Yamaha Star XVS1100C Owner'S Manual Download Page 64 | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-21

6

EAU22091

Adjusting the brake lever free
play

The brake lever free play should mea-
sure 5.0–8.0 mm (0.20–0.31 in) as
shown. Periodically check the brake le-
ver free play and, if necessary, adjust it
as follows.

1. Loosen the locknut at the brake le-

ver.

2. To increase the brake lever free

play, turn the adjusting bolt in di-
rection (a). To decrease the brake
lever free play, turn the adjusting
bolt in direction (b).

3. Tighten the locknut.

WARNING

EWA10630

●

After adjusting the brake lever
free play, check the free play
and make sure that the brake is
working properly.

●

A soft or spongy feeling in the
brake lever can indicate the
presence of air in the hydraulic

system. If there is air in the hy-
draulic system, have a Yamaha
dealer bleed the system before
operating the motorcycle. Air in
the hydraulic system will dimin-
ish the braking performance,
which may result in loss of con-
trol and an accident.

1. Brake lever free play

1. Locknut
2. Brake lever free play adjusting bolt

5YS10.book Page 21 Wednesday, May 14, 2003 6:32 PM

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Summary of Contents for Star XVS1100C

Page 1: ...5YS 28199 10 LIT 11626 17 24 XVS1100S C XVS1100AS C XVS1100ATS C OWNER S MANUAL ...

Page 2: ...EAU10041 5YS10 book Page 1 Wednesday May 14 2003 6 32 PM ...

Page 3: ... of this motorcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle To maintain...

Page 4: ...KLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE DO NOT ATTEMPT TO OPERATE THIS MOTOR CYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILIT...

Page 5: ...ha Motor Corporation U S A 1st edition April 2003 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 17 24 AFFIX DEALER LABEL HERE 5YS10 book Page 2 Wednesday May 14 2003 6 32 PM ...

Page 6: ...Parking 5 5 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1 PERIODIC MAINTENANCE 6 1 Owner s tool kit 6 1 Periodic maintenance chart for the emission control system 6 3 General maintenance and lubrication chart 6 4 Removing and installing the panel 6 8 Checking the spark plugs 6 8 Canister for California only 6 10 Engine oil 6 10 Final gear oil 6 12 Cleaning the air filter element 6 13 Adjusting the car...

Page 7: ... Replacing a turn signal light bulb or the tail brake light bulb 6 33 Supporting the motorcycle 6 33 Troubleshooting 6 34 Troubleshooting chart 6 35 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND E...

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

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

Page 10: ...sonally be re sponsible for the proper selection in stallation and use of non Yamaha accessories Use extreme caution when selecting and installing any ac cessories Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fully inspect the accessory bef...

Page 11: ...e off before leaving the motorcycle unattended and remove the key from the main switch When parking the motor cycle note the following The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fall over Do not park the motorcycle near...

Page 12: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle 5YS10 book Page 5 Wednesday May 14 2003 6 32 PM ...

Page 13: ...SAFETY INFORMATION 1 6 1 3 XVS1100 3 XVS1100A XVS1100AT 4 California only 2 1 5YS10 book Page 6 Wednesday May 14 2003 6 32 PM ...

Page 14: ...cock page 3 8 3 Shock absorber assembly spring preload adjusting ring page 3 13 4 Helmet holder page 3 12 5 Storage compartment page 3 12 6 Owner s tool kit page 6 1 7 Fuse box page 6 30 8 Engine oil level check window page 6 10 5YS10 book Page 1 Wednesday May 14 2003 6 32 PM ...

Page 15: ... page 3 8 3 Shock absorber assembly spring preload adjusting ring page 3 13 4 Helmet holder page 3 12 5 Storage compartment page 3 12 6 Owner s tool kit page 6 1 7 Fuse box page 6 30 8 Engine oil level check window page 6 10 5YS10 book Page 2 Wednesday May 14 2003 6 32 PM ...

