Yamaha XVS1100 (L). Service Manual

7-45

2. Battery

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

Open-circuit voltage

12.8 V or more at 20

Is the battery OK?

YES

EAS00739

Clean the battery
terminals.

Recharge or re-
place the battery.

EAS00749

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

Is the main switch OK?

YES

Replace the main
switch.

3. Main switch

EAS00751

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

Is the neutral switch OK?

YES

Replace the neutral
switch.

4. Neutral switch

CARBURETOR HEATER SYSTEM

ELEC

NOTE:

YES

Replace the fuse(-s).

1. Main, and carburetor heater fuses

Check the main, and carburetor heater
fuses for continuity.
Refer to “CHECKING THE FUSES” in chap-
ter 3.

Are the main, and carburetor heater fuses
OK?

EAS00781

TROUBLESHOOTING

The carburetor heater fails to operate.

Check:
1. main, and carburetor heater
2. battery
3. main switch
4. neatral switch
5. carburetor heater relay
6. thermo
7. carburetor heater
8. wiring

(of the entire charging system)

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

Troubleshoot with the following special tool
(-s).

Pocket tester

90890-03112

EAS00738

7-46

CARBURETOR HEATER SYSTEM

ELEC

YES

Replace the carbure-
tor heater relay.

Battery (+) terminal

Brown / Yellow terminal

Battery (–) terminal

Sky blue terminal

Tester (+) lead

Brown / Black terminal

Tester (–) lead

Black / Yellow terminal

Does the carburetor heater relay have conti-
nuity between brown / black and black / yel-
low?

Remove the thermo switch from the thermo
switch plate.

Connect the pocket tester to the thermo
switch lead.

6. Thermo switch

5. Carburetor heater relay

Remove the carburetor heater relay from the
wire harness.

Connect the pocket tester (

Ω

1) and bat-

tery (12 V) to the carburetor heater relay ter-
minals.

Tester (+) lead

Brown / Yellow terminal

Tester (–) lead

Black / Yellow terminal

Immerse the thermo switch in the water

Check the thermo switch for continuity.
Note the temperatures while heating the wa-
ter with the temperature gauge

Test step

Water temperature

Good

condition

Less than 23

More than 23

More than 12

Less than 12

Test 1 & 2 : Heat-up test
Test 3 & 4 : Cool-down test

: Continuity

: No continuity

Is the thermo switch OK?

YES

Replace the thermo
switch.

OFF

Thermoswitch
12

Thermoswitch
23

7-47

CARBURETOR HEATER SYSTEM

ELEC

7. Carburetor heater

Remove the carburetor heater from the car-
buretor body.

Connect the pocket tester to the carburetor
heater.

Tester (+) lead

Heater terminal

Tester (–) lead

Heater body

YES

Replace the carbure-
tor heater.

8. Wiring

Check the entire carburetor heater system’s
wiring.
Refer to “CIRCUIT DIAGRAM”.

Is the carburetor heater system’s wiring
properly connected and without defects?

Measure the heater resistance.

Carburetor heater resistance:

12 V 30 W : 6

Ω

at 20

Is the carburetor heater OK?

EAS00766

YES

The carburetor heat-
er system circuit is
OK.

Properly connect or
repair the carburetor
heater system’s wir-
ing.

7-48

Light on

Light off

1 Light on (seconds)

0.5 seconds

. . . . .

2 Light off (seconds)

0.5 seconds

. . . . .

3 Number of blinks

Fault code

. . . . . .

4 Light off (seconds)

3 seconds

. . . . .

Repetition

SELF-DIAGNOSIS

ELEC

NOTE:

SELF-DIAGNOSIS

The XVS1100 features self-diagnosis.
When the main switch is turned to “ON”, the following items are monitored and the condition codes are
displayed on the engine indicator light (irrespective of whether the engine is running or not).

The XVS1100 features a self-diagnosing system.
In the XVS1100, when the main switch is turned on the “Engine indicator light” in the speedometer
comes on for 1.4 seconds then goes off. However, if there is a malfunction, it comes on for 1.4 seconds,
goes off and then begins flashing. (However, it is on while the engine is running.)

