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Yamaha XVS1100 2001 Supplementary Service Manual

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  • Page 3 XVS1100 (L) SERVICE MANUAL: 5EL1-AE1 EB000000 XVS1100 (N) SUPPLEMENTARY SERVICE MANUAL 2000 by Yamaha Motor Co.,Ltd. First edition, September 2000 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 4 It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha mo- torcycles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair.
  • Page 5 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.
  • Page 6 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic inspections and adjustments 4 Engine 5 Cooling system 6 Carburetion 7 Chassis 8 Electrical 9 Troubleshooting...

  • Page 7: Table Of Contents

    CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS ........MAINTENANCE SPECIFICATIONS .

  • Page 9: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: XVS1100: 5PB2 Basic weight: With oil and a full fuel tank 275 kg Tire: Type With tube Size front 110/90-18 61S rear 170/80-15M/C 77S Manufacturer front DUNLOP rear DUNLOP Type front K555F rear...

  • Page 10: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Camshaft: Drive method Chain drive (left & right) 25.000 X 25.021 mm Cam cap inside diameter 24.96 X 24.98 mm Camshaft outside diameter 0.020 X 0.061 mm Shaft-to-cap clearance Cam dimensions 39.112 X 39.212 mm Intake “A”...

  • Page 11: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Front suspension: Front fork travel 140 mm Fork spring free length 356.9 mm 350 mm Fitting length 319.4 mm Collar length 183 mm Spring rate (K1) 4.41 N/mm (0.9 kg/mm) (K2) 6.37 N/mm (1.3 kg/mm) 0 X 77.5 mm Stroke (K1)

  • Page 12: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard Limit Ignition coil: Model/manufacturer F6T541 /MITSUBISHI 3.57 X 4.83 Ω at 20_C Primary winding resistance 10.7 X 14.5 kΩ at 20_C Secondary winding resistance Charging system: Type A.C. magneto Model/manufacturer F4T654 /MITSUBISHI Nominal output 14 V 305 W at 5,000 r/min 0.36 X 0.44 Ω...

  • Page 13: Cable Routing

    SPEC CABLE ROUTING EB206000 CABLE ROUTING Clutch cable Speed sensor lead Heat protector Starter cable Sidestand switch lead Speed meter lead Handlebar switch lead (left) Neutral switch lead Wireharness Handlebar switch lead (right) Pickup coil lead Purge hose (carburetor-sole- High tension code To engine noid valve) (for CAL) Throttle cable...
  • Page 14 SPEC CABLE ROUTING A Fasten the handlebar switch D When installing the pipe of G When connecting the sensing lead (left and rihgt) to the hand- throttle cable press it inside. hose (carburetor joint-AIS) with lebar with plastic locking tie and E Clamp the fuel hoses to the a nozzle.
  • Page 15 SPEC CABLE ROUTING J Position the all connectors inside O Route the clutch cable through S When installing the fitting plate, of the connector cover. the cable guide. do not pinch the each hoses and K Through the wireharness of so- P Position the throtlle cable and wireharness.
  • Page 16 SPEC CABLE ROUTING Battery Ignition coil Rear brake switch lead Battery positive (+) lead Breather hose Carburetor heater connecter Starter motor positive lead Purge hose (carburetor-solenoid Light reduce relay Speedmeter lead valve) (for CAL) Rectifier/ regulator Fuel hose (carburetor-fuel pump) Rear brake switch Stay.
  • Page 17 SPEC CABLE ROUTING Flasher relay A Clamp the battery positive (+) D Route rectifire / regulator Handlebar switch lead (left) lead to the battery with battery lead, wireharness and starter Silencer band. motor positive (+) lead through Throttle position sensor lead B Connect the battery negative (–) the out of frame bracket and fas- Carburetor heater lead...
  • Page 18 SPEC CABLE ROUTING E Connect the purge hose (carbu- I Fasten the rear brake switch M Fasten the rear brake switch lead retor side-solenoid valve side) lead to the rear brake switch and master cylinder reservoir with joint, knob is out side of frame. bracket with a plastic locking tie hose to the down tube with a plas- F Route the front turn signal / posi-...
  • Page 19 SPEC CABLE ROUTING Q To rear brake. U Fasten the oil level sensor lead V Clamp the handlebar switch lead R Fasten the rear brake switch with a locking tie to battery box. (right) to the frame with a holder. lead with a band to down tube.
  • Page 20 SPEC CABLE ROUTING Brake hose Battery positive (+) lead Throttle position sensor lead Throttle cable Taillight lead Carburetor heater lead Master cylinder reservoir hose Starter relay Tappet cover High tension code Starter motor positive (+) lead Clutch cable Purge hose (carburetor-solenoid Fuel tank breather hose (fuel Thermo switch lead valve) (for CAL)
  • Page 21 SPEC CABLE ROUTING A Clamp the throttle cables with E Position the steel band end to I Connect the wireharness to the the holder. Position the end of right side. ignitar unit through the hole of clip downword. F Route the battery positive (+) LID.
  • Page 22 SPEC CABLE ROUTING K Position the mark on the steel O Clamp the clutch cable and start- S Clamp the taillight lead with a band to forward. er cable with a holder. holder on the mud guard. L Fasten the wireharness with a Position the end of holder down T Position the locking tie upward.
  • Page 23 SPEC CABLE ROUTING Throttle cable Starter cable Clutch cable Handlebar switch lead (left) Headlight lead Brake hose Handlebar switch lead (right) A Route the handlebar switch lead (right) rear side of the throttle cable. –15–...