Page 16: ...2 3 2 EAU32230 Right view XVS1100 1 Battery page 6 29 2 Main fuse page 6 30 3 Main switch steering lock page 3 1 4 Air filter element page 6 13 5 Brake pedal page 3 6 5YS10 book Page 3 Wednesday May 14 2003 6 32 PM ...

Page 17: ...ION 2 4 2 XVS1100A XVS1100AT 1 Battery page 6 29 2 Main fuse page 6 30 3 Main switch steering lock page 3 1 4 Air filter element page 6 13 5 Brake pedal page 3 6 5YS10 book Page 4 Wednesday May 14 2003 6 32 PM ...

Page 18: ...ver page 3 4 2 Left handlebar switches page 3 3 3 Starter choke lever page 3 9 4 Speedometer unit page 3 3 5 Fuel tank cap page 3 6 6 Right handlebar switches page 3 3 7 Throttle grip page 6 14 8 Brake lever page 3 5 5YS10 book Page 5 Wednesday May 14 2003 6 32 PM ...

Page 19: ...0 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to OFF while still pushing it WARNING EWA10060 Never turn the key to OFF or LOCK w...

Page 20: ...r a few seconds then go off have a Yamaha dealer check the electrical cir cuit NOTE Even if the oil level is sufficient the warning light may flicker when riding on a slope or during sudden acceleration or deceleration but this is not a mal function EAU11500 Engine trouble warning light This warning light comes on or flashes when an electrical circuit monitoring the engine is defective When this o...

Page 21: ...push the TRIP button again and hold it down for at least one second The trip meter can be used to estimate the dis tance that can be traveled with a full tank of fuel This information will enable you to plan future fuel stops NOTE This model is not equipped with a ta chometer however it has a built in speed limiter which prevents the en gine speed from exceeding approxi mately 6800 r min and the v...

Page 22: ... not self cancel while you are stopped at an intersec tion EAU12500 Horn switch Press this switch to sound the horn EAU12660 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter ...

Page 23: ...00AT The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever when shifting the gears of the 5 speed con stant mesh transmission equipped on this motorcycle NOTE Use your toes or heel to shift up and your toes to shift down EAU12890 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward th...

Page 24: ...stall the fuel tank cap 1 Insert the fuel tank cap into the tank opening with the key inserted in the lock and with the mark facing forward 2 Turn the key counterclockwise to the original position remove it and then close the lock cover NOTE The fuel tank cap cannot be installed unless the key is in the lock In addition the key cannot be removed if the cap is not properly installed and locked WARN...

Page 25: ... engine has been de signed to use regular unleaded gaso line with a pump octane number R M 2 of 86 or higher or a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premi um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gaso hol containing ethanol and that c...

Page 26: ...le fire hazards such as grass or other materials that easily burn Do not allow the engine to idle too long EAU13550 Fuel cock The fuel cock supplies fuel from the tank to the carburetors while also filter ing it The fuel cock lever positions are ex plained as follows and shown in the il lustrations OFF With the fuel cock lever in this position fuel will not flow Always turn the fuel cock lever to ...

Page 27: ...tarter choke Move the lever in direction b to turn off the starter choke CAUTION ECA10990 Do not use the starter choke for more than 3 minutes as the exhaust pipe may discolor from excessive heat In addition extended use of the starter choke will cause after burning If this occurs turn off the starter choke EAU14211 Seats XVS1100 Passenger seat To remove the passenger seat Remove the nut and then ...

Page 28: ...eat 1 Insert the projections on the front of the rider seat into the seat hold ers as shown and then place the seat in the original position 2 Install the seat bracket and bolts 3 Install the passenger seat NOTE Make sure that the seats are properly secured before riding 1 Projection 2 Seat holder 1 Bolt 2 Seat bracket 1 Projection 2 Seat holder 5YS10 book Page 10 Wednesday May 14 2003 6 32 PM ...

