Table Of Contents - Yamaha V star 1100 Owner's Manual

Table of Contents

Warnings, Cautions And Notes1
Safety1
Handling Gasoline Safely1
General Information2
Serial Numbers2
Cleaning Parts2
Warning Labels2
Fasteners3
Threaded Fasteners3
Torque Specifications4
Self-Locking Fasteners4
Washers4
Cotter Pins4
Lubricants And Fluids5
Shop Supplies5
Snap Rings And E-Clips5
Brake Fluid6
Engine Oils6
Greases6
Cleaners, Degreasers And Solvents7
Gasket Sealant7
Applying Rtv Sealant7
Tools8
Gasket Remover8
Threadlocking Compound8
Screwdrivers8
Adjustable Wrenches9
Socket Wrenches, Ratchets And Handles9
Impact Driver10
Allen Wrenches10
Torque Wrenches10
Torque Adapters11
Pliers11
How To Measure Torque Wrench Effective Length12
Precision Measuring Tools13
Snap Ring Pliers13
Hammers13
Feeler Gauge14
Calipers14
Micrometers15
Reading15
Decimal Place Values15
Adjustment16
Standard Metric Micrometer16
Care17
Telescoping And Small Bore Gauges17
Dial Indicator17
Electrical System Fundamentals18
Cylinder Bore Gauge18
Compression Gauge18
Multimeter18
Basic Service Methods19
Voltage19
Resistance19
Amperage19
Removing Frozen Fasteners20
Removing Broken Fasteners20
Repairing Damaged Threads21
Stud Removal/Installation21
Removing Hoses21
Bearings21
Interference Fit23
Storage25
Seal Replacement25
Storage Area Selection25
Preparing The Motorcycle For Storage25
Returning The Motorcycle To Service26
Xvs1100 Serial Numbers26
Xvs1100A Serial Numbers27
Model Names And Numbers28
Vehicle Dimensions And Weight28
Decimal And Metric Equivalents29
General Torque Specifications29
Conversion Formulas30
Technical Abbreviations30
Metric Tap And Drill Size31
Troubleshooting33
Operating Requirements33
Starting The Engine33
Starting Preliminaries33
Four-Stroke Engine Operating Principles34
Engine Is Cold35
Engine Is Warm Or Hot35
Engine Is Flooded35
Starting Difficulties36
Spark Test36
Engine Is Difficult To Start37
Engine Performance38
Engine Does Not Crank38
Engine Will Not Idle38
Low Or Poor Engine Power38
Poor Idle Speed Or Low Speed Performance39
Poor High Speed Performance39
Engine Overheating39
Engine Runs Roughly39
Engine Noises40
Engine Lacks Acceleration40
Engine Backfires40
Engine Misfires During Acceleration40
Engine Lubrication41
Oil Consumption High Or Engine Smokes Excessively41
Excessive Engine Oil Leaks41
Black Smoke41
Engine Leakdown Test42
Clutch Lever Hard To Pull In42
Clutch Lever Soft Or Spongy42
Rough Clutch Operation42
Gearshift Linkage43
Transmission43
Clutch Slips43
Clutch Drag43
Final Drive44
Carburetor44
Jumps Out Of Gear44
Incorrect Shift Lever Operation44
Carburetor Heater45
Incorrect Fast Idle Speed45
Poor Fuel Mileage And Engine Performance45
Rich Fuel Mixture45
Fuel Pump46
Electrical Testing46
Fuel Pump Circuit Troubleshooting46
Preliminary Checks And Precautions46
Electrical Test Equipment47
Test Light Or Voltmeter47
Ammeter47
Self-Powered Test Light47
Ohmmeter48
Jumper Wire48
Basic Electric Test Procedures49
Voltage Testing49
Voltage Drop Test49
Electrical System50
Continuity Test50
Testing For A Short With A Self-Powered Test Light Or Ohmmeter50
Testing For A Short With A Test Light Or Voltmeter50
Electrical Component Replacement51
Charging System51
Ignition System51
Starting System51
Lighting System52
The Taillight Does Not Turn On52
Signal System52
The Horn Does Not Sound52
Front Suspension And Steering53
Front Suspension Noise53
Wheel Wobble/Vibration53
Hard Suspension (Front Fork)53
Brake Drag54
Brakes Grab54
Brake Squeal Or Chatter54
Soft Or Spongy Brake Lever Or Pedal54
Lubrication, Maintenance And Tune-Up55
Fuel Type55
Maintenance Intervals55
Cylinder Numbering56
Engine Rotation56
Tune-Up56
Air Filter Replacement56
Compression Test57
Ignition Timing58
Valve Clearance59
Spark Plugs Removal61
Gap And Installation62
Heat Range63
Normal Condition63
Spark Plugs Conditions64
Carbon Fouled64
Oil Fouled64
Gap Bridging64
Worn Out65
Preignition65
Engine Oil Level Check65
Engine Oil And Filter Change65
Fuel Line Inspection67
Fuel Filter Replacement67
Carburetor Synchronization67
Exhaust System Inspection67
Idle Speed Adjustment68
Throttle Cable Adjustment69
Control Cables70
Throttle Cable Lubrication70
Clutch Cable Lubrication70
Sidestand71
Clutch Cable Adjustment71
Shift Pedal Adjustment71
General Lubrication72
Battery72
Swing Arm Bearings72
Steering Stem Bearings72
Removal/Installation73
Inspection73
Charging74
New Battery Initialization75
Tire Pressure75
Tire Inspection75
Rim Inspection And Runout75
Front Suspension76
Steering Head76
Fork Oil Change76
Front Suspension Inspection76
