEST

7-43

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

ELEC

CARBURETOR HEATER SYSTEM

7-44

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

CIRCUIT DIAGRAM

7-44

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

TROUBLESHOOTING

7-45

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

SELF-DIAGNOSIS

7-48

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

TROUBLESHOOTING

7-49

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

7-1

ELECTRICAL COMPONENTS

ELEC

1

Main switch

2

Thermo switch

3

Flasher relay

4

Starting circuit cut off relay

5

Ignition coil

6

Starter relay

7

Fuse

8

Igniter unit

9

Side stand switch

10

Neutral switch

11

Rectifier / regulator

12

Oil lamp relay

13

Battery

14

Rear brake switch

15

Horn

EB800000

ELECTRICAL

ELECTRICAL COMPONENTS

7-2

B

B

SWITCHES

ELEC

CAUTION:

NOTE:

NOTE:

EAS0010

SWITCHES

CHECKING SWITCH CONTINUITY
Check each switch for continuity with the pocket
tester. If the continuity reading is incorrect,
check the wiring connections and if necessary,
replace the switch.

Never insert the tester probes into the cou-
pler terminal slots 

1

. Always insert the

probes from the opposite end of the coupler,
taking care not to loosen or damage the
leads.

Pocket tester

90890-03112

Before checking for continuity, set the pocket
tester to “0” and to the “

Ω

 

 1” range.

When checking for continuity, switch back and
forth between the switch positions a few times.

The terminal connections for switches (e.g.,
main switch, engine stop switch) are shown in
an illustration similar to the one on the left.
The switch positions 

a

 are shown in the far left

column and the switch lead colors 

b

 are shown

in the top row in the switch illustration.

“

” indicates a continuity of electricity

between switch terminals (i.e., a closed circuit
at the respective switch position).

The example illustration on the left shows
that:
There is continuity between blue / red and red
when the switch is set to “

”.

There is continuity between blue / red and blue,
between brown / blue and red, and between
blue / yellow and  black when the switch is set to
“ON”.

7-3

*1

*2

CHECKING THE SWITCHES

ELEC

EAS00731

CHECKING THE SWITCHES

Check each switch for damage or wear, proper connections, and also for continuity between the termi-
nals. Refer to “CHECKING SWITCH CONTINUITY”.

Damage / wear 

 Repair or replace the switch.

Improperly connected 

 Properly connect.

Incorrect continuity reading 

 Replace the switch.

7-4

9

Engine stop switch

10

Start switch

11

Fuse

12

Rear brake switch

13

Sidestand switch

14

Neutral switch

*

1

: for Europe

*

2

: for AUS

1

Clutch switch

2

Pass switch

3

Horn switch

4

Dimmer switch

5

Turn switch

6

Main switch

7

Front brake switch

8

Lights switch (for Europe)

CECKING THE SWITCHES

ELEC

7-5

CHECKING THE BULBS AND BULB SOCKETS

ELEC

EAS00732

CHECKING THE BULBS AND
BULB SOCKETS

Check each bulb and bulb socket for damage or
wear, proper connections, and also for continu-
ity between the terminals.
Damage / wear 

 Repair or replace the bulb,

bulb socket or both.
Improperly connected 

 Properly connect.

Incorrect continuity reading 

 Repair or replace

the bulb, bulb socket or both.

TYPES OF BULBS
The bulbs used on this motorcycle are shown in
the illustration on the left.

Bulbs 

A

 and 

B

 are used for headlights and

usually use a bulb holder which must be de-
tached before removing the bulb. The majority
of these bulbs can be removed from their re-
spective socket by turning them counterclock-
wise.

Bulb 

C

 is used for turn signal and tail / brake

lights and can be removed from the socket by
pushing and turning the bulb counterclock-
wise.

Bulbs 

D

 and 

E

 are used for meter and indica-

tor lights and can be removed from their re-
spective socket by turn 

D

 and pulling 

E

 them

out.

CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1. Remove:

bulb

CHECKING THE BULBS AND BULB SOCKETS

ELEC

7-6

WARNING

CAUTION:

NOTE:

Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.

Be sure to hold the socket firmly when re-
moving the bulb. Never pull the lead, other-
wise it may be pulled out of the terminal in
the coupler.

Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adverse-
ly affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.

2. Check:

bult (for continuity)
(with the pocket tester)
No continuity 

 Replace.

Pocket tester

90890-03112

Before checking for continuity, set the pocket
tester to “0” and to the “

Ω

 

 1” range.

a. Connect the tester positive probe to terminal

1

 and the tester negative probe to terminal

2

, and check the continuity.

b. Connect the tester positive probe to terminal

1

 and the tester negative probe to terminal

3

, and check the continuity.

c. If either of the readings indicate no continuity,

replace the bulb.

7-7

CHECKING THE BULBS AND BULB SOCKETS

ELEC

NOTE:

CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the bulb
sockets.
1. Check:

bulb socket (for continuity)
(with the pocket tester)
No continuity 

 Replace.

Pocket tester

90890-03112

Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.

a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the re-

spective leads of the bulb socket.

c. Check the bulb socket for continuity.

If any of the readings indicate no continuity,
replace the bulb socket.

