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Yamaha 2004 XVS1100AS, Owner'S Manual, Page: 57 / 94

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Yamaha 2004 XVS1100AS Owner'S Manual Download Page 57

PERIODIC MAINTENANCE AND MINOR REPAIR

6-11

6

EAU20670

Cleaning the air filter element 

The air filter element should be cleaned
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart. Clean the air filter element
more frequently if you are riding in un-
usually wet or dusty areas.

1. Remove the air filter case cover by

removing the screws.

2. Pull the air filter element out.
3. Lightly tap the air filter element to

remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as shown.
If the air filter element is damaged,
replace it.

4. Insert the air filter element into the

air filter case as shown.

CAUTION:

ECA10480

●

Make sure that the air filter ele-
ment is properly seated in the
air filter case.

●

The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.

5. Install the air filter case cover by in-

stalling the screws.

1. Air filter case cover

2. Screw

1. Air filter element
2. Projection

3. Slot

5YS20.book  Page 11  Thursday, June 19, 2003  1:41 PM

Summary of Contents for 2004 XVS1100AS

Page 1: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2003 07 0 3 1 CR E 5YS 28199 20 XVS1100S XVS1100AS OWNER S MANUAL ...

Page 2: ...5YS20 book Page 2 Thursday June 19 2003 1 41 PM ...

Page 3: ...s to enjoy all advantages of your XVS1100 XVS1100A The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and others from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible con dition If you have any further questions do not hesitate to contact your...

Page 4: ...n your motorcycle and this manual If you have any questions concerning this manual please consult your Yamaha dealer WARNING EWA10030 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the motor cycle operator a...

Page 5: ...NER S MANUAL 2003 by Yamaha Motor Co Ltd 1st edition June 2003 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan 5YS20 book Page 2 Thursday June 19 2003 1 41 PM ...

Page 6: ... up a cold engine XVS1100A 5 2 Starting a warm engine 5 4 Shifting 5 4 Tips for reducing fuel consumption 5 5 Engine break in 5 5 Parking 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1 Owner s tool kit 6 1 Periodic maintenance and lubrication chart 6 2 Removing and installing the panel 6 6 Checking the spark plugs 6 6 Engine oil 6 8 Final gear oil 6 10 Cleaning the air filter element 6 11 Adjusting...

Page 7: ...6 27 Battery 6 27 Replacing the fuses 6 28 Replacing the headlight bulb 6 30 Replacing a turn signal light bulb or the tail brake light bulb 6 31 Supporting the motorcycle 6 32 Troubleshooting 6 33 Troubleshooting chart 6 34 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Motorcycle noise regulation for Australia 9 2 5YS20...

Page 8: ...dents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when ap proaching and passing through intersections since intersec tions are the most likely places for motorcycle accidents to oc cur Ride where other motori...

Page 9: ...face shield or goggles Wind in your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the eng...

Page 10: ... those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit suspension travel steering travel or control operation or ob scure lights or reflectors Accessories fitte...

Page 11: ...ust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fall over Do not park the motorcycle near a flammable source e g a kero sene heater or near an open flame otherwise it could catch fire When transporting the motorcycle in another vehicle make su...

Page 12: ...TY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle 1 2 3HP 21568 E0 5YS20 book Page 5 Thursday June 19 2003 1 41 PM ...

Page 13: ...cock page 3 11 3 Shock absorber assembly spring preload adjusting ring page 3 16 4 Helmet holder page 3 14 5 Storage compartment page 3 15 6 Owner s tool kit page 6 1 7 Fuse box page 6 28 8 Engine oil level check window page 6 8 5YS20 book Page 1 Thursday June 19 2003 1 41 PM ...

Page 14: ... 3 11 3 Shock absorber assembly spring preload adjusting ring page 3 16 4 Helmet holder page 3 14 5 Storage compartment page 3 15 6 Owner s tool kit page 6 1 7 Fuse box page 6 28 8 Engine oil level check window page 6 8 5YS20 book Page 2 Thursday June 19 2003 1 41 PM ...