Display condition

code

Item

Condition

Response

When

engine is

stationary

When

engine is

running

Throttle position
sensor (TPS)

Disconnected
Short-circuit
Locked

Enables the motorcycle to
run so that the ignition timing
is fixed when the throttle is
fully opened.

Displays the condition code
on the engine indicator light.

Blinks in
Fault code: 3

Light on

Speed sensor

Disconnected
short-circuit

Displays the condition code
on the enigne indicator light.

Blinks in
Fault code: 4

Light on

Display order on the engine indicator light

7-49

Repair or replace the
wire harness.

1. Wire harness

Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.

Is the wire harness OK?

YES

2. Throttle position sensor

Check the throttle position sensor for conti-
nuity.
Refer to “CHECKING AND ADJUSTING
THE THROTTLE POSITION SENSOR” in
chapter 6.

Is the throttle position sensor OK?

YES

Replace the throttle
position sensor.

Replace the ignitor
unit.

EB812401

SELF-DIAGNOSIS

ELEC

NOTE:

Throttle position sensor

Ignitor unit

EAS00835

TROUBLESHOOTING

The engine warning light starts to display
the self-diagnosis sequence.

Check:
1. throttle position sensor
2. speed sensor

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

1) rider seat
2) fuel tank
3) air filter case
4) left side cover

Troubleshoot with the following special
tool(-s).

Pocket tester

90890-03112

EAS00836

1. Throttle position sensor
CIRCUIT DIAGRAM

7-50

YES

Replace the speed
sensor.

Set the main switch to “ON”.

Turn the rear wheel slowly.

Check the tester voltage (0V - 5V - 0V).

Is the speed sensor OK?

Replace the ignitor
unit.

SELF-DIAGNOSIS

ELEC

Ignitor unit

Speed sensor

YES

Repair or replace the
wire harness.

1. Wire harness

Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.

Is the wire harness OK?

2. Speed sensor

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

Connect the pocket tester (DC 20V) to the
speed sensor connector.

Tester (+) lead

White

terminal

Tester (–) lead

Body earth

2. Speed sensor
CIRCUIT DIAGRAM

TRBL

SHTG

CHAPTER 8.

TROUBLESHOOTING

STARTING FAILURE/ HARD STARTING

8-1

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

FUEL SYSTEM

8-1

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

ELECTRICAL SYSTEM

8-1

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

COMPRESSION SYSTEM

8-2

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

POOR IDLE SPEED PERFORMANCE

8-2

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

POOR IDLE SPEED PERFORMANCE

8-2

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

POOR MEDIUM-AND HIGH-SPEED PERFORMANCE

8-2

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

POOR MEDIUM-AND HIGH-SPEED PERFORMANCE

8-2

. . . . . . . . . .

FAULTY GEAR SHIFTING

8-3

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

HARD SHIFTING

8-3

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

SHIFT PEDAL DOES NOT MOVE

8-3

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

JUMPS-OUT-OF GEAR

8-3

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

CLUTCH SLIPPING / DRAGGING

8-3

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

CLUTCH SLIPPING

8-3

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

CLUTCH DRAGGING

8-3

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

OVERHEATING

8-4

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

OVERHEATING

8-4

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

FAULTY BRAKE

8-4

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

POOR BRAKING PERFORMANCE

8-4

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

FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION

8-4

MALFUNCTION

8-4

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

OIL LEAKAGE

8-4

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

UNSTABLE HANDLING

8-5

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

UNSTABLE HANDLING

8-5

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

FAULTY LIGHTING AND SIGNAL SYSTEMS

8-5

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

HEADLIGHT DOES NOT LIGHT

8-5

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

BULB BURNT OUT

8-5

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

FLASHER DOES NOT LIGHT

8-5

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

FLASHER BLINKS SLOWLY

8-5

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

FLASHER REMAINS LIT

8-5

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

FLASHER BLILNKS QUICKLY

8-5

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

HORN DOES NOT SOUND

8-5

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

8-1

STARTING FAILURE/HARD STARTING

TRBL

SHTG

NOTE:

