Yamaha XVS1100 2000 Supplementary Service Manual
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Yamaha XVS1100 2000 Supplementary Service Manual

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  • Page 3 Service Manual together with the following manual. XVS1100 SERVICE MANUAL: 5EL1-AE1 EB000000 XVS1100A SUPPLEMENTARY SERVICE MANUAL 1999 by Yamaha Motor Co., Ltd. First edition, December 1999 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 4 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.
  • 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 The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 8 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetor 6 Chassis 7 Electrical system CHAS CARB...

  • 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: 5KS4 (For Europe) 5KS5 (For Australia) Dimensions: Overall length 2,465 mm Overall width 945 mm Overall height 1,095 mm Seat height 710 mm Wheelbase 1,645 mm Minimum ground clearance 145 mm Minimum turning radius 3,300 mm...

  • Page 10: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Carburetor: I. D. mark 5KS4 00 Main jet (M.J) #1: #110, #2: #112.5 Main air jet (M.A.J) Jet needle (J.N) #1, #2: 5DL44-53-3 Needle jet (N.J) P-0M Pilot air jet (P.A.J.1) #63.8 (P.A.J.2) #145...
  • Page 11 SPEC MAINTENANCE SPECIFICATIONS Item Standard Lubrication chart: Needle bearing (starter) Connecting rod big end Main axle Crank shaft Drive axle Pressure feed Pinion drive Splashed Orifice Middle driveshaft Camshaft (EX) Camshaft (IN) Rocker arm (EX) Rocker arm (EX) Rocker arm (IN) Rocker arm (IN) Oil filter Relief valve...

  • Page 12: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Front suspension: Front fork travel 140 mm Fork spring free length 361.9 mm 350 mm Fitting length 324.4 mm Collar length 183 mm Spring rate (K1) 8.8 N/mm (0.9 kg/mm) (K2) 12.7 N/mm (1.3 kg/mm) 0 X 77.5 mm Stroke (K1)

  • Page 13: 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 Electric starter system: Type Constant mesh type Starter motor: Model/manufacturer SM-13/MITSUBA Output 0.6 kW...

  • Page 14: Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES EB203010 CHASSIS Lubrication point Symbol Drive shaft coupling gear oil seal –6–...

  • Page 15: Lubrication Diagrams

    SPEC LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS Camshaft Middle drive shaft Crankshaft Drive axle Main axle Connecting rod big end –7–...

  • Page 16: 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 17 SPEC CABLE ROUTING A Fasten the handlebar switch D When installing the pipe of G When connecting the sensing lead (left and right) 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 18 SPEC CABLE ROUTING J Through the wireharness of so- O Route the clutch cable through S Wher install the AIS push the lenoid valve between AIS duct the cable guide. wireharness to space of rearside. and fuel hose (for CAL). P Fasten the handlebar switch K Fasten the alarm lead with a plas- leads (left and right) under the...
  • Page 19 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 20 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 21 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 22 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 23 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 24 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. igniter unit through the hole of clip downword. F Route the battery positive (+) igniter plate.
  • Page 25 SPEC CABLE ROUTING K Position the mark on the steel O Clamp the clutch cable and start- T Position the locking tie upward. band to forward. er cable with a holder. U Forward. L Fasten the wireharness with a Position the end of holder down band on the tool box plate.
  • Page 26 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. –18–...

  • Page 27: Periodic Checks And Adjustments

    INTRODUCTION/ PERIODIC MAINTENANCE AND LUBRICATION CHART EB300000 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. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
  • Page 28 S Correct if necessary. and switches S Adjust headlight beam if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: D The annual checks must be performed every year except if a 6,000 or 12,000 km maintenance is performed instead.

  • Page 29: Fuel Tank And Seats

    FUEL TANK AND SEATS FUEL TANK AND SEATS 23 Nm (2.3 mSkg) 7 Nm (0.7 mSkg) 7 Nm (0.7 mSkg) Order Job/Part Q’ty Remarks Fuel tank and seats removal Remove the parts in the order below. Passenger seat Passenger seat bracket Rider’s seat Fuel hose NOTE:...

  • Page 30: Chassis

    ADJUSTING THE REAR BRAKE CHASSIS EAS00110 ADJUSTING THE REAR BRAKE 1. Check: S brake pedal position (distance a from the top of the rider footrest to the top of the brake pedal) Out of specification ! Adjust. Brake pedal position (below the top of the rider footrest) 98.5 mm 2.

  • Page 31: Adjusting The Shift Pedal

    ADJUSTING THE SHIFT PEDAL/ CHECKING THE TIRES EAS00137 ADJUSTING THE SHIFT PEDAL NOTE: The shift pedal position is determined by the ad- justing bolt length a . 1. Measure: S adjusting the length a Incorrect ! Adjust. Adjusting bolt length 114.9 mm 2.
  • Page 32 CHECKING THE TIRES Basic weight: (with 288 kg (635 lb) oil and full fuel tank) Maximum 200 kg (441 lb) load*: Cold tire Front Rear pressure: 225 kPa 225 kPa Up to 90 kg (2.25 kg/cm (2.25 kg/cm (198 lb) load* 2.25 bar) 2.25 bar) 90 kg (198 lb)
  • Page 33 No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle. Front tire: Manufactur- Type...

