1999-2005 Yamaha XVS1100 Service & Repair Manual

EAS00001 XVS1100L/XVS1100LC SERVICE MANUAL 1999 by Yamaha Motor Corporation, U.S.A. First Edition, March 1999 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohidited. Printed in U.S.A. P/N LIT-11616-12-63

NOTE: CAUTION: EAS00003 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. There fore, anyone who uses this book to perform maintenance and repairs on Yamaha Vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. 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 vehicle will operate as designed. If there is any question about a service procedure, it is imperative 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 vehicle and to conform with federal environmental quality objectives. Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig- nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully. Designs and specifications are subject to change without notice. IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. NOTE: A NOTE provides key information to make procedures easier or clearer.

1 2 6 3 5 4 7 8 EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1 : This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2 : This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper right corner of the page. 3rd title 3 : This title indicates a sub-section that is followed by step-by-step procedures accompa- nied by corresponding illustrations. EXPLODED DIAGRAMS To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs. 2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step. 3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 6 . The meanings of the symbol marks are given on the next page. 4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition to the exploded diagram and the job instruction chart.

22 1 3 5 7 9 2 4 8 6 24 23 21 19 18 16 15 14 13 11 12 10 GEN INFO SPEC ENG CARB ELEC CHAS CHK ADJ TRBL SHTG 20 17 EB003000 ILLUSTRATED SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 8 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Caburetor 6 Chassis 7 Electrical system 8 Troubleshooting Symbols 9 to 16 indicate the following. 9 Serviceable with engine mounted 10 Filling fluid 11 Lubricant 12 Special tool 13 Tightening torque 14 Wear limit, clearance 15 Engine speed 16 Electrical data Symbols 17 to 22 in the exploded diagrams indicate the types of lubricants and lubrication points. 17 Engine oil 18 Gear oil 19 Molybdenum disulfide oil 20 Wheel bearing grease 21 Lithium soap base grease 22 Molybdenum disulfide grease Symbols 23 to 24 in the exploded diagrams indicate the following: 23 Apply locking agent (LOCTITE _ ) 24 Replace the part

CHK ADJ GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS ENGINE CARBURETION CHASSIS ELECTRICAL SYSTEM TROUBLESHOOTING GEN INFO 1 SPEC 2 3 ENG 4 CARB 5 CHAS 6 ELEC 7 TRBL SHTG 8 E004000 TABLE OF CONTENTS

GEN INFO CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . MODEL LABEL 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IMPORTANT INFORMATION 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR REMOVAL PROCEDURES 1-2 . . . . . . . . . . . . . . . REPLACEMENT PARTS 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKETS, OIL SEALS AND O-RINGS 1-2 . . . . . . . . . . . . . . . . . . . . . . . . LOCK WASHERS/PLATES AND COTTER PINS 1-3 . . . . . . . . . . . . . . . . BEARINGS AND OIL SEALS 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCLIPS 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING OF CONNECTIONS 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS 1-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1 MOTORCYCLE IDENTIFICATION GEN INFO EB100000 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EB100010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head. MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.

1-2 IMPORTANT INFORMATION GEN INFO EB101000 IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCE- DURES 1. Remove all dirt, mud, dust and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS” section. 3. When disassembling the machine, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or re- placed as an assembly. 4. During machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly and al- low for the correct installation of all parts. 5. Keep all parts away from any source of fire. EB101010 REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all re- placements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality. EB101020 GASKETS, OIL SEALS AND O-RINGS 1. Replace all gaskets, seals and O-rings when overhauling the engine. All gasket surfaces, oil seal lips and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.

1-3 IMPORTANT INFORMATION GEN INFO CAUTION: EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1. Replace all lock washers / plates 1 and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. EB101040 BEARINGS AND OIL SEALS 1. Install bearings and oil seals so that the manufacturer’s marks or numbers are vis- ible. When installing oil seals, apply a light coating of lightweight lithium base grease to the seal lips. Oil bearings liberally when installing, if appropriate. 1 Oil seal Do not use compressed air to spin the bearings dry. This will damage the bearing surfaces. 1 Bearing EB101050 CIRCLIPS 1. Check all circlips carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip 1 , make sure that the sharp- edged corner 2 is positioned opposite the thrust 3 it receives. See sectional view. 4 Shaft

1999-2005 Yamaha XVS1100 Service & Repair Manual

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