Carburetor

Deteriorated or contaminated fuel

Clogged pilot jet

Clogged pilot air passage

Sucked-in air

Deformed float

Worn needle valve

Improperly sealed valve seat

Improperly adjusted fuel level

Improperly set pilot jet

Clogged starter jet

Faulty starter plunger

Improperly adjusted starter cable

Air filter

Clogged air filter element

Fuel pump

Faulty fuel pump

Faulty relay unit (fuel pump relay)

Switch and wiring

Faulty main switch

Faulty engine stop switch

Broken or shorted wiring

Faulty neutral switch

Faulty start switch

Faulty sidestand switch

Faulty clutch switch

Starter motor

Faulty starter motor

Faulty starter relay

Faulty relay unit (starting circuit cut-off relay)

Faulty starter clutch

EB900000

TROUBLESHOOTING

The following guide for troubleshooting does not cover all the possible causes of problems.
It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this
manual for inspection, adjustment and replacement of parts.

STARTING FAILURE/HARD STARTING

FUEL SYSTEM
Fuel tank

Empty

Clogged fuel filter

Clogged fuel strainer

Clogged fuel tank drain hose

Clogged roll-over valve

Clogged roll-over valve breather hose

Deteriorated or contaminated fuel

Fuel cock

Clogged fuel hose

ELECTRICAL SYSTEM
Spark plug

Improper plug gap

Worn electrodes

Wire between terminals severed

Improper heat range

Faulty spark plug cap

Ignition coil

Broken or shorted primary / secondary

Faulty spark plug lead

Broken body

Full-transistor system

Faulty ignitor unit

Faulty pickup coil

8-2

STARTING FAILURE /HARD STARTING /POOR IDLE SPEED

PERFORMANCE/POOR MEDIUM-AND HIGH-SPEED PERFORMANCE

TRBL

SHTG

Piston and piston ring

Improperly installed piston ring

Worn, fatigued or broken piston ring

Seized piston ring

Seized or damaged piston

Crankcase and crankshaft

Improperly seated crankcase

Seized crankshaft

Electrical system

Faulty battery

Faulty spark plug

Faulty ignitor unit

Faulty pickup coil

Faulty ignition coil

Valve train

Improperly adjusted valve clearance

Air filter

Clogged air filter element

Air filter

Clogged air filter element

Fuel pump

Faulty fuel pump

COMPRESSION SYSTEM
Cylinder and cylinder head

Loose spark plug

Loose cylinder head or cylinder

Faulty cylinder head gasket

Worn, damaged or seized cylinder

Improperly sealed valve

Improper valve-to-valve seat contact

Improper valve timing

Faulty valve spring

EB901000

POOR IDLE SPEED PERFORMANCE

POOR IDLE SPEED PERFORMANCE
Carburetor

Improperly returned starter plunger

Loose pilot jet

Clogged pilot air jet

Improperly synchronized carburetors

Improperly adjusted idle speed
(throttle stop screw)

Improper throttle cable free play

Flooded carburetor

EB902000

POOR MEDIUM-AND HIGH-SPEED PERFORMANCE

POOR MEDIUM-AND HIGH-SPEED PERFORMANCE
Refer to “STARTING FAILURE/ HARD STARTING”. (Fuel system, electrical system, compression
system and valve train)

Carburetor

Faulty diaphragm

Improperly adjusted fuel level

Clogged or loose main jet

8-3

FAULTY GEAR SHIFTING/

CLUTCH SLIPPING/DRAGGING

TRBL

SHTG

Transmission

Seized transmission gear

Jammed impurities

Incorrectly assembled transmission

Shift cam

Improper thrust play

Worn shift cam groove

Transmission

Worn gear dog

Engine oil

Improper oil level

Improper viscosity (low)

Deterioration

Engine oil

Improper oil level

Improper viscosity (high)

Deterioration

EB903000

FAULTY GEAR SHIFTING

HARD SHIFTING
Refer to “CLUTCH DRAGGING”.