Page 15: ...2 3 2 EAU32230 Right view XVS1100 1 Battery page 6 27 2 Main fuse page 6 28 3 Main switch steering lock page 3 2 4 Air filter element page 6 11 5 Brake pedal page 3 9 5YS20 book Page 3 Thursday June 19 2003 1 41 PM ...

Page 16: ...CRIPTION 2 4 2 XVS1100A 1 Battery page 6 27 2 Main fuse page 6 28 3 Main switch steering lock page 3 2 4 Air filter element page 6 11 5 Brake pedal page 3 9 5YS20 book Page 4 Thursday June 19 2003 1 41 PM ...

Page 17: ...ver page 3 7 2 Left handlebar switches page 3 6 3 Starter choke lever page 3 12 4 Speedometer unit page 3 5 5 Fuel tank cap page 3 9 6 Right handlebar switches page 3 6 7 Throttle grip page 6 13 8 Brake lever page 3 8 5YS20 book Page 5 Thursday June 19 2003 1 41 PM ...

Page 18: ...TELY IF IT IS LOST If the code re reg istering key is lost registering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle however if code re registering is required i e if a new standard key is made or all keys are lost the entire immobi lizer system must be replaced Therefore it is highly recom mended to use either standard key and keep the code ...

Page 19: ...a safe place and only use it for code re registering EAU10480 ON XVS1100 All electrical systems are supplied with power and the headlight meter lighting and taillight come on and the engine can be started The key cannot be re moved EAU10570 ON XVS1100A All electrical circuits are supplied with power the meter lighting taillight and auxiliary light come on and the engine can be started The key cann...

Page 20: ... systems will be switched off which may result in loss of control or an accident Make sure that the vehicle is stopped be fore turning the key to OFF or LOCK EAU10920 Parking XVS1100A The steering is locked the taillight and auxiliary light are on and the hazard light can be turned on but all other electrical systems are off The key can be removed The steering must be locked before the key can be ...

Page 21: ...s not a mal function EAU11500 Engine trouble warning light This warning light comes on or flashes when an electrical circuit monitoring the engine is defective When this occurs have a Yamaha dealer check the self diagnosis system The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha deal...

Page 22: ...y ring Immobilizer system keys may cause signal interfer ence which may prevent the engine from starting 2 If the engine starts turn it off and try starting the engine with the standard keys 3 If one or both of the standard keys do not start the engine take the vehicle the code re registering key and both standard keys to a Yamaha dealer and have the stan dard keys re registered EAU11731 Speedomet...

Page 23: ... h EAU12342 Handlebar switches Left Right XVS1100 Right XVS1100A EAU12350 Pass switch Press this switch to flash the headlight EAU12400 Dimmer switch Set this switch to for the high beam and to for the low beam EAU12460 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When re leased the switch returns to the center 1 Pass switch 2 Di...

Page 24: ...key in the ON or posi tion use this switch to turn on the haz ard light simultaneous flashing of all turn signal lights The hazard light is used in case of an emergency or to warn other drivers when your vehicle is stopped where it might be a traffic hazard CAUTION ECA10060 Do not use the hazard light for an ex tended length of time otherwise the battery may discharge EAU12820 Clutch lever The clu...

Page 25: ...The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever when shifting the gears of the 5 speed con stant mesh transmission equipped on this motorcycle NOTE Use your toes or heel to shift up and your toes to shift down EAU12890 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the han...

Page 26: ... the fuel tank cap 1 Insert the fuel tank cap into the tank opening with the key inserted in the lock and with the mark facing forward 2 Turn the key counterclockwise to the original position remove it and then close the lock cover NOTE The fuel tank cap cannot be installed unless the key is in the lock In addition the key cannot be removed if the cap is not properly installed and locked WARNING E...