Page 29: ...and then install the bolt Rider seat To remove the rider seat 1 Remove the passenger seat 2 Remove the bolt and then pull the rider seat up To install the rider seat 1 Insert the projections on the front of the rider seat into the holders as shown place the seat in the origi nal position and then install the bolt 2 Install the passenger seat NOTE Make sure that the seats are properly secured befor...

Page 30: ...possibly an accident EAU14481 Storage compartment The storage compartment is located on the left side of the vehicle To open the storage compartment 1 Slide the lock cover open insert the key into the lock and then turn it clockwise 2 Pull the storage compartment cov er out as shown To close the storage compartment 1 Place the storage compartment cover in its original position as shown 1 Helmet ho...

Page 31: ... adjusting mechanism beyond the maximum or minimum settings Adjust the spring preload as follows 1 Remove the rider seat See page 3 9 2 Remove each quick fastener from the ignitor unit panel by pushing the center in with a screwdriver then pulling the fastener out 3 Pull the ignitor unit panel out to the right 4 Remove the mudguard by remov ing each quick fastener XVS1100 1 Storage compartment cov...

Page 32: ...ent XVS1100 XVS1100A XVS1100AT 6 Install the mudguard and ignitor unit panel by installing the quick fasteners NOTE To install a quick fastener push the pin back so that it will protrude from the fas tener head and then insert the fastener and push the protruding pin in until it is flush with the fastener head 1 Quick fastener 2 Mudguard 1 Spring preload adjusting ring 2 Position indicator 3 Speci...

Page 33: ... not tamper with or attempt to open the gas cylinder Do not subject the shock ab sorber to an open flame or other high heat sources otherwise it may explode due to excessive gas pressure Do not deform or damage the gas cylinder in any way as this will result in poor damping per formance Always have a Yamaha dealer service the shock absorber EAU15150 Luggage strap holders There is a luggage strap h...

Page 34: ...ng the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly as described below and have a Yamaha dealer re pair it if it does not function proper ly EAU15311 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the tr...

Page 35: ...ter the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden This check is most reliable if performed with a warmed up engine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle ...

Page 36: ...sequences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the Pre operation check list is not...

Page 37: ... free play Adjust if necessary Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 21 6 23 6 23 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add...

Page 38: ...hat operation is smooth Lubricate pedal pivoting points if necessary 6 25 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 26 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 26 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and swit...

Page 39: ...ulled and the sid estand up WARNING EWA10290 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 16 Never ride with the sidestand down 1 Turn the fuel cock lever to ON 2 Turn the key to ON and make sure that the engine stop switch is set to 3 Shift the transmission into the neu tral position NOTE When the transmissio...

Page 40: ...1130 For maximum engine life always warm the engine up before starting off Never accelerate hard when the engine is cold 7 When the engine is warm turn the starter choke off NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off To avoid the possi bility of excessive exhaust emissions never leave the starter choke on long er than necessary The time nece...

Page 41: ...sion Always use the clutch while changing gears to avoid damag ing the engine transmission and drive train which are not designed to withstand the shock of forced shifting EAU16680 To start out and accelerate 1 Pull the clutch lever to disengage the clutch 2 Shift the transmission into first gear The neutral indicator light should go out 3 Open the throttle gradually and at the same time release t...

Page 42: ... more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing material carefully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle oper...

Page 43: ...ouble should occur during the engine break in period immediately have a Yamaha dealer check the vehicle EAU17170 Parking When parking stop the engine remove the key from the main switch and then turn the fuel cock lever to OFF WARNING EWA10310 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope o...

Page 44: ...ED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER EN GINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOW ING PERIODIC MAINTENANCE CHARTS THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIP MENT YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PER FORM THESE PARTICULAR SER V...

Page 45: ...WARNING EWA10340 Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes 5YS10 book Page 2 Wednesday May 14 2003 6 32 PM ...

