Yamaha 5KSJ Service Manual Download | Manualshive

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CABLE ROUTING

SPEC

1

Clutch cable

2

Starter cable

3

Handlebar switch lead (left)

4

Handlebar switch lead (right)

5

Spark plug lead

6

Throttle cable

7

Fuel hose (fuel cock to filter)

8

Fuel breather hose (fuel tank roll
over valve) (for CAL)

9

Fuse box

10

Alarm connector

11

Fuel pump lead

12

Speed sensor lead

13

Sidestand switch lead

14

Neutral switch lead

15

Pickup coil lead

16

To engine

17

A.C. magneto lead

18

Ventilation hose

19

Sensing hose (AI system to car-
buretor joint)

20

Fuel hose (fuel pump to carbure-
tor)

21

Clip

22

Brake hose

23

Heat protector

24

Speedometer lead

25

Wire harness

26

Purge hose (carburetor to sole-
noid valve) (for CAL)

27

Fitting plate

28

Fuel hose (inlet) (fuel filter to fuel
pump)

29

Fuel hose (outlet) (fuel pump to
carburetor)

30

Alarm connector lead

31

Wire harness

EB206000

CABLE ROUTING

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Summary of Contents for 5KSJ

Page 1: ......

Page 2: ... with the following manual XVS1100L XVS1100LC SERVICE MANUAL LIT 11616 12 63 5EL 28197 E0 XVS1100AM XVS1100AMC SUPPLEMENTARY SERVICE MANUAL LIT 11616 13 36 5KS 28197 E0 EB000000 XVS1100AWR C XVS1100ATR C SUPPLEMENTARY SERVICE MANUAL 2002 by Yamaha Motor Co Ltd First edition November 2002 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd ...

Page 3: ...his policy is intended to provide the customer with the most satisfaction from his vehicle and to conform with federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manua...

Page 4: ...help identify parts and clarify procedure steps there are exploded diagrams at the start of each re moval and disassembly section 1 An easy to see exploded diagram 4 is provided for removal and disassembly jobs 2 Numbers 5 are given in the order of the jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in ...

Page 5: ...tem 8 Troubleshooting Symbols 9 to 16 indicate the following 9 Serviceable with engine mounted 10 Filling fluid 11 Lubricant 12 Special tool 13 Tightening torque 14 Wear limit clearance 15 Engine speed 16 Electrical data Symbols 17 to 22 in the exploded diagrams indi cate the types of lubricants and lubrication points 17 Engine oil 18 Gear oil 19 Molybdenum disulfide oil 20 Wheel bearing grease 21...

Page 6: ...NANCE AND LUBRICATION CHART 15 CHASSIS FRONT WHEEL AND BRAKE DISCS 17 REMOVING THE FRONT WHEEL 19 CHECKING THE FRONT WHEEL 19 CHECKING THE BRAKE DISCS 21 INSTALLING THE FRONT WHEEL 23 REAR WHEEL AND BRAKE DISC 24 MUFFLER AND BRAKE CALIPER 24 REAR WHEEL 25 REMOVING THE REAR WHEEL 27 CHECKING THE REAR WHEEL 27 CHECKING THE REAR WHEEL DRIVE HUB 28 INSTALLING THE REAR WHEEL 28 ELECTRICAL CHECKING THE ...

Page 7: ... in 140 mm 5 5 in 3400 mm 133 9 in Basic weight With oil and a full fuel tank 285 kg 628 lb Tire Type Size front rear Manufacturer front rear Type front rear Tubeless 130 90 16M C 67S 170 80 15M C 77S BRIDGESTONE DUNLOP BRIDGESTONE DUNLOP EXEDRA G703 D404F EXEDRA G702 D404G Tire pressure cold tire 0 X 90 kg 0 X 198 lb load front rear 90 kg 198 lb X Maximum load front rear 225 kPa 2 25 kg cm2 32 6 ...

Page 8: ... X 37 3 kPa 260 X 280 mmHg 75 X 85_C 167 X 185_F SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS Fuel pump Type Model manufacturer Consumption amperage max Output pressure Electrical type UC Z61B MITSUBISHI 0 8 A 12 kPa 0 12 kg cm2 1 7 psi SSS SSS SSS SSS CHASSIS Item Standard Limit Front suspension Front fork travel Fork spring free length Fitting length Collar...