Page 27: ... only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line with a research octane number of 91 or higher If knocking or pinging oc curs use a gasoline of a different brand or premium unleaded fuel Use of un leaded fue...

Page 28: ...ON With the fuel cock lever in this position fuel flows to the carburetors Turn the fuel cock lever to this position when starting the engine and riding RES This indicates reserve With the fuel cock lever in this position the fuel re serve is made available Turn the fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn ...

Page 29: ...use of the starter choke will cause after burning If this occurs turn off the starter choke EAU14211 Seats XVS1100 Passenger seat To remove the passenger seat Remove the nut and then pull the pas senger seat up To install the passenger seat Insert the projection on the front of the passenger seat into the seat holder as shown place the seat in the original po sition and then install the nut Rider ...

Page 30: ... NOTE Make sure that the seats are properly secured before riding EAU14200 Seats XVS1100A Passenger seat To remove the passenger seat Remove the bolt and then pull the pas senger seat up To install the passenger seat Insert the projection on the front of the passenger seat into the holder as shown place the seat in the original po sition and then install the bolt 1 Bolt 2 Seat bracket 1 Projection...

Page 31: ... holders as shown place the seat in the origi nal position and then install the bolt 2 Install the passenger seat NOTE Make sure that the seats are properly secured before riding EAU14281 Helmet holder XVS1100 XVS1100A To open the helmet holder insert the key into the lock and then turn the key as shown 1 Projection 2 Seat holder 1 Bolt 1 Projection 2 Seat holder 1 Helmet holder 1 Helmet holder 5Y...

Page 32: ...nt The storage compartment is located on the left side of the vehicle To open the storage compartment 1 Slide the lock cover open insert the key into the lock and then turn it clockwise 2 Pull the storage compartment cov er out as shown To close the storage compartment 1 Place the storage compartment cover in its original position as shown 1 Storage compartment cover 2 Storage compartment lock cov...

Page 33: ...adjusting mechanism beyond the maximum or minimum settings Adjust the spring preload as follows 1 Remove the rider seat See page 3 12 2 Remove each quick fastener from the ignitor unit panel by pushing the center in with a screwdriver then pulling the fastener out 3 Pull the ignitor unit panel out to the right 4 Remove the mudguard by remov ing each quick fastener XVS1100 1 Storage compartment cov...

Page 34: ...the ad justment XVS1100 XVS1100A 6 Install the mudguard and ignitor unit panel by installing the quick fasteners NOTE To install a quick fastener push the pin back so that it will protrude from the fas tener head and then insert the fastener and push the protruding pin in until it is flush with the fastener head 1 Quick fastener 2 Mudguard 1 Spring preload adjusting ring 2 Position indicator 3 Spe...

Page 35: ... not tamper with or attempt to open the gas cylinder Do not subject the shock ab sorber to an open flame or other high heat sources otherwise it may explode due to excessive gas pressure Do not deform or damage the gas cylinder in any way as this will result in poor damping per formance Always have a Yamaha dealer service the shock absorber EAU15150 Luggage strap holders There is a luggage strap h...

Page 36: ...ng the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly as described below and have a Yamaha dealer re pair it if it does not function proper ly EAU15311 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the tr...

Page 37: ...ter the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden This check is most reliable if performed with a warmed up engine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle ...

Page 38: ...sequences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the Pre operation check list is not...

Page 39: ... free play Adjust if necessary Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 19 6 21 6 22 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add...

Page 40: ...hat operation is smooth Lubricate pedal pivoting points if necessary 6 24 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 24 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 25 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and swit...

Page 41: ...r pulled and the sid estand up WARNING EWA10290 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 19 Never ride with the sidestand down 1 Turn the fuel cock lever to ON 2 Turn the key to ON and make sure that the engine stop switch is set to 3 Shift the transmission into the neu tral position NOTE When the transmis...

Page 42: ...ngine life always warm the engine up before starting off Never accelerate hard when the engine is cold 7 When the engine is warm turn the starter choke off NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off EAU32890 Starting and warming up a cold engine XVS1100A In order for the ignition circuit cut off system to enable starting one of the following...

