Yamaha 1999 XVS1100 Manuals

Manuals and User Guides for Yamaha 1999 XVS1100. We have 1 Yamaha 1999 XVS1100 manual available for free PDF download: Service Manual

Yamaha 1999 XVS1100 Service Manual

Yamaha 1999 XVS1100 Service Manual (355 pages)

1999 Motorcycle

Brand: Yamaha | Category: Motorcycle | Size: 7.63 MB

Table of Contents

Gen Info

8
- How to Use this Manual
  4
- Table of Contents
  8
- Chapter 1
  9
- General Information
  9
- Motorcycle Identification
  9
  - Vehicle Identification Number
    9
  - Model Label
    9
- Important Information
  10
  - Preparation for Removal Procedures
    10
  - Replacement Parts
    10
  - Gaskets, Oil Seals and O-Rings
    10
  - Lock Washers/Plates and Cotter Pins
    11
  - Bearings and Oil Seals
    11
  - Circlips
    11
- Checking of Connections
  12
- Special Tools
  13
2 Spec

18
- Chapter 2. Specifications
  19
- General Specifications
  19
- Maintenance Specifications
  22
  - Engine
    22
  - Chassis
    32
  - Electrical
    36
- Conversion Table
  38
- General Torque Specifications
  38
- Lubrication Points and Lubricant Types
  39
  - Engine
    39
  - Chassis
    40
- Lubrication Diagrams
  41
- Cable Routing
  45
Insp Adj

55
- Chapter 3 Periodic Inspections and Adjustments
  57
- Introduction
  57
- Periodic Maintenance/Lubrication Intervals
  57
- Fuel Tank and Seats
  59
  - Removal
    60
  - Installation
    60
- Engine
  61
- Chassis
  78
- Electrical System
  93
  - Checking and Charging the Battery
    93
  - Checking the Fuses
    99
  - Replacing the Headlight Bulb
    100
  - Adjusting the Headlight Beam
    101
Table of Contents

103
- Chapter 4 Engine
  106
- Engine Removal
  106
  - Mufflers, Brake Pedal and Side Cover
    106
  - Leads, Shift Pedal and Clutch Cable
    108
  - Engine Mounting Bolts
    109
  - Installing the Engine
    110
- Cylinder Heads
  111
  - Rear Cylinder Head
    111
  - Front Cylinder Head
    113
  - Removing the Cylinder Heads
    115
  - Checking the Cylinder Heads
    117
  - Checking the Timing Chain Tensioner
    118
  - Installing the Cylinder Heads
    118
- Rocker Arms and Camshaft
  121
- Valves and Valve Springs
  126
  - Removing the Valves
    127
  - Checking the Valves and Valve Guides
    127
  - Checking the Valve Seats
    129
  - Checking the Valve Springs
    131
  - Installing the Valves
    131
- Cylinders and Pistons
  133
  - Removing the Cylinders and Pistons
    133
  - Checking the Cylinders and Pistons
    134
  - Checking the Piston Rings
    136
  - Checking the Piston Pins
    137
  - Installing the Pistons and Cylinders
    137
- Timing Gears
  139
  - Removing the Timing Drive Gears
    140
  - Checking the Timing Chains, Camshaft
    140
  - Checking the Primary Drive
    141
  - Installing the Timing Drive Gears
    141
  - Right Crankcase Cover
    143
  - Clutch Assembly
    145
  - Removing the Clutch
    147
  - Checking the Friction Plates
    147
  - Checking the Pressure Plate
    148
  - Checking the Clutch Boss
    148
  - Checking the Clutch Push Rods
    148
  - Checking the Clutch Plates
    149
  - Checking the Clutch Spring and Clutch Spring Seat Plate
    149
  - Checking the Clutch Housing
    149
  - Installing the Clutch
    150
- Generator and Starter Clutch
  152
  - Stator Coil and Pickup Coil
    152
  - Generator and Starter Clutch
    153
  - Removing the Generator
    154
  - Checking the Starter Clutch
    155
  - Installing the Generator
    156
- Shift Shaft
  158
  - Checking the Shift Shaft
    159
  - Checking the Stopper Lever
    159
  - Installing the Shift Shaft
    159
- Oil Pump
  160
  - Checking the Oil Pump
    162
  - Checking the Oil Delivery Pipes
    162
  - Checking the Oil Strainer
    162
  - Crankshaft and Connecting Rods
    164
- Crankshaft and Connecting Rods Crankcase
  164
  - Disassembling the Crankcase
    166
  - Removing the Connecting Rods
    167
  - Checking the Crankshaft and Connecting Rods
    167
  - Checking the Bearing and Oil Seals
    170
  - Installing the Crankshaft
    170
  - Assembling the Crankcase
    171
- Transmission
  173
  - Checking the Shift Forks
    174
  - Checking the Shift Drum Assembly
    174
  - Checking the Transmission
    175
  - Installing the Transmission
    176
- Middle Gear
  177
5 Carb

189
- Carburetor
  190
- Chapter 5
  193
- Checking the Carburetors
  193
- Assembling the Carburetors
  195
- Installing the Carburetors
  195
- Measuring and Adjusting the Fuel Level
  196
- Checking and Adjusting the Throttle Position Sensor
  197
- Air Induction System (Ais)
  199
  - Air Induction
    199
  - Air Cut-Off Valve
    199
  - Air Induction System Inspection
    200
6 Chas

