FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the XVS1100A. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. XVS1100L/XVS1100LC SERVICE MANUAL: LIT-11616-12-63 (5EL-28197-E0) XVS1100AM/XVS1100AMC SUPPLEMENTARY SERVICE MANUAL: LIT-11616-13-36 (5KS-28197-E0) EB000000 XVS1100AWR(C) XVS1100ATR(C) SUPPLEMENTARY SERVICE MANUAL 2002 by Yamaha Motor Co., Ltd.
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. Therefore, 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.
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.
EB003000 1 ILLUSTRATED SYMBOLS 2 GEN INFO SPEC 3 4 CHK ADJ ENG 5 6 CHAS CARB 7 8 TRBL SHTG ELEC 11 12 13 14 15 16 20 23 Symbols 9 to 16 indicate the following. 9 Serviceable with engine mounted 10 9 17 The following symbols are not relevant to every vehicle. Symbols 1 to 8 indicate the subject of each chapter.
CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code XVS1100: 5KSJ (For U.S.A.) 5KSK (For CAL) 5KSU (For U.S.A.) 5KSV (For CAL) Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2460 mm (96.9 in) 945 mm (37.2 in) 1,095 mm (43.1 in) 710 mm (28 in) 1645 mm (64.8 in) 140 mm (5.5 in) 3400 mm (133.
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Item Standard Carburetor I.D. mark Main jet Main air jet Jet needle Needle jet Pilot air jet (M.J) (M.A.J) (J.N) (N.J) (P.A.J.1) (P.A.J.2) Pilot outlet (P.O) Pilot jet (P.J) Bypass 1 (B.P.1) Bypass 2 (B.P.2) Bypass 3 (B.P.3) Valve seat size (V.S) Starter jet (G.S.1) Starter jet (G.S.2) Throttle valve size (Th.V) Fuel level (above the line on the float chamber) (F.
MAINTENANCE SPECIFICATIONS Item Rear suspension Shock absorber travel Spring free length Fitting length Spring rate Stroke Optional spring Front wheel Type Rim size Rim material Rim runout limit Rear wheel Type Rim size Rim material Rim runout limit SPEC Standard Limit 51 mm (2.01 in) 181 mm (7.13 in) 169 mm (6.65 in) 132.3 N/mm (13.49 kg/mm, 755.43 lb/in) 0 X 51 mm (0 X 2.01 in) No SSS SSS SSS SSS SSS SSS radial Cast wheel 16M/C MT 3.00 Aluminum SSS lateral SSS SSS SSS SSS 1.0 mm (0.04 in) 0.
MAINTENANCE SPECIFICATIONS Item Electric starter system Type Starter motor: Model/manufacturer Output Armature coil resistance Brush overall length Brush spring pressure SPEC Standard Limit Constant mesh type SSS SM-13/MITSUBA 0.6 kW 0.025 X 0.035 Ω at 20_C (68_F) 12.5 mm (0.49 in) SSS SSS SSS 4 mm (0.16 in) SSS 7.65 X 10.01 N (780 X 1021 g, 27.51 X 36.01 OZ) 28 mm (1.10 in) 0.7 mm (0.03 in) 27 mm (1.
CABLE ROUTING SPEC EB206000 CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 Clutch cable Starter cable Handlebar switch lead (left) Handlebar switch lead (right) Spark plug lead Throttle cable Fuel hose (fuel cock to filter) Fuel breather hose (fuel tank roll over valve) (for CAL) Fuse box Alarm connector Fuel pump lead Speed sensor lead Sidestand switch lead Neutral switch lead Pickup coil lead To engine A.C.
CABLE ROUTING A Fasten the handlebar switch C Clamp the wire harness with the lead (left and right) to the handlehook of frame side. bar with plastic locking tie and D When installing the pipe of cut the end of tie. throttle cable press it inside. B Lay out the throttle and starter E Clamp the fuel hoses to the cables in three rows and secure frame with the clamp. them with a clip. (Two points at F Cross the fuel hose (fuel cock the front and rear.
CABLE ROUTING M Fasten the lead with locking tie near the side cover. N Position the all connectors inside of the connector cover. O Route the clutch cable through the cable guide. P Fasten the handlebar switch leads (left and right) under the handle crown with a plastic band. Set the band at four notches and install it no slacking. Q Route the each hoses through the frame guide and do not pinch it. R When installing the fitting plate, do not pinch the each hoses and wireharness.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 Battery Battery positive (+) lead Starter motor positive (+) lead Speedometer lead Fuel hose (fuel pump to carburetor) Spark plug lead Main switch lead Throttle cable Front brake hose Handlebar switch lead (right) Headlight lead Ignition coil 13 Breather hose 14 Purge hose (carburetor to sole15 16 17 18 19 20 21 22 23 24 noid valve) (For CAL) Rear brake switch Reserve hose Air filter drain hose Delay relay Battery negative (–) lead Oil level switch lead Rear brake
CABLE ROUTING 36 Rectifire/ regulator and light (re- duce relay) lead A Clamp the battery positive (+) lead to the battery with battery band. B Connect the battery negative (–) lead and push it in to the space between battery box and battery. C Push the wireharness into the space between frame and starter motor relay.