Page 43: ...ing light again If the warning light does not come on when turning the key to ON or if it does not go off after starting the engine with sufficient engine oil have a Yamaha dealer check the elec trical circuit The engine trouble warning light should also come on when the key is turned to ON If the warning light does not come on when the key is turned to ON flashes or remains on after starting the ...

Page 44: ...nsmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it CAUTION ECA10260 Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate...

Page 45: ... g in traffic jams at traffic lights or at railroad crossings EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing material carefully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and...

Page 46: ...ouble should occur during the engine break in period immediately have a Yamaha dealer check the vehicle EAU17170 Parking When parking stop the engine remove the key from the main switch and then turn the fuel cock lever to OFF WARNING EWA10310 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope o...

Page 47: ...not familiar with mainte nance work have a Yamaha dealer do it for you EAU17450 Owner s tool kit The owner s tool kit is located inside the storage compartment See page 3 15 The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torqu...

Page 48: ...NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING 1000 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Fuel filter Check condition 3 Spark plugs Check condition Clean and regap Replace 4 Valves Check valve clearance Adjust 5 Air filter element Clean Replace 6 Clutch Check operation Adjust 7 Front brake Check operation fluid level and vehicle for fluid leakage Repl...

Page 49: ... grease Every 50000 km 15 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20000 km 16 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 17 Sidestand Check operation Lubricate 18 Sidestand switch Check operation 19 Front fork Check operation and for oil leakage 20 Shock absorber assem bly Check operation ...

Page 50: ...nge Check oil level and vehicle for oil leakage 24 Engine oil filter element Replace 25 Final gear oil Check oil level and vehicle for oil leakage Change 26 Front and rear brake switches Check operation 27 Moving parts and ca bles Lubricate 28 Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable...

Page 51: ...PERIODIC MAINTENANCE AND MINOR REPAIR 6 5 6 Replace the brake hoses every four years and if cracked or damaged 5YS20 book Page 5 Thursday June 19 2003 1 41 PM ...

Page 52: ...n and then install the bolt EAU19551 Checking the spark plugs The spark plugs are important engine components which are easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plugs should be removed and checked in accordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plugs can re veal the condition of the engine To...

Page 53: ...tead have a Yamaha dealer check the vehicle 3 Check each spark plug for elec trode erosion and excessive car bon or other deposits and replace it if necessary To install a spark plug 1 Measure the spark plug gap with a wire thickness gauge and if nec essary adjust the gap to specifica tion 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spar...

Page 54: ...n an upright posi tion NOTE Make sure that the vehicle is positioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil set tles and then check the oil level through the check window located at the bottom left side of the crank case NOTE The engine ...

Page 55: ... enters the crankcase 6 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause NOTE After the engine is started the engine oil level warning light should go off if the oil level is sufficient CAUTION ECA10400 If the oil level warning light flickers or remains on immediately turn the engi...

Page 56: ...nal gear case NOTE The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the fill er hole add sufficient oil of the rec ommended type to raise it to the correct level To change the final gear oil 1 Place an oil pan under the final gear case to collect the used oil 2 Remove the oil filler bolt and drain bolt to drain the oil from the final gear case 3 Install the ...

Page 57: ...o remove most of the dust and dirt and then blow the remaining dirt out with compressed air as shown If the air filter element is damaged replace it 4 Insert the air filter element into the air filter case as shown CAUTION ECA10480 Make sure that the air filter ele ment is properly seated in the air filter case The engine should never be op erated without the air filter ele ment installed otherwis...

Page 58: ... engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart The engine should be warm before making this adjustment NOTE The engine is warm when it quickly responds to the throttle A diagnostic tachometer is needed to make this adjustment 1 Attach the tachometer to the spark plug lead...

Page 59: ...als specified in the periodic maintenance and lubrication chart EAU32771 Tires XVS1100 To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10500 The tire air pressure must be checked and adjusted on cold t...