203
- Front Wheel and Brake Discs
  205
- Chapter 6
  207
- Checking the Front Wheel
  207
- Removing the Front Wheel
  207
- Checking the Brake Discs
  209
- Installing the Front Wheel
  211
- Adjusting the Front Wheel Static Balance
  212
- Rear Wheel and Brake Disc
  214
  - Muffler and Brake Caliper
    214
  - Rear Wheel
    215
  - Removing the Rear Wheel
    217
  - Checking the Rear Wheel
    217
  - Checking the Rear Wheel Drive Hub
    218
  - Installing the Rear Wheel
    218
  - Adjusting the Rear Wheel Static Balance
    219
- Front and Rear Brakes
  220
  - Front Brake Pads
    220
  - Rear Brake Pads
    221
  - Replacing the Front Brake Pads
    222
  - Replacing the Rear Brake Pads
    224
  - Front Brake Master Cylinder
    226
  - Rear Brake Master Cylinder
    228
  - Removing the Front Brake Master Cylinder
    230
  - Removing the Rear Brake Master Cylinder
    230
  - Checking the Front and Rear Brake Master Cylinder
    231
  - Installing the Front Brake Master Cylinder
    232
  - Installing the Rear Brake Master Cylinder
    234
  - Front Brake Calipers
    236
  - Rear Brake Caliper
    238
  - Removing the Front Brake Calipers
    240
  - Removing the Rear Brake Caliper
    240
  - Checking the Front and Rear Brake Calipers
    241
  - Installing the Front Brake Calipers
    242
  - Installing the Rear Brake Caliper
    244
- Front Fork
  247
  - Removing the Front Fork Legs
    250
  - Disassembly the Front Fork Legs
    250
  - Checking the Front Fork Legs
    251
  - Assembling the Front Fork Legs
    252
- Handlebar
  256
  - Removing the Handlebar
    258
  - Checking the Handlebar
    258
  - Installing the Handlebar
    259
- Steering Head
  262
  - Removing the Lower Bracket
    264
  - Checking the Steering Head
    264
  - Installing the Steering Head
    265
- Rear Shock Absorber and Swingarm
  267
  - Right Side Cover and Battery Box
    267
  - Left Side Cover and Tool Box
    268
  - Rear Shock Absorber and Swingarm
    268
    
    Disposing of a Rear Shock Absorber and Gas Cylinder
    270
  - Removing the Rear Shock Absorber
    271
  - Removing the Swingarm
    272
    
    Cylinder
    273
  - Checking the Swingarm
    273
  - Installing the Rear Shock Absorber
    274
  - Installing the Swingarm
    274
- Shaft Drive
  276
7 Elec

294
- Chapter 7 Electrical
  296
- Electrical Components
  296
- Switches
  297
  - Checking Switch Continuity
    297
- Checking the Switches
  298
- Checking the Bulbs and Bulb Sockets
  300
- Ignition System
  303
  - Circuit Diagram
    303
  - Troubleshooting
    304
- Electric Starting System
  308
  - Circuit Diagram
    308
  - Starting Circuit Operation
    309
  - Troubleshooting
    310
  - Starter Motor
    314
- Charging System
  318
  - Circuit Diagram
    318
  - Troubleshooting
    319
- Lighting System
  321
  - Circuit Diagram
    321
  - Troubleshooting
    322
  - Checking the Lighting System
    323
- Signal System
  326
  - Circuit Diagram
    326
  - Troubleshooting
    328
  - Checking the Signaling System
    329
  - Signaling System
    330
- Fuel Pump System
  334
  - Circuit Diagram
    334
  - Fuel Pump Circuit Operation
    335
  - Troubleshooting
    336
  - Fuel Pump Test
    338
- Carburetor Heater System
  339
  - Circuit Diagram
    339
  - Troubleshooting
    340
- Self-Diagnosis
  343
Trbl Shtg

347
- Troubleshooting
  347
- Chapter 8
  348
- Electrical System
  348
- Fuel System
  348
- Starting Failure/Hard Starting
  348
- Compression System
  349
- Poor Idle Speed Performance
  349
- Poor Idle Speed Performance Poor Idle Speed Performance
  349
- Poor Medium-And High-Speed Performance
  349
- Clutch Slipping/Dragging
  350
  - Clutch Slipping
    350
  - Clutch Dragging
    350
- Faulty Gear Shifting
  350
  - Hard Shifting
    350
  - Shift Pedal Does Not Move
    350
  - Jumps-Out-Of Gear
    350
- Faulty Brake
  351
- Faulty Brake Poor Braking Performance
  351
- Front Fork Oil Leakage and Front Fork Malfunction
  351
  - Malfunction
    351
  - Oil Leakage
    351
  - Unstable Handling
    352
- Overheating Overheating
  351
- Faulty Lighting and Signal Systems
  352
  - Headlight Does Not Light
    352
  - Bulb Burnt out
    352
  - Flasher Does Not Light
    352
  - Flasher Blinks Slowly
    352
  - Flasher Remains Lit
    352
  - Horn Does Not Sound
    352
- Unstable Handling Unstable Handling
  352

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