Page 46: ...ge Replace if necessary 2 Fuel filter Replace Replace 3 Spark plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 4 Valve clearance Check and adjust valve clearance when engine is cold 5 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 6 Carburetor synchro nization Adjust synchronization of carbu retors 7 Idl...

Page 47: ...ration Adjust or replace cable 3 Front brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 4 Rear brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 5 Brake hoses Check for cracks or damage Replace Every 4 years 6 Wheels XVS1100 Check runout spoke tightness and for damage Tighten spokes if necessary 7 Wheels XVS1100A XVS1100A...

Page 48: ...e and clutch le ver pivot shafts Apply lithium soap based grease all purpose grease lightly 14 Brake and shift ped al pivot shafts Apply lithium soap based grease all purpose grease lightly 15 Sidestand pivot Check operation Apply lithium soap based grease all purpose grease lightly 16 Sidestand switch Check operation and replace if necessary 17 Front fork Check operation and for oil leak age Repl...

Page 49: ... ele ment Replace 22 Final gear oil Check oil level and for oil leakage Change at initial 600 mi 1000 km or 1 month and thereafter every 16000 mi 25000 km or 24 months Change Change 23 Control cables Apply Yamaha chain and cable lube or engine oil SAE 10W 30 thoroughly 24 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the t...

Page 50: ...isassembling the brake master cylinders and calipers always change the fluid Regularly check the brake fluid levels and fill the reservoirs as required Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 5YS10 book Page 7 Wednesday May 14 2003 6 32 PM ...

Page 51: ...n and then install the bolt EAU19551 Checking the spark plugs The spark plugs are important engine components which are easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plugs should be removed and checked in accordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plugs can re veal the condition of the engine To...

Page 52: ...tead have a Yamaha dealer check the vehicle 3 Check each spark plug for elec trode erosion and excessive car bon or other deposits and replace it if necessary To install a spark plug 1 Measure the spark plug gap with a wire thickness gauge and if nec essary adjust the gap to specifica tion 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spar...

Page 53: ... sure the vent hose is not blocked Clean it if necessary EAU19821 Engine oil The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter ele ment replaced at the intervals specified in the periodic maintenance and lubri cation chart To check the engine oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE Make ...

Page 54: ...Check the washer for damage and re place it if necessary 5 Add the specified amount of the recommended engine oil and then install and tighten the oil filler cap CAUTION ECA11620 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a high er quality than specified In addi...

Page 55: ...l gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart WARNING EWA10370 Make sure that no foreign mate rial enters the final gear case Make sure that no oil gets on the tire or wheel To check the final gear oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE The final gear o...

Page 56: ...iodic maintenance and lubrica tion chart Clean the air filter element more frequently if you are riding in un usually wet or dusty areas 1 Remove the air filter case cover by removing the screws 2 Pull the air filter element out 3 Lightly tap the air filter element to remove most of the dust and dirt and then blow the remaining dirt out with compressed air as shown If the air filter element is dam...

Page 57: ...carburetors The carburetors are important parts of the engine and emission control sys tem which require very sophisticated adjustment Therefore all carburetor adjustments should be left to a Yamaha dealer who has the necessary profes sional knowledge and experience EAU21380 Adjusting the throttle cable free play The throttle cable free play should mea sure 4 0 6 0 mm 0 16 0 24 in at the throttle ...

Page 58: ...t temperature The tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model WARNING EWA10510 Proper loading of your vehicle is im portant for several characteristics of your vehicle such as handling braking performance and safety Do not carry loosely packed items that can shift Securely pack y...

Page 59: ...tely The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience It is not recommended to patch a punctured tube If unavoid able however patch the tube very carefully and replace it as soon as possible with a high quality product Tire information This motorcycle is equipped with spoke wheel...