Page 60: ... a nail or glass fragments in it or if the sidewall is cracked con tact a Yamaha dealer immediately and have the tire replaced NOTE The tire tread depth limits may differ from country to country Always comply with the local regulations WARNING EWA10560 It is dangerous to ride with a worn out tire When a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately The...

Page 61: ...afe operation of your motor cycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10500 The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature The tire air pressure must be ad justed in accordance with...

Page 62: ...enly on both sides Adjust the suspension and tire air pressure with regard to the load Check the tire condition and air pressure before each ride Tire inspection Always check the tires before operating the motorcycle If a tire tread shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked con tact a Yamaha dealer immediately and have t...

Page 63: ... ap proved for this model by Yamaha Motor Co Ltd EAU21940 Spoke wheels XVS1100 To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage and the spokes for looseness or dam age before each ride If any dam age is found have a Yamaha dealer replace the wheel Do n...

Page 64: ... after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics After repairing or replacing a tire tighten the valve stem nut and locknut to the specified torques EAU22020 Adjusting the clutch lever free play The clutch lever free play should mea sure 5 0 10 0 mm 0 20 0 39 in as shown Periodically check the clutch le ver free play and if neces...

Page 65: ...essary adjust it as follows 1 Loosen the locknut at the brake le ver 2 To increase the brake lever free play turn the adjusting screw in di rection a To decrease the brake lever free play turn the adjusting screw in direction b 3 Tighten the locknut WARNING EWA10630 After adjusting the brake lever free play check the free play and make sure that the brake is working properly A soft or spongy feeli...

Page 66: ...00A 98 5 mm 3 88 in above the top of the foot rest as shown Periodically check the brake pedal position and if necessary have a Yamaha dealer adjust it WARNING EWA10690 A soft or spongy feeling in the brake pedal can indicate the presence of air in the hydraulic system If there is air in the hydraulic system have a Yamaha dealer bleed the system be fore operating the motorcycle Air in the hydrauli...

Page 67: ...22321 Checking the front and rear brake pads Front brake Rear brake The front and rear brake pads must be checked for wear at the intervals spec ified in the periodic maintenance and lubrication chart Each brake pad is provided with a wear indicator groove which allows you to check the brake pad wear without having to disassem ble the brake To check the brake pad wear check the wear indicator groo...

Page 68: ...the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid ...

Page 69: ... the condition of the cables should be checked before each ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING EWA10720 Damage to the outer sheath may in terfere with proper cable operation and will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent ...

Page 70: ...d be lu bricated if necessary EAU23140 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all pur pose grease Recommended lubricant Lithium soap based grease all pur pose grease 5YS20 book Page 24 Thursday June 19 ...

Page 71: ...king the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on...

Page 72: ...ng must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Ya...

Page 73: ...ry cell seals as this would permanent ly damage the battery WARNING EWA10760 Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities...

Page 74: ... After installation make sure that the battery leads are properly con nected to the battery terminals CAUTION ECA10630 Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a special constant volt age battery charger is required Using a conventional battery charger will damage the battery If you do not have access to a se...

Page 75: ...ied amperage CAUTION ECA10640 Do not use a fuse of a higher amper age rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire 1 Fuse box 2 Headlight fuse 3 Signaling system fuse 4 Ignition fuse 5 Carburetor heater fuse 6 Parking lighting fuse 7 Backup fuse for odometer and immobilizer system 8 Spare fuse 1 Quick fastener 1 Ignitor unit panel 2 Spare m...

Page 76: ...it will protrude from the fas tener head then insert the fastener and push the protruding pin in until it is flush with the fastener head 10 Install the rider seat EAU23791 Replacing the headlight bulb This model is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove the headlight unit by re moving the screws 2 Disconnect the headlight coupler and t...