Page 9: ...3 00 Aluminum SSS SSS SSS SSS SSS 1 0 mm 0 04 in 0 5 mm 0 02 in Rear wheel Type Rim size Rim material Rim runout limit radial lateral Cast wheel 15M C MT4 50 Aluminum SSS SSS SSS SSS SSS 1 0 mm 0 04 in 0 5 mm 0 02 in ELECTRICAL Item Standard Limit T C I Pickup coil resistance color T C I unit model manufacturer 189 X 231 Ω at 20_C 68_F Gray Black J4T142 MITSUBISHI SSS SSS Rectifier regulator Regul...

Page 10: ... manufacturer Amperage rating Constant mesh type SM 13 MITSUBA 0 6 kW 0 025 X 0 035 Ω at 20_C 68_F 12 5 mm 0 49 in 7 65 X 10 01 N 780 X 1021 g 27 51 X 36 01 OZ 28 mm 1 10 in 0 7 mm 0 03 in MS5F 421 JIDECO 180 A SSS SSS SSS SSS 4 mm 0 16 in SSS 27 mm 1 06 in SSS SSS SSS Starting circuit cut off relay Model manufacturer Coil resistance G8R 30Y U OMRON 202 5 X 247 5 Ω at 20_C 68_F SSS Thermostat swit...

Page 11: ...d 13 Sidestand switch lead 14 Neutral switch lead 15 Pickup coil lead 16 To engine 17 A C magneto lead 18 Ventilation hose 19 Sensing hose AI system to car buretor joint 20 Fuel hose fuel pump to carbure tor 21 Clip 22 Brake hose 23 Heat protector 24 Speedometer lead 25 Wire harness 26 Purge hose carburetor to sole noid valve for CAL 27 Fitting plate 28 Fuel hose inlet fuel filter to fuel pump 29 ...

Page 12: ... D When installing the pipe of throttle cable press it inside E Clamp the fuel hoses to the frame with the clamp F Cross the fuel hose fuel cock side and fuel hose carburetor side between guide of frame and clamp carburetor side is upper G When connecting the sensing hose carburetor joint to AI sys tem with a nozzle H Push the wire harness inside of the side cover I Push the sensing hose inside of...

Page 13: ...le guide P Fasten the handlebar switch leads left and right under the handle crown with a plastic band Set the band at four notches and install it no slacking Q Route the each hoses through the frame guide and do not pinch it R When installing the fitting plate do not pinch the each hoses and wireharness S When install the AI system push the wire harness to space of rear side ...

Page 14: ...3 Breather hose 14 Purge hose carburetor to sole noid valve For CAL 15 Rear brake switch 16 Reserve hose 17 Air filter drain hose 18 Delay relay 19 Battery negative lead 20 Oil level switch lead 21 Rear brake light switch lead 22 Light reduce relay 23 Rectifier regulator 24 Stay 1 25 Down tube 26 Rear brake hose 27 Frame 28 Stay 2 29 Turn signal relay 30 Handlebar switch lead left 31 Silencer 32 T...

Page 15: ...harness into the space between frame and start er motor relay D Route the harness and starter motor lead that are con nected to the rectifier regulator and other equipment by the out side of the frame side bracket and then secure it by passing the band through the weight saving hole of the bracket The secur ing point should be within 0 to 10 mm 0 to 0 39 in right above the junction point of harnes...

Page 16: ...cylinder reservoir hose to the down tube with a plas tic locking tie and cut the end of locking tie and position is inside of frame M 20 mm 0 79 in from bead end N Locate the band to forward of down tube E Connect the purge hose carbu retor side solenoid valve side with joint knob is out side of frame F Route the front turn signal posi tion light lead and headlight lead through the rear of headlig...

Page 17: ...ght to the frame with a holder The part to open and shut is out side of the body CABLE ROUTING SPEC V Arrange the throttle position sen sor connector carburetor heater connector and thermo switch connector between the starting circuit cut off relay and high ten sion code W Secure to the battery box with the band cut the surplus section and then point the locking sec tion to the regulator side X Pu...

Page 18: ...ive lead 14 Tail brake light lead 15 Starter relay 16 Starter motor positive lead 17 Fuel tank breather hose fuel tank to roll over valve for CAL 18 Fuel pump outlet hose 19 Fuel pump inlet hose 20 Ventilation hose 21 Starter cable 22 Sensing hose AI system to car buretor joint 23 Fuel hose fuel cock to fuel filter 24 Throttle position sensor lead 25 Carburetor heater lead 26 Tappet cover 27 Clutc...

Page 19: ... unit lead and tail brake light lead to the frame with a clamp Point the open close section to the upper side of the vehicle H To the rear fender I Connect the wire harness to the igniter unit through the hole of ig niter plate J Position the mark on the steel band to forward K Fasten the wire harness with a band on the tool box plate L Fasten the wire harness to the frame with a plastic locking t...

Page 20: ...igniter plate hole to the wire harness P To the wire harness Q Clamp the tail brake light lead with mud guard clamp R Clamp the tail brake light lead with a holder on the mud guard S Position the locking tie upward T Forward CABLE ROUTING SPEC ...

Page 21: ...Ǹ Ǹ Ǹ Ǹ Ǹ 5 Fuel filter S Replace initial 20 000 mi 31 000 km and thereafter every 20 000 mi 31 000 km Ǹ 6 Exhaust system S Check for leakage S Tighten if necessary S Replace gasket s if necessary Ǹ Ǹ Ǹ Ǹ Ǹ 7 Carburetor synchronization S Adjust synchronization of carburetors Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ 8 Idle speed S Check and adjust engine idle speed S Adjust cable free play Ǹ Ǹ Ǹ Ǹ Ǹ 9 Evaporative emission cont...

Page 22: ...essary Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ 18 Tires S Check tire tread wear and for damage S Replace if necessary Ǹ Ǹ Ǹ Ǹ Ǹ 19 Shock absorber assembly S Check operation and for oil leakage S Replace if necessary Ǹ Ǹ Ǹ Ǹ Ǹ 20 Chassis fasteners S Make sure that all nuts bolts and screws are properly tightened S Tighten if necessary Ǹ Ǹ Ǹ Ǹ Ǹ 21 Throttle grip hous ing and cable S Check operation and free play S Adjust the t...

Page 23: ...rts in the order listed Stand the motorcycle on a level surface For installation reverse the removal procedure Refer to INSTALLING THE FRONT WHEEL WARNING Securely support the motorcycle so there is no danger of it falling over Refer to REMOVING INSTALLING THE FRONT WHEEL 59 Nm 5 9 mSkg 43 ftSlb 20 Nm 2 0 mSkg 14 ftSlb 40 Nm 4 0 mSkg 29 ftSlb 23 Nm 2 3 mSkg 17 ftSlb FRONT WHEEL AND BRAKE DISCS CHA...

Page 24: ... AND BRAKE DISCS CHAS Order Job name Part name Q ty Remarks Disassembling the front wheel Oil seals Bearings Collar 2 2 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 ...

Page 25: ...nd right Sbrake calipers 2 left and right Do not squeeze the brake lever when removing the brake calipers 3 Loosen Spinch bolt front wheel axle 1 Sfront wheel axle 2 4 Elevate Sfront wheel Place the motorcycle on a suitable stand so that the front wheel is elevated EAS00526 CHECKING THE FRONT WHEEL 1 Check Swheel axle Roll the wheel axle on a flat surface Bends Replace Do not attempt to straighten...

Page 26: ...pproximately 100 km 62 mi should be traveled at normal speed before any highspeed riding is done 5 Check Swheel bearings Front wheel turns roughly or is loose Re place the wheel bearings Soil seals Damage wear Replace 6 Replace Swheel bearings New Soil seals New a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver To prevent damaging the wheel place a ra...

Page 27: ...easure Sbrake disc deflection 1 Out of specification Correct the brake disc deflection or replace the brake disc Brake disc deflection limit maximum Front 0 15 mm 0 006 in Rear 0 15 mm 0 006 in a Place the motorcycle on a suitable stand so that the wheel is elevated b Before measuring the front brake disc deflec tion turn the handlebar to the left or right to ensure that the front wheel is station...

Page 28: ...disc deflection a Remove the brake disc b Rotate the brake disc by one bolt hole c Install the brake disc Tighten the brake disc bolts in stages and in a crisscross pattern Brake disc bolt 23 Nm 2 3 mSkg 17 ftSlb LOCTITE d Measure the brake disc deflection e If out of specification repeat the adjustment steps until the brake disc deflection is within specification f If the brake disc deflection ca...

Page 29: ...el axle Soil seallips Recommended lubricant Lithium soap base grease 2 Install Sfront wheel assembly The arrow mark a on the tire must point in the direction of the wheel 3 Tighten Swheel axle 1 Swheel axle pinch bolt 2 Before tightening the wheel axle nut push down hard on the handlebar several times and check if the front fork rebounds smoothly 4 Install Sbrake calipers Sreflectors Make sure tha...

Page 30: ...ke caliper 1 1 1 1 Remove the parts in the order listed Refer to REMOVING THE REAR WHEEL For installation reverse the removal procedure 40 Nm 4 0mSkg 29 ftSlb 25 Nm 2 5mSkg 18 ftSlb 20 Nm 2 0mSkg 14 ftSlb 30 Nm 3 0mSkg 22 ftSlb 20 Nm 2 0mSkg 14 ftSlb REAR WHEEL AND BRAKE DISC CHAS REAR WHEEL AND BRAKE DISC MUFFLER AND BRAKE CALIPER ...

Page 31: ... Remove the parts in the order listed Securely support the motorcycle so there is no danger of it falling over Drain Refer to FINAL GEAR OIL REPLACE MENT in CHAPTER 3 Refer to FUEL TANK AND SEATS in CHAPTER 3 Loosen For installation reverse the removal procedure Refer to REMOVING INSTALLING THE REAR WHEEL WARNING 40 Nm 4 0mSkg 29 ftSlb 23 Nm 2 3mSkg 17 ftSlb 23 Nm 2 3mSkg 17 ftSlb 74 Nm 7 4mSkg 54...

Page 32: ...marks Rear wheel disassembly Disassembling the rear wheel Lock washers Clutch hub Dampers O rings Oil seal Bearing Spacer Bearings 2 1 6 2 1 1 1 2 Remove the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 62 Nm 6 2mSkg 45 ftSlb ...

Page 33: ...ove Sbrake caliper 1 Sbrake caliper bracket bolt Do not depress the brake pedal when removing the brake caliper 4 Remove Swheel axle nut Swasher 5 Remove Srear axle end nut 2 6 Remove Srear axle holder 3 7 Remove Srear wheel EAS00566 CHECKING THE REAR WHEEL 1 Check Swheel axle Srear wheel Swheel bearings Soil seals Refer to FRONT WHEEL AND BRAKE DISCS 2 Check Stire Damage wear Replace Refer to CHE...

Page 34: ...wheel assembly a Install the rear wheel assembly 1 with the rear brake caliper bracket 2 and hold the bracket to keep the specified position b After installation of the rear axle shaft 3 slide the wheel assembly to forward direc tion c To make sure the caliper bracket mounts on the swingarm and then fix the holder of swin garm temporally The holder should installed with the punch mark a facing upp...

Page 35: ...nut 23 Nm 2 3 mSkg 17 ftSlb g Tighten the rear brake caliper bracket bolt with specified tightening torque Brake caliper bracket bolt 40 Nm 4 0 mSkg 29 ftSlb h Install the rear brake caliper on the bracket and tighten the bolts with specified tightening torque Brake caliper bolt 40 Nm 4 0 mSkg 29 ftSlb ...

Page 36: ...CHES 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 ...

Page 37: ... SWITCHES ELEC 7 Engine stop switch 8 Start switch 9 Fuse 10 Rear brake switch 11 Sidestand switch 12 Neutral switch 1 Clutch switch 2 Horn switch 3 Dimmer switch 4 Turn signal switch 5 Main switch 6 Front brake switch ...

Page 38: ...PRINTED IN U S A ...

Page 39: ...4 Engine stop switch 15 Start switch 16 Oil level gauge 17 Sidestand switch 18 Fuel pump 19 Throttle position sensor 20 Igniter unit 21 Ignition coil 22 Spark plug 23 Speed sensor 24 Meter assembly 25 Oil level warning light 26 Engine trouble warning light 27 Speedometer 28 Meter light 29 Turn signal indicator light 30 Neutral indicator light 31 High beam indicator light 32 Neutral switch 33 Trip ...

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