1995 Yamaha XV1100 Virago Service & Repair Manual

GJYAMAHA XV700/XV750 XV1000/XV1100 L~L ('85~'99) Service Manual 428 LIT-11616-XV-11 ---------

OYAMAHA Supplementary liP ice IIIII LIT-11616-06-10

FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the XV1100U/UC. For complete information on service procedures, it is necessary to use this Supple- mentary Service Manual together with following manuals: XV700L/XV1000L Service Manual (LIT~11616-04-13) XV1100S/SC Supplementary Service Manual (LIT-11616-04-99) XV1100U/UC SUPPLEMENTARY SERVICE MANUAL © 1987 by Yamaha Motor Corporation, U.S.A. 1st edition, September 1987 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A., is expressly prohibited. Printed in U.S.A. P/N LIT~11616-06-10

NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motorcycles have a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit to use and/or unsafe. This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools is necessary to ensure that the motorcycle will operate as designed. If there is any question about a service procedure, it is impera- tive that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his motorcycle and to conform with federal environmental quality objectives. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual. NOTE:------------------------------------------------------------ This Service Manual contains information regarding periodic maintenance to the emission control system for the XV750LIXV1000L. Please read this material carefully. TECHNICAL PUBLICATIONS SERVICE DIVISION MOTORCYCLES OPERATIONS YAMAHA MOTOR CO., LTO. HOW TO USE THIS MANUAL PARTICULARLY IMPOTANT INFORMATION This material is distinguished by the following notations. NOTE: WARNING: A NOTE provides key information to make procedures easier or clearer. A CAUTION indicates special procedures that must be followed to avoid damage to the motorcycle. A WARNING indicates special procedures that must be followed to avoid injury to a motorcycle operator or person inspecting or repairing the motorcycle. MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., • Bearings: Pitting/Damage~ Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures.

CD ® ~~~~''"'' lr8fl~l ® @ I ENG l'-1 ~KI ® @ ~Relfl EH~~I (j) ® IELECIIiliiii I IAPPxl•'l ® ~ @ ~ @ ~ @ ~ @ [0] @ rmTI @ ~ @ ~ ®~ ® @ ® ~ ~ ~ ® • ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols CD to @ are designed as thumb tabs to indicate the chapter's number and content. CD General information ® Periodic inspection and adjustment @Engine @ Cooling system @ Carburetion @Chassis (j) Electrical @Appendices Illustrated symbols ® to @ are used to identify the specifications appearing. ®Filling fluid · @ Lubricant @Tightening @Wear limit, clearance @ Engine speed . @.st,V,A Illustrated symbols @ to ® in the exploded diagram indicate grade of lubricant and location of lubrication point. @Apply engine oil @Apply gear oil @Apply molybdenum disulfide oil @Apply wheel bearing grease @Apply lightweight lithium-soap base grease ®Apply molybdenum disulfide grease @Apply locking agent (LOCTITE®)

CONTENTS GENERAL INFORMATION ......................................... 1 MOTORCYCLE IDENTIFICATION ................................ 1 INSPECTIONS AND ADJUSTMENTS ................................. 2 IDLING SPEED ADJUSTMENT ................................... 2 THROTTLE CABLE FREE PLAY ADJUSTMENT .................... 2 CARBURATOR SYNCHRONIZATION ............................ .4 ENGINE ........................................................ 6 INSPECTION AND REPAIR ................................... :.6 CYLINDER AND PISTON ....................................... 6 CARBURETION .......................................... - ........ 8 CARBURETOR ............................................... 8 COASTING ENRICHER SYSTEM SECTION VIEW .................... 9 AIR INDUCTION SYSTEM ..................................... 10 DISASSEMBLY .............................................. 11 INSPECTION ................................................ 13 ASSEMBLY ................................................. 14 ADJUSTMENT ............................................... 17 SP·ECIFICATIONS ............................................... 19 GENERAL SPECIFICATIONS ................................... 19 MAINTENANCE SPECIFICATIONS .............................. 19 WI RING DIAGRAM

-1- GENERAL INFORMATION MOTORCYCLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number CD is stamped into the steering head pipe. NOTE=-------------------------- The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your state. Starting Serial Number: XV1100U ........ 1TE-029101 XV1100UC . ..... . 1TA-007101 ENGINE SERIAL NUMBER The engine serial number CD is stamped into the left side of the engine. NOTE=-------------------------- The first three digits of these numbers are for model identifications; the remaining digits are the unit production number. Starting Serial Number: XV1100U ...... JYA1TEEO * JA029101 XV1100UC ..... JYA1TACO * JA007101 NOTE:------------- Designs and specifications are subject to change without notice.