SHIFT PEDAL DOES NOT MOVE
Shift shaft

Improperly adjusted shift pedal link

Bent shift shaft

Shift cam, shift fork

Groove jammed with impurities

Seized shift fork

Bent shift fork guide bar

JUMPS-OUT-OF GEAR
Shift shaft

Improperly adjusted shift lever position

Improperly returned stopper lever

Shift fork

Worn shift fork

EB904000

CLUTCH SLIPPING/DRAGGING

CLUTCH SLIPPING
Clutch

Improperly adjusted clutch cable

Loose clutch spring

Fatigued clutch spring

Worn friction plate / clutch plate

Incorrectly assembled clutch

CLUTCH DRAGGING
Clutch

Warped pressure plate

Unevenly tensioned clutch springs

Bent push rod

Broken clutch boss

Burnt primary driven gear bushing

Bent clutch plate

Swollen friction plate

Match marks not aligned

8-4

OVERHEATING/FAULTY BRAKE/FRONT FORK OIL

LEAKAGE AND FRONT FORK MALFUNCTION

TRBL

SHTG

Compression system

Heavy carbon build-up

Engine oil

Improper oil level

Improper oil viscosity

Inferior oil quality

Brake

Brake drag

OIL LEAKAGE

Bent, damaged or rusty inner tube

Damaged or cracked outer tube

Damaged oil seal lip

Improperly installed oil seal

Improper oil level (too high)

Loose damper rod holding bolt

Broken cap bolt O-ring

Loose drain bolt

Damaged drain bolt gasket

EB905000

OVERHEATING

OVERHEATING
Ignition system

Improper spark plug gap

Improper spark plug heat range

Faulty ignitor unit

Fuel system

Improper carburetor main jet setting

Improper fuel level

Clogged air filter element

EB906001

FAULTY BRAKE

POOR BRAKING PERFORMANCE
Disc brake

Worn brake pad

Worn disc

Air in brake fluid

Leaking brake fluid

Faulty cylinder kit cup

Faulty caliper kit seal

Loose union bolt

Broken brake hose

Oily or greasy disc / brake pad

Incorrect brake fluid level

EB907000

FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION

MALFUNCTION

Bent, deformed or damaged inner tube

Bent or deformed outer tube

Damaged fork spring

Worn or damaged slide metal

Bent or damaged damper rod

Improper oil viscosity

Improper oil level

8-5

UNSTABLE HANDLING/

FAULTY LIGHTING AND SIGNAL SYSTEMS

TRBL

SHTG

Front fork

Uneven oil levels on both sides

Uneven spring tension
(uneven damping force adjuster position)

Broken spring

Twisted front fork

Wheel

Incorrect wheel balance

Deformed cast wheel

Damaged bearing

Bent or loose wheel axle

Excessive wheel runout

Loosed spoke

Frame

Bent

Damaged steering head tube

Improperly installed bearing race

BULB BURNT OUT

Improper bulb

Faulty battery

Faulty rectifier / regulator

Improperly grounded

Faulty main and / or lights switch

Bulb life expired

FLASHER REMAINS LIT

Faulty flasher relay

Burnt-out bulb

FLASHER BLINKS QUICKLY

Improper bulb

Faulty flasher relay

Burnt-out bulb

HORN DOES NOT SOUND

Faulty battery

Faulty fuse

Faulty main and / or horn switch

Improperly adjusted horn

Faulty horn

Broken wire harness

EB908000

UNSTABLE HANDLING

UNSTABLE HANDLING
Handlebar

Improperly installed or bent

Steering

Improperly installed handlebar crown

Bent steering stem

Improperly installed steering shaft
(improperly tightened ring nut)

Damaged ball bearing or bearing race

Swingarm

Worn bearing or bushing

Bent or damaged

Rear Shock absorber

Faulty spring

Oil and gas leakage

Tire

Uneven tire pressures on both sides

Incorrect tire pressure

Uneven tire wear

EB909000

FAULTY LIGHTING AND SIGNAL SYSTEMS

HEADLIGHT DOES NOT LIGHT

Improper bulb

Too many electric accessories

Hard charging (broken stator coil wire, faulty
rectifier / regulator)

Incorrect connection

Improperly grounded

Poor contacts (main or lights switch)

Bulb life expired

FLASHER DOES NOT LIGHT

Improperly grounded

Discharged battery

Faulty turn switch

Faulty flasher relay

Faulty wire harness

Loosely connected coupler

Burnt-out bulb

Faulty fuse

FLASHER BLINKS SLOWLY

Faulty flasher relay

Faulty main and / or turn switch

Improper bulb

COLOR CODE

Black

. . . . .

Brown

. . . .