Page 77: ... the luminosity of the bulb and the bulb life will be adversely af fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with al cohol or thinner 5 Install the headlight bulb cover and then connect the coupler 6 Install the headlight unit by install ing the screws 7 Have a Yamaha dealer adjust the headlight beam if necessary EAU24281 Replacing a turn s...

Page 78: ...and up right Check that the motorcycle is in a stable and level position before starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack un der the frame in front of the rear wheel 2 Raise the fr...

Page 79: ... troubleshooting chart represents a quick and easy procedure for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often infe...

Page 80: ...gnition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over ...

Page 81: ... leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical products on plastic part...

Page 82: ...ion After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be re moved through polishing 3 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal including chrome a...

Page 83: ...ock that has an OFF posi tion Turn the fuel cock lever to OFF 3 Drain the carburetor float cham bers by loosening the drain bolts this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to pro tect the cyl...

Page 84: ...eels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlets with plas tic bags to prevent moisture from entering them 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C...

Page 85: ...or SAE20W50 Recommended engine oil grade API service SE SF SG type or higher Engine oil quantity Without oil filter element replacement 3 00 L 3 17 US qt 2 64 Imp qt With oil filter element replacement 3 10 L 3 28 US qt 2 73 Imp qt Final gear oil Type SAE80 API GL 4 Hypoid gear oil Quantity 0 20 L 0 21 US qt 0 18 Imp qt Air filter Air filter element Dry element Fuel Recommended fuel Unleaded gasol...

Page 86: ...del XVS1100 BRIDGESTONE EXEDRA G546G XVS1100A BRIDGESTONE EXEDRA G702 Loading Maximum load XVS1100 200 kg 441 lb XVS1100A 203 kg 448 lb Total weight of rider passenger cargo and accessories Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front XVS1100 200 kPa 29 psi 2 00 kgf cm XVS1100A 225 kPa 33 psi 2 25 kgf cm Rear XVS1100 225 kPa 33 psi 2 25 kgf cm XVS1100A 250 kPa ...

Page 87: ... Bulb type Halogen bulb Bulb voltage wattage x quantity Headlight 12 V 60 W 55 0 W 1 Tail brake light 12 V 5 W 21 0 W 1 Front turn signal light 12 V 21 0 W 2 Rear turn signal light 12 V 21 0 W 2 Meter lighting 14 V 1 4 W 2 Neutral indicator light 12 V 1 7 W 1 High beam indicator light 12 V 1 7 W 1 Oil level warning light 12 V 1 7 W 1 Turn signal indicator light 12 V 1 7 W 1 Engine trouble warning ...

Page 88: ...L INFORMATION EAU26381 Key identification number XVS1100 XVS1100A The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU26400 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided 1 Key identification number 1 Ke...

Page 89: ...EAU26570 Motorcycle noise regulation for Australia TAMPERING WITH NOISE CON TROL SYSTEM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inopera tive by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or delivery to the ul...

Page 90: ...mmobilizer system indicator light XVS1100A 3 4 Immobilizer system XVS1100A 3 1 Indicator and warning lights 3 4 K Key identification number 9 1 L Labels location of 1 5 Luggage strap holders 3 18 M Main switch steering lock XVS1100 3 2 Main switch steering lock XVS1100A 3 2 Model label 9 2 N Neutral indicator light 3 4 Noise regulation for Australia 9 2 O Oil level warning light 3 4 P Panel removi...

Page 91: ...3 Troubleshooting chart 6 34 Turn signal indicator light 3 4 Turn signal light bulb or tail brake light bulb replacing 6 31 Turn signal switch 3 6 V Valve clearance adjusting 6 13 Vehicle identification number 9 1 W Wheel bearings checking 6 27 Wheels XVS1100 6 17 Wheels XVS1100A 6 18 5YS20 book Page 2 Thursday June 19 2003 1 41 PM ...

Page 92: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 93: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 94: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2003 07 0 3 1 CR E 5YS 28199 20 XVS1100S XVS1100AS OWNER S MANUAL ...

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