Page 60: ... est items close to the center of the vehicle and distribute the weight evenly from side to side Properly adjust the suspension for your load and check the condition and pres sure of your tires NEVER OVER LOAD YOUR VEHICLE Make sure that the total weight of the cargo rid er passenger and accessories cowling saddlebags etc if ap proved for this model does not ex ceed the maximum load of the vehicle...

Page 61: ...rformance durabil ity and safe operation of your motor cycle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage and the spokes for looseness or dam age before each ride If any dam age is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The...

Page 62: ...ring or replacing a tire tighten the valve stem nut and locknut to the specified torques EAU22010 Accessories and replacement parts WARNING EWA10620 This motorcycle is not designed to pull a trailer or to be attached to a sidecar The accessories or replace ment parts you choose for your motorcycle should be designed spe cifically for this model and they must be securely mounted to main tain the in...

Page 63: ...s follows 1 Loosen the locknut at the clutch le ver 2 To increase the clutch lever free play turn the adjusting bolt in di rection a To decrease the clutch lever free play turn the adjusting bolt in direction b 3 Tighten the locknut NOTE If the specified free play cannot be ob tained as described above or if the clutch does not operate correctly have a Yamaha dealer check the internal clutch mecha...

Page 64: ...ng bolt in direction b 3 Tighten the locknut WARNING EWA10630 After adjusting the brake lever free play check the free play and make sure that the brake is working properly A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hy draulic system have a Yamaha dealer bleed the system before operating the motorcycle Air in the hydr...

Page 65: ...rcycle Air in the hydraulic system will diminish the braking performance which may result in loss of control and an acci dent EAU22270 Adjusting the rear brake light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting nut...

Page 66: ...ng to disassem ble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indicator groove has almost disappeared have a Yamaha dealer replace the brake pads as a set EAU22580 Checking the brake fluid level Front brake Rear brake Insufficient brake fluid may allow air to enter the brake system possibly caus ing it to become ineffec...

Page 67: ...t water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to grad ually go down However if the brake fluid level goes down sud denly ...

Page 68: ... cable movement Replace damaged ca bles as soon as possible to prevent unsafe conditions EAU23110 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart EAU23131 Checking and lubricating the brake and shift pedals T...

Page 69: ...of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary WARNING EWA10730 If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it Recommended lubricant Lithium soap based grease all pur pose grease Recommended lubricant Lithium soap based grease all pur pose grease Recommend...

Page 70: ...dition WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion 2 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds sm...

Page 71: ...ly support the vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart...

Page 72: ...t medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the batt...

Page 73: ... the igni tor unit panel The fuse box which contains the fuses for the individual circuits is located in side the storage compartment See page 3 12 If a fuse is blown replace it as follows NOTE Include steps 1 3 and 9 10 only for the main fuse 1 Remove the rider seat See page 3 9 2 Remove the quick fasteners shown by pushing the center in with a screwdriver then pulling the fastener out 3 Pull the...

Page 74: ...he electrical system 8 Install the storage compartment cover 9 Place the ignitor unit panel in the original position and install the quick fasteners NOTE To install a quick fastener push its pin back so that it will protrude from the fas tener head then insert the fastener and push the protruding pin in until it is flush with the fastener head 10 Install the rider seat 1 Ignitor unit panel 2 Spare...

Page 75: ...has cooled down 4 Place a new headlight bulb into po sition and then secure it with the bulb holder CAUTION ECA10660 Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely af fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened wi...

Page 76: ...cautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand up right Check that the motorcycle is in a stable and level position before starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional ...

Page 77: ...n cause poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation par...

Page 78: ...gnition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over ...

Page 79: ... leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical products on plastic part...

Page 80: ...ion After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be re moved through polishing 3 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal including chrome a...

Page 81: ...ock that has an OFF posi tion Turn the fuel cock lever to OFF 3 Drain the carburetor float cham bers by loosening the drain bolts this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to pro tect the cyl...

Page 82: ...heels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlets with plas tic bags to prevent moisture from entering them 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 ...