Chocolate

. . .

Dark green

. . .

Green

. . . .

Gray

. . .

Blue

. . . . .

Light green

. . . .

Orange

. . . .

Pink

. . . . .

Red

. . . . .

Sky blue

. . . .

White

. . . .

Yellow

. . . . .

B / L

Black / Blue

. . .

B / W

Black / White

. .

B / Y

Black / Yellow

. . .

Br / B

Brown / Black

. .

Br / L

Brown / Blue

. .

Br / W

Brown / White

Br / Y

Brown / Yellow

. .

L / B

Blue / Black

. . .

L / R

Blue / Red

. . .

L / W

Blue / White

. .

L / Y

Blue / Yellow

. . .

R / B

Red / Black

. . .

R / G

Red / Green

. .

R / W

Red / White

. .

R / Y

Red / Yellow

. . .

Pickup coil

A.C. magneto

Rectifier / regulator

Main switch

Alarm system (Option)

Ignition fuse

Battery

Main fuse

Starter relay

Starter motor

Oil level gauge

Oil lamp relay

Starting circuit cut-off relay

Fuel pump

Throttle position sensor

Igniter unit

Ignition coil

Spark plug

Speed sensor

Neutral switch

Engine warning light

Oil warning light

Speedometer

Turn signal indicator light

Meter light

Neutral indicator light

High beam indicator light

Trip switch

Sidestand switch

Flasher relay

Turn signal switch

Rear turn signal light (right)

Rear turn signal light (left)

Front turn signal light (right)

Front turn signal light (left)

Clutch switch

Start switch

Engine stop switch

Light switch

Front brake switch

Right handlebar switch

Horn

Horn switch

Dimmer switch

Rear brake switch

Pass switch

Left handlebar switch

Headlight

Auxiliary light

Tail / brake light

Backup fuse

Headlight fuse

Signal fuse

Carburetor heater fuse

Thermo switch

Carburetor heater relay

Carburetor heater 1

Carburetor heater 2

Carburetor heater earth

Diode

XVS1100 WIRING DIAGRAM (for Europe)

COLOR CODE

Black

. . . . .

Brown

. . . .

Chocolate

. . .

Dark green

. . .

Green

. . . .

Gray

. . .

Blue

. . . . .

Light green

. . . .

Orange

. . . .

Pink

. . . . .

Red

. . . . .

Sky blue

. . . .

White

. . . .

Yellow

. . . . .

B / L

Black / Blue

. . .

B / W

Black / White

. .

B / Y

Black / Yellow

. . .

Br / B

Brown / Black

. .

Br / L

Brown / Blue

. .

Br / W

Brown / White

Br / Y

Brown / Yellow

. .

L / B

Blue / Black

. . .

L / R

Blue / Red

. . .

L / W

Blue / White

. .

L / Y

Blue / Yellow

. . .

R / B

Red / Black

. . .

R / G

Red / Green

. .

R / W

Red / White

. .

R / Y

Red / Yellow

. . .

Pickup coil

A.C. magneto

Rectifier / regulator

Main switch

Ignition fuse

Battery

Main fuse

Starter relay

Starter motor

Oil level gauge

Oil lamp relay

Starting circuit cut-off relay

Fuel pump

Throttle position sensor

Igniter unit

Ignition coil

Spark plug

Speed sensor

Neutral switch

Engine warning light

Oil warning light

Speedometer

Turn signal indicator light

Meter light

Neutral indicator light

High beam indicator light

Trip switch

Sidestand switch

Flasher relay

Turn signal switch

Rear turn signal light (right)

Rear turn signal light (left)

Front turn signal light (right)

Front turn signal light (left)

Clutch switch

Start switch

Engine stop switch

Front brake switch

Right handlebar switch

Horn

Horn switch

Dimmer switch

Rear brake switch

Pass switch

Left handlebar switch

Headlight

Tail / brake light

Backup fuse

Headlight fuse

Signal fuse

Carburetor heater fuse

Thermo switch

Carburetor heater relay

Carburetor heater 1

Carburetor heater 2

Carburetor heater earth

Diode

XVS1100L WIRING DIAGRAM (for AUS)

Yamaha XVS1100 (L). Service Manual - part 22