7-8

1

4

5

6

7

8

13

16

17

18

29

Pickup coil

Main switch

Alam system (option)

Ignition fuse

Battery

Main fuse

Starting circuit cut-of

f relay

Ignitor unit

Ignition coil

Spark plug

Sidestand switch

Neutral switch

Engine stop switch

20

38

Diode

60

IGNITION SYSTEM

ELEC

EB802000

IGNITION SYSTEM

CIRCUIT DIAGRAM

7-9

IGNITION SYSTEM

ELEC

2. Battery

S

Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.

Min. open-circuit voltage

12.8 V or more at 20 

_

C

S

Is the battery OK?

YES

NO

3. Spark plugs

The following procedure applies to all of the
spark plugs.

S

Check the condition of the spark plug.

S

Check the spark plug type.

S

Measure the spark plug gap.
Refer to “CHECKING THE SPARK PLUGS”
in chapter 3.

Standard spark plug

BPR7ES
W22EPR-U

Spark plug gap

0.7 

X

 0.8 mm

S

Is the spark plug in good condition, is it of the
correct type, and its gap within specifica-
tion?

YES

Re-gap or replace
the spark plug.

NO

S

Clean the battery
terminals.

S

Recharge or re-
place the battery.

EAS00741

NOTE:

YES

NO

Replace the fuse(-s).

1. Main and ignition fuses

S

Check the main and ignition fuses for conti-
nuity.
Refer to “CHECKING THE FUSES” in chap-
ter 3.

S

Are the main and ignition fuses OK?

EAS00737

EAS00739

TROUBLESHOOTING

The ignition system fails to operate (no
spark or intermittent spark).

Check:

1. main and ignition fuses
2. battery
3. spark plugs
4. ignition spark gap
5. spark plug cap resistance
6. ignition coil resistance
7. pickup coil resistance
8. main switch
9. engine stop switch

10. neutral switch
11. sidestand switch
12. diode
13. starting circuit cut-off relay (diode)
14. wiring

(of the entire ignition system)

S

Before troubleshooting, remove the following
part(-s):

1) battery cover
2) rider’s seat
3) fuel tank
4) steering head side covers
5) tool box cover
6) left side cover
7) cylinder head covers

S

Troubleshoot with the following special
tool(-s).

Ignition checker

90890-06754

Pocket tester

90890-03112

EAS00738

7-10

4. Ignition spark gap

The following procedure applies to all of the
spark plugs.

S

Disconnect the spark plug cap from the
spark plug.

S

Connect the ignition checker 

 as shown.

S

 Spark plug cap

S

Set the main switch to “ON”.

S

Measure the ignition spark gap 

.

S

Crank the engine by pushing the start switch
and gradually increase the spark gap until a
misfire occurs.

Min. ignition spark gap

6 mm

S

Is there a spark and is the spark gap within
specification ?

NO

The ignition system
is OK.

YES

EAS00745

5. Spark plug cap resistance.

The following procedure applies to all of the
spark plug caps.

S

Disconnect the spark plug cap from the
spark plug.

S

Connect the pocket tester (

Ω

 

 

 1k) to the

spark plug cap as shown.

S

Measure the spark plug cap resistance.

Spark plug cap resistance

10 k

Ω

 at 20 

_

C

S

Is the spark plug cap OK?

YES

Replace the spark
plug cap.

NO

EAS00747

Tester positive probe 

 

spark plug lead 

Tester negative probe 

 

Orange (gray) lead 

1

1

2

a

2

6. Ignition coil resistance

The following procedure applies to all of the
ignition coils.

S

Disconnect the ignition coil connectors from
the ignition coil terminals.

S

Connect the pocket tester (

Ω

 

 

 1) to the

ignition coil as shwon.

Tester positive probe 

 red / black

Tester negative probe 

 orange (gray)

S

Measure the primary coil resistance.

Primary coil resistance

3.57 

X

 4.83 

Ω

 at 20

_

C

S

Connect the pocket tester (

Ω

 

 

 1k) to the

ignition coil as shown.

S

Measure the secondary coil resistance.

IGNITION SYSTEM

ELEC

EAS00743

7-11

IGNITION SYSTEM

ELEC

Secondary coil resistance

10.7 

X

 14.5 k

Ω

 20 

_

C

S

Is the ignition coil OK?

YES

Replace the ignition
coil.

NO

EAS00748

7. Pickup coil resistance

S

Disconnect the pickup coil coupler from the
wire harness.

S

Connect the pocket tester (

Ω

 

 

 100) to the

pickup coil terminal.

Pickup coil resistance

189 

X

 231 

Ω

 at 20 

_

C

(between gray and black / blue)

S

Is the pickup coil OK?

YES

Replace the pickup
coil.

NO

Tester positive probe 

 gray

Tester negative probe 

 black / blue

1

2

S

Measure the pickup coil resistance.

EAS00749

S

Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.

S

Is the main switch OK?

YES

Replace the main
switch.

NO

8. Main switch

EAS00750

S

Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.

S

Is the engine stop switch OK?

YES

Replace the right
handlebar switch.

NO

9. Engine stop switch

EAS00751

S

Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.

S

Is the neutral switch OK?

YES

Replace the neutral
switch.

NO

10. Neutral switch

EAS00752

S

Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.

S

Is the sidestand switch OK?

YES

Replace the side-
stand switch.

NO

11. Sidestand switch