Page 83: ...nt V type 2 cylinder Displacement 1063 0 cm 64 86 cu in Bore stroke 95 0 75 0 mm 3 74 2 95 in Compression ratio 8 30 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type YAMALUBE 4 SAE10W30 or SAE20W40 Recommended engine oil grade API service SE SF SG type or higher Engine oil quantity Without oil filter element replacement 3 00 L 3 17 US qt 2 64 Imp qt With oil filter el...

Page 84: ...00A DUNLOP D404F XVS1100AT DUNLOP D404F Manufacturer model XVS1100 BRIDGESTONE EXEDRA L309 XVS1100A BRIDGESTONE EXEDRA G703 XVS1100AT BRIDGESTONE EXEDRA G703 Rear tire Type XVS1100 With tube XVS1100A Tubeless XVS1100AT Tubeless Size 170 80 15M C 77S Manufacturer model XVS1100 DUNLOP K555 XVS1100A DUNLOP D404G XVS1100AT DUNLOP D404G Manufacturer model XVS1100 BRIDGESTONE EXEDRA G546G XVS1100A BRIDG...

Page 85: ...isc brake Operation Right foot operation Recommended fluid Dot 4 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Wheel travel 140 0 mm 5 51 in Rear suspension Type Swingarm link suspension Spring shock absorber type Coil spring gas oil damper Wheel travel 113 0 mm 4 45 in Electrical system Ignition system Transistorized coil ignition digital Charging system ...

Page 86: ...SPECIFICATIONS 8 4 8 Signaling system fuse 10 0 A Ignition fuse 10 0 A Carburetor heater fuse 15 0 A Ignitor unit fuse 5 0 A CAL Backup fuse 5 0 A 5YS10 book Page 4 Wednesday May 14 2003 6 32 PM ...

Page 87: ...entification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU26400 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and...

Page 88: ...bel is affixed to the frame under the rider seat See page 3 9 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label 5YS10 book Page 2 Wednesday May 14 2003 6 32 PM ...

Page 89: ...estigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Tr...

Page 90: ...hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc ...

Page 91: ...eminder that maintenance work is required It is not acceptable proof of maintenance work Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 24000 mi 37000 km or 36 months 28000 mi 43000 k...

Page 92: ...FORMATION 9 6 9 36000 mi 55000 km or 54 months 40000 mi 61000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 5YS10 book Page 6 Wednesday May 14 2003 6 32 PM ...

Page 93: ...CONSUMER INFORMATION 9 7 9 EAU26661 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 5YS10 book Page 7 Wednesday May 14 2003 6 32 PM ...

Page 94: ...CONSUMER INFORMATION 9 8 9 5YS10 book Page 8 Wednesday May 14 2003 6 32 PM ...

Page 95: ...ed repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing...

Page 96: ...cked protection even after your Yamaha Limited Warranty expires A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 1 866 YES EXTD 1 866 937 3983 5YS10 book Page 10 Wednesday May 14 2003 6 32 PM ...

Page 97: ...circuit cut off system 3 16 Indicator and warning lights 3 2 K Key identification number 9 1 L Labels location of 1 5 Luggage strap holders 3 15 M Main switch steering lock 3 1 Maintenance and lubrication periodic 6 4 Maintenance emission control system 6 3 Maintenance periodic 6 1 Maintenance record 9 5 Model label 9 2 N Neutral indicator light 3 2 Noise regulation 9 4 O Oil level warning light 3...

Page 98: ...r light 3 2 Turn signal light bulb or tail brake light bulb replacing 6 33 Turn signal switch 3 4 V Valve clearance adjusting 6 15 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 28 Wheels XVS1100 6 18 Wheels XVS1100A XVS1100AT 6 19 5YS10 book Page 2 Wednesday May 14 2003 6 32 PM ...

Page 99: ...PRINTED IN JAPAN 2003 05 3 3 2 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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