  • Page 24: Introduction

    S The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. S From 50,000 km, repeat the maintenance intervals starting from 10,000 km. S Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (...
  • Page 25 INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS ODOMETER READING ( 1,000 km) ANNUAL ITEM ITEM CHECK OR MAINTENANCE JOB CHECK OR MAINTENANCE JOB CHECK S Check operation and for oil leakage. 17 * Front fork S Check operation and shock absorber for oil leak- age.

  • Page 26: Electrical System

    REPLACING THE HEADLIGHT BULB ELECTRICAL SYSTEM EAS00182 REPLACING THE HEADLIGHT BULB 1. Disconnect: S connector 1 2. Remove S headlight bulb cover 2 3. Remove: S headlight bulb holder 1 4. Remove: S headlight bulb 2 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.

  • Page 27: Adjusting The Headlight Beam

    ADJUSTING THE HEADLIGHT BEAM EAS00184 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: S headlight beam (vertically) a. Turn the adjusting screw 1 in direction a or ! Headlight beam is raised. Direction ! Headlight beam is Direction lowered. 2. Adjust: S headlight beam (horizontally) a.

  • Page 28: Carburetion

    CARB AIR INDUCTION SYSTEM CARBURETION AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM DIAGRAMS 1 Reed valve 2 Air filter 3 Orifice 4 Carburetor joint (near cylinder) A To the front cylinder head B To the rear cylinder head C To the orifice D To the carburetor joint (rear cylinder) E To the air cut-off valve NOTE:...
  • Page 29 CARB AIR INDUCTION SYSTEM Order Job name/Part name Q’ty Remarks Removeing the air induction system Remove the parts in the order listed. Side cover Air filter Air filter to air cut valve hose Air cut valve Vacuume hose 2 Orifice Vacuum hose 1 Reed valve case to rear cylinder head pipe...

  • Page 30: Checking The Air Induction System

    CARB AIR INDUCTION SYSTEM EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: S hoses Loose connection ! Connect properly. Cracks/damage ! Replace. S pipes Cracks/damage ! Replace. 2. Check: S reed valve 1 S reed valve stopper S reed valve seat Cracks/damage ! Replace the reed valve.

  • Page 31: Chassis

    CHAS FRONT AND REAR BRAKES CHASSIS FRONT AND REAR BRAKES FRONT BRAKE CALIPERS 6 Nm (0.6 mSkg) 30 Nm (3.0 mSkg) 27 Nm (2.7 mSkg) Order Job name/Part name Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. Brake fluid Drain Brake hose holder...

  • Page 32: Steering Head

    CHAS STEERING HEAD STEERING HEAD 52 Nm (5.2 mSkg) 18 Nm (1.8 mSkg) 110 Nm (11.0 mSkg) 7 Nm (0.7 mSkg) Order Job name/Part name Q’ty Remarks Removing the lower bracket Remove the parts in the order listed. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over.
  • Page 33 CHAS STEERING HEAD 52 Nm (5.2 mSkg) 18 Nm (1.8 mSkg) 110 Nm (11.0 mSkg) 7 Nm (0.7 mSkg) Order Job name/Part name Q’ty Remarks Rubber washer Lower ring nut Refer to “REMOVING THE LOWER Bearing cover BRACKET/INSTALLING THE Lower bracket STEERING HEAD”.

This manual is also suitable for:

Xvs1100n 20015pb2

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