IDLING SPEED ADJUSTMENT/,INSP I Q I THROTTLE CABLE FREE PLAY ADJUSTMENT ADJ -2- INSPECTIONS AND ADJUSTMENTS IDLING SPEED ADJUSTMENT 1. Start the engine and let it warm up. 2. Inspect: •Idle speed Out of specification -+ Adjust. lwl Idle Speed: 950- 1,060 r/min 3. Adjust: • Idle speed Turn the throttle stop screw CD Turn in Engine speed is increased. Turn out Engine speed is decreased. THROTTLE CABLE FREE PLAY ADJUST- MENT NOTE=------------------------- Before adjusti,ng the throttle cable free play, the engine idle speed should be adjusted. 1. Check: • Throttle cable free play ® Out of specification -+ Adjust. Throttle Cable Free Play®: 2- 3 mm (0.08- 0.12 in) 2. Remove: • Air cleaner 3. Adjust: • Throttle cable free play Throttle cable adjustment steps: First step: • Loosen the locknuts (Throttle cable 2) CD . • Turn the adjuster (Throttle cable 2) CID clockwise or counterclockwise until the specified free play ® .

I ~f I Q I THROTTLE CABLE FREE PLAY ADJUSTMENT -3- ~~ Throttle Cable 2 Free Play ®: r A.' Zero mm (Zero in) @ Throttle cable 2 • Tighten the locknuts CD . Second step: • Loosen the locknuts (Throttle cable 1) @ . • Turn the adjuster (Throttle cable 1) @ clockwise or counterclockwise until proper free play (Throttle grip) is attained. ~ Throttle Cable Free Play r ~ (Throttle Grip): 2"" 3 mm (0.08"" 0.12 in) @ Throttle cable 1 • Tighten the locknuts@. Third step: • If the free play is incorrect, adjust the throttle cable free play with the adjuster (Throttle grip side). • Loosen the locknut (Throttle cable 1 - Throttle grip side) (j) . • Turn the adjuster (Throttle cable 1 - Throttle grip side) ® clockwise or counterclockwise unti I proper free play (Throttle grip) ® is attained. ~~ Throttle Cable Free Play r A (Throttle Grip) ® : 1---.a.~ 2"" 3 mm (0.08 ~ 0.12 in) • Tighten the locknut (j) . Final step: •Start the engine and let it at idling. • Steer the handlebar all the way to right and left. •Check the idle speed for steadiness . .t\ Idle Speed: 950 ~ 1,050 r/min • If the idle speed is fluctuated, repeat the "Third step".

CARBURETOR SYNCHRONIZATION I ~8! I G. I CARBURETOR SYNCHRONIZATION Carburetors must be adjusted to open and close simultaneously. NOTE=------------------------- Valve clearance must be set properly before synchronizing the carburetors. -4- 1. Remove: • Fuel tank • Cover ( Left) • Air cleaner 2. Remove: • Hose CD From the front carburetor joint. • Blind plug ® From the rear carburetor joint. 3. Install: • Vacuum gauge CD • Air cleaner ® I ~ Vacuum Gauge: w- 1 P/N vu-oso3o-A 4. Start the engine and let it warm up. 5. Adjust: • Idle speed Turn the throttle stop screw CD . Turn in Engine speed is increased. Turn out Engine speed is decreased. IC'J:IIdle Speed: 950- 1,050 r/min 6. Adjust: •Carburetors synchronization Carburetor synchronization adjustment steps: •Synchronize carburetor No. 1 to carburetor No. 2 by turning synchronizing screw CD until both gauges read the same.

1995 Yamaha XV1100 Virago Service & Repair Manual

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