CABLE ROUTING SPEC E Connect the purge hose (carbu- J Fasten the wire harness, starter O Make sure to insert the rectifier retor side-solenoid valve side) motor positive (+) lead and batregulator coupler sufficiently unwith joint, knob is out side of frame. tery negative (–) lead to the til the sound is heard. F Route the front turn signal / posiframe with a plastic locking tie. P To rear brake. tion light lead and headlight lead K 70 mm (2.
CABLE ROUTING T Fasten the oil level sensor lead V Arrange the throttle position senwith a locking tie to battery box. sor connector, carburetor heater Fix to the battery box with the connector and thermo switch band. To fix, align the band to the connector between the starting bottom of the box’s hole while fixcircuit cut off relay and high tening the lead to the back of the box sion code. (inside the body).
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 Front brake hose Throttle cable Master cylinder reservoir hose Spark plug lead Purge hose (carburetor to solenoid valve) (for CAL) Rear brake light switch lead Rear brake hose Fuel hose (fuel pump to carburetor) Delay relay Battery negative (–) lead Battery negative (–) lead connector 12 13 14 15 16 17 18 19 20 21 22 Battery Battery positive (+) lead Tail/ brake light lead Starter relay Starter motor positive (+) lead Fuel tank breather hose (fuel tank to roll over v
CABLE ROUTING SPEC A Clamp the throttle cables with F Route the battery positive (+) J Position the mark on the steel the holder. Position the end of lead through the slit of the batband to forward. clip downword. tery box. K Fasten the wire harness with a B Route the rear brake switch lead G Secure the igniter unit lead and band on the tool box plate. under the master cylinder resertail brake light lead to the frame L Fasten the wire harness to the vor hose. with a clamp.
CABLE ROUTING O Route the igniter lead through the igniter plate hole to the wireharness. P To the wire harness. Q Clamp the tail / brake light lead with mud guard clamp. R Clamp the tail / brake light lead with a holder on the mud guard. S Position the locking tie upward. T Forward.
INTRODUCTION/PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM / GENERAL MAINTENANCE AND LUBRICATION CHART CHK ADJ EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work.
CHK ADJ GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL NO. ITEM 600 mi (1,000 km) or 1 month REMARKS S Check swingarm pivot for play. S Correct if necessary. S Moderately repack every 16,000 mi (25,000 km) or 24 months with lithium-soap-based grease.
FRONT WHEEL AND BRAKE DISCS CHAS CHASSIS FRONT WHEEL AND BRAKE DISCS 59 Nm (5.9 mSkg, 43 ftSlb) 20 Nm (2.0 mSkg, 14 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) Order Job name/Part name Q’ty Remarks Remove the parts in the order listed. Stand the motorcycle on a level surface. Removing the front wheel and brake discs WARNING Securely support the motorcycle so there is no danger of it falling over.
FRONT WHEEL AND BRAKE DISCS Order 1 2 3 Job name/Part name Disassembling the front wheel Oil seals Bearings Collar Q’ty CHAS Remarks Disassemble the parts in the order listed. 2 2 1 For assembly, reverse the disassembly procedure.
FRONT WHEEL AND BRAKE DISCS CHAS EAS00521 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Remove: S reflectors 1 (left and right) S brake calipers 2 (left and right) NOTE: Do not squeeze the brake lever when removing the brake calipers. 3. Loosen: S pinch bolt (front wheel axle) 1 S front wheel axle 2 4.
FRONT WHEEL AND BRAKE DISCS CHAS 3. Measure: S front wheel radial runout 1 S front wheel lateral runout 2 Over the specified limits ! Replace. Front wheel radial runout limit 1.0 mm (0.04 in) Front wheel lateral runout limit 0.5 mm (0.02 in) 4. Check: S collars Damage/wear ! Replace. WARNING S New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km (62 mi) should be traveled at normal speed before any highspeed riding is done. 5.
FRONT WHEEL AND BRAKE DISCS CHAS CAUTION: Do not contact the wheel bearing center race 4 or balls 5 . Contact should be made only with the outer race 6 . NOTE: Use a socket 3 that matches the diameter of the wheel bearing outer race and oil seal. EAS00531 CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs. 1. Check: S brake disc Damage/galling ! Replace. 2.