  • Page 34: Electrical System

    ADJUSTING THE HEADLIGHT BEAM ELECTRICAL SYSTEM 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 35: Chassis

    CHAS FRONT AND REAR BRAKES CHASSIS FRONT AND REAR BRAKES FRONT BRAKE PADS 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. Retaining bolt Brake caliper Refer to “REPLACING THE FRONT Brake pads BRAKE PADS”.

  • Page 36: Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER 64 Nm (6.4 mSkg) 30 Nm (3.0 mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake master Remove the parts in the order listed. cylinder Brake fluid Drain Brake switch connector Disconnect...

  • Page 37: Front Brake Calipers

    CHAS FRONT AND REAR BRAKES FRONT BRAKE CALIPERS 6 Nm (0.6 mSkg) 30 Nm (3.0 mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. Brake fluid Drain Brake hose holder Union bolt Refer to “REMOVING/INSTALLING Copper washers...
  • Page 38 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Disassembling the front brake Remove the parts in the order listed. calipers Pad spring Brake caliper pistons Refer to “REMOVING THE FRONT Dust seals BRAKE CALIPERS”. Caliper piston seals Bleed screw For assembly, reverse the disassembly procedure.

  • Page 39: Front Fork

    CHAS FRONT FORK FRONT FORK 110 Nm (11.0 mSkg) 23 Nm (2.3 mSkg) 20 Nm (2.0 mSkg) 7 Nm (0.7 mSkg) 30 Nm (3.0 mSkg) 40 Nm (4.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the front fork Remove the parts in the order listed.
  • Page 40 CHAS FRONT FORK 110 Nm (11.0 mSkg) 23 Nm (2.3 mSkg) 20 Nm (2.0 mSkg) 7 Nm (0.7 mSkg) 30 Nm (3.0 mSkg) 40 Nm (4.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Upper fork covers Upper fork cover spacers Upper fork cover washers Front fork legs Lower fork covers...
  • Page 41 CHAS FRONT FORK 23 Nm (2.3 mSkg) 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Disassembling the front fork Disassemble the parts in the order listed. Cap bolt O-ring Spacer Spring seat Fork spring Refer to “DISASSEMBLING/ASSEM- Dust seal BLING THE FRONT FORK LEGS”. Oil seal clip Damper rod bolt Copper washer...
  • Page 42 CHAS FRONT FORK 23 Nm (2.3 mSkg) 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Seal spacer Outer tube bushing Refer to “DISASSEMBLING/ASSEM- Inner tube/inner tube bushing BLING THE FRONT FORK LEGS”. Oil lock piece Outer tube For assembly, reverse the disassembly procedure.

  • Page 43: Removing The Front Fork Legs

    CHAS FRONT FORK EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 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.

  • Page 44: Checking The Front Fork Legs

    CHAS FRONT FORK 4. Remove: S damper rod bolt S copper washer NOTE: While holding the damper rod with the T-handle 1 and damper rod holder 2 , loosen the damp- er rod bolt 3 . T-handle 90890-01326 Damper rod holder 90890-01460 5.

  • Page 45: Assembling The Front Fork Legs

    CHAS FRONT FORK 3. Check: S damper rod 1 Damage/wear ! Replace. Obstruction ! Blow out all of the oil pas- sages with compressed air. S oil lock piece 2 Damage ! Replace. WARNING When disassembling and assembling the front fork leg, do not allow any foreign mate- rial to enter the front fork.
  • Page 46 CHAS FRONT FORK 2. Lubricate: S inner tube’s outer surface Recommended lubricant Yamaha fork and shock oil 10 W or equivalent 3. Tighten: S damper rod bolt 1 30 Nm (3.0 mSkg) NOTE: While holding the damper rod with the T-handle 1 and damper rod holder 2 , tighten the damp- er rod bolt 3 .
  • Page 47 (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) 0.464 L Recommended oil Yamaha fork and shock oil 10W or equivalent CAUTION: S Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance.

  • Page 48: Installing The Front Fork Legs

    CHAS FRONT FORK NOTE: S Install the fork spring with its smaller pitch up- word. S Before installing the cap bolt, apply grease to the O-ring. S Temporarily tighten the cap bolt. INSTALLING THE FRONT FORK LEGS 1. Install: Lower fork covers 1 S Front forks Temporarily tighten the lower bracket pinch bolts.
  • Page 49 CHAS FRONT FORK 6. Install: S Upper bracket 1 S Steering stem nut 2 110 Nm (11.0 mSkg) 7. Tighten: S Upper bracket pinch bolts 20 Nm (2.0 mSkg) –41–...

  • Page 50: Steering Head

    CHAS STEERING HEAD STEERING HEAD 52 Nm (5.2 mSkg) 18 Nm (1.8 mSkg) 110 Nm (11.0 mSkg) 23 Nm (2.3 mSkg) Order Job/Part 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 51 CHAS STEERING HEAD 52 Nm (5.2 mSkg) 18 Nm (1.8 mSkg) 110 Nm (11.0 mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Rubber washer Lower ring nut Refer to “REMOVING THE LOWER Bearing cover BRACKET/INSTALLING THE Lower bracket STEERING HEAD”. Bearing (upper) Rubber seal Bearing (lower)

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