Steering Head Inspection77
Rear Suspension Inspection77
Shock Absorber Spring Preload Adjustment78
Final Gearcase Oil Check78
Final Gearcase Oil Change78
Brake Hoses And Seals79
Brake Fluid Change79
Checking Brake Fluid Level79
Front Brake Pads79
Brake Pad Inspection80
Front Brake Lever Adjustment80
Rear Brake Pedal Adjustment80
Rear Brake Light Switch Adjustment81
Maintenance Schedule81
Tire Specifications83
Recommended Lubricants And Fluids83
Maintenance And Tune-Up Specifications84
Engine Top End86
Servicing Engine In The Frame86
Cylinder Head Covers86
Cylinder Head Removal87
Rear Cylinder Head88
Front Cylinder Head89
Cylinder Head Installation93
Camshaft Removal/Installation98
Camshaft Inspection98
Camshaft And Rocker Arms99
Rocker Arms Removal101
Rocker Arms Installation102
Rocker Arms Inspection102
Cam Chain And Cam Chain Drive Assembly103
Rear Cylinder Removal103
Rear Cylinder Installation104
Front Cylinder Removal/Installation106
Cam Chain, Chain Guides And Timing Gears107
Valves And Valve Components109
Valve Removal109
Valve Assembly109
Valve Lifter Bore109
Valve Installation111
Valve Guide Replacement113
Special Tools113
Valve Seat Inspection116
Valve Seat Reconditioning116
Valve Seat Lapping118
Cylinder Removal/Installation119
Cylinder And Piston120
Cylinder Inspection121
Piston And Piston Ring122
Piston Removal122
Piston Installation123
Piston Inspection124
Piston Clearance125
Piston Pin Inspection126
Piston Ring Removal And Inspection126
Piston Ring Installation128
General Engine Specifications129
Engine Top End Specifications129
Engine Top End Torque Specifications130
Engine Lower End132
Engine Removal133
Engine Installation137
Alternator Cover Removal/Installation138
Alternator Cover139
Stator And Pickup Coils141
Flywheel And Starter Clutch Removal141
Flywheel And Starter Clutch142
Flywheel And Starter Clutch Installation144
Flywheel Inspection145
Starter Clutch Operational Test146
Starter Clutch Disassembly/Assembly146
Starter Clutch Inspection146
Oil Pump Removal/Installation147
Oil Pump Disassembly/Inspection/Assembly148
Oil Pump149
Crankcase Disassembly153
Crankcase Assembly157
Crankcase Inspection159
Crankcase Bearing Replacement160
Right Crankcase Half160
Left Crankcase Half160
Crankshaft Removal/Installation161
Crankshaft Inspection161
Connecting Rods Removal/Installation162
Connecting Rod Inspection163
Connecting Rod Oil Clearance164
Connecting Rod Bearing Selection164
Break-In165
Engine Lower End Specifications165
Connecting Rod Bearing Insert Selection165
Engine Lower End Torque Specifications166
Clutch And Primary Drive Gear167
Clutch Cover Removal/Installation167
Clutch Cover168
Clutch Cover Inspection169
Clutch Removal169
Clutch170
Clutch Installation173
Clutch Inspection174
Clutch Release Mechanism Disassembly/Inspection176
Clutch Release Mechanism177
Clutch Cable Replacement178
Clutch Release Mechanism Assembly178
Primary Drive Gear Removal180
Clutch Specifications183
Clutch And Primary Drive Torque Specifications183
Transmission, Shift Mechanism And Middle Gear184
Shift Pedal/Footrest Assembly Removal/Installation184
External Shift Mechanism185
External Shift Mechanism Removal/Installation186
External Shift Mechanism Disassembly/Assembly187
External Shift Mechanism Inspection187
Internal Shift Mechanism Removal/Installation187
Internal Shift Mechanism Inspection187
Internal Shift Mechanism188
Transmission Removal/Installation189
Transmission Service Notes189
Snap Plug Installation189
Mainshaft Disassembly/Assembly190
Countershaft Disassembly191
Countershaft Assembly192
Transmission Inspection193
Middle Drive Shaft Assembly Removal/Installation194
Middle Drive Shaft Assembly195
Middle Driven Shaft Assembly Removal/Installation197
Middle Drive Shaft Assembly Inspection197
Middle Drive Shaft Shim Selection197
Middle Driven Shaft Assembly198
Checking Middle Gear Backlash201
Transmission And Gearshift Specifications201
Transmission, Shift Mechanism And Middle Gear Torque Specifications201
Air/Fuel, Exhaust And Emission Control Systems202
Fuel Tank Removal/Installation202
Fuel Tank And Seats203
Fuel Valve Removal/Installation204
Fuel Valve205
Air Intake206
Air Filter Housing Removal/Installation206
Air Filter Inspection208
Surge Tank Removal208
Surge Tank Installation209
Surge Tank Inspection209
Carburetor Operation210
Carburetor Removal/Installation210
Carburetor Separation212
Carburetor Joining213
Carburetor Disassembly213
Carburetor Assembly217
Carburetor Cleaning And Inspection219
Fuel Level221
Pilot Screw Removal/Installