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Yamaha DRAG STAR XVS1100A, Owner'S Manual

The Yamaha DRAG STAR XVS1100A Owner's Manual is an essential guide for every XVS1100A owner. This comprehensive manual provides detailed instructions and valuable insights for maintaining and operating this exceptional motorcycle. Easily download your free copy of the manual from manualshive.com, ensuring you have all the necessary information at your fingertips.

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passenger footpegs . . . . . . . . . . . . . . 389
rider floorboards . . . . . . . . . . . . 388-389
seats . . . . . . . . . . . . . . . . . . . . . 381
side cover

left . . . . . . . . . . . . . . . . . . . . . 383
right . . . . . . . . . . . . . . . . . . . . 386

sidestand . . . . . . . . . . . . . . . . 389-390
toolbox

cover. . . . . . . . . . . . . . . . . . 383-384
panel . . . . . . . . . . . . . . . . . . . . 384

torque specifications . . . . . . . . . . . . . 394
windshield . . . . . . . . . . . . . . . . . . 393

Fuel

and exhaust systems . . . . . . . . . . . . 68-71
filter . . . . . . . . . . . . . . . . . . . 229-230
level . . . . . . . . . . . . . . . . . . . 222-223
pump . . . . . . . . . . . . . . . . . . 230-231

troubleshooting . . . . . . . . . . . . . . . 47

system specifications, electrical . . . . . . . 240
tank . . . . . . . . . . . . . . . . . . . 203-205
valve . . . . . . . . . . . . . . . . . . 205-207

Fuses . . . . . . . . . . . . . . . . . . . 279-280

G

Gearshift

linkage, troubleshooting. . . . . . . . . . . . 44
specifications . . . . . . . . . . . . . . . . 202

H

Handlebar. . . . . . . . . . . . . . . . . 321-323
Headlight . . . . . . . . . . . . . . . . . 258-261
Horn . . . . . . . . . . . . . . . . . . . 268-269

I

Idle speed adjustment . . . . . . . . . . . . . 224
Ignition

coil . . . . . . . . . . . . . . . . . . . 245-246
system. . . . . . . . . . . . . . . . . . 243-245

Ignitor

panel . . . . . . . . . . . . . . . . . . 381-383
unit . . . . . . . . . . . . . . . . . . . 247-248

Internal shift mechanism . . . . . . . . . 188-190

L

Laced wheel service . . . . . . . . . . . 296-298
Lighting system . . . . . . . . . . . . . . . . 258
Linkage . . . . . . . . . . . . . . . . . . 332-334
Lower bearing replacement . . . . . . . . . . 328

Lubricants and fluids recommendations . . . 84-85

M

Maintenance

battery . . . . . . . . . . . . . . . . . . . 73-76

specifications . . . . . . . . . . . . . . . . 84

brakes . . . . . . . . . . . . . . . . . . . 80-82
control cables . . . . . . . . . . . . . . . 71-72
engine oil . . . . . . . . . . . . . . . . . 66-68
fasteners . . . . . . . . . . . . . . . . . . . . 82
final drive . . . . . . . . . . . . . . . . . . . 79
fuel

and exhaust systems . . . . . . . . . . . 68-71
type . . . . . . . . . . . . . . . . . . . . . 56

intervals . . . . . . . . . . . . . . . . . . 56-57
lubrication recommendations . . . . . 73, 84-85
schedule . . . . . . . . . . . . . . . . . . 82-83
sidestand . . . . . . . . . . . . . . . . . . 72-73
spark plugs . . . . . . . . . . . . . . . . . 62-66
steering head . . . . . . . . . . . . . . . . 77-78
suspension

front . . . . . . . . . . . . . . . . . . . . . 77
rear . . . . . . . . . . . . . . . . . . . . 78-79

specifications

torque . . . . . . . . . . . . . . . . . . . . 86
tune-up. . . . . . . . . . . . . . . . . . . . 85

tires . . . . . . . . . . . . . . . . . . . . 76-77
transmission . . . . . . . . . . . . . . . . . . 72

Master cylinder

front . . . . . . . . . . . . . . . . . . . 362-367
rear . . . . . . . . . . . . . . . . . . . 371-375

Meter assembly . . . . . . . . . . . . . . 261-263
Model names and numbers . . . . . . . . . . 1, 29

N

Neutral indicator light . . . . . . . . . . . . . 273

O

Oil

level indicator light . . . . . . . . . . . 273-274
pump . . . . . . . . . . . . . . . . . . 148-154

Operating requirements, troubleshooting . . . . 34

P

Pedal/footrest assembly. . . . . . . . . . 375-376
Pickup coil . . . . . . . . . . . . . . . . 246-247
Pilot screw . . . . . . . . . . . . . . . . . . . 222
Pistons and rings . . . . . . . . . . . . . 123-129

INDEX

397

15

Summary of Contents for DRAG STAR XVS1100A

Page 1: ...iginal ones 9 Keep the work area clean and organized 10 Wear eye protection any time the safety of your eyes is in question This includes procedures in volving drilling grinding hammering compressed air and chemicals 11 Wear the correct clothing for the job Tie up or cover long hair so it cannot be caught in moving equipment 12 Do not carry sharp tools in clothing pockets 13 Always have an approve...

Page 2: ...label before using any chemical Always know what type of chemical is being used and whether it is poisonous and or flammable 2 Do not use more than one type of cleaning sol vent at a time If mixing chemicals is called for measure the proper amounts according to the manu facturer s instructions 3 Work in a well ventilated area 4 Wear chemical resistant gloves 5 Wear safety glasses 6 Wear a vapor re...

Page 3: ... U S standard system and the metric system Figure 5 Pay par ticular attention when working with unidentified fasteners Mismatching thread types can damage threads CAUTION To ensure the fastener threads are not mismatched or cross threaded start all fasteners by hand If a fastener is hard to start or turn determine the cause before tightening it with a wrench The length L Figure 6 diameter D and di...

Page 4: ... screws and nuts use vari ous means to create interference between the threads of two fasteners to prevent the fasteners from loosening The most common types are the ny lon insert nut or a dry adhesive coating on the threads of a bolt Self locking fasteners improve resistance to vi bration and therefore provide greater holding strength than standard fasteners Most self locking fasteners cannot be ...

Page 5: ... rings Figure 10 are manufactured with a sharp edge and a round edge When installing a stamped snap ring in a thrust application install the sharp edge facing away from the part producing the thrust E clips are used when it is not practical to use a snap ring Remove E clips with a flat blade screw driver by prying between the shaft and E clip To in stall an E clip center it over the shaft groove a...

Page 6: ...mmend multigrade oil Multigrade oils 10W 40 for example are less vis cous thinner at low temperatures and more vis cous thicker at high temperatures This allows the oil to perform efficiently across a wide range of en gine operating conditions The lower the number the better the engine will start in cold climates Higher numbers are usually recommended when operating an engine in hot weather Grease...

Page 7: ...aving any residue Carburetor cleaner is a powerful solvent used to remove fuel deposits and varnish from fuel system components Use this cleaner carefully as it may damage finishes Most solvents are designed to be used in a parts washing cabinet for individual component clean ing For safety use only nonflammable or high flash point solvents Gasket Sealant Sealants are used in combination with a ga...

Page 8: ...tment When building a new tool kit consider purchas ing a basic set Figure 11 from a large tool sup plier These sets contain a variety of commonly used tools and they provide substantial savings when compared to individually purchased tools As one becomes more experienced and tasks become more complicated specialized tools can be added Some of the procedures call for special tools In most cases th...

Page 9: ...ts nearly any nut or bolt head that has clear access around its entire perimeter An adjustable wrench is best used as a backup wrench to hold a large nut or bolt while the other end is being loos ened or tightened with a box end or socket wrench Adjustable wrenches contact the fastener at only two points which makes them more subject to slip ping off the fastener The fact that one jaw is adjust ab...

Page 10: ... impact driver make sure the socket is designed for impact use Refer to Socket Wrenches Ratchets and Handles in this section WARNING Do not use hand sockets with air or impact tools They may shatter and cause injury Always wear eye protec tion when using impact or air tools Allen Wrenches Allen or setscrew wrenches Figure 18 are used on fasteners with hexagonal recesses in the fastener head These ...

Page 11: ...enter of the drive to the center of adapter box end Figure 21 L is the lever length of the wrench as measured from the center of the drive to the center of the grip The effective length of the torque wrench is mea sured along the centerline of the torque wrench as is the sum of L and A For example To apply 20 ft lb to a fastener using an adapter as shown in the top example in Figure 21 TA 20 ft lb...

Page 12: ...GENERAL INFORMATION 13 1 21 HOW TO MEASURE TORQUE WRENCH EFFECTIVE LENGTH L L L L L A Effective length L Effective length No calculation needed A A 22 23 ...

Page 13: ...ion when using ham mers Make sure the hammer face is in good condi tion and the handle is not cracked Select the correct hammer for the job and make sure to strike the ob ject squarely Do not use the handle or the side of the hammer to strike an object PRECISION MEASURING TOOLS Each type of measuring instrument is designed to measure a dimension with a particular degree of ac curacy and within a c...

Page 14: ...ce the caliper closed around an object Close the cali per around the highest point so it can be removed with a slight drag Some calipers require calibra tion Always refer to the manufacturer s instruc tions when using a new or unfamiliar caliper Figure 28 shows a measurement taken with a metric vernier caliper To read the measurement note that the fixed scale is graduated in centimeters which is i...

Page 15: ...ne hundredth of a millimeter 0 01 mm The sleeve line is graduated in millime ter and half millimeter increments The marks on the upper half of the sleeve line equal 1 00 mm Ev ery fifth mark above the sleeve line is identified with a number The number sequence depends on the size of the micrometer A 0 25 mm micrometer for example has sleeve marks numbered 0 through 25 in 5 mm increments This numbe...

Page 16: ...re is applied b The adjustment is correct if the 0 mark on the thimble aligns exactly with the 0 mark on the sleeve line If the marks do not align the mi crometer is out of adjustment c Follow the manufacturer s instructions to ad just the micrometer 2B To check a micrometer larger than 1 in or 25 mm use the standard gauge supplied by the manu facturer A standard gauge is a steel block disc or rod...

Page 17: ...bore Carefully move the gauge in the bore to make sure it is cen tered Tighten the knurled end of the gauge to hold the movable post in position Remove the gauge and measure the length of the posts with a microme ter Telescoping gauges are typically used to mea sure cylinder bores To use a small bore gauge select the correct size gauge for the bore Carefully insert the gauge into the bore Tighten ...

Page 18: ...ltimeter Figure 39 is an essential tool for electrical system diagnosis The voltage function indicates the voltage applied or available to various electrical components The ohmmeter function tests circuits for continuity and measures the resistance of a circuit Some test specifications for electrical compo nents are based on results using a specific test meter Results may vary if a meter not recom...

Page 19: ...actual flow of elec tricity The higher the current the more work can be performed However if the current flow exceeds the circuit or component capacity the system will be damaged Electrical Tests Refer to Chapter Two for a description of various electrical tests BASIC SERVICE METHODS Most of the procedures in this manual are straightforward and can be performed by anyone reasonably competent with ...

Page 20: ... and position 17 Whenever a rotating part contacts a stationary part look for a shim or washer 18 Use new gaskets if there is any doubt about the condition of old ones 19 If self locking fasteners are used replace them with new ones Do not reuse a self locking fastener Also do not install standard fasteners in place of self locking ones 20 Use grease to hold small parts in place if they tend to fa...

Page 21: ...ut 4 Remove any threadlocking compound from the threaded hole Clean the threads with an aerosol parts cleaner 5 Install the stud removal tool onto the new stud or thread two nuts onto the stud 6 Apply threadlocking compound to the threads of the stud 7 Install the stud and tighten it with the stud re moval tool or the top nut 8 Install the stud to the height noted in Step 1 or torque it to specifi...

Page 22: ...r arms next to the inner bearing race See Figure 44 2 When using a hammer to remove a bearing from a shaft do not strike the hammer directly against the shaft Instead use a brass or aluminum spacer be tween the hammer and shaft Figure 45 and make sure to support both bearing races with wooden blocks as shown 3 A hydraulic press is the ideal tool for bearing re moval Note the following when using a...

Page 23: ...aring inside diameter will be smaller than the shaft In this case driving the bearing onto the shaft using nor mal methods may cause bearing damage Instead heat the bearing before installation Note the following a Secure the shaft so it is ready for bearing in stallation b Clean all residue from the bearing surface of the shaft Remove burrs with a file or sandpa per c Fill a suitable pot or beaker...

Page 24: ...r ing and will likely warp the housing b Remove the housing from the oven or hot plate and hold onto the housing with a kitchen potholder heavy gloves or heavy shop cloth It is hot NOTE Remove and install the bearings with a suitable size socket and extension c Hold the housing with the bearing side down and tap the bearing out Repeat for all bear ings in the housing d Before heating the bearing h...

Page 25: ...n be minimized with careful preparation for storage A properly stored motorcy cle will be much easier to return to service Storage Area Selection When selecting a storage area consider the fol lowing 1 The storage area must be dry A heated area is best but not necessary It should be insulated to minimize extreme temperature variations 2 If the building has large window areas mask them to keep sunl...

Page 26: ...t with plastic ma terial that will trap moisture Returning the Motorcycle to Service The amount of service required when returning a motorcycle to service after storage depends on the length of non use and storage conditions In addi tion to performing the reverse of the above proce dure make sure the brakes clutch throttle and engine stop switch work properly before operating the motorcycle Refer ...

Page 27: ...M Aus 5KS5 2001 XVS1100AN USA JYAVP11E 1A011255 VP11E 0011255 5KS7 XVS1100AN C Ca JYAVP11Y 1A001520 VP11Y 0001520 5KS8 XVS1100AN Cdn XVS1100AN Eur 5KSB XVS1100AN Aus 2002 XVS1100AP USA JYAVP11E 2A020769 VP11E 0020769 5KSC XVS1100AP C Ca JYAVP11Y 2A002720 VP11Y 0002720 5KSD XVS1100AP Cdn XVS1100AP Eur 5KSG XVS1100AP Aus 2003 XVS1100AR USA JYAVP11E 3A034461 VP11E 0034461 5KSR XVS1100AR C Ca JYAVP11Y...

Page 28: ...urb mass with oil and full tank USA California Canada Germany Austria and Finland models 275 606 3 Europe and Australia models 274 604 1 Maximum load USA California Canada Germany Austria and Finland models 200 440 9 Europe and Australia models 1999 2000 models 201 443 1 2001 on models 200 440 9 Load equals the total weight of the cargo rider passenger and accessories Table 5 VEHICLE DIMENSIONS AN...

Page 29: ... 28125 7 14375 25 32 0 78125 19 84375 19 64 0 296875 7 54062 51 64 0 796875 20 24062 5 16 0 3125 7 93750 13 16 0 8125 20 63750 21 64 0 328125 8 33437 53 64 0 828125 21 03437 11 32 0 34375 8 73125 27 32 0 84375 21 43125 23 64 0 359375 9 12812 55 64 0 859375 22 82812 3 8 0 375 9 52500 7 8 0 875 22 22500 25 64 0 390625 9 92187 57 64 0 890625 22 62187 13 32 0 40625 10 31875 29 32 0 90625 23 01875 27 6...

Page 30: ...ters Foot pounds 0 138255 Meters kilograms Inch pounds 0 11299 Newton meters Newton meters 0 7375622 Foot pounds Newton meters 8 8507 Inch pounds Meters kilograms 7 2330139 Foot pounds Volume Cubic inches 16 387064 Cubic centimeters Cubic centimeters 0 0610237 Cubic inches Temperature Fahrenheit F 32 0 556 Centigrade Centigrade C 1 8 32 Fahrenheit Weight Ounces 28 3495 Grams Pounds 0 4535924 Kilog...

Page 31: ...igh altitude hp Horsepower in Inches in lb Inch pounds I D Inside diameter kg Kilograms kgm Kilogram meters km Kilometer kPa Kilopascals L Liter m Meter MAG Magneto ml Milliliter mm Millimeter N m Newton meters O D Outside diameter oz Ounces psi Pounds per square inch PTO Power take off pt Pint qt Quart rpm Revolutions per minute SCCR Starting circuit cutoff relay TCI Transistor controlled ignitio...

Page 32: ...0 90 No 20 0 161 5 32 6 1 00 No 9 0 196 13 64 7 1 00 16 64 0 234 15 64 8 1 00 J 0 277 9 32 8 1 25 17 64 0 265 17 64 9 1 00 5 16 0 3125 5 16 9 1 25 5 16 0 3125 5 16 10 1 25 11 32 0 3437 11 32 10 1 50 R 0 339 11 32 11 1 50 3 8 0 375 3 8 12 1 50 13 32 0 406 13 32 12 1 75 13 32 0 406 13 32 GENERAL INFORMATION 33 1 ...

Page 33: ...t to be high OPERATING REQUIREMENTS An engine needs three basic requirements to run properly correct air fuel mixture compression and a spark at the proper time If any element is missing the engine will not run Four stroke engine operat ing principles are described in Figure 1 If the machine has been sitting for any length of time and refuses to start check and clean the spark plugs and then look ...

Page 34: ...SSION INTAKE Intake valve closes and piston rises in cylinder compressing air fuel mixture EXHAUST POWER Spark plug ignites compressed mixture driving piston downward Force is applied to crankshaft causing it to rotate 1 Air fuel Cylinder Intake valve Carburetor Exhaust valve Exhaust Exhaust valve opens as piston rises in cylinder pushing spent gasses out through the valve ...

Page 35: ...t the transmission into neutral 2 Move the choke lever Figure 3 to the fully on position 3 Turn the ignition switch on 4 Make sure the engine stop switch A Figure 2 is in the run position NOTE When a cold engine is started with the throttle open and the choke on a lean mixture will result and cause hard starting 5 Press the starter button B Figure 2 and start the engine Do not open the throttle wh...

Page 36: ... the integrity of the ignition system by per forming the Spark Test described in this section 6 If the test produces a good spark proceed with Step 7 If the spark is weak or if there is no spark troubleshoot the ignition system as described in this chapter 7 Check engine compression as described in Chapter Three If the compression is good perform Step 8 If the compression is low check for one or m...

Page 37: ...a problem with that spark plug s wire plug cap or ignition coil Retest it with a spark tester or use a new spark plug If there is still no spark at that plug make sure the spark plug cap is installed correctly Check the spark plug wiring and cap and test the re lated ignition coil as described in Chapter Nine Engine is Difficult to Start 1 Check for fuel flow to the carburetors If fuel is reaching...

Page 38: ...synchronized 2 Incorrect idle speed adjustment 3 Fouled or improperly gapped spark plug s 4 Leaking head gasket s or vacuum leak 5 Incorrect valve clearance or valve timing 6 Obstructed fuel line or fuel valve 7 Low engine compression 8 Starter valve choke stuck in the open position 9 Incorrect pilot screw adjustment 10 Clogged pilot jet or pilot air jet 11 Clogged air filter element 12 Faulty fue...

Page 39: ...he following ignition system components as described in Chapter Nine a Pickup coil b Ignition coils c Ignitor unit 3 Perform the fuel pump operational test described in Chapter Eight If the fuel flow is acceptable check for one or more of the following a Clogged fuel line b Stuck or clogged carburetor float valve 4 Remove the carburetor assembly as described in Chapter Eight Then remove the float ...

Page 40: ...strange noise Distinguish ing a normal noise from an abnormal one can be dif ficult If possible have an experienced mechanic help you sort out the noises Consider the following when troubleshooting en gine noises 1 A knocking or pinging during acceleration is usually caused by the use of a low octane fuel It may also be caused by poor fuel a spark plug of the wrong heat range or carbon buildup in ...

Page 41: ...ed oil filter 5 Internal oil leak 6 Incorrect type of engine oil being used 7 Oil pressure relief valve stuck open High Oil Pressure 1 Incorrect type of engine oil being used 2 Plugged oil filter oil gallery or metering ori fices 3 Oil pressure relief valve stuck closed No Oil Pressure 1 Damaged oil pump 2 Excessively low oil level 3 Damaged oil pump drive shaft 4 Damaged oil pump drive sprocket 5...

Page 42: ...instructions Read the percent of leak on the gauge Note the following a For a new or rebuilt engine a leak rate of 0 to 5 percent per cylinder is desirable A leak rate of 6 to 14 percent is acceptable and means the engine is in good condition b For a used engine the critical rate is not the leak percent for each cylinder but the differ ence between the cylinders On a used engine a leak rate of 10 ...

Page 43: ... removed and the crank case split Common gearshift linkage troubles and their checks are listed below Transmission Jumps Out of Gear 1 Incorrect shift pedal position 2 Bent or worn shift fork 3 Bent shift fork shaft 4 Gear groove worn 5 Damaged stopper bolt 6 Weak or damaged stopper arm spring 7 Loose or damaged shift cam 8 Worn gear dogs or slots 9 Damaged shift drum grooves 10 Weak or damaged ge...

Page 44: ...gh CARBURETOR Test the indicated items when experiencing a par ticular symptom Engine Will Not Start Check the following items if the engine will not start and the electrical and mechanical systems are working correctly 1 If there is no fuel going to the carburetors check for the following a Clogged fuel tank breather b Clogged fuel tank to carburetor line c Clogged fuel filter d Faulty fuel pump ...

Page 45: ...etor s 6 Damaged vacuum piston Lean Fuel Mixture A lean carburetor fuel mixture can be caused by one or more of the following conditions 1 Clogged carburetor jet s 2 Clogged fuel filter 3 Restricted fuel line 4 Intake air leak 5 Incorrect float level too low 6 Worn or damaged float valve 7 Faulty throttle valve 8 Faulty vacuum piston Engine Backfires 1 Lean fuel mixture 2 Incorrect carburetor adju...

Page 46: ...king properly The tests can yield invalid results if they are performed out of sequence If a test indicates that a component is working properly reconnect the electrical connec tions and proceed to the next step 1 Inspect the main fuse and the ignition fuse as de scribed Chapter Nine 2 Check the battery Chapter Three 3 Check the continuity of the main switch Chap ter Nine 4 Check the continuity of...

Page 47: ...ad to vari ous points along the circuit The bulb lights when battery voltage is present A voltmeter is used in the same manner as the test light to find out if battery voltage is present in any given circuit The voltmeter unlike the test light also indicates how much voltage is present at each test point When using a voltmeter attach the posi tive test lead to the component or wire to be checked a...

Page 48: ...other end of the scale indicating infinite resistance During a continuity test a reading of infinity in dicates that there is an open in the circuit or compo nent A reading of zero indicates continuity which means there is no measurable resistance in the cir cuit or component being tested If the meter needle falls between the two ends of the scale this indi cates the actual resistance to current f...

Page 49: ... one side may be loose or corroded thus preventing elec trical flow through the connector This type of test can be performed with a test light or a voltmeter A voltmeter gives the best results NOTE When using a test light either lead can be attached to ground 1 Attach the voltmeter negative test lead to a good ground Make sure the part used for ground is not insulated with a rubber gasket or rubbe...

Page 50: ...for a ground is not insulated with a rubber gasket or rubber grommet 5 With the self powered test light or ohmmeter at tached to the fuse terminal and ground wiggle the wiring harness of the suspect circuit at 15 2 cm 6 in increments Start next to the fuse panel and work away from the fuse panel 6 Watch the self powered test light or ohmmeter as you progress along the harness If the test light bli...

Page 51: ... you will probably be unable to return the unit for a refund Consider any test results carefully before replac ing a component that tests only slightly out of speci fication especially resistance A number of variables can affect test results dramatically These include the testing meter s internal circuitry ambi ent temperature and conditions under which the ma chine has been operated All instructi...

Page 52: ...and each connector in the lighting circuit Chapter Nine 8 Locate the symptom among the following de scriptions and perform the indicated tests The headlight and high beam indicator do not turn on 1 Check the continuity of the headlight bulb and socket 2 Perform the headlight voltage test in Chapter Nine A meter light does not turn on 1 Check the continuity of the affected meter bulb and socket 2 P...

Page 53: ...fork bridge 3 Damaged steering head bearings 4 Tire pressure too low 5 Worn or damaged tire Steering to One Side 1 Bent front or rear axle 2 Bent frame or fork 3 Worn or damaged wheel bearings 4 Worn or damaged swing arm pivot bearings 5 Damaged steering head bearings 6 Bent swing arm 7 Incorrectly installed wheels 8 Front and rear wheels are not aligned 9 Uneven front fork adjustment 10 Fork legs...

Page 54: ...r cylinder piston 4 Incorrectly installed brake caliper 5 Warped brake disc 6 Incorrect wheel alignment 7 Contaminated brake pad and disc 8 Excessively worn brake disc or pad 9 Caliper not sliding correctly Brakes Grab 1 Contaminated brake pads and disc 2 Incorrect wheel alignment 3 Warped brake disc 4 Caliper not sliding correctly Brake Squeal or Chatter 1 Contaminated brake pads and disc 2 Incor...

Page 55: ...ly torque fasteners to the specified torque FUEL TYPE The engine is designed to use gasoline with a pump octane rating of 86 or higher or a research octane of 91 or higher The pump octane rating R M 2 is normally displayed at the service station fuel pump Using gasoline with a lower octane rating can cause pinging or spark knock Either condition can lead to engine damage When adding fuel note the ...

Page 56: ...om those in this manual use the specifications from the label When performing a tune up service the follow ing items as described in this chapter 1 Air filter 2 Spark plugs 3 Engine compression 4 Engine oil and filter 5 Ignition timing 6 Valve clearance 7 Carburetor adjustment 8 Brake system 9 Suspension components 10 Tires and wheels 11 Fasteners Air Filter Replacement The air filter removes dust...

Page 57: ...gage the posts Figure 3 on the air filter housing b Torque the air filter cover bolts A Figure 2 to 10 N m 89 in lb Compression Test An engine compression test is one of the quickest ways to check the condition of the rings head gas ket piston and cylinder Record the compression reading during each tune up in the maintenance log at the end of the manual Compare the current read ing with those take...

Page 58: ...ngine over once to distribute the oil then take another compression test and record the reading If the compression returns to normal the rings are worn or defective If compression does not increase the valves are leaking NOTE If the compression is low the engine cannot be tuned to maximum perfor mance The worn parts must be re placed Ignition Timing Ignition timing is not adjustable However the ti...

Page 59: ...lywheel nut cover B from the alternator cover NOTE A breather plate is not used in the rear cylinder head 6 Remove the mounting screws A Figure 12 and remove the cam sprocket cover B and its O ring from each cylinder head When working on the front cylinder make sure the breather plate and its O ring A Figure 13 come out with the cam sprocket cover B 7 Remove both spark plugs This makes it easier t...

Page 60: ...t the valve clearance by per forming the following a Loosen the locknut on the valve adjuster b With the feeler gauge between the valve stem and the adjuster end turn the valve adjuster to obtain the specified clearance c Hold the adjuster to prevent it from turning and torque the valve adjuster locknut to 27 N m 20 ft lb 12 Use the flywheel nut to turn the crankshaft clockwise until the front cyl...

Page 61: ...nder head covers as described in Chapter Four SPARK PLUGS Removal A spark plug can be used to help determine the operating condition of its cylinder when it is prop erly read As each spark plug is removed label it with its cylinder number 1 Remove the cylinder head covers as described in Chapter Four 2 Grasp the spark plug lead Figure 19 as near to the plug as possible and pull the lead off the pl...

Page 62: ... the gauge will not pass through bend the side electrode with a gaping tool Figure 22 and set the gap to specification 3 Apply a light coat of antiseize compound onto the threads of the spark plug before installing it Do not use engine oil on the plug threads CAUTION The cylinder head is aluminum Cross threading the spark plug can easily damage the spark plug hole threads 4 Screw the spark plug in...

Page 63: ...dverse engine or carburetion condi tions When replacing plugs make sure the reach Fig ure 24 is correct A longer than standard plug could interfere with the piston and cause engine damage Refer to Table 5 for recommended spark plugs Reading Reading the spark plugs can provide information about spark plug operation air fuel mixture compo sition and engine conditions such as oil consump tion or pist...

Page 64: ...dition are 1 Incorrect air fuel mixture 2 Low idle speed or prolonged idling 3 Ignition component failure 4 Spark plug heat range too cold 5 Engine still being broken in 6 Valve guides worn 7 Piston rings worn or broken Oil fouled spark plugs may be cleaned in an emergency but it is better to replace them It is im portant to correct the cause of fouling before the en gine is returned to service Ga...

Page 65: ...let the oil settle CAUTION If the bike is not parked correctly the oil level reading will be incorrect 3 Have an assistant hold the motorcycle so it stands straight up and level 4 The oil level should be between the maximum and minimum window marks If necessary remove the oil filler cap D Figure 9 from the top of the al ternator cover and add enough of the recommended oil see Table 4 to raise the ...

Page 66: ...l be hot Wear thick work gloves when removing the exhaust pipes 7 Replace the oil filter 6 Figure 27 as follows a Remove the mufflers and front exhaust pipe as described in Chapter Eight NOTE The emblem does not have to be re moved when the oil filter is changed a Remove the outer cover bolts A and B Figure 28 and remove the outer cover C from the clutch cover Note that the shouldered bolt is in s...

Page 67: ...cks or deterioration replace them if necessary Make sure the hose clamps are in place and holding securely Fuel Filter Replacement Replace the fuel filter when it is dirty or at the in terval specified in Table 1 Refer to the procedure in Chapter Eight Exhaust System Inspection Check for leaks at all fittings Tighten all bolts and nuts replace any gaskets as necessary Refer to Chapter Eight Emissi...

Page 68: ...nt 12 Reinstall the plug Figure 33 onto the intake manifold vacuum fittings On models with an AIS system reconnect the AIS hose Figure 34 to the fitting on the rear cylinder intake manifold Idle Speed Adjustment Before adjusting the idle speed clean or replace the air filter test the engine compression and syn chronize the carburetors Idle speed cannot be prop erly adjusted if these items are not ...

Page 69: ... the fuel tank air filter housing and surge tank as described in Chapter Eight 3 At the handlebar make sure the throttle cable locknut and adjuster are tight 4 At the carburetor assembly loosen the pull cable locknut A Figure 38 5 Rotate the pull cable adjuster B Figure 38 un til the correct amount of free play is achieved 6 Tighten the locknut securely NOTE If the correct amount of free play cann...

Page 70: ...rom the throttle drum 3 Attach a cable lubricator to the cable following the manufacturer s instructions 4 Insert the nozzle of the lubricant can into the lu bricator Figure 40 press the button on the can and hold it down until the lubricant begins to flow out of the other end of the cable NOTE Place a shop cloth at the carburetor end of the cable to catch all excess lu bricant that flows out NOTE...

Page 71: ...uster 2 Loosen the clutch cable locknut B Figure 42 3 Turn the adjuster C Figure 42 in or out to at tain the amount of free play specified in Table 5 4 Tighten the locknut and reinstall the rubber boot 5 If the proper free play cannot be achieved at the hand lever adjuster adjust the clutch release mecha nism as follows a Remove the clutch adjuster cover Figure 43 from the alternator cover b Loose...

Page 72: ... service the bearings Refer to Chapter Twelve Steering Stem Bearings Remove clean and lubricate the steering stem bearings with lithium soap grease at the interval specified in Table 1 Refer to the procedure in Chapter Eleven Wheel Bearings Worn wheel bearings cause excessive wheel play that results in vibration and other steering troubles Inspect the wheel bearings at the inter vals specified in ...

Page 73: ... mounted in the frame 2 Inspect the battery pads in the battery box for contamination or damage Clean the pads and com partment with a solution of baking soda and water 3 Set the battery on a stack of newspapers or shop cloths to protect the workbench surface 4 Check the entire battery case for cracks or other damage If the battery case is warped discolored or has a raised top the battery has been...

Page 74: ... chargers can be used while the battery is connected to the motorcycle These types of charg ers are specifically designed for mo torcycle batteries and will not damage the diodes in the regula tor rectifier 1 Remove the battery from the motorcycle as de scribed in this section 2 Set the battery on a stack of newspapers or shop cloths to protect the surface of the workbench 3 Connect the positive c...

Page 75: ...t the majority of all tire fail ures occur during the last 10 of usable tread wear Check tire tread for excessive wear deep cuts and embedded objects such as stones nails etc Also check for high spots that indicate internal tire dam age Replace tires that show high spots or swelling If there is a nail in a tire mark its location with a light crayon before pulling it out This will help lo cate the ...

Page 76: ... as vigorously as possible Check for smooth fork operation and check for any oil leaks NOTE Figure 50 shows the two lower fork bridge clamp bolts on an XVS1100A model An XVS1100 model uses only one lower fork bridge clamp bolt 2 Make sure the upper Figure 51 and lower Figure 50 fork bridge clamp bolts are tight 3 Make sure the handlebar holder bolts Figure 52 are tight and the handlebar is securel...

Page 77: ... bottom of the two fork sliders and try to rock the fork legs back and forth There should be little or no rocking in the steering head b If there is any play the steering head is too loose Adjust the steering head bearings as described in Steering Head Installation in Chapter Eleven REAR SUSPENSION Inspection 1 Securely support the motorcycle on a level sur face with the rear wheel off the ground ...

Page 78: ...ses preload FINAL DRIVE Final Gearcase Oil Check 1 Move the bike to a level surface Use a suitable stand to support the bike in an upright position 2 Remove the oil filler bolt C Figure 58 from the final gearcase 3 The oil level should sit at the bottom on the oil filler brim as shown in Figure 59 4 If the oil level is low add final gear oil until the final gear case is full Refer to Table 4 for t...

Page 79: ...he cali per s until the fluid leaving the caliper is clean and free of contaminants and air bubbles Refer to the brake bleeding procedure in Chapter Thirteen Checking Brake Fluid Level If the brake fluid level reaches the lower level mark front C Figure 39 rear Figure 60 correct the fluid level by adding fresh brake fluid 1 Securely support the motorcycle on level ground 2A When adding fluid to th...

Page 80: ...3 If the free play is outside the range specified in Table 5 perform the following a Loosen the brake adjuster locknut A Figure 62 b Turn the adjuster B Figure 62 in or out un til free play is within the specification Turn ing the adjuster in clockwise decreases free play turning it out counterclockwise in creases free play 4 After adjusting free play spin the wheel and check for any brake drag Re...

Page 81: ...l the rear brake light operates properly FASTENERS Constant vibration can loosen many fasteners on a motorcycle Check the tightness of all fasteners especially those on 1 Engine mounting hardware 2 Engine crankcase covers 3 Handlebar and front fork 4 Gearshift lever 5 Drive shaft components 6 Brake pedal and lever 7 Exhaust system 8 Lighting equipment 82 CHAPTER THREE 65 Table 1 MAINTENANCE SCHEDU...

Page 82: ...earings for smoothness or excessive play adjust as necessary Check the operation of the shock absorber and check for leaks Check the wheel bearings for wear or damage replace if necessary Check the wheels for runout and balance adjust as necessary Check the spoke tightness adjust as necessary Check tire tread for wear or damage replace as necessary Check all fasteners tighten them as necessary 800...

Page 83: ...5 kPa 32 psi Rear 225 kPa 32 psi 90 200 kg 198 441 lb load 2 Front 225 kPa 32 psi Rear 250 kPa 36 psi Minimum tread depth 1 6 mm 0 06 in 1 Tire inflation pressure for original equipment tires Aftermarket tires may require different inflation pres sures refer to aftermarket manufacturer s specifications 2 Load equals the total weight of the cargo rider passenger and accessories Table 3 BATTERY Batt...

Page 84: ... Denso W22EPR U Spark plug gap 0 7 0 8 mm 0 028 0 031 in Idle Speed 950 1050 rpm Pilot screw Europe and Australia models 3 turns out Valve clearance Intake 0 07 0 12 mm 0 0028 0 0047 in Exhaust 0 12 0 17 mm 0 0047 0 0067 in Compression pressure at sea level Standard 1000 kPa 142 psi 10 kg cm2 Minimum 900 kPa 128 psi 9 kg cm 2 Maximum 1100 kPa 156 psi 11 kg cm 2 Ignition timing 10 BTDC 1000 rpm Vac...

Page 85: ...999 on XVS1100 models 23 17 All models except 1999 on XVS1100 models 27 20 Lower fork bridge clamp bolt 30 22 Oil drain bolt 43 32 Oil filter outer cover bolt 10 89 Rear axle clamp nut 23 17 Rear axle nut 107 79 Rear brake adjuster locknut 16 12 Rear caliper bracket bolt 40 30 Rear caliper mounting bolt 40 30 Rocker arm bolt 38 28 Sidestand nut 56 41 Spark plugs 20 15 Steering head nut 110 81 Stee...

Page 86: ...head camshaft SOHC V twin Two main bearings support the crankshaft in a vertically split crankcase The camshaft in each cyl inder is chain driven by a cam chain drive assembly that meshes with the timing gear on the crankshaft Cam chain tension is maintained by an automatic spring loaded tensioner that bears against the rear run of the cam chain The engine and transmission share a common case and ...

Page 87: ... 01701 or its equivalent is needed to per form this procedure 1 Securely support the motorcycle on level ground 2 Remove the engine from the frame as described in Chapter Five 3 Remove the intake and exhaust valve covers Figure 5 from the cylinder head Watch for the ca ble clamp on one intake valve cover bolt on the front cylinder head 4 Remove the two cam sprocket cover bolts A Figure 6 and remov...

Page 88: ...r bolt 6 Valve cover bolt 7 Intake valve cover 8 O ring 9 Intake manifold 10 Intake manifold bolt 11 Dowel 3 12 Gasket 13 Rear cylinder head 14 Exhaust valve cover 15 Exhaust manifold 16 Manifold nut 17 Exhaust gasket 18 Cam sprocket 19 Washer 20 Cam sprocket bolt 21 Cam sprocket cover 22 Cam sprocket cover bolt ...

Page 89: ...ther plate 19 O ring 20 Cam sprocket cover 21 Cam sprocket cover bolt 22 Gasket 23 Dowel 4 1 Cylinder head cap nut 2 Washer 3 Cylinder head nut 4 Cylinder head cover bracket 5 Cylinder head bolt 6 Valve cover bolt 7 Clamp 8 Intake valve cover 9 O ring 10 Exhaust valve cover 11 Intake manifold bolt 12 Intake manifold ...

Page 90: ...shaft clockwise until the T mark on the flywheel A Figure 9 aligns with the cutout in the al ternator cover B b Make sure the timing mark on the rear cam sprocket A Figure 10 aligns with the pointer on the rear cylinder head B 8B When servicing the front cylinder set it to TDC on the compression stroke as follows a Set the rear cylinder to TDC by rotating the engine clockwise until the T mark A Fi...

Page 91: ...move the cam chain tensioner B and gasket from the rear of the cylinder The air filter housing bracket C Figure 13 comes out with the chain tensioner on the front cylinder 11 Remove the alternator cover as described in Chapter Five 12 Hold the flywheel with a sheave holder 13A When servicing the rear cylinder head re move the cam sprocket bolt C Figure 10 along with its washer NOTE A cam sprocket ...

Page 92: ...ft the two cylinder head cover brackets Fig ure 16 from the cylinder studs Mark these brack ets so they can be reinstalled in the correct locations during assembly CAUTION The cooling fins are fragile and may be damaged if they are tapped too hard Never use a metal hammer to loosen the cylinder head 19 Loosen the head by tapping around its perime ter with a plastic mallet 20 Remove the cylinder he...

Page 93: ...ankcase See Figure 17 Make sure the guide s raised edge faces the cam chain 5 Lower the cylinder head part way down the cyl inder studs and feed the cam chain and safety wire up through the cam chain tunnel in the head 6 Carefully lower the cylinder head until it is seated on the cylinder block While lowering the head into place note the following a The top of the front chain guide must be cap tur...

Page 94: ...C on the compres sion stroke when the T mark A Figure 9 on the rotor aligns with the cutout in the alterna tor cover B and when the locating pin on the camshaft aligns B Figure 21 with the pointer on the cylinder head C b The front cylinder is at TDC on the compres sion stroke when the I mark A Figure 11 on the rotor aligns with the cutout in the alter nator cover B and when the locating pin on th...

Page 95: ...ner into the cylinder while holding the screwdriver Make sure the UP mark on the tensioner faces up Do not release the screwdriver until the tensioner is seated in the cylinder f Press the tensioner against the cylinder Re lease the plunger by turning the screwdriver slightly counterclockwise and remove the screwdriver See Figure 26 g When installing the chain tensioner into the front cylinder sli...

Page 96: ...t valve area on the combustion chamber side If the valve and seats are in good condi tion there will be no leaks past the valve seats If any area is wet the valve seat is not sealing correctly This can be caused by a damaged valve seat and or valve face or by a bent or damaged valve Remove the valve and inspect the valve and seat for wear or damage c Pour solvent into the intake port and check the...

Page 97: ...placed 9 Inspect the threads on the exhaust pipe mounting studs A Figure 32 Clean the threads with an ap propriate size metric die Replace a stud if the dam age is severe 10 After the head has been thoroughly cleaned place a straightedge across the gasket surface at several points Measure the warp by inserting a feeler gauge B Figure 32 between the straight edge and the cylinder head at each locat...

Page 98: ...r head the No 2 camshaft fits in the front Make sure each camshaft is installed in the cor rect cylinder head 1 If removed install the locating pin A Figure 39 into the end of the cylinder head 2 Apply molybdenum disulfide oil to the surfaces of the camshaft journals 3 Install the camshaft into the cylinder head so the locating pin A Figure 39 aligns with the pointer B on the top of the cylinder h...

Page 99: ...Figure 38 for wear The lobes should not be scored and the edges should be square Slight damage can be removed with silicon carbide oil stone Use No 100 120 grit initially then polish the lobe with No 280 320 grit 5 Even if the cam lobe surfaces appears satisfac tory they must be measured with a micrometer 100 CHAPTER FOUR 1 Rocker shaft bolt 2 Washer 3 Rocker shaft 4 Adjuster locknut 5 Valve adjus...

Page 100: ...2 6 Measure the camshaft runout with a dial indica tor and V blocks Replace the camshaft if the runout exceeds the service limit 7 Measure the camshaft journal outside diameter Figure 43 and measure the inside diameter of the camshaft bushing Figure 44 Calculate the cam shaft to bushing clearance by subtracting the cam ENGINE TOP END 101 4 38 39 40 41 42 43 44 ...

Page 101: ...lts are used on each cylinder head The bolt with the single oil hole A Figure 45 goes on the exhaust side the bolt with the two oil holes B goes on the intake side This bolt also secures the oil line to the head 3 If the rocker arm bolt is still installed remove it from the exhaust side of the cylinder head 4A If a slide hammer is available perform the fol lowing a Assemble the slide hammer per th...

Page 102: ...nstall the shaft into the head Figure 50 Make sure the shaft passes through the boss on the rocker arm and bottoms in the cylinder head 4 When installing an exhaust rocker arm slide a new copper washer on the rocker arm bolt A Fig ure 45 with a single hole Turn the rocker arm bolt into the cylinder head and torque the bolt to 37 N m 27 ft lb 5 Repeat Steps 1 4 for the other rocker arm Do not insta...

Page 103: ...mshaft for each cylinder is chain driven by the cam chain drive assembly which consists of a spring loaded gear and a sprocket The cam chain drive assembly sits between the cam sprocket and the timing gear The timing gear on the crankshaft drives the gear on the cam chain drive assembly The cam chain runs from the sprocket on the cam chain drive assembly and turns the cam sprocket on the end of th...

Page 104: ...lled in this direction during assembly 5 Lift the cam chain and cam chain drive assembly Figure 54 from the cam chain tunnel Installation Rear Cylinder 1 Make sure the rear cylinder is still set to top dead center on the compression stroke a If necessary install the Woodruff key into the crankshaft keyway and slide the flywheel onto the crankshaft Temporarily install the alternator cover onto the ...

Page 105: ... m 89 in lb 8 If removed set the starter idler gear assembly A Figure 60 into the crankcase and secure it in place with the shaft B 9 If the timing gear was removed from the fly wheel install the timing gear as described in Fly wheel and Starter Gear in Chapter Five 10 Set the flywheel assembly face down on the bench so the timing gear is up Mark the edge of the tooth Figure 61 on either side of t...

Page 106: ... shaft collects oil that lubricates the shaft and bushing in the cam chain drive assembly The shaft must be installed so this oil slot faces up 4 Remove the drive assembly shaft Note that the oil slot A Figure 69 in the shaft faces up It must be reinstalled in this direction during assembly 5 Lift the cam chain cam chain drive assembly Figure 59 from the cam chain tunnel 6 Inspect the cam chain an...

Page 107: ...n guide bolt 3 Cam chain drive assembly 4 Cam chain 5 Front chain guide 6 Retainer bolt 7 Shaft retainer 8 Drive assembly shaft 66 9 Woodruff key 10 Primary drive nut 11 Lockwasher 12 Keyed washer 13 Timing gear 14 Pin 15 Spring 16 Primary drive gear ...

Page 108: ...ear C 5 Install the shaft so the oil cutout faces up A Figure 69 6 Slide the retainer B Figure 68 over the end of the shaft so the retainer fingers seat in the cutout in the shaft 7 Install the retainer bolt A Figure 68 Apply a medium strength threadlocking compound to the bolt threads and torque the cam chain drive assem bly retainer bolt to 10 N m 89 in lb 8 Remove the 6 mm pin Figure 58 from th...

Page 109: ...e the needed service A valve spring compressor Yamaha part No YM 04019 or 90890 04019 or equivalent is needed to remove and install the valves Valve Removal Refer to Figure 73 CAUTION Keep the components of each particu lar valve assembly together Do not mix components from different valve assemblies or excessive wear may oc cur 1 Remove the cylinder head as described in this chapter 110 CHAPTER F...

Page 110: ...ion do not compress thevalvespring anymorethan necessary to remove the valve keepers 6 Tighten the compressor until the valve keepers separate from the valve stem Remove both valve keepers with a magnet tweezers or needlenose pli ers Figure 76 CAUTION Remove any burrs from the valve stem grooves before removing the valve Burrs on the valve stem will damage the valve guide when the stem passes thro...

Page 111: ... install the seal over the end of the valve guide Figure 80 Push the seal straight down onto the valve guide until the seal bottoms 4 Apply molybdenum disulfide oil to the valve stem Install the valve partway into the guide Fig ure 82 Slowly turn the valve as it enters the oil seal and continue turning the valve until it is com pletely installed 5 Install the valve spring Figure 79 so the end with...

Page 112: ...cessive wear will occur 1 Clean the valve in solvent Do not gouge or dam age the valve seating surface 2 Inspect the contact surface of each valve for burning Figure 85 Minor roughness or pitting can be removed by lapping the valve as described in this chapter Excessive unevenness indicates that the valve is not serviceable Replace the valve and the valve guide 3 Inspect the valve stem for wear an...

Page 113: ...g for bends or other signs of distortion b Measure each valve spring free length with a vernier caliper Figure 90 Replace the spring if its free length is less than the service limit c Use a square to measure the tilt of each spring Figure 91 Tilt should be within the specifi cation in Table 2 d Replace any defective or worn spring 10 Measure the valve margin thickness Figure 92 with a vernier cal...

Page 114: ...e rear cylinder head remove the exhaust manifold and exhaust gasket Discard the gasket CAUTION Do not heat the cylinder head with a torch Never bring a flame into con tact with the cylinder head Direct flame can warp the cylinder head 4 Place the cylinder head in a shop oven and warm it to 100 C 212 F Check the temperature of the cylinder head by flicking tiny drops of water onto the head The cyli...

Page 115: ...is completely seated against the cylin der head 14 After the cylinder head has cooled down ream the new valve guides as follows a Apply cutting oil to both the new valve guide and to the valve guide reamer CAUTION Always rotate the valve guide reamer clockwise The valve guide will be damaged if the reamer is rotated counterclockwise b Insert the 8 mm 0 31 in valve guide reamer from the top side Fi...

Page 116: ...tap the valve up and down in the cylinder head Do not rotate the valve or the impres sion will not be accurate e Remove the valve and examine the impres sion left by the marking compound If the im pression left in the dye on the valve or in the cylinder head is not even and continuous and if the valve seat width Figure 98 is not within the tolerance specified in Table 2 the valve seat must be reco...

Page 117: ...CAUTION Measure the valve seat contact area in the cylinder head Figure 101 after each cut to make sure the contact area is correct and to prevent removing too much material If too much material is removed the cylinder head must be replaced 2 If the seat is still pitted or burned turn the 45 cutter additional turns until the surface is clean Avoid removing too much material from the cylin der head...

Page 118: ...at Lapping is also recommended after the valve seat has been refaced or when a new valve and valve guide have been installed 1 Smear a light coat of fine grade valve lapping compound such as Carborendum or Clover Brand on the seating surface of the valve 2 Apply molybdenum disulfide oil to the valve stem and insert the valve into the cylinder head 3 Wet the suction cup of the valve lapping tool Fi...

Page 119: ...ns against so the rings will not be marred if the piston is accidentally struck 9 Inspect the cylinder as described in this section Installation 1 Make sure the top and bottom cylinder surfaces are clean of all gasket residue 2 Install the two dowels A Figure 110 and new base gasket B 3 Lubricate the cylinder and piston liberally with engine oil prior to installation 4 Rotate the crankshaft so the...

Page 120: ...ENGINE TOP END 121 4 1 Cylinder bolt 2 Cylinder 3 Compression ring 4 Oil ring 5 Piston pin circlip 6 Piston 7 Base gasket 8 Dowel 9 Front cam chain guide 10 Piston pin 108 ...

Page 121: ...r an oil leak will result 2 Wash the cylinder block in solvent to remove any oil and carbon particles The cylinder bore must be cleaned thoroughly before any measurement oth erwise incorrect readings may be obtained 3 Check the cylinder wall B Figure 114 for scratches If there are scratches the cylinder should be rebored 5 Measure the cylinder bore with a cylinder bore gauge Figure 115 at a point ...

Page 122: ...gure 117 Any rocking motion do not confuse with the normal sliding motion indicates wear on the piston pin piston pin bore or connecting rod small end bore more likely a combination of these If necessary replace the piston and piston pin as a set NOTE Wrap a clean shop cloth under the piston so the piston pin clip will not fall into the crankcase 4 Remove a circlip Figure 118 from one side of the ...

Page 123: ... the connecting rod Figure 111 Make sure the EX on the piston crown A Figure 122 faces the exhaust side of the cylinder This is the front side on the front cylinder and the rear side on the rear cylinder CAUTION When installing the piston pin in Step 5 do not push the pin in too far The piston pin circlip installed in Step 2 will be forced into the piston metal destroying the clip groove and loos ...

Page 124: ... carbon ring around the circumference of the piston above the top ring If the piston rings and cylinder are dimensionally correct and can be reused removal of the carbon ring from the top of the piston or re moval of the carbon ridge from the top of the cylin der block wall will promote excessive oil consumption in this cylinder CAUTION Do not use a wire brush on the piston skirts 2 After cleaning...

Page 125: ...stalling the new piston lightly hone the cylinder with a bottlebrush hone 8 Measure the piston to cylinder clearance as de scribed in Piston Clearance in this section If clear ance is out of specification Table 2 replace the cylinder piston and rings as a set Oversized pistons are not available Piston Clearance 1 Make sure the pistons and cylinder walls are clean and dry 2 Measure the cylinder bor...

Page 126: ...ton pin and check for ra dial and lateral play Figure 128 If there is play the connecting rod should be replaced if the piston pin outside diameter is within specification In spect the connecting rod as described in Chapter Five Piston Ring Removal and Inspection A three ring assembly is used with each piston The top and second rings are compression rings The lower ring is an oil control ring asse...

Page 127: ...g to a point 40 mm 1 57 in below the top of the cylinder Push the ring with the crown of the piston to ensure the ring is square in the cylin der bore Measure the ring end gap with a flat feeler gauge Figure 133 If the gap is out of specifica tion Table 2 replace the rings 7 Install the piston rings as described below and measure the side clearance of each ring in its groove with a flat feeler gau...

Page 128: ... ring over the top of the piston Figure 129 Install each compression ring with its manufacturing marks Figure 138 facing up 3 Make sure the rings are seated completely in their grooves all the way around the piston and the ends are distributed around the piston 4 Check the side clearance of each ring as shown in Figure 134 If the side clearance is not within the specification shown in Table 2 re e...

Page 129: ...17 32 100 1 2638 2001 on XVZ1100 Intake 32 093 32 193 1 2635 1 2674 31 993 1 2596 Exhaust 32 127 32 227 1 2648 1 2688 32 027 1 2609 Camshaft bushing inside diameter 25 000 25 021 0 9843 0 9851 Camshaft journal outside diameter 24 96 24 98 0 9827 0 9835 Camshaft to bushing clearance 0 020 0 061 0 0008 0 0024 Camshaft runout 0 03 0 0012 Rocker arm Rocker arm bore inside diameter 14 000 14 018 0 5512...

Page 130: ...0 0001 0 0009 Piston rings Side clearance ring to groove clearance Top 0 04 0 08 0 0015 0 0031 0 1 0 004 Second 0 03 0 07 0 0012 0 0027 0 1 0 004 Ring thickness Top 1 5 0 059 Second 1 2 0 047 Oil ring 2 5 0 098 Ring end gap Top 0 30 0 50 0 012 0 020 0 8 0 031 Second 0 30 0 45 0 012 0 018 0 8 0 031 Oil ring 0 2 0 7 0 008 0 028 1 Measured 40 mm 1 54 in from top of cylinder 2 Measured 5 mm 0 197 in f...

Page 131: ...er 20 15 Flywheel nut 175 129 Intake manifold bolts 10 89 Oil delivery pipe banjo bolt 20 15 Primary drive nut 110 81 Rear chain guide bolt 10 89 Rocker arm bolts Exhaust 37 27 Intake 20 15 Spark plugs 20 15 Timing sprocket shaft retainer bolt 10 89 Valve adjuster locknut 27 20 Valve cover bolts 10 89 132 CHAPTER FOUR ...

Page 132: ...frame not how it may sit on the work bench Refer to Basic Service Methods in Chapter One SERVICING THE ENGINE IN THE FRAME The following components can be serviced while the engine is in the frame 1 External gearshift mechanism 2 Clutch 3 Carburetors 4 Starter 5 Alternator and starter clutch 6 Oil pump ENGINE CAUTION Examine the position of the cam tim ing marks for each cylinder before re moving ...

Page 133: ...racket upper nut 8 Engine bracket lower through bolt 9 Upper rear engine mounting bolt 10 Engine mounting nut 11 Front frame member bolt 12 Removable frame member 1 Frame 2 Cylinder head bracket bolt 3 Front frame member nut 4 Rear engine through bolt 5 Cylinder head bracket nut 6 Cylinder head bracket 7 Engine bracket bolt ENGINE REMOVAL ...

Page 134: ...linder head 4 Refer to Chapter Eight and remove the fuel tank air filter housing surge tank carburetor assembly and exhaust system 5 Remove the brake pedal footrest assembly Chapter Thirteen 6 Remove the right and left side covers toolbox panel frame neck covers and the sidestand as de scribed in Chapter Fourteen 7 Follow the oil level switch wire A Figure 3 and disconnect the bullet connector fro...

Page 135: ...move the alternator cover as described in this chapter 14 Place a hydraulic jack under the crankcase to support the engine once the mounting bolts are re moved Figure 8 15 Split a few lengths of coolant hose lengthwise Install the hoses over the left frame member Fig ure 9 so the alternator cover mating surface on the crankcase will not be damaged 16 Loosen each of the four cylinder head bracket n...

Page 136: ...all cables wires and hoses are dis connected from the engine and safely moved out of the way 23 Remove the cylinder head bracket bolts B Figure 10 from each side of the frame 24 Lower the engine slightly and tilt it to the right 25 Turn the cylinder head nuts A Figure 10 off the studs and remove the cylinder head bracket C from the head studs The engine cannot be removed with this bracket in place...

Page 137: ...er en gine mount aligns with the frame mount on the right side 7 Install and finger tighten the cylinder head bracket bolts B Figure 10 8 Set the removable frame member into place on the right side 9 Loosely install the upper frame member bolts Figure 13 and the lower frame member bolts B Figure 3 Finger tighten them at this point 10 Install the front engine bracket as follows a Position the engin...

Page 138: ...oute the oil level switch wire A Figure 3 along the path noted during removal and connect the bullet connector to its harness mate 23 Install the right and left side covers toolbox panel frame neck covers and the sidestand Chapter Fourteen 24 Install the brake pedal footrest assembly Chapter Thirteen 25 Install the carburetor assembly exhaust sys tem surge tank air filter housing and fuel tank Cha...

Page 139: ...140 CHAPTER FIVE 17 ALTERNATOR COVER 1 Dowel 2 Gasket 3 Wire clamp 4 Stator pickup coil assembly 5 Stator mounting bolt 6 Alternator cover 7 Alternator cover bolt 18 19 ...

Page 140: ...ternator cover bolts Figure 23 Remove the bolts and pull the alternator cover from the crankcase Watch for the starter idler gear assembly A Figure 24 It may come out with the cover If it does reinstall the assembly into the crankcase so the idler assembly engages the starter wheel gear and the starter drive gear 10 Remove the alternator cover gasket B Figure 24 and the two dowels C from the crank...

Page 141: ...r stator and pickup coil re moval and inspection procedures FLYWHEEL AND STARTER CLUTCH The following Yamaha special tools or their equivalents are needed to remove or install the fly wheel and starter clutch 1 Sheave holder part No YS 01880 or 90890 01701 2 Flywheel puller part No YU 33270 or 90890 01362 3 Flywheel puller adapter part No YM 38145 or 90890 04131 Refer to Figure 28 Removal NOTE Whe...

Page 142: ...gns with the cutout in the al ternator cover B d Check the timing mark on the rear cam sprocket A Figure 30 It should align with the pointer on the rear cylinder head B Figure 30 ENGINE LOWER END 143 5 28 FLYWHEEL AND STARTER CLUTCH 1 Bolt 2 One way clutch housing 3 One way clutch 4 Flywheel 5 Washer 6 Nut 7 Pin 8 Spring 9 Timing gear 10 Snap ring 11 Washer 12 Bearing 13 Starter wheel gear 14 Star...

Page 143: ...s behind on the crankshaft the six springs and six pins may get scat tered Be prepared to catch loose parts Stuff rags into any openings in the crankcase so nothing falls into the case 4 Install the flywheel puller and adapter onto the flywheel Figure 32 Make sure the puller is par allel to the flywheel 5 Turn the puller s center screw and drive the rotor off the crankshaft If necessary adjust a p...

Page 144: ...r into place A Figure 35 5 Mark the edge of the tooth Figure 39 on either side of the timing mark so you can locate the mark as the flywheel is installed 6 If the Woodruff key was removed install it into the keyway in the crankshaft 7 Install the starter idler gear assembly A Figure 34 into the crankcase Secure it in place with the idler shaft B Figure 34 8 Preload the cam chain drive assembly as ...

Page 145: ...heel Inspection 1 Clean the parts in solvent and dry them with compressed air WARNING Replace a cracked or chipped fly wheel A damaged flywheel can fly apart at high speed throwing metal fragments into the engine Do not at tempt to repair a damaged flywheel 2 Inspect the flywheel Figure 42 for cracks or breaks Make sure the magnet is free of all metal parts 3 Check the flywheel tapered bore and th...

Page 146: ...tch bolts A Figure 46 and lift the starter clutch assembly B from the back of the flywheel 5 Installation is the reverse of removal Note the following a Apply a medium strength threadlocking compound to the threads of each starter clutch bolt and install the bolts b Hold the rotor with the sheave holder and torque the starter clutch bolts to 12 N m 106 in lb 6 Install the starter wheel gear into t...

Page 147: ...nsmission The pri mary side of the pump delivers oil to the oil filter through the crankshaft and onto the upper end The secondary side pumps oil to the transmission shafts In general this oil pump is not serviceable The oil pump sprocket sprocket cover and chain are the only parts that can be replaced other parts are not available separately If inspection reveals any faulty part s replace the oil...

Page 148: ...Figure 54 and new oil pump O rings B Figure 53 Lubricate each O ring with lithium soap grease c Make sure the oil pump properly engages the dowel A Figure 53 in the crankcase d Torque the oil delivery pipe mounting bolt C Figure 53 to 10 N m 89 in lb Torque the oil pump mounting bolts A Figure 52 to 10 N m 89 in lb Torque the oil pump driven sprocket bolt A Figure 51 to 12 N m 106 in lb Torque the...

Page 149: ...IVE 55 OIL PUMP 1 Primary body 2 Oil strainer 3 Indexing pin 4 Outer rotor 5 Inner rotor 6 Secondary body 7 Outer rotor 8 Inner rotor 9 Drive pin 10 Pump shaft 11 Snap ring 12 Washer 13 Oil pump cover 14 Screw 56 57 ...

Page 150: ...r A Figure 60 and inner rotor B Store these rotors with the primary pump body 6 Remove the drive pin Figure 61 from the pump shaft 7 Remove the secondary body A Figure 62 and the two indexing pins B 8 Remove the outer rotor A Figure 63 and inner rotor from the pump cover Store these rotors with the secondary body 9 Remove the drive pin Figure 64 from the shaft 10 Remove the snap ring Figure 65 and...

Page 151: ...xing pins B Figure 62 8 Install the second drive pin Figure 61 into the shaft 9 Install the thick set of rotors Install the inner ro tor B Figure 60 onto the shaft so the rotor en gages the drive pin then install the outer rotor A 10 Install the primary body Figure 59 over the rotors Make sure the body engages the indexing pins 11 Turn the assembly over and install the Phillips screw A Figure 58 A...

Page 152: ...easure the clearance between the outer rotor and the oil pump body B Figure 70 8 Measure the pump rotor depth which is the dis tance from the top of the pump body to the top of the rotors C Figure 70 9 Replace the oil pump if any measurement ex ceeds the service limit in Table 1 10 Inspect the oil pump cover A Figure 71 for cracks and inspect the oil pump shaft B for wear or abrasion 11 Replace th...

Page 153: ...y and inspection pro cedures for the transmission shaft assemblies mid dle driven gear and internal shift mechanism are in Chapter Seven Removal installation disassem bly assembly and inspection procedures for the middle drive assembly and the middle driven assembly also appear in Chapter Seven 1 Remove the engine as described in this chapter 2 Remove the following exterior assemblies from the cra...

Page 154: ...bolt hole These numbers also indicate the crankcase bolt tight ening sequence See Figure 76 6 Before removing the crankcase bolts draw an outline of each case half on a piece of cardboard Punch holes along the drawing outline correspond ing to the bolt location in each crankcase half shown in Figure 76 As each bolt is removed insert it and ENGINE LOWER END 155 5 76 LEFT CRANKCASE RIGHT CRANKCASE ...

Page 155: ... crankcases will not separate as the cases are turned over 9 Turn the crankcase over so the left crankcase half faces up Starting with bolt No 14 loosen and remove the left crankcase bolts in descending order Place each bolt in its corresponding hole in the card board template 10 Turn the crankcase over so the right crankcase half faces up Remove the one remaining right crankcase bolt CAUTION If i...

Page 156: ...led in this orienta tion during assembly NOTE The left center and right shift forks are identified by a letter L C or R embossed on their faces Figure 81 Note the location and orientation of the shift forks Each fork must be rein stalled into its original location with the identification mark facing up out of the crankcase 16 Rotate the center shift fork Figure 82 away from the shift drum and remo...

Page 157: ...s assemble the crankshaft installer pot A Figure 87 crankshaft installer bolt B adapter C and spacer D onto the crankshaft and pull the crank shaft into the left crankcase half Make sure the con necting rods align within their respective cylinder openings Continually monitor this alignment until the crankshaft is completely seated in the left crankcase half 5 Mesh the mainshaft A Figure 85 and cou...

Page 158: ...Check the left and right crankcase mating sur faces for old sealant material or other residue Clean them as necessary 21 Apply engine oil to the transmission shafts and journals in the left case half Also lubricate the bear ings including the inner races in the right crank case half Do not add so much oil that it will drip from the bearing when the case half is turned over 22 Apply a light coat of...

Page 159: ...move all sealer residue from all crankcase mating surfaces WARNING When drying the crankcase bearings in Step 2 do not allow the inner bear ing race to spin The bearings lack lu brication and damage will occur When drying the bearings with com pressed air hold both races with your hand so the bearing will not rotate The air jet will force the bearings to turn at speeds that exceed their design lim...

Page 160: ...te Do not heat the crankcase with a torch This type of lo calized heating may warp the cases 5 Drive the bearing out with a suitable size bearing driver socket or a drift 6 After removing bearings and bushings clean the crankcase half in solvent and dry it thoroughly 7 A blind bearing remover Figure 90 is required to remove some of the blind bearings in the follow ing procedures 8 When installing ...

Page 161: ...ive wear or tooth damage Replace the sprocket as nec essary 6 Check the connecting rod big end for signs of sei zure bearing or thrust washer damage or for connect ing rod damage 7 Check the connecting rod small end for signs of excessive heat blue coloration or other damage 8 Check the connecting rod big end side clearance Slide the connecting rods to one side Measure the big end side clearance F...

Page 162: ...ing rods and recheck the clearance If the side clearance is still outside the specified range re place the crankshaft CAUTION Prior to disassembly mark each con necting rod and cap with an F Front or R rear so the rods can be in stalled in their original locations 3 Remove the connecting rod cap nuts Figure 97 and separate the rods from the crankshaft CAUTION Keep each bearing insert A Figure 98 i...

Page 163: ...n 43 N m 32 ft lb then tighten it to 48 N m 35 ft lb in one continu ous motion g Using a beam type torque wrench tighten each connecting rod nut to 48 N m 35 ft lb Apply continuous torque when tight ening the nut from 43 N m 32 ft lb to 48 N m 35 ft lb Do not stop tightening the nut until the final torque specification is reached Connecting Rod Inspection When inspecting the connecting rods compar...

Page 164: ...tighten each connecting rod nut to 48 N m 35 ft lb Apply continuous torque when tightening the nut from 43 N m 32 ft lb to 48 N m 35 ft lb Do not stop tightening the nut until the final torque specification is reached CAUTION Do not rotate the crankshaft while Plastigage is in place 5 Remove the rod cap 6 Determine the oil clearance by measuring the width of flattened Plastigage according to the m...

Page 165: ...torcycle Avoid prolonged steady running at one speed no matter how moderate Also avoid prolonged full throttle operation hard acceleration or any situation that could result in excessive heat 1 During the first 600 miles 1000 km of opera tion avoid running above 1 3 throttle 2 Between 600 to 1000 miles 1000 1600 km of operation avoid running above 1 2 throttle 3 At the end of the break in period 1...

Page 166: ...ting bolt nut 48 35 Frame member bolts 48 35 Rear engine through bolt 48 35 Upper rear engine mounting bolt 48 35 Flywheel nut 175 129 Neutral switch 20 15 Oil pipe banjo bolt 20 15 Oil delivery pipe mounting bolt 10 89 Oil drain bolt 43 32 Oil filter cover bolt 10 89 Oil pump sprocket cover bolts 10 89 Oil pump gear cover bolts 10 89 Oil pump mounting bolts 10 89 Oil pump driven sprocket bolt 12 ...

Page 167: ...dlebar NOTE In the interest of clarity the clutch and clutch release mechanism proce dures were photographed with the en gine removed from the frame These components can be serviced while the engine is in the frame CLUTCH COVER Removal Installation Refer to Figure 1 1 Securely support the motorcycle on level ground 2 Remove the brake pedal footrest assembly as described in Chapter Thirteen 3 Remov...

Page 168: ...llation is the reverse of removal Note the following a Install the two dowels A Figure 3 and a new gasket B into the crankcase b Install the air filter housing bracket behind the two bolts B Figure 2 noted during re moval CLUTCH AND PRIMARY DRIVE GEAR 169 6 1 CLUTCH COVER 1 Oil filter cover bolt 2 Oil filter outer cover 3 Air filter housing bracket 4 Cap bolt 5 Cap 6 O ring 7 Oil filter 8 Clutch c...

Page 169: ... if the seal is be coming brittle 4 Replace the seal as follows a If still installed remove the oil seal retainer B Figure 5 b Pry the crankshaft oil seal Figure 6 from the clutch cover c Lubricate a new seal with lithium soap grease Position the seal so the manufac turer s marks face out and drive the seal into the cover with a driver or socket that matches the outside diameter of the seal d Inst...

Page 170: ...3 Clutch boss spring 4 Plate seat 5 Clutch boss 6 Thrust washer 7 Clutch housing 8 Pushrod No 2 9 Friction disc 10 Clutch plate 11 Clutch nut 12 Lock plate 13 Clutch spring bolt 14 Spring plate 15 Clutch spring 16 Spring seat 17 Pressure plate 18 Washer 19 Release bearing 20 Pushrod No 1 ...

Page 171: ...tab on each friction disc must be in stalled in this marked slot during assembly 9 Remove all of the friction discs and clutch plates Stack the disc and plates in the order of removal 10 Straighten the ears A Figure 16 of the lockwasher away from the flats on the clutch nut B CAUTION Do not clamp the special tool too tightly The tool could damage the grooves in the clutch hub 11A Hold the clutch b...

Page 172: ... the clutch nut B Figure 16 and dis card the lockwasher A 13 Remove the clutch boss Figure 19 14 Remove the thrust washer A Figure 20 and the clutch housing B NOTE Clutch plate No 1 is part of a damper assembly on the clutch boss This as sembly does not have to be disassem bled unless the clutch experiences severe clutch chatter 15 If necessary remove the clutch hub damper as sembly as follows a P...

Page 173: ... mainshaft as follows a Apply oil to the bushing in the clutch housing hub b Slide the clutch housing B Figure 20 onto the mainshaft until the teeth of the primary driven gear A Figure 23 on the housing en gage the teeth of the primary drive gear C Figure 20 Gently push the clutch housing onto the mainshaft until it bottoms 3 Install the thrust washer A Figure 20 onto the mainshaft 4 Slide the clu...

Page 174: ...tall the spring seat A Figure 10 onto the pressure plate and set the clutch spring Figure 9 into the spring seat Make sure the convex side of the spring faces out 17 Install the spring plate B Figure 8 into place and loosely install the clutch spring bolts A Ap ply a medium strength threadlocking compound to the threads of the bolts 18 Evenly tighten the bolts in a crisscross pattern Torque the cl...

Page 175: ...it in Table 1 4 If clutch plate No 1 was disassembled from the clutch boss perform the following a Measure the thickness of clutch plate No 1 at four places around its circumference Replace it if any measurement exceeds the service limit b Check the warp on a surface plate or piece of plate glass Figure 31 Replace clutch plate No 1 if its warp equals or exceeds the service limit 5 Inspect the clut...

Page 176: ... is excessive the clutch boss must be replaced 8 Check the pressure plate Figure 33 for cracks wear or galling Inspect the splines Figure 34 on the inside face of the pressure plate for roughness or excessive wear Replace the pressure plate as neces sary 9 Visually inspect the clutch spring A Figure 35 and spring seat B for cracks wear and other signs of fatigue 10 Measure the free height of the c...

Page 177: ...sh screw B 6 Inspect the clutch lever A Figure 42 for signs of wear or damage 7 Inspect the balls in the ball assembly B Figure 42 for scratches heat discoloration or other signs of damage 8 Inspect the detents C Figure 42 in the push screw for scratches wear or heat discoloration 9 Inspect the clutch release mechanism oil seal Figure 43 for damage or brittleness 10 Replace any part that is worn o...

Page 178: ...t on the alternator cover 8 Install the washer B Figure 38 and turn the locknut A onto the shaft Finger tighten the locknut It will be tightened once the clutch cable free play is adjusted 9 Install the alternator cover as described in Chap ter Five 10 Adjust the clutch cable free play Chapter Three CLUTCH CABLE REPLACEMENT In time the clutch cable will stretch to the point where it can no longer ...

Page 179: ...ough the frame It is very easy to forget how it was routed once it has been re moved The new cable must be re routed along the same path as the old cable Avoid any sharp turns 6 Pull the clutch cable out from behind the steering head area through the retaining loop Figure 47 on the left side of the frame and from any clips on the frame 7 Remove the cable and replace it with a new ca ble 8 Installa...

Page 180: ...te the position of the timing marks on the cam sprocket plate and cylinder head Take a photograph or make a drawing so the camshaft can be correctly timed during assembly Also note that the timing mark on the timing gear A Figure 48 the mark on the cam chain drive assembly B and the center of the drive assembly shaft C align when the front cylinder is at TDC Refer to Figure 49 1 Remove the engine ...

Page 181: ...iscard the lockwasher Figure 51 7 Remove the slotted washer Figure 52 from the crankshaft NOTE The primary drive gear A Figure 53 and the timing gear B come out as an assembly However if the timing gear slips from the primary drive gear during removal the six springs and six pins may be scattered Stuff rags into the opening in the crankcase so nothing falls into the case 8 Grasp the primary drive ...

Page 182: ...ll the primary drive gear timing gear assem bly onto the crankshaft and install the Woodruff key C Figure 53 into the keyway 5 Install the slotted washer Figure 52 so its slot engages the Woodruff key 6 Install a new lockwasher Figure 51 and the primary drive gear nut B Figure 50 7 Hold the flywheel with the sheave holder and torque the primary drive gear nut to 110 N m 81 ft lb 8 Bend the ears of...

Page 183: ...rive gear timing gear slot ted washer and in the crankshaft 4 Inspect the threads of the primary gear nut Re place the nut as necessary 184 CHAPTER SIX 60 Table 1 CLUTCH SPECIFICATIONS Item New mm in Service limit mm in Friction disc Thickness 2 9 3 1 0 114 0 122 2 8 0 11 Quantity 8 Clutch plate Thickness 1 9 2 1 0 075 0 083 0 1 0 004 Quantity 7 Warp Less than 0 1 mm 0 004 in Clutch plate No 1 Thi...

Page 184: ...rk is worn or missing make a new one so the shift lever can be properly installed on the shift shaft during assembly 2 Loosen the shift lever clamp bolt B Figure 2 3 Remove the footrest bracket bolts Figure 3 4 Slide the shift lever C Figure 2 from the shift shaft and remove the shift pedal footrest Watch for the washer behind the shift lever 5 If necessary remove the shift pedal from the footrest...

Page 185: ... 3 Stopper lever spring 4 Stopper lever 5 Collar 6 Pin 7 Shift shaft spring 8 Shift shaft assembly 9 Shift lever 10 Clamp bolt 11 Locknut 12 Shift rod 13 Snap ring 14 Shift pedal XVS1100A models 15 Wave washer XVS1100A models 16 Shift pedal XVS1100 models XVS1100 ...

Page 186: ...l footrest assembly as de scribed earlier in this chapter 3 Drain the engine oil as described in Chapter Three 4 Remove the alternator cover and pull it from the flywheel Chapter Five 5 Press the shift arm away from the shift cam so the shift pawls A Figure 4 clear the shift pins 6 Grasp the shift shaft B Figure 4 and pull the assembly from the crankcase Watch for the washer A Figure 5 on the inbo...

Page 187: ... damaged 1 Inspect the shift shaft for bends or damage 2 Inspect the shift arm for bends or damage Pay particular attention to the shift pawls 3 Check the shift arm spring the shift shaft spring and the stopper lever spring for cracks or signs of fatigue Replace any spring as necessary 4 Check the operation of the roller on the stopper lever It should move smoothly 5 Inspect the stopper lever for ...

Page 188: ...AND MIDDLE GEAR 189 7 8 9 10 11 12 INTERNAL SHIFT MECHANISM 1 Retainer screw 2 Shift fork shaft retainer 3 Shift fork shaft 4 Shift fork 5 Shift drum 6 Neutral pin 7 Bearing 8 Pin 20 mm 9 Pin 16 mm 10 Shift cam 11 Shift drum screw ...

Page 189: ... way to retain the correct relationship of all parts 2 The snap rings fit tightly on the transmission shafts They usually become distorted during re moval All snap rings must be replaced during as sembly 3 Snap rings will turn and fold over making re moval and installation difficult To ease replace ment open a snap ring with a pair of snap ring pliers while at the same time holding the back of the...

Page 190: ...nap ring and the washer 5 Remove fourth gear from the mainshaft 6 Inspect the mainshaft Figure 18 and gears as described in this chapter Mainshaft Assembly NOTE Before installing any component coat all surfaces with molybdenum disul fide oil TRANSMISSION SHIFT MECHANISM AND MIDDLE GEAR 191 7 17 TRANSMISSION 1 Middle drive gear 2 Countershaft first gear 3 Countershaft fourth gear 4 Snap ring 5 Spli...

Page 191: ...ng so its end gap sits within a groove in the mainshaft Figure 16 4 Install the second third combination gear so third gear Figure 21 faces toward fourth gear 5 Install fifth gear A Figure 22 so its flat side faces away from the second third combination gear 6 Install the washer B Figure 22 and a new snap ring C The flat side of the snap ring should face out away from the washer Countershaft Disas...

Page 192: ...nd slide the gear up against the stop The gear s engagement slots must face out 2 Install a splined washer B Figure 25 and a new snap ring C The snap ring s flat side must face away from splined washer and the snap ring must be completely seated in its groove Position the end gap Figure 16 so it sits above a groove in the countershaft 4 Install fifth gear Figure 26 so its fork groove faces away fr...

Page 193: ...r chips as well as for broken or burnt teeth Figure 32 3 Check the engagement dogs A Figure 33 and engagement slots Figure 34 Replace any gear s with rounded or damaged edges on the dogs or within the slots 4 Inspect all free wheeling gear bearing surfaces B Figure 33 for wear discoloration and galling Also inspect the respective shaft s bearing surfaces A Figure 24 If there is any metal flaking o...

Page 194: ...le gear backlash band part No YM 01231 or 90890 01231 3 Damper spring compressor part No YM 33286 or 90890 04090 4 Middle drive shaft holder part No YM 04055 or 90890 04055 5 Middle drive shaft nut wrench part No YM 045054 or 90890 04138 Refer to Figure 37 when servicing the middle drive shaft assembly Removal 1 Remove the engine split the crankcase and dis assemble the cases as described in Chapt...

Page 195: ...MIDDLE DRIVE SHAFT ASSEMBLY 38 39 1 Bearing retainer 2 Spring retainer 3 Spring seat 4 Damper spring 5 Damper cam male 6 Damper cam female 7 Middle drive shaft nut 8 Bearing 9 Middle drive shaft shims 10 Middle drive shaft ...

Page 196: ... Unstake the threads of the middle drive shaft nut 5 Install the middle drive shaft nut wrench B Fig ure 42 Loosen and remove the nut from the mid dle drive shaft 6 Install a bearing splitter onto the middle drive shaft Support the splitter in a press and press the shaft from the bearing 7 Remove the bearing and shims 8 Inspect the middle drive shaft assembly as de scribed in this section Assembly...

Page 197: ...top of the left crankcase half c For example if the number on the upper crankcase is 46 Figure 43 then shim thick ness 43 00 42 00 0 46 or 0 54 2 Middle drive shaft shims are available in three sizes 0 10 0 15 and 0 20 mm round off shim thickness to the nearest five hundredths of a milli meter as follows a If the hundredths digit in the calculated value is 0 2 round shim thickness down to the ex i...

Page 198: ...ide of the drive yoke B b Using a front end ball joint remover Figure 47 or a hydraulic press with the proper size TRANSMISSION SHIFT MECHANISM AND MIDDLE GEAR 199 7 44 MIDDLE DRIVEN SHAFT ASSEMBLY 45 1 Bearing 2 Middle driven shaft 3 Washer 4 Collapsible collar 5 Collar 6 O ring 7 Bearing housing 8 Bearing 9 Bearing retainer 10 Oil seal 11 Speed sensor bracket 12 Bolt 13 Rotor 14 Drive yoke 15 Wa...

Page 199: ...he bearing from the bear ing housing 12 If necessary remove the bearing from the end of the middle driven shaft Assembly 1 Install the bearing onto the inboard end of the middle driven shaft if it was removed Thoroughly lubricate the bearing with engine oil 2 If the bearing housing was disassembled assem ble it as follows a Lubricate the bearing with engine oil and set the bearing into the bearing...

Page 200: ...n crements and check the middle gear backlash If the nut is overtightened the collapsible collar will be crushed and will have to be replaced 12 Gradually tighten the middle driven gear nut B Figure 48 while measuring the middle gear backlash a Tighten the nut in a small increment and stop b Turn the universal joint holder and read the backlash on the dial gauge c Repeat substeps a and b until the...

Page 201: ...the middle gear backlash band Figure 49 onto the middle drive shaft assembly 3 Set a dial gauge against the backlash band so the plunger sits 68 2 mm 2 69 in from the center of the middle drive shaft See Figure 50 4 Rotate the universal joint and read the backlash on the dial gauge The middle gear backlash should be within the range specified in Table 1 202 CHAPTER SEVEN Table 1 TRANSMISSION AND G...

Page 202: ...i ance pilot lights Do not allow any smoking in the area Keep a B C rated fire extinguisher on hand Removal Installation NOTE During removal label each hose and its fitting Also note how a hose is routed through the frame This as sures that each hose will be connected to the correct fitting and properly routed during assembly 1 Securely support the motorcycle on a level sur face 2 Make sure the ma...

Page 203: ...9 On California models disconnect the EVAP hose B Figure 6 from the fitting on the fuel tank 10 If necessary release any cable holder that se cures a hose or wire to the motorcycle Note the lo cation of these cable holders 204 CHAPTER EIGHT 1 2 FUEL TANK AND SEATS 1 Fuel tank 2 Fuel hose 3 Fuel tank bolt 4 Rider s seat 5 Seat bracket 6 Seat bracket bolt 7 Passenger seat 8 Nut 9 Meter connector ...

Page 204: ...que the fuel tank bolts to 23 N m 17 ft lb e Insert the meter connector B Figure 5 be neath the ignitor panel d Secure the harness and hoses with any cable holders released during removal FUEL VALVE Removal Installation WARNING Some fuel may spill during the follow ing procedure Work in a well venti lated area at least 50 feet from any sparks or flames including gas appli ance pilot lights Do not ...

Page 205: ...as semble the valve as shown in Figure 8 b Replace the packing or fuel valve seal c Assemble the fuel valve by reversing these disassembly steps 7 Install the fuel valve by reversing these removal steps Note the following a Install a new O ring 1 Figure 8 during in stallation b Tighten the fuel valve bolts B Figure 3 to 7 N m 62 in lb c After installing the fuel valve pour a small amount of fuel i...

Page 206: ...this chap ter AIR FUEL EXHAUST AND EMISSION CONTROL SYSTEMS 207 8 9 AIR INTAKE 1 Cover bolt 2 Air filter cover 3 Air filter 4 Screw 5 Surge tank 6 Gasket 7 Bolt 8 Collar 9 Damper 10 Intake duct 11 Surge tank base 12 Air filter housing 13 Air filter housing duct 14 Bolt 15 Washer 16 Air filter housing bracket upper 17 Clamp 18 Surge tank duct 19 Damper 20 Air filter housing bracket lower 21 Cylinde...

Page 207: ... Stuff a rag into the surge tank duct A Figure 14 so dirt or other contaminants cannot enter the duct while the housing is removed 10 Installation is the reverse of removal Note the following a Make sure the drain hose C Figure 13 is se cured to the holder of the bracket on the clutch cover b Press the housing toward the engine until the housing post A Figure 13 engages the grommet B on the air fi...

Page 208: ...he surge tank duct A from the surge tank 3 Disconnect the cylinder head breather hose C Figure 14 from the cam sprocket cover on the front cylinder 4 Remove the surge tank bolt D Figure 14 and collar 5 Remove the air filter housing bracket bolts A Figure 17 On California models note that the EVAP purge hose B Figure 17 runs behind the bracket Release the fuel hose C Figure 17 from the holder on th...

Page 209: ...t securely 7 Tighten the clamps A Figure 18 that secure the surge tank to the carburetor ducts B Also refer to A Figure 19 8 Secure the air filter housing bracket to the frame with its mounting bolts A Figure 17 On Califor nia models route the EVAP purge hose B Figure 17 behind the bracket Secure the fuel hose C Fig ure 17 in the holder on the bracket 9 Install the surge tank duct A Figure 14 onto...

Page 210: ... Also note how each hose is routed along the motorcycle Hoses must be rerouted along their original paths 1 Securely support the motorcycle on a level sur face and disconnect the electrical lead from the neg ative battery terminal Figure 2 2 Remove the fuel tank as described in this chap ter 3 Remove the air filter housing and the surge tank as described in this chapter 4 Loosen the clamp A Figure...

Page 211: ...the motorcycle 17 On California models remove the heat shield Figure 30 18 While the carburetor assembly is removed exam ine the intake manifold on each cylinder head Look for cracks or other damage that would allow unfiltered air into the engine Replace any damaged part 19 Stuff clean shops rag into each intake manifold to keep foreign matter out of the cylinder heads 20 Install the carburetor as...

Page 212: ...ors unless the coasting enricher or starter plunger requires service The carburetors mount to a bracket that sits be tween them The following procedure describes re moving the front carburetor from this bracket 1 Disconnect the connector A Figure 31 from the carburetor heater on the front carburetor 2 Release the cable ties B Figure 31 that secure the wires to the bracket 3 Disconnect the connecto...

Page 213: ... connector tubes Figure 34 6 Install the bracket bolts Figure 33 and secure the front carburetor to the bracket 7 Connect the connectors to the carburetor heater A Figure 32 and the heater ground B on the rear carburetor 8 Secure the wires in the clamp C Figure 32 on the float bowl 9 Connect the connector A Figure 31 to the car buretor heater on the front carburetor 10 Secure the wires to the brac...

Page 214: ...r 11 Carburetor body 12 Bracket bolt 13 Cover bracket 14 Coasting enricher diaphragm 15 Spring 16 Coasting enricher cover 17 Gasket 18 Throttle position sensor TPS 19 Carburetor heater 20 Ground terminal 21 Pilot jet 22 Spacer 23 Starter jet 24 Needle jet 25 O ring 26 Jet holder 27 Main jet 28 Valve seat 29 Float valve 30 Float 31 Pin 32 Float bowl 33 Drain screw 34 Washer 35 Pilot air jet No 1 36...

Page 215: ... Watch for the collar Figure 42 beneath the outboard screw on the rear carburetor d Remove the top cover C Figure 41 from the carburetor 6 Remove the spring A Figure 43 and vacuum piston B 7 Remove and discard the small O ring A Figure 44 8 Remove the needle retainer Figure 45 from the vacuum piston and remove the jet needle Figure 46 9 Remove pilot air jet No 2 B Figure 44 from the vacuum piston ...

Page 216: ... ground terminal B Figure 48 12 Remove the mounting screws A Figure 49 and lift the float bowl B from the carburetor body Watch for the float bowl O ring Figure 50 13 Remove the screw A Figure 51 and pull the float pin B from the float 14 Lift out the float and float valve A Figure 52 AIR FUEL EXHAUST AND EMISSION CONTROL SYSTEMS 217 8 45 46 47 48 49 50 51 ...

Page 217: ...e scribed in Pilot Screw in this chapter 22 Clean and inspect the components as described in this section Assembly 1 If the pilot screw was removed install it as de scribed in Pilot Screw in this chapter 2 Install the needle jet Figure 58 so the concave side goes into the carburetor body 3 Install the needle jet holder Figure 57 with a new O ring and install the main jet Figure 56 4 Install the st...

Page 218: ...igure 44 onto the top of the vacuum piston bore 14 Assemble the vacuum piston if it was disas sembled as follows a Lower the jet needle Figure 46 into the vac uum piston b Secure the needle in place with the needle re tainer Figure 45 15 Lower the vacuum piston Figure 60 into the slide bore so the piston diaphragm sits within the lip on top of the bore 16 Install the spring A Figure 43 into the va...

Page 219: ...acket with new ca ble ties B Figure 64 Cleaning and Inspection 1 Thoroughly clean and dry all parts Do not use a caustic carburetor cleaning solvent Instead clean carburetor parts in a petroleum based solvent Rinse them thoroughly in clean water CAUTION If compressed air is not available al low the parts to air dry or dry them with a clean lint free cloth Do not use a paper towel to dry carburetor...

Page 220: ...bles appear replace the float 11 Inspect the needle valve assembly as follows a Inspect the end of the needle valve for wear or damage See Figure 68 b Check the inside of the valve seat B Figure 67 A damaged needle valve or a particle of dirt or grit in the float valve assembly will cause the carburetor to flood and fuel to over flow c Inspect the filter on the end of the valve seat If there are a...

Page 221: ...rburetor body as shown in Figure 71 Do not drill too deeply The pilot screw will be difficult to remove if the head is damaged 3 Screw a sheet metal screw into the plug and pull the plug from the bore 4 Screw the pilot screw clockwise until it lightly seats in the bore while counting and recording the number of turns The pilot screw must be reinstalled to this same position during assembly 5 Remov...

Page 222: ...vertically against the float bowl 4 Loosen the carburetor drain screw B Figure 73 5 Wait until the fuel in the gauge settles 6 Fuel level C Figure 73 equals the distance be tween the fuel level in the gauge and the upper edge of the float bowl Record the fuel level and compare the reading to the specification in Table 1 7 Repeat this procedure for the other carburetor The fuel level of one carbure...

Page 223: ...ng as follows a Disconnect the triangular three pin throttle position sensor connector A Figure 75 from its harness mate b Disconnect the eight pin connector Figure 76 from the ignitor unit c Check the continuity on the blue yellow and black blue wires between the ignitor connec tor and throttle position sensor connector d Make any necessary repairs to the wiring 3 Refer to Figure 77 and check the...

Page 224: ...ensor screws se curely CARBURETOR HEATER Troubleshooting Refer to Chapter Two Carburetor Heater Relay Test Europe and Australia Models NOTE A carburetor heater relay is used on those models with two carburetor heaters per carburetor Models with only one heater per carburetor do not use a carburetor heater relay 1 Remove the carburetor heater relay as described below 2 Use jumpers to connect the ba...

Page 225: ... in Figure 81 NOTE The thermometer and the thermo switch must not touch the side or bot tom of the container during this test If either does test results will be inaccu rate 5 Suspend a thermometer in the water Use a cook ing or candy thermometer that is rated higher than the test temperatures 6 Set an ohmmeter to the R 1 range 7 Connect the ohmmeter positive test lead to the brown yellow terminal...

Page 226: ...ove the fuel tank air filter housing and surge tank as described in this chapter 3 Remove the frame neck covers Chapter Four teen 4 Note how the throttle cables are routed along the left side and through the fork legs The new cable must be rerouted along the same path 5 Loosen the pull cable locknut A Figure 83 and the return cable locknut B Release each cable from the carburetor bracket and disco...

Page 227: ...rburetor throttle wheel and secure it to the bracket with its locknut A Figure 83 17 At the handlebar lubricate the ends of the new cable with lithium soap grease Connect the cable ends A Figure 85 to the throttle grip Make sure the cables rests in the grooves of the throttle drum 18 Reinstall the halves of the right handlebar switch assembly Make sure the index pin B Fig ure 85 on the switch asse...

Page 228: ...g back through the frame routing the new cable through the same path as the old 14 Remove the string and lubricate the cable end with lithium soap grease 15 Connect the cable end B Figure 88 to the choke linkage and secure the cable with the clamp screw A 16 At the handlebar lubricate the cable end with lithium soap grease and connect the cable to the choke lever linkage Figure 89 17 Operate the c...

Page 229: ...d remove it 7 Installation is the reverse of removal Note the following a Securely seat the fuel pump in its mounting grommet b Connect the inlet B Figure 91 and outlet hoses C to the proper fittings on the pump Troubleshooting Refer to Chapter Two Operational Test Check the operation of the fuel pump by applying battery power directly to the fuel pump 1 Remove the toolbox cover and the side cover...

Page 230: ... the positive bat tery terminal to the red black terminal A Figure 94 on the relay and connect the nega tive battery terminal to the blue red terminal B c Connect the ohmmeter positive test lead to the red black terminal A Figure 94 on the relay and connect the negative test lead to the blue black terminal C d The fuel pump relay should have continuity during this test Replace the starting circuit...

Page 231: ...SYSTEM 1 Vacuum hose to rear cylinder intake manifold 2 Orifice 3 AIS air filter 4 Air filter housing 5 Air cut valve 6 Reed valve 7 Housing 8 Bracket 9 AIS output hose 10 AIS pipe to rear cylinder 11 AIS pipe to front cylinder 12 Gasket ...

Page 232: ...perly secure each hose to its respective fit ting c Apply silicone sealant to the threads of the rear alternator cover bolt D Figure 97 Torque the two alternator cover bolts to 10 N m 89 in lb Inspection 1 Release the lock tabs and lift the AIS air filter A Figure 99 from the air filter housing 2 Inspect the air filter and housing for cracks or damage 3 Remove the mounting screws and lift the air ...

Page 233: ...tmo sphere Inspection Maintenance to the evaporative emission control system consists of inspecting the condition and routing of the hoses making sure the canister is se curely mounted to the engine mounting bracket and testing the EVAP solenoid valve No attempt should be made to modify or remove the emission control system WARNING Because the evaporative emission control system stores fuel vapors...

Page 234: ...AIR FUEL EXHAUST AND EMISSION CONTROL SYSTEMS 235 8 101 1 Fitting 2 Solenoid valve 3 Rollover valve 4 Clamp 5 Canister ...

Page 235: ...er 7 Installation is the reverse of removal Note the following a Each hose must be connected to the correct port on the EVAP canister See Figure 101 b Make sure the hose clamps and bolts are tight Solenoid Valve Testing Perform these test procedures in the listed se quence Each test presumes that the components tested in the earlier steps are working properly The tests can yield invalid results if...

Page 236: ...Table 2 5 Check the circuit wiring and grounds from the battery through the main fuse main switch igni tion fuse and to the EVAP solenoid valve EXHAUST SYSTEM Removal Installation Refer to Figure 106 AIR FUEL EXHAUST AND EMISSION CONTROL SYSTEMS 237 8 106 EXHAUST SYSTEM 1 Hanger bolt 2 Muffler assembly 3 Muffler gasket 4 Clamp screw 5 Rear exhaust pipe 6 Bolt 7 Heat shield clamp gasket 8 Exhaust g...

Page 237: ...haust pipe from the manifold c Remove and discard the exhaust gasket Fig ure 109 6 Remove the front exhaust pipe as follows NOTE The front exhaust pipe can be re moved with the cover A Figure 110 installed on the pipe a Remove the nuts B Figure 110 and pull the exhaust pipe from the exhaust port b Remove and discard the exhaust gasket Fig ure 109 7 Inspect the system as described below 8 Installat...

Page 238: ...rnal rust buildup periodically re move the drain bolt from each muffler to drain away trapped moisture 1 Check for leaks where each muffler joins an ex haust pipe A Figure 112 2 Inspect the drain bolts for corrosion or exhaust leaks Replace the bolts and washers if necessary 3 Inspect the muffler mounting brackets B Fig ure 112 for wear or damage Replace the muffler as necessary AIR FUEL EXHAUST A...

Page 239: ...to 3 01 4 51 k ohms Fully closed resistance 0 56 0 84 k ohms Resistance specification 20 C 68 F Table 3 AIR FUEL AND EXHAUST SYSTEM SPECIFICATIONS AIS reed valve height 0 4 mm 0 016 in Fuel pump output pressure 12 kPa 1 7 psi Fuel tank capacity Total 17 liter 4 49 US gal 3 74 Imp gal Reserve 4 5 liter 1 19 US gal 0 99 Imp gal Fuel Regular unleaded Octane 86 R M 2 method or research octane 91 or hi...

Page 240: ...During as sembly tighten fasteners to the specified torque Refer to Electrical Component Replacement in Chapter Two Refer to the appropriate wiring diagram at the end of this manual when working on the electrical sys tem CHARGING SYSTEM The charging system consists of the battery main fuse main switch alternator and the regulator recti fier assembly Alternating current generated by the alternator ...

Page 241: ...boot from the electrical cables 3 Disconnect the three pin stator connector A Figure 4 from its mate on the wiring harness 4 Measure the stator coil resistance NOTE In each of the following tests connect the ohmmeter s positive lead to the connector s center terminal A Fig ure 5 and the ohmmeter s negative lead to the other terminal B or C 5 Measure the resistance between the center termi nal A Fi...

Page 242: ...e along the same path noted during removal d Apply a dielectric compound to the electrical connectors prior to reconnecting them e Make sure the electrical connector is free of corrosion and both sides are completely cou pled to each other f Reinstall the alternator cover as described in Chapter Five VOLTAGE REGULATOR RECTIFIER Removal Installation The voltage regulator rectifier mounts to the in ...

Page 243: ...nd distribution circuits in the ignitor unit The ignitor unit interrupts current flow through the igni tion coil and the magnetic field within the coil col lapses This induces a very high voltage in the sec ondary windings of the ignition coil This voltage is sufficient to jump the gap at the spark plugs Troubleshooting Refer to Chapter Two The ignition system is designed to operate only when the ...

Page 244: ...n coil or battery 5 Each solid state unit is mounted on a rubber vi bration isolator Make sure the isolators are in place when replacing any units SPARK PLUG CAP Resistance 1 Disconnect the spark plug cap from the spark plug 2 Measure the resistance between each end of the cap as shown in Figure 9 3 Replace the spark plug cap if the resistance ex ceeds the specification in Table 1 4 Repeat this te...

Page 245: ...ion listed in Table 1 8 Repeat this test for the other ignition coil Removal Installation 1 Use jack stands or a scissors jack to securely support the motorcycle on level ground 2 Remove the fuel tank and surge tank as de scribed in Chapter Eight and remove the frame neck cover Chapter Fourteen 3 Disconnect the electrical lead from the negative battery terminal A Figure 1 4 Disconnect the spark pl...

Page 246: ...A Figure 14 in the diode connect the negative test probe to the blue white terminal B The diode should have continuity in this direction 4 Reverse the ohmmeter leads and check the conti nuity The diode should not have continuity in this direction 5 Replace the diode if it fails either portion of the test IGNITOR UNIT Testing The ignitor unit cannot be tested If all other igni tion system component...

Page 247: ...the starter for more than five seconds at a time Let it cool approximately ten seconds then use it again Troubleshooting Refer to Chapter Two STARTER Operational Test 1 Securely support the motorcycle on a level sur face and shift it into neutral 2 Make sure the main switch is off 3 Remove the fuel tank as described in Chapter Eight WARNING The negative lead is still connected to the battery in th...

Page 248: ... the O ring with lithium soap grease b Tighten the starter mounting bolts B Figure 16 to 10 N m 89 in lb c Make sure the electrical connector is free of corrosion and is tight Disassembly Refer to Figure 18 1 If still installed remove and discard the O ring A Figure 17 from the front cover 2 Remove the outer snap ring B Figure 17 the starter gear C and the inner snap ring 3 Remove the case bolts F...

Page 249: ... the recess in the ring gear holder 7 Remove the ring gear holder Figure 23 and washer Figure 24 from the front end cap 8 Remove the gear plate Figure 25 from the ar mature housing 9 Slide the washers Figure 26 from the armature shaft 10 Remove the rear end cap A Figure 27 from the armature housing NOTE Count and label the number of shims removed in Step 11 These shims must be reinstalled in the o...

Page 250: ...ghly dry them 14 Clean all grease dirt and carbon from the arma ture housing and end caps NOTE Further disassembly is not necessary unless the brush holder assembly must be replaced The brushes can be removed and inspected at this stage CAUTION The cable terminal assembly consists of several washers shims and a nut Label each component as it is re moved They must be reinstalled in the same order t...

Page 251: ...end cap 3 Install the ring gear Figure 22 so its male index engages the female recess in the ring gear holder 4 Install a planetary gear Figure 21 onto each post in the front end cap CAUTION When installing the positive brush as sembly make sure an insulated por tion of each positive brush wire E Figure 34 sits within a cutout in the brush holder If bare wire touches the holder the starter will sh...

Page 252: ...e Figure 37 Each cable tie will hold the spring away from the brush during armature installation 10 Insert the armature into the housing Figure 38 until the armature bottoms against the brush holder Exercise caution so the commutator Figure 29 is not damaged 11 Slip the cable tie Figure 39 from each brush holder The springs can now press the brushes against the commutator 12 Install the shims A Fi...

Page 253: ...ep d 19 Install the front end cap onto the housing so the index mark on the cap aligns with the mark on the housing Figure 42 20 Install the starter case bolts Figure 19 Apply a medium strength threadlocking compound to the bolt threads and tighten the bolts securely 21 Lubricate a new O ring A Figure 17 with lithium soap grease and install it onto the front end cap 22 Install the inner snap ring ...

Page 254: ... damage If it is damaged replace the starter 7 Inspect the bearing and oil seal in the front end cover A Figure 41 If either is worn or damaged replace the starter 8 Inspect the teeth of the planetary gears B Fig ure 41 and ring gear C for chipped cracked or broken teeth 9 Clean all dirt and contaminants from the mount ing lugs of the rear end cover The lugs ground the starter so there must be goo...

Page 255: ...as no continuity SCCR Diode Test Starting Circuit 1 Remove the starting circuit cutoff relay as de scribed in this chapter 2 Disconnect the harness connector from the relay 3 Check the continuity of the starting system diode as follows a Connect the ohmmeter positive test lead to the sky blue terminal A Figure 49 in the re lay connect the negative test lead to the re lay s black yellow terminal B ...

Page 256: ... connector from the starter relay 5 Pull back the boot on each starter relay cable connector and remove the terminal nuts 6 Disconnect the red battery lead B Figure 51 from the relay s positive terminal and disconnect the black starter lead C from the relay s negative terminal 7 Remove the relay from the rubber mount 8 Installation is the reverse of removal Note the following a Install the relay i...

Page 257: ...artz halogen bulb Do not touch the bulb glass with your fingers be cause traces of oil on the bulb will drastically reduce the life of the bulb Clean any traces of oil from the bulb with a cloth moistened in alcohol or lacquer thinner 1 Remove the mounting screw Figure 53 on ei ther side of the headlight housing and lower the lens assembly from the housing 2 Disconnect the headlight connector A Fi...

Page 258: ...e of corrosion and are pushed tightly together b Adjust the headlight as described in this chap ter c Torque the headlight housing bolts to 8 N m 71 in lb Headlight Adjustment Adjust the headlight horizontally and vertically according to the Department of Motor Vehicles reg ulations in your area 1999 2000 XVS1100 models The horizontal adjuster on these models is at 2 o clock A Figure 62 on the fro...

Page 259: ...bulb and remove the lens assembly 3 Set a voltmeter to the DC 20 volt range 4 Turn the dimmer switch to LO and check the voltage as follows a Connect the voltmeter negative test lead to the black terminal A Figure 64 in the head light connector connect the voltmeter posi tive test lead to the green terminal B b Turn the main switch on and check the volt meter It should read battery voltage 5 Turn ...

Page 260: ... wiring between the main switch and the headlight connector is faulty METER ASSEMBLY Removal Installation Refer to Figure 67 1 Remove the fuel tank as described in Chapter Eight 2 Remove the mounting screws A Figure 68 3 Raise the meter cover B Figure 68 and dis connect the two pin trip meter button connector A Figure 69 from it mate Remove the cover 4 Remove the mounting nuts B Figure 69 and lift...

Page 261: ...N m 35 in lb Meter Indicator Light Test If the meter illumination lights do not operate perform the following test 262 CHAPTER NINE HEADLIGHT XVS110A MODELS 1 Screw 2 Washer 3 Adjuster 4 Headlight rim 5 Spring 6 Nut 7 Bulb clip 8 Retaining clip 61 9 Lens 10 Mounting ring 11 Bulb 12 Socket cover 13 Screw 14 Headlight housing 15 Collar 16 Damper 62 63 ...

Page 262: ...clockwise and remove it 3 Push the new bulb into the socket and turn it clockwise to lock it in position 4 Make sure the gasket B Figure 71 is in place and reinstall the lens Taillight Brake Light Assembly Removal Installation Refer to Figure 72 and Figure 73 1 Remove the taillight lens B Figure 70 and gasket B Figure 71 2A On XVS1100 models remove the taillight housing as follows a Remove the nut...

Page 263: ...264 CHAPTER NINE METER ASSEMBLY 1 Screw 2 Washer 3 Trip meter button 4 Bezel 5 Guide 6 Meter 7 Harness 8 Clamp 9 Bulb 10 Meter cover 11 Nut 12 Damper 13 Meter bracket 14 Lockwasher 67 68 69 ...

Page 264: ...AL SYSTEM 265 9 70 71 TAILLIGHT XVS1100 MODELS 1 Reflector 2 Gasket 3 Bulb 4 Lens 5 Screw 6 Reflector 7 License plate bracket 8 Bolt 9 Taillight housing 10 Washer 11 Nut 12 Fender bracket 13 Taillight cable 72 ...

Page 265: ...the taillight bracket d Connect the voltmeter positive test lead to the blue terminal A Figure 75 in the harness side of the taillight brake light connector connect the voltmeter negative test lead to the black terminal B e Turn the main switch on On models with a light switch turn it on also f If the voltmeter does not read battery voltage the wiring between the main switch and the taillight brak...

Page 266: ... connectors inside the housing on the li cense plate bracket Figure 74 c Connect the voltmeter positive test lead to the harness side of the yellow bullet connector connect the voltmeter negative test lead to the harness side of the black bullet connector e Turn the main switch on On models with a light switch turn it on also f Apply the brake lever or pedal g If the voltmeter does not read batter...

Page 267: ...ct the connectors Figure 78 from the two spade terminals on the back of the horn and re move the horn 3 Installation is the reverse of removal Circuit Test Perform the following test if the horn does not sound 1 Check the continuity of the horn switch as de scribed in this chapter Replace the left handlebar switch if the horn switch is faulty 2 Check the voltage on the battery side of the horn cir...

Page 268: ... d If the voltage is less than battery voltage re place the horn TURN SIGNALS Refer to Figure 81 and Figure 82 Turn Signal Bulb Replacement 1 Remove the two screws A Figure 83 and the lens ring from the housing 2 Wash the lens inside and outside with a mild detergent ELECTRICAL SYSTEM 269 9 TURN SIGNALS XVS1100 MODELS 1 Bulb 2 Clamp bolt 3 Clamp nut 4 Turn signal housing 5 Gasket 6 Lens rim 7 Lens...

Page 269: ...ens screws A Figure 83 as this will crack the lens Turn Signal Assembly Removal Installation Front turn signal 1 Remove the mounting screw Figure 53 on ei ther side of the headlight housing and lower the lens assembly from the housing 270 CHAPTER NINE TURN SIGNALS XVS1100A MODELS 1 Screw 2 Lens 3 Lens rim 4 Gasket 5 Clamp bolt 6 Bulb 7 Turn signal housing 8 Clamp nut 9 Damper 10 Blind plug 11 Turn...

Page 270: ... Figure 83 typical 3 Pull the turn signal assembly and its wiring from the mounting stalk Watch for the damper 4 Installation is the reverse of removal Note the following a On XVS1100A models make sure the damper is in place b Apply a dielectric compound to the electrical connectors prior to reconnecting them This will help seal out moisture c Make sure the electrical connectors are free of corros...

Page 271: ...st lead to the harness side of the bullet connector connect the voltmeter negative test lead to a good ground d Turn the main switch on turn on the turn sig nal switch for that side and check the voltage on the voltmeter It should read battery volt age e The wiring between the turn signal switch and the connector is faulty if voltage is less than battery voltage 5B If the turn signal indicator lam...

Page 272: ...est lead to the brown terminal in the harness side of the me ter assembly connector A Figure 89 Con nect the voltmeter negative test lead to the connector s sky blue terminal B Figure 89 c Shift the transmission into neutral turn the main switch to on and check the voltage on the meter It should read battery voltage d If the reading is less than battery voltage the wiring between the main switch a...

Page 273: ... Chap ter Fourteen Remove the side cover from the left side as described in Chapter Fourteen 2 Roll the boot back from the electrical connector and disconnect the three pin speed sensor connec tor A Figure 92 from its harness mate 3 Release any cable ties or holders that secure the speed sensor wire to the frame Note the location of these ties and note how the speed sensor wire is routed along the...

Page 274: ...r should indicate infinite resis tance a test lamp should not light between the black and pink terminals When testing switches note the following 1 First check the fuses in the relevant circuit as de scribed in this chapter 2 Check the battery as described in Chapter Three Charge the battery to the correct state of charge if required 3 Disconnect the negative cable from the battery if the switch c...

Page 275: ...aligns with the index mark B on the handlebar b Apply a dielectric grease to the electrical con nector prior to reconnecting it c Make sure the electrical connectors are free of corrosion and the two sides are securely connected to each other d Adjust the choke cable free play as described in Chapter Three Right Handlebar Switch Replacement 1 Remove the fuel tank as described in Chapter Eight 2 Re...

Page 276: ...ies to secure the switch cable to the places noted during removal f Securely tighten the pull cable mounting screw g Adjust the throttle cable free play as de scribed in Chapter Three Main Switch Replacement 1 Remove the fuel tank and surge tank as de scribed in Chapter Eight 2 Remove the frame neck covers as described in Chapter Fourteen 3 Disconnect the switch s red four pin connector A Figure 1...

Page 277: ... Replacement 1 Remove the toolbox cover and the left side cover as described in Chapter Fourteen 2 Roll back the boot and disconnect the two pin sidestand switch connector B Figure 92 from its harness mate 3 Follow the sidestand switch electrical wire and disconnect any holders or cable ties that secure it in place Note how the wire is routed along the frame The new switch wire must be rerouted al...

Page 278: ...never the main switch is turned on the engine indicator light on the meter as sembly turns on and the system runs a series of checks If the throttle position sensor and the speed sensor are operating properly the engine indicator light goes out after approximately 1 4 seconds or when the engine is started If the self diagnostic system detects an error in ei ther component the engine indicator ligh...

Page 279: ...ter Fourteen 2 Remove the fuse box cover and open the box 3 Remove the suspected fuse by pulling it out of the holder with needlenose pliers Fuse Testing 1 Remove the suspected fuse as described in this chapter 2 Visually inspect the fuse Figure 112 Replace it if it is blown or cracked 3 If necessary check the continuity across the two spade connectors Replace a fuse that does not have continuity ...

Page 280: ...il resistance 0 026 0 034 ohms 20 C 68 F Armature insulation resistance Greater than 1 meg ohm 20 C 68 F Brush length 10 12 mm 0 41 0 49 in Brush length service limit 5 mm 0 20 in Brush spring pressure 7 65 10 01 N 27 51 36 01 oz Commuator diameter 28 mm 1 102 in Commutator diameter service limit 27 mm 1 063 in Mica undercut 0 7 mm 0 028 in Starter relay amperage rating 180 A Horn maximum amperage...

Page 281: ...gnal 10 A Ignition 10 A Odometer 5 A Carburetor heater 15 A Table 4 ELECTRICAL SYSTEM TORQUE SPECIFICATIONS Item N m in lb ft lb Alternator cover bolts 13 115 Flywheel nut 175 129 Headlight housing bolts 8 71 Ignition coil bolts 2 5 22 Meter cover screws 4 35 Neutral switch 20 15 Pickup coil screws 7 62 Stator mounting screws 10 89 Starter mounting bolts 10 89 Spark plugs 20 15 Speed sensor screw ...

Page 282: ... lifting the motorcycle An adjustable centerstand can also be used to support the motorcycle with a wheel off the ground Again check the manufacturer s instructions and perform any necessary modifications before sup porting the motorcycle with the adjustable centerstand When using a motorcycle stand have an assistant standing by Some means to tie down one end of the motorcycle is also needed Regar...

Page 283: ...fication in Table 1 Replace any part that is damaged out of specification or worn to the service limit 1 Remove the wheel as described in this chapter 2 Inspect the seals A Figure 3 for excessive wear hardness cracks or other damage If neces sary replace the seals as described in the front or rear hub section later in this chapter 3 Inspect the bearings as follows a Turn each bearing inner race B ...

Page 284: ...as shown in Figure 7 7 If the wheel runout is out of specification Table 1 inspect the wheel bearings as described earlier in this section a If the wheel bearings are good the wheel must be replaced b If either wheel bearing is worn disassemble the hub and replace both bearings as a set 8 Check the tightness of the brake disc bolts C Figure 3 If a bolt is loose remove and reinstall the bolts with ...

Page 285: ...ng 5 Remove the distance collar Note how the collar is positioned in the hub It will have to be reinstalled with the same orientation during assembly 6 Repeat this procedure and remove the bearing from the other side The left side of the rear hub has two bearings Drive out each bearing as described in this procedure NOTE If the Kowa Seiki tool or its equiva lent is not available remove the bearing...

Page 286: ...g and drive the bearing partway into the bore Stop and check the distance collar It must still be centered within the bearing If it is not install the axle partway through the hub and center the spacer Remove the axle and continue install ing the bearing until it bottoms 4B Install bearings in the front hub as follows a Position the bearing with the manufacturer s marks facing out and place the be...

Page 287: ... the motorcycle with the front wheel off the ground 2 Test the wheel bearings as follows a Hold the wheel along its side hands 180 apart and try to rock it back and forth If there is any play at the axle the wheel bear ings are worn or damaged b Have an assistant apply the brake while you rock the wheel again On wheels with se 288 CHAPTER TEN 15 FRONT WHEEL 1 Front axle 2 Axle clamp bolt 3 Collar ...

Page 288: ...liper off the brake disc Use a stiff wire or bunjee cord to suspend the cali per from the motorcycle d Wrap a shop rag around the caliper so the front fender will not be scratched Secure the rag with a zip tie or rubber band 5 Repeat Step 4 for the other front brake caliper CAUTION Since the full size front fender on XVS1100A models wraps low over the front wheel the motorcycle must be raised very...

Page 289: ...medium strength threadlocking compound to the bolt threads and torque them to 40 N m 30 ft lb d Install the brake hose holder onto the reflector bracket and tighten the brake hose holder bolt Figure 16 to 7 N m 62 in lb 8 Repeat Step 7 to install the other brake caliper 9 After the wheel is completely installed rotate it several times to make sure it turns freely Apply the front brake as many time...

Page 290: ...ll amount of medium strength threadlocking compound on the brake disc bolts prior to installation e Evenly tighten the brake disc bolts in a crisscross pattern Torque the bolts to 23 N m 17 ft lb REAR WHEEL Removal 1 Securely support the motorcycle on a level sur face Drain the final gear oil as described in Chapter Three 2 Remove the mufflers Chapter Eight CAUTION Since the rear fender on XVS1100...

Page 291: ... remove the wheel assembly Watch for the stepped collar in the right side of the hub 13 If necessary lift the final drive unit Figure 28 from the hub Watch for the distance collar Figure 29 Reinstall it in the final drive unit A Figure 30 so it will not be misplaced 14 Inspect the rear wheel as described in Wheel In spection in this chapter 15 If necessary disassemble the hub as described later in...

Page 292: ...ced outside the swing arm the inner brake pad will ride against the brake disc causing excessive wear and overheat ing 7 Install the spacer B Figure 26 onto the axle A and slide the axle through the hub 8 Roll the wheel forward so the driveshaft splines completely engage those of the universal joint Hold the caliper bracket up so its cutout slides over the mount on the swing arm Make sure the spac...

Page 293: ...e pads during installation 16 Install the two caliper mounting bolts Figure 22 Apply medium strength threadlocking com pound to the bolts and torque them to 40 N m 30 ft lb 17 Secure the brake hose clamp Figure 21 to the swing arm 18 On XVS1100A models install the rear fender as described in Chapter Fourteen 19 Add final drive oil to the final gearcase Chap ter Three REAR HUB Preliminary Inspectio...

Page 294: ...35 from the right side of the hub Place a shop rag beneath the pry tool so the hub will not be damaged 4 Inspect the bearings as described in Wheel In spection in this chapter If necessary remove and replace the bearings as described in this chapter 5 If the final gear clutch hub must be removed re move it as follows a Bend the lock tab away from the flat of each clutch hub nut A Figure 36 b Loose...

Page 295: ...pples and hub containing the wheel bearings distance collars and seals Loose or improperly tightened spokes can cause hub damage Periodically inspect the wheel assem bly for loose broken or missing spokes rim dam age and runout Wheel bearing service is described in this chapter Component Condition Wheels are subjected to a significant amount of punishment Inspect the wheels regularly for lateral s...

Page 296: ...40 or swing arm and slowly rotating the wheel 4 Perform major wheel truing with the tire re moved and the wheel mounted in a wheel truing stand 5 Use a spoke nipple wrench of the correct size Using the wrong type of tool or one that is the incor rect size will round off the spoke nipples making adjustment difficult Quality wrenches Figure 41 grip the nipple on four corners to prevent damage Tighte...

Page 297: ...ruing the wheel seat each spoke in the hub by tapping it with a flat nose punch and ham mer Recheck the spoke tension and wheel runout Readjust if necessary 7 Check the ends of the spokes on the tube side of the rim Grind off any spoke that protrudes from the nipple so it will not puncture the tube WHEEL BALANCE An unbalanced wheel is unsafe Depending on the degree of unbalance and the speed of th...

Page 298: ...from motorcycle dealerships These are adhesive backed weights that can be cut to the desired length and at tached directly to the rim 8 Loosely attach a balance weight or tape a test weight at the upper or light side 12 o clock of the wheel 9 Rotate the wheel 1 4 turn 3 o clock Release the wheel and observe the following a If the wheel does not rotate if it stays at the 3 o clock position the corr...

Page 299: ...apter 2 If the tire will be reinstalled place a balance mark on the tire opposite the valve stem location Figure 46 so the tire can be reinstalled in the same position for easier balancing 3 Remove the valve core to deflate the tire 4 Press the entire bead on both sides of the tire away from the rim and into the center of the rim 5 Lubricate both beads with soapy water NOTE Use rim protectors Figu...

Page 300: ...lation 1 Reinstall the rubber rim band Align the hole in the band with the valve hole in the rim 2 Liberally sprinkle the inside of the tire with tal cum powder to reduce chafing between the tire and tube 3 Most tires have directional arrows on the side wall Install the tire so the arrow points in the direc tion of forward rotation 4 If the tire was removed lubricate the lower bead of the tire wit...

Page 301: ... is not trapped under the bead Set the valve squarely in its hole WARNING In the next step seat the tire on the rim by inflating the tire to approximately 10 above the recommended infla tion pressure listed in Table 3 Do not exceed 10 Never stand directly over a tire while inflating it The tire could burst with enough force to cause severe injury 11 Check the bead on both sides of the tire for an ...

Page 302: ...d from the outside of the tire should only be used as a temporary roadside repair Follow the repair kit manufacturer s instructions as to applicable repairs and any speed limitations In most cases it is a good idea to consider replacing a patched or plugged tire as soon as possible Removal The wheels can easily be damaged during tire re moval Special care must be taken with tire irons to avoid scr...

Page 303: ...tire iron next to the first to hold the bead over the rim Figure 63 Then work around the tire with the first tool prying the bead over the rim NOTE Step 7 is required only if it is neces sary to completely remove the tire from the rim 7 Set the wheel on its edge Insert a tire tool be tween the second bead and the same side of the rim that the first bead was pried over Figure 64 Force the bead on t...

Page 304: ...itial point with a tire tool working around the rim to the valve Figure 67 8 Check the bead on both sides of the tire for an even fit around the rim 9 Place an inflatable band around the circumfer ence of the tire Slowly inflate the band until the tire beads are pressed against the rim Inflate the tire enough to seat it against the rim Deflate and re move the band WARNING Never exceed 56 psi 4 0 k...

Page 305: ...0 16 67S Manufacturer Dunlop D404F Rear tire size 170 80 15M C 77S Manufacturer Dunlop D404G Minimum tread depth 1 6 mm 0 06 in Table 3 TIRE INFLATION PRESSURE1 XVS1100 models 0 90 kg 0 198 lb load 2 Front 200 kPa 28 5 psi Rear 225 kPa 32 psi 90 200 kg 198 441 lb load 2 Front 225 kPa 32 psi Rear 250 kPa 36 psi XVS1100A models 0 90 kg 0 198 lb load 2 Front 225 kPa 32 psi Rear 225 kPa 32 psi 90 200 ...

Page 306: ...t 40 30 Front caliper retaining bolt 1999 on XVS1100 models 23 17 All models except 1999 on XVS1100 models 27 20 Front axle 59 43 Front axle clamp bolt 20 15 Hub plate bolt 23 17 Muffler bracket bolt 30 22 Rear axle nut 107 79 Rear axle clamp nuts 23 17 Rear caliper bracket bolt 40 30 Rear caliper mounting bolts 40 30 Spokes 3 27 Apply a medium strength threadlocking compound WHEEL AND TIRES 307 1...

Page 307: ...k ing around the seals or a tendency to bottom or top out follow the service procedures in this section To simplify fork service and to prevent the mix ing of parts service each fork leg individually Removal Fork Leg Will Not Be Serviced Refer to Figure 1 or Figure 2 NOTE The photographs show the front fork removal and installation for an XVS1100A model Except for the fork covers these photographs...

Page 308: ...ION AND STEERING 309 11 1 1 Clamp bolt 2 Upper fork bridge 3 Lower fork bridge 4 Front turn signal 5 Front fender 6 Fender bolt 7 Fork leg 8 Fork leg protector 9 Washer 10 Collar 11 Nut FORK ASSEMBLY XVS1100 MODELS ...

Page 309: ...ASSEMBLY XVS1100A MODELS 1 Upper fork bridge handlebar assembly 2 Clamp bolt 3 Upper fork cover 4 Upper fork cover spacer 5 Upper fork cover washer 6 Lower fork bridge 7 Front fender 8 Lower fork cover 9 Fender bolt 10 Fork leg ...

Page 310: ... turn signal bracket d Rotate the fork leg and slide the fork tube B Figure 5 from the upper fork bridge the turn signal bracket and the lower fork bridge 5B On XVS1100Amodels perform the following CAUTION The edges of the fork covers are sharp Wear gloves and exercise cau tion to avoid injury a Remove the fuel tank Chapter Eight so it will not be scratched or marred CAUTION Cover the front fender...

Page 311: ...ve the steering head nut B Figure 4 and washer f Place a tarp or plastic cover over the frame Lift the upper fork bridge from the fork tubes with the handlebar attached and lay the fork bridge handlebar assembly across the tarp Figure 8 g Slide the upper fork cover Figure 9 from the fork tube Watch for the index pin A Fig ure 10 in the lower fork bridge h Remove the indexing pin A Figure 10 up per...

Page 312: ...k leg Allen bolt can be re moved without using the damper rod holder and T handle However the Allen bolt cannot be torqued without these tools 2 Securely support the motorcycle on a level sur face 3 Remove the front wheel Chapter Ten and the front fender Chapter Fourteen FRONT SUSPENSION AND STEERING 313 11 12 1 Cap 2 O ring 3 Spacer 4 Dust seal 5 Retaining clip 6 Oil seal 7 Washer 8 Slider bushin...

Page 313: ...9 Use a 6 point 22 mm socket to break loose the cap bolt and slowly loosen the cap bolt C Figure 4 Remove the cap bolt spring seat collar and the fork spring Note that the closer wound coils on the spring face up 10 If the Allen bolt could not be loosened during Step 7 remove it now as follows a Place a drain pan beneath the fork leg b Install the damper rod holder onto the T han dle c Insert the ...

Page 314: ...der the upper fork bridge These also secure the windshield bracket to the upper fork bridge b Remove the front brake master cylinder clamp bolts Figure 6 and remove the front brake master cylinder from the handlebar Suspend the master cylinder from the motorcycle with a bunjee cord Keep the master cylinder reser voir upright This prevents brake fluid spills and helps keep air out of the brake syst...

Page 315: ...he top of the fork tube with the top edge of the upper fork bridge as shown in Figure 3 4 Torque the fasteners in the following order NOTE A single clamp bolt is used on each side of the lower fork bridge on XVS1100 models a Torque the lower fork bridge clamp bolt A Figure 5 to 30 N m 22 ft lb b Torque the front turn signal clamp bolt to 7 N m 62 in lb NOTE Use a 6 point 22 mm socket on the cap bo...

Page 316: ... 11 Install the upper fork bridge handlebar assem bly onto the fork legs and steering stem Install the steering head nut B Figure 4 and washer Torque the steering head nut to 110 N m 81 ft lb 12 Make sure the upper edge of each fork tube aligns with the upper edge of the upper fork bridge as shown in Figure 3 Adjust the fork leg as neces sary 13 Torque the upper fork bridge clamp bolt A Figure 4 o...

Page 317: ...llen bolt to 30 N m 22 ft lb 10 Slide a new slider bushing E Figure 20 and washer D down the fork tube NOTE Use the Yamaha fork seal driver and adapter to install the slider bushing and washer in the next step If these tools are not available use a univer sal oil seal driver or a piece of galva nized pipe and a hammer If both ends of the pipe are threaded wrap one end with duct tape to prevent the...

Page 318: ...eal Figure 27 into the slider 18 Secure the fork leg upright in a vise and fill the fork leg with the correct quantity of SAE 10W fork oil Refer to Table 1 for the specified quantity 19 Slowly pump the fork up and down several times to distribute the fork oil 20 Compress the fork completely and measure the fluid level after the fork oil settles Use an oil level gauge to measure the fluid level fro...

Page 319: ...eplace it 6 Check the fork tube for chrome flaking or creas ing This condition will damage the oil seal Re place the fork tube if necessary 7 Check the seal area of the slider Figure 34 for dents scratches or other damage that would allow oil leaks Replace the slider if necessary 8 Check the slider for dents or exterior damage that may cause the upper fork tube to hang up dur ing riding Replace it...

Page 320: ...If handlebar replacement is not re quired proceed to Step 10 1 Securely support the motorcycle on level ground 2 Remove all cable ties that secure cables to the handlebar 3 Remove the two master cylinder clamp bolts A Figure 39 and remove the master cylinder from the handlebar Secure the master cylinder to the frame with a bunjee cord Make sure the master cylinder reservoir remains upright This pr...

Page 321: ...Loss of control will occur 13 Installation is the reverse of removal Note the following a Replace the handlebar if it is bent b Make sure the punch mark on the handlebar A Figure 42 aligns with the top edge of the lower handlebar holder c Install the upper handlebar holders so the punch mark on the top of each holder B Fig ure 42 faces forward d Tighten the handlebar holder clamp bolts to 28 N m 2...

Page 322: ...ic tarp to protect them from acci dental brake fluid spills b Remove the steering head nut C Figure 41 and washer c Lift the upper fork bridge from the steering stem with the handlebar attached and lay the fork bridge handlebar assembly across the tank d Remove the mounting nut and bolt and re move each flasher assembly from the lower fork bridge 5B On XVZ1100A models remove the flasher as sembly ...

Page 323: ...r 5 Washer 6 Damper 7 Cable holder 8 Nut 9 Steering head nut 10 Upper fork bridge 11 Lockwasher 12 Locking ring nut 13 Adjusting ring nut 14 Bearing cap 15 Bearing 16 Dust seal 17 Headlight housing bracket 18 Steering stem 19 Headlight housing bracket 20 Steering stem XVS1100 MODELS XVS1100A MODELS ...

Page 324: ... the upper bearing inner race A Fig ure 51 and the bearing B from the steering head 13 Lower the steering stem assembly down and out of the steering head 14 Remove the lower bearing from the steering stem Figure 52 The lower bearing race and the dust seal will remain on the steering stem FRONT SUSPENSION AND STEERING 325 11 46 47 48 49 50 51 52 ...

Page 325: ... nut slots 10 Install the upper fork bridge onto the steering stem shaft Loosely install the washer and the steer ing head nut C Figure 41 11 Temporarily insert both fork tubes through the lower and upper fork bridges NOTE On XVS1100 models a single pinch bolt is used on each side of the lower fork bridge 12 Tighten thelower bridgepinch bolts Figure54 to holdtheforktubesinposition Thentightenthest...

Page 326: ...for wear or damage Inspect the nut threads If necessary clean them with an appropriate size metric tap or replace the nut s If the threads are damaged inspect the appropriate steering stem thread s for damage If necessary clean the threads with an appropriate size metric die 9 Check the underside of the steering head nut for damage Replace the nut as necessary 10 Inspect the steering stem and the ...

Page 327: ...aring assembly if reused 1 Install the adjusting and locking ring nuts as well as the steering head nut onto the top of the steering stem to protect the threads 2 Use a chisel to drive the bearing seal assembly from the steering stem Figure 58 Work around in a circle and slowly drive the assembly from the shoulder on the steering stem Remove the bearing and seal Discard them both 3 Clean the steer...

Page 328: ... 0 9 kg mm K2 12 7 N mm 72 80 lb in 1 3 kg mm Collar length 183 mm 7 20 in Table 2 FRONT SUSPENSION AND STEERING TORQUE SPECIFICATIONS Item N m in lb ft lb Brake hose union bolt 7 62 Fork damper rod Allen bolt 30 22 Fork cap bolt 23 17 Front axle 59 43 Front axle clamp bolt 20 15 Front brake caliper mounting bolt 40 29 Front brake master cylinder clamp bolts 10 89 Front turn signal clamp bolt XVS1...

Page 329: ...tery box and toolbox panel as de scribed in Chapter Fourteen 4 Remove the rear wheel Chapter Ten NOTE The shock absorber preload adjuster sits at the top of the shock absorber Locate the preload adjuster indicator and note which direction it faces The shock absorber must be reinstalled in this same orientation 5 Remove the nut and washer from the shock ab sorber lower bolt A Figure 2 6 Remove the ...

Page 330: ... Swing arm 2 Stud 3 Clamp 4 Nut 5 Bearing 6 Boot 7 Washer 8 Bolt 9 Collar 10 Pivot bolt 11 Thrust cover 12 Washer 13 Collar 14 Shock bolt 15 Shock absorber 16 Nut 17 Connecting arm bolt 18 Connecting arm 19 Washer 20 Bearing 21 Relay arm bolt 22 Collar 23 Seal 24 Relay arm ...

Page 331: ...t bushing Figure 5 and inspect the lower mount Look for elongation cracks or other damage 4 Inspect the spring for cracks or other signs of fa tigue 5 Inspect the shock absorber for signs of a gas or oil leak 6 If any part of the shock absorber is worn or dam aged replace the shock absorber Replacement parts are unavailable 7 Replace the mounting hardware as necessary Shock Absorber Disposal The g...

Page 332: ...in each mount in the relay arm Install each collar in the proper mount a Remove the collar A Figure 8 from the re lay arm mount b Wipe excess grease from the bearing B Fig ure 8 and visually inspect the needles for pitting wear or other damage c Insert the collar into its bearing and turn the collar by hand The bearing should turn smoothly without binding or excessive noise d If any bearing is wor...

Page 333: ...ed rod bearing and nuts as shown in Figure 11 Hold the lower nut with a wrench and turn the upper nut to press the bearing into the bearing bore Turn the nut slowly and watch the bearing carefully Make sure it does not turn sideways 7 Position a bearing in its bore as described in Swing Arm or Suspension Linkage SWING ARM Refer to Figure 1 Removal 1 Securely support the motorcycle on level ground ...

Page 334: ...turn the 6 mm bolt Figure 14 into the threads in the pivot bolt Grab the bolt with a pair of pliers and strike the pliers with a hammer to remove the pivot bolt 7 Remove the swing arm from the frame 8 Remove the thrust cover Figure 15 and its washer from the swing arm pivot on the each side of the frame 9 Remove the collar A Figure 16 from the frame 10 Inspect the swing arm as described in this ch...

Page 335: ...ents Inspection 1 Check the pivot bolt for straightness A bent bolt will restrict the movement of the swing arm 2 Inspect the pivot threads A Figure 19 in the swing arm Clean and dress the threads as neces sary 3 Check the welds B Figure 19 on the swing arm for cracks or fractures 4 Remove the collar Figure 20 from the con necting arm pivot on the swing arm 5 Check the swing arm pivot bearings Fig...

Page 336: ...the distance collar A Figure 24 is seated within the ring gear b Apply molybdenum disulfide grease to the splines of the ring gear B Figure 24 and to the splines on the rear wheel hub Figure 25 c Make sure the ring gear splines mesh with those on the rear wheel Inspection 1 Inspect the gearcase for any external damage 2 Make sure the oil filler bolt B Figure 22 and drain bolt C are in good conditi...

Page 337: ...emove the final drive assembly as described in this chapter 2 Remove the final gearcase cover nuts A Figure 29 3 Pull the cover drive shaft assembly B Figure 29 from the final gearcase 4 Remove the spring seated against the pinion gear nut 338 CHAPTER TWELVE 26 27 28 1 Bearing housing nut 2 Washer 3 Distance collar 4 Bearing housing bolt 5 Bearing housing 6 O ring 7 Oil seal 8 Ring gear shim 9 Bea...

Page 338: ...REAR SUSPENSION AND FINAL DRIVE 339 12 ...

Page 339: ... Do not overtighten the 14 100 mm bolt Finger tight is sufficient 3 Turn a 14 100 mm bolt Figure 30 into the drain hole and finger tighten the bolt enough to hold the ring gear 4 Install the gear lash tool A Figure 31 onto the gear coupling 5 Secure a dial indicator B Figure 31 in place so the indicator s plunger rests against the gear lash tool The plunger must rest at a point 54 5 mm 2 1 in from...

Page 340: ...dures Note the following a Pack the lips of the oil seal with lithium soap grease b Evenly tighten the bearing housing nuts A Figure 32 and bolts B in a criss cross pat tern Apply a medium strength threadlocking compound to the threads of the bearing hous ing bolts B Figure 32 Torque the nuts to 23 N m 17 ft lb Torque the bolts to 40 N m 30 ft lb c Recheck the gear lash Final Gearcase Disassembly ...

Page 341: ...be in stalled during assembly 8 Remove the gear coupling NOTE The bearing retainer has left hand threads Turn the nut clockwise to re move it 9 Use the Yamaha bearing retainer wrench Fig ure 35 to remove the bearing retainer 10 Use the crankshaft installer bolt adapter A Figure 36 armature shock puller B and the weight C to remove the pinion gear Assemble the tools according to their instructions ...

Page 342: ...ure and adjust the gear lash as described in this chapter 11 Measure the ring gear thrust clearance as follows a Remove the bearing housing and the ring gear as an assembly b Place four pieces of Plastigage around the in ner circumference of the ring gear Figure 37 and install the original thrust washer Make sure the Plastigage is between the ring gear and the thrust washer CAUTION Do not turn the...

Page 343: ...earcase in a hydrau lic press 3 Use a driver A Figure 38 that matches the di ameter of the collar B and press the collar oil seal C and ring gear bearing D from the gearcase NOTE Drive pinion bearing replacement is a difficult procedure However it is rarely necessary 4 Place the final gearcase in an oven and heat the gearcase to 150 C 302 F WARNING The final gearcase is extremely hot Use welding g...

Page 344: ...ew ring gear bearing and press it over the collar and into the housing Refer to the typical bearing procedures in Chapter One Pinion Gear Ring Gear Alignment The pinion gear and ring gear must be aligned whenever the final gearcase or any bearing is re placed To align the pinion and rings gears select and install new pinion gear shim s and new ring gear shim s See Figure 28 1 Calculate the thickne...

Page 345: ...in incre ments of tenths of a millimeter round off the hun dredths digit according to the chart in Figure 42 In the above example round the 0 51 mm thick ness down to 0 50 mm Refer to the chart in Figure 33 for available ring gear shims and select the ring gear shim that is 0 50 mm thick 346 CHAPTER TWELVE 05 43 Table 1 REAR SUSPENSION AND FINAL DRIVE SPECIFICATIONS Item Specification Service limi...

Page 346: ...inal gearcase mounting stud1 10 mm 18 13 8 mm 9 80 Pinion gear bearing retainer 2 115 85 Pinion gear nut 1 130 96 Rear axle clamp nut 23 17 Rear axle nut 107 79 Relay arm nut 48 35 Ring gear bearing housing bolts1 40 30 Ring gear bearing housing nuts 23 17 Shock absorber lower nut 48 35 Shock absorber upper nut 40 30 Swing arm pivot bolt 90 66 1 Apply a medium strength threadlocking compound 2 Use...

Page 347: ... doubt about your ability to service a brake component safely and correctly take the job to a Yamaha dealership or brake specialist Consider the following when servicing the front and rear brake systems 1 Disc brake components rarely require disassem bly Do not disassemble them unless necessary 2 When adding brake fluid only use brake fluid clearly marked DOT 4 from a sealed container Other grades...

Page 348: ...es on a mo torcycle To prevent brake fluid damage note the following 1 Protect the motorcycle before beginning any ser vice requiring draining bleeding or handling of brake fluid Anticipate which parts are likely to leak brake fluid and use a large tarp or piece of plastic to cover the areas beneath those parts Even a few drops of brake fluid can extensively damage painted plated or plastic surfac...

Page 349: ...ec tions in the brake line Manual Bleeding 1 Check all banjo bolts in the system They must be tight 2 Remove the dust cap from the bleed valve on the caliper assembly 3 Connect a length of clear tubing to the bleed valve Figure 2 typical Place the other end of the tube into a clean container Fill the container with enough fresh brake fluid to keep the end sub merged The tube should be long enough ...

Page 350: ...cycle until the front and rear brakes and the brake light are working properly 15 Test ride the motorcycle slowly at first to make sure the brakes are operating properly Vacuum Bleeding 1 Check all banjo bolts in the system They must be tight 2 Remove the dust cap from the bleed valve on the caliper assembly NOTE When bleeding the front brakes turn the handlebars to level the front mas ter cylinde...

Page 351: ... cap is secured in place NOTE Do not ride the motorcycle until both brakes and the brake light are work ing properly 16 Test ride the motorcycle slowly at first to make sure the brakes are operating properly BRAKE FLUID DRAINING Before disconnecting a front or rear brake hose drain the brake fluid as described below Draining the fluid reduces the amount of fluid that can spill out when system comp...

Page 352: ...e that the brake hose does not need to be dis connected from the caliper during brake pad re placement If the hose is removed the brakes will have to be bled Disconnect the hose only when ser vicing the brake caliper WARNING Use brake fluid clearly marked DOT 4 from a sealed container Other types may vaporize and cause brake failure Always use the same brand of brake fluid Do not mix brake fluids ...

Page 353: ...and the diaphragm from the master cylinder c Slowly push the caliper pistons B Figure 10 into the caliper Constantly check the res ervoir to make sure brake fluid does not over flow Remove fluid if necessary d The pistons should move freely If they do not move smoothly without sticking the caliper should be removed and serviced as described in this chapter 8 Push the caliper pistons until they bot...

Page 354: ...o replace the pads in the op posite front caliper 14 Support the motorcycle with the front wheel off the ground Spin the wheel and pump the brake le ver until the pads are seated against the disc WARNING Use brake fluid clearly marked DOT 4 from a sealed container Other types may vaporize and cause brake failure Always use the same brand of brake fluid Do not intermix brake fluids Many brands are ...

Page 355: ...oes not overflow Remove brake fluid if necessary d Remove the outboard pad and repeat substep c with the inboard pad e The pistons should move freely If they do not move smoothly without sticking the caliper should be removed and serviced as described in this chapter NOTE When purchasing new pads check with the dealership to make sure the friction compound of the new pads is compatible with the di...

Page 356: ... same brand of brake fluid Do not intermix brake fluids Many brands are not compatible with one another 16 Check the fluid level in the master cylinder res ervoir Add brake fluid as necessary to correct the fluid level Install the diaphragm and top cover WARNING Do not ride the motorcycle until you are sure the brakes are operating cor rectly with full hydraulic advantage If necessary bleed the br...

Page 357: ...aner 5 Check the pad springs Figure 23 and Figure 11 for the front and Figure 16 for the rear for wear or fatigue Replace a pad spring if it shows any sign of damage or excessive wear 6 Install new pad spring s when installing new brake pads FRONT CALIPER Refer to Figure 24 Removal 1 Securely support the motorcycle on level ground 2 Note that the brake hose neck sits against the in board side of t...

Page 358: ...t 4 Caliper 2001 on XVS1100 models all XVS1100A models 5 Cap 6 Bleed valve 7 Retaining bolt 8 Brake pad 9 Pad spring 10 Piston 11 Dust seat 12 Piston seal 13 Caliper pin 1999 2000 XVS1100 models 14 Boot 1999 2000 XVS1100 models 15 Caliper 1999 2000 XVS1100 models 1999 2000 XVS1100 ...

Page 359: ...to 30 N m 22 ft lb 5 Add brake fluid to the reservoir and bleed the brakes as described earlier in this chapter Disassembly Assembly 1 Remove the brake pads and brake caliper as de scribed in this chapter WARNING In the next step the pistons may shoot out of the caliper body with consider able force Keep your fingers out of the way Wear shop gloves and apply air pressure gradually Do not use high ...

Page 360: ...ure the seals are properly seated in their respective grooves 8 Coat the pistons and caliper cylinders with fresh DOT 4 brake fluid 9 Position each piston with the open end facing to ward the brake pads Figure 31 and slide the pis tons into the caliper cylinders Push the pistons in until they bottom in the cylinders 10 Install the pad spring Make sure the spring is completely seated in the bottom ...

Page 361: ...eplace the caliper assembly if necessary c Inspect the boots C Figure 35 in the pad holder Replace a boot that is torn or hard 9 Inspect the mounting bolt holes D Figure 35 on the pad holder If they are worn or damaged re place the caliper assembly and inspect the bolt holes on the fork leg 10 Remove the bleed valve from the caliper body Apply compressed air to the opening and make sure it is clea...

Page 362: ...y remaining brake fluid Never reuse brake fluid 7 Installation is the reverse of removal Note the following a Position the master cylinder so the face of the clamp mating surface aligns with the mark on the handlebar See A Figure 39 b Install the master cylinder clamp so the UP stamp faces up c Torque the clamp bolts Figure 38 to 10 N m 89 in lb Tighten the upper clamp bolt first then the lower bo...

Page 363: ...2 Reservoir cap 3 Gasket 4 Diaphragm 5 Blow back baffle 6 Boot 7 Snap ring 8 Secondary cup 9 Piston 10 Washer 11 Primary cup 12 Spring seat 13 Spring 14 Reservoir body 15 Banjo bolt 16 Copper washer 17 Brake hose 18 Banjo bolt 19 Clamp 20 Clamp bolt ...

Page 364: ...igure 43 from the master cylinder 6 Remove the boot C Figure 42 from the master cylinder bore 7 Remove the snap ring Figure 44 from its groove in the cylinder bore then remove the piston assembly A Figure 45 Assembly Refer to Figure 40 1 If removed install the spring seat A Figure 46 onto the piston B and install the small end of the spring C onto the spring seat CAUTION When installing the piston...

Page 365: ...r to the body with the pivot bolt and nut Figure 41 8 Install the blow back baffle Figure 43 into the master cylinder reservoir 9 Install the diaphragm diaphragm plate and cover after the master cylinder has been installed onto the handlebar Inspection 1 Clean all parts in fresh DOT 4 brake fluid Place the master cylinder components on a clean lint free cloth when performing the following inspecti...

Page 366: ...sted in Table 1 REAR BRAKE CALIPER Refer to Figure 53 Removal 1 Securely support the motorcycle on level ground 2 Drain the brake fluid from the rear brake as de scribed in this chapter 3 Remove the bolt and release the brake hose from the cable holder Figure 54 on the swing arm NOTE Note the stop washer A Figure 55 that sits between the hose fitting and the caliper This washer s upper stop sits a...

Page 367: ...TEEN 53 REAR BRAKE CALIPER 1 Piston seal 2 Dust seal 3 Piston 4 Brake pad 5 Bracket bolt 6 Washer 7 Caliper bracket 8 Caliper mounting bolt 9 Caliper 10 Bleed valve 11 Cap 12 Pad cover 13 Pad spring 14 Pad pin 15 Clip ...

Page 368: ...s as described earlier in this chapter Disassembly Refer to Figure 53 1 Remove the caliper and the brake pads as de scribed in this chapter 2 Set the caliper on a bench with the outboard side facing down 3 Insert a piece of wood through the calipers and press the wood down against the outboard piston Figure 56 WARNING In the next step the piston may shoot out of the caliper body with great force K...

Page 369: ...ont Caliper in this chapter Assembly NOTE Never reuse the old dust seals or pis ton seals Very minor damage or age deterioration can make the seals use less 1 Coat the new dust seal and piston seal with fresh DOT 4 brake fluid 2 Carefully install the new piston seal B Figure 58 and dust seal A into the grooves in each cali per cylinder Make sure the seals are properly seated in their respective gr...

Page 370: ... ring A Figure 61 The snap ring must be completely seated within the groove in the port 3 Install the brake master cylinder clevis A Fig ure 60 onto the brake lever B 4 Secure it in place with the clevis pin B Figure 59 5 Install the washer over the clevis pin and install a new cotter pin A Figure 59 6 Install the brake pedal footrest assembly as de scribed in this chapter 7 Add brake fluid and bl...

Page 371: ...over 6 Bolt 7 Clamp 8 Reservoir hose 9 Clevis pin 10 Nut 11 Clevis 12 Washer 13 Cotter pin 14 Locknut 15 Adjuster 16 Boot 17 Snap ring 18 Push rod 19 Secondary cup 20 Piston 21 Primary cup 22 Spring 23 Master cylinder body 24 O ring 25 Reservoir hose fitting 26 Snap ring 27 Master cylinder bracket 28 Guard ...

Page 372: ...end of the spring C Figure 67 onto the master piston CAUTION When installing the piston assembly do not allow the cups to turn inside out This will damage the cups and al low brake fluid to leak within the cyl inder bore 3 Install the piston spring assembly B Figure 66 into the master cylinder 4 Place a dab of grease on the end of the pushrod A Figure 68 and slowly push the spring and pis ton into...

Page 373: ...nspect the end of the pushrod A Figure 68 where it contacts the piston for damage 6 Inspect the pushrod dust boot C Figure 68 for tears or other signs of damage 7 If any of the parts inspected in Steps 2 6 are worn damaged or bent replace all of them with the master cylinder kit 8 Inspect the clevis D Figure 68 and brake lever B Figure 60 for cracks bending or other signs of damage 9 Inspect the c...

Page 374: ...nnector A Figure 75 and unhook the switch spring B from the brake lever 5 Remove the cable tie C Figure 75 that secures the brake reservoir hose to the frame downtube 6 Loosen the master cylinder bracket bolts A Figure 76 and the footrest bracket bolts B Note that the indexing pin on the master cylinder bracket engages the hole in the frame Figure 77 7 Remove the bolts and lower the brake pedal fo...

Page 375: ...ts to 64 N m 47 ft lb and torque the master cylinder bracket bolts to 23 N m 17 ft lb 4 Hook the rear brake switch spring B Figure 75 to the brake lever and connect the switch con nector A to its harness mate 5 Place the cover over the master cylinder reser voir B Figure 74 and secure the reservoir in place with the mounting bolt A 6 Use a new cable tie C Figure 75 to secure the reservoir hose to ...

Page 376: ...s described in Chapter Eleven CAUTION Set the tire on two wooden blocks Do not set the wheel down on the brake disc surface It could be scratched or damaged NOTE Insert a piece of wood or vinyl tube between the pads in the caliper s This way if the brake lever or pedal is inadvertently applied the pistons will not be forced out of the cylinders If this does happen the caliper s will have to be dis...

Page 377: ...N 82 FRONT BRAKE HOSE 1 Copper washer 2 Banjo bolt 3 Boot 4 Nut 5 Brake pipe 6 Brake hose 7 Union bracket 8 Bolt 9 Brake hose 10 Brake union 11 Bolt 1999 2000 XVS1100 MODELS 2001 ON XVS1100 MODELS AND ALL XVS1100A MODELS ...

Page 378: ...the hose fitting on each end of the hose Discard the copper washer on each side of the hose fitting 7 When replacing a rear brake reservoir hose slide the hose clamps along the hose and pull the hose from the fitting on the brake reservoir and on the master cylinder 8 Installation is the reverse of removal Note the following a Compare the new and old hoses Make sure they are the same b Clean the b...

Page 379: ...per cylinder bore inside diameter 42 9 1 689 Master cylinder bore inside diameter 12 7 0 50 Brake pedal height XVS1100 models above footpeg 81 8 3 22 XVS1100A models above floorboard 98 5 3 88 Brake pedal free play at pedal end 0 Table 3 BRAKE SYSTEM TORQUE SPECIFICATIONS Item N m in lb ft lb Brake hose banjo bolt 30 22 Brake hose holder bolt 10 89 Brake caliper bleed valve 6 53 Brake disc mountin...

Page 380: ...lts and remove the seat bracket A Figure 3 5 Installation is the reverse of removal a Slide the rider s seat forward until its tangs Figure 5 engage the tank bracket b Torque the seat bracket bolts to 7 N m 62 in lb c Torque the rider s seat bolt to 7 N m 62 in lb on models so equipped d Slide the passenger seat forward until its tang Figure 6 engages the seat bracket B Fig ure 3 e Torque the pass...

Page 381: ...382 CHAPTER FOURTEEN FUEL TANK AND SEATS 1 Fuel tank 2 Fuel hose 3 Fuel tank bolt 4 Rider s seat 5 Seat bracket 6 Seat bracket bolt 7 Passenger seat 8 Nut 9 Meter connector 1 2 3 ...

Page 382: ...lts A and B Figure 8 along with their washers 3 Lift the side cover from the motorcycle 4 Installation is the reverse of removal Note the following a Make sure a grommet and collar are in place on the four lower mounts B Figure 8 b Install the long bolt 6 54 mm at the upper forward mounts on the cover A Figure 8 Install a short bolt 6 25 mm and washer at the four lower mounts B Figure 8 c Install ...

Page 383: ...VAP solenoid valve b Disconnect the two pin electrical connector from the EVAPsolenoid valve B Figure 13 c Disconnect the fuel tank hose C Figure 13 from the EVAProllover valve This valve can be found just forward of the EVAP solenoid valve behind the fuel pump hoses See D Figure 13 8 Disconnect the fuel pump inlet hose A Figure 14 and its outlet hose B from their fittings on the fuel pump 9 Roll ...

Page 384: ...FRAME 385 14 TOOLBOX PANEL 1 Toolbox panel 2 Toolbox panel bolt 3 Side cover 4 Fuel hose 5 Tool kit 6 Hose bracket 7 Toolbox cover 10 11 12 ...

Page 385: ...t Figure 19 4 Pull the rear of the cover out until the cover s post disengages from its grommet 5 Installation is the reverse of removal Note the following a Align the cover s post with its grommet and press the cover in until it snaps into place b Torque the side cover bolt Figure 19 to 7 N m 62 in lb c Install the brake pedal footrest assembly as described in Chapter Thirteen d Adjust the rear b...

Page 386: ...tifier and remove the battery box 7 Installation is the reverse of removal FRAME NECK COVER Removal Installation 1 Remove the rider and passenger seats as de scribed in this chapter 2 Remove the fuel tank Chapter Eight 3 Remove the fuel tank grommet A Figure 22 from the post on each side of the frame 4 Remove each neck cover screws Figure 23 from the front of the frame 5 Separate the top edges of ...

Page 387: ... properly in place install the neck cover screws Figure 23 and the fuel tank grommets A Figure 22 RIDER FLOORBOARDS Disassembly Assembly Refer to Figure 24 1A Remove the brake pedal footrest assembly as described in Chapter Thirteen 388 CHAPTER FOURTEEN RIDER FLOORBOARDS 1 Floorboard pad 2 Screw 3 Floorboard 4 Mole 5 Spring 6 Circlip 7 Bracket bolt 8 Floorboard bracket 9 Pivot pin 24 ...

Page 388: ...he pivot pin Discard the cotter pin b Pull the pivot pin and separate the footpeg from the bracket 4 Installation is the reverse of removal Note the following a Install a new cotter pin b Torque the passenger footpeg bolts to 26 N m 19 ft lb SIDESTAND Refer to Figure 26 Removal Installation 1 Securely support the motorcycle on a level sur face 2 Remove the bracket bolts A Figure 27 and lower the s...

Page 389: ...igh to remove the front wheel with the fender installed Un less you have a jack that can safely provide the necessary clearance re move the fender while the front wheel is installed on XVS1100A models 1 On XVS1100 models remove the front wheel as described in Chapter Ten 2 Remove the front fender bolts Figure 29 from the inside of the fender and remove the fender from between the front fork legs O...

Page 390: ...oval 1 Remove the rider and passenger seats the bat tery cover the toolbox cover and ignitor panel as described in this chapter FRAME 391 14 FRONT FENDER 1 Front fender 2 Fender bolt 3 Reflector bracket 4 Nut 5 Brake hose holder 6 Bolt 7 Reflector 28 XVS 1100 MODELS XVS 1100A MODELS 29 ...

Page 391: ...392 CHAPTER FOURTEEN REAR FENDER 1 Fender bolt 2 Fender bracket 3 Rear fender 4 Nut 30 XVS1100 MODELS XVS1100A MODELS 5 Taillight brake light assembly 6 Screw 7 Push pin 8 Mud guard ...

Page 392: ...acers are removed the backrest could scrape the fender and scratch the paint 6 Remove the seat bracket bolts Figure 33 and remove the seat bracket from the fender This bracket is directional Place an arrow on the bracket indicating forward 7 Lift the fender from the motorcycle 8 Installation is the reverse of removal Note the following a Install the seat bracket so the arrow made dur ing removal p...

Page 393: ... in lb ft lb Battery cover bolt 7 62 Front fender bolts 10 89 Passenger footpeg bolts 26 19 Passenger seat nut 7 62 Rear fender bolts 26 19 Seat bracket bolts 7 62 Side cover bolt 7 62 Sidestand bracket bolts 64 47 Sidestand nut 56 41 394 CHAPTER FOURTEEN ...

Page 394: ...t 380 rear 380 torque 380 troubleshooting 55 Break in 166 C Caliper front 358 362 rear 367 370 Cam chain and drive assembly 104 110 Camshaft 99 102 Carburetor 211 222 heater 225 227 troubleshooting 46 47 specifications 239 240 troubleshooting 45 46 Charging system 241 242 Choke cable 228 229 Clutch 170 177 cable replacement 179 180 cover 168 170 release mechanism 177 179 specifications 184 torque ...

Page 395: ...eadlight dimmer switch Trip switch Turn signal switch Clutch switch Carb Heater fuse 15A Signal fuse 10A Headlight fuse 15A Ignition fuse 10A Free Push Gauge Warning lights Assy Speedometer Engine indicator High beam Oil level Neutral Turn signal Gauge lights On Off Front brake switch High Low Flasher relay Left Neut Right Horn 1999 ON USA CALIFORNIA AND CANADA MODELS ...

Page 396: ...r Starting circuit cutoff relay Fuel pump Speed sensor Side stand switch Solenoid valve California Diode Oil level relay Ignition coil Ignition coil Throttle position sensor Pick up coil Ignitor unit Left rear turn signal Right rear turn signal Tail brake light Diagram Key Connectors Ground Frame ground No connection Connection Thermo switch Carb heaters Carb Heater relay 1 2 ...

Page 397: ...n 166 connecting rods 163 166 crankcase 154 161 crankshaft 162 163 flywheel and starter clutch 142 148 oil pump 148 154 servicing in frame 133 specifications 166 torque 167 stator and pickup coils 142 oil 66 68 rotation 57 top end cam chain and drive assembly 104 110 camshaft 99 102 cylinder 120 122 head 88 99 covers 87 88 pistons and rings 123 129 rocker arms 102 104 servicing in frame 87 specifi...

Page 398: ...298 Lighting system 258 Linkage 332 334 Lower bearing replacement 328 Lubricants and fluids recommendations 84 85 M Maintenance battery 73 76 specifications 84 brakes 80 82 control cables 71 72 engine oil 66 68 fasteners 82 final drive 79 fuel and exhaust systems 68 71 type 56 intervals 56 57 lubrication recommendations 73 84 85 schedule 82 83 sidestand 72 73 spark plugs 62 66 steering head 77 78 ...

Page 399: ...e top end 131 132 frame and body 394 general 30 maintenance and tune up 86 middle gear 202 suspension front and steering 329 rear and final drive 347 shift mechanism 202 transmission 202 wheels 307 transmission and gearshift 202 wheels 306 wiring diagrams 400 Speed sensor 274 275 Starter 248 255 relay 257 258 Starting circuit cutoff relay 255 257 difficulties troubleshooting 34 37 37 39 system 248...

Page 400: ...0 51 engine leakdown test 43 lubrication 42 noises 41 performance 39 41 final drive 45 fuel pump 47 gearshift linkage 44 operating requirements 34 starting the engine 34 37 difficulties 37 39 suspension and steering 54 55 transmission 44 45 Tune up 57 62 cylinder numbering 57 engine rotation 57 Turn signals 269 273 V Valves and components 110 120 Voltage regulator rectifier 243 W Wheels balance 29...

Page 401: ...gnal switch Clutch switch Carb Heater fuse 15A Signal fuse 10A Headlight fuse 15A Ignition fuse 10A Free Push Gauge Warning lights Assy Speedometer Engine indicator High beam Oil level Auxiliary light Neutral Turn signal Gauge lights Front brake switch High Low Left Neut Right Horn Ignition switch On Off P Passing light switch Off On Light switch Off Pos On Flasher relay 1999 ON EUROPE MODELS ...

Page 402: ...r Starting circuit cutoff relay Fuel pump Speed sensor Side stand switch Diode Oil level relay Ignition coil Ignition coil Throttle position sensor Alarm system optional Pick up coil Ignitor unit Left rear turn signal Right rear turn signal Tail brake light Diagram Key Connectors Ground Frame ground No connection Connection Thermo switch Carb heaters Carb Heater relay 1 2 2 1 ...

Page 403: ...itch Turn signal switch Clutch switch Carb Heater fuse 15A Signal fuse 10A Headlight fuse 15A Ignition fuse 10A Free Push Gauge Warning lights Assy Speedometer Engine indicator High beam Oil level Neutral Turn signal Gauge lights Front brake switch High Low Left Neut Right Horn Ignition switch On Off Passing light switch Off On Flasher relay 1999 ON AUSTRALIA MODELS ...

Page 404: ...lugs Diagram Key Connectors Ground Frame ground No connection Connection Rear brake switch Neutral switch Oil level switch Rectifier Regulator Starting circuit cutoff relay Fuel pump Speed sensor Thermo switch Side stand switch Diode Carb heaters Oil level relay Ignition coil Ignition coil Throttle position sensor Carb Heater relay 1 2 2 Pick up coil Ignitor unit 1 ...

Page 405: ...manufacturer s specifications 2 Load equals the total weight of rider passenger accessories and all cargo RECOMMENDED LUBRICANTS AND FLUIDS Fuel Regular unleaded Octane 86 R M 2 method or research octane of 91 or higher Capacity 17 liter 4 49 US gal 3 74 Imp gal Reserve 4 5 liter 1 19 US gal 0 99 Imp gal Engine oil API classification SE SF or SG Viscosity 5 C 40 F or above SAE 20W40 15 C 60 F or b...

Page 406: ...re at sea level Standard 1000 kPa 142 psi 10 kg cm2 Minimum 900 kPa 128 psi 9 kg cm2 Maximum 1100 kPa 156 psi 11 kg cm2 Ignition timing 10 BTDC 1000 rpm Vacuum pressure at idle 34 7 37 3 kPa 260 289 mm Hg 10 2 11 4 in Hg Front brake pad wear limit 0 8 mm 0 03 in Rear brake pad wear limit 0 5 mm 0 020 in Brake pedal height XVS1100 models above footpeg 81 8 mm 3 22 in XVS1100A models above floorboar...

Page 407: ...Lower fork bridge clamp bolt 30 22 Oil drain bolt 43 32 Oil filter outer cover bolt 10 89 Rear axle clamp nut 23 17 Rear axle nut 107 79 Rear brake adjuster locknut 16 12 Rear caliper bracket bolt 40 30 Rear caliper mounting bolt 40 30 Rocker arm bolt 38 28 Sidestand nut 56 41 Spark plugs 20 15 Steering head nut 110 81 Steering stem adjuster nut First stage 52 38 Second stage 18 13 Upper fork brid...

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