FRONT WHEEL AND BRAKE DISCS CHAS 3. Measure: S brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification ! Replace. Brake disc thickness limit (minimum) Front: 4.5 mm (0.18 in) Rear: 5.5 mm (0.22 in) 4. Adjust: S brake disc deflection a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. Brake disc bolt 23 Nm (2.3 mSkg, 17 ftSlb) LOCTITE d.
CHAS FRONT WHEEL AND BRAKE DISCS EAS00544 INSTALLING THE FRONT WHEEL The following procedure applies to both brake discs. 1. Lubricate: S wheel axle S oil seallips Recommended lubricant Lithium soap base grease 2. Install: S front wheel assembly NOTE: The arrow mark a on the tire must point in the direction of the wheel. 3. Tighten: 59 Nm (5.9 mSkg, 29 ftSlb) S wheel axle 1 S wheel axle pinch bolt 2 20 Nm (2.
CHAS REAR WHEEL AND BRAKE DISC REAR WHEEL AND BRAKE DISC MUFFLER AND BRAKE CALIPER 20 Nm (2.0mSkg, 14 ftSlb) 30 Nm (3.0mSkg, 22 ftSlb) 40 Nm (4.0mSkg, 29 ftSlb) 25 Nm (2.5mS kg, 18 ftSlb) Order 1 2 3 4 Job name/Part name Removing the muffler and brake caliper Muffler Muffler stay Brake hose holder Brake caliper Q’ty 20 Nm (2.0mSkg, 14 ftSlb) Remarks Remove the parts in the order listed. 1 1 1 1 –24– Refer to “REMOVING THE REAR WHEEL”. For installation, reverse the removal procedure.
REAR WHEEL AND BRAKE DISC CHAS REAR WHEEL 23 Nm (2.3mSkg, 17 ftSlb) 40 Nm (4.0mSkg, 29 ftSlb) 23 Nm (2.3mSkg, 17 ftSlb) 74 Nm (7.4mSkg, 54 ftSlb) 107 Nm (10.7mSkg, 77 ftSlb) Order Job name/Part name Q’ty Remarks Remove the parts in the order listed. Removing the rear wheel WARNING Securely support the motorcycle so there is no danger of it falling over. Drain Refer to “FINAL GEAR OIL REPLACEMENT” in CHAPTER 3. Refer to “FUEL TANK AND SEATS” in CHAPTER 3.
REAR WHEEL AND BRAKE DISC CHAS 62 Nm (6.2mSkg, 45 ftSlb) Order 1 2 3 4 5 6 7 8 Job name/Part name Rear wheel disassembly Disassembling the rear wheel Lock washers Clutch hub Dampers O-rings Oil seal Bearing Spacer Bearings Q’ty Remarks Remove the parts in the order listed. 2 1 6 2 1 1 1 2 For assembly, reverse the disassembly procedure.
REAR WHEEL AND BRAKE DISC CHAS EAS00562 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: S rear gear case fitting bolts 3. Remove: S brake caliper 1 S brake caliper bracket bolt NOTE: Do not depress the brake pedal when removing the brake caliper. 4. Remove: S wheel axle nut S washer 5.
REAR WHEEL AND BRAKE DISC CHAS EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1. Check: S rear wheel drive hub Cracks/damage ! Replace. S rear wheel drive hub dampers Damage/wear ! Replace. EAS00572 INSTALLING THE REAR WHEEL 1. Lubricate: S drive shaft splines Recommended lubricant Molybdenum disulfide grease 2. Lubricate: S wheel axle S wheel bearings S oil seal lips Recommended lubricant Lithium soap base grease 3. Install: S rear wheel assembly a.
REAR WHEEL AND BRAKE DISC CHAS f. Tighten the rear axle holder with specified torque. Rear axle end nut 23 Nm (2.3 mSkg, 17 ftSlb) g. Tighten the rear brake caliper bracket bolt with specified tightening torque. Brake caliper bracket bolt 40 Nm (4.0 mSkg, 29 ftSlb) h. Install the rear brake caliper on the bracket and tighten the bolts with specified tightening torque. Brake caliper bolt 40 Nm (4.
CHECKING THE SWITCHES ELEC ELECTRICAL EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear ! Repair or replace the switch. Improperly connected ! Properly connect. Incorrect continuity reading ! Replace the switch.
CHECKING THE SWITCHES 1 2 3 4 5 6 Clutch switch Horn switch Dimmer switch Turn signal switch Main switch Front brake switch 7 8 9 10 11 12 Engine stop switch Start switch Fuse Rear brake switch Sidestand switch Neutral switch –31– ELEC
PRINTED IN U.S.A.
XVS1100AWR(C)/XVS1100ATR(C) WIRING DIAGRAM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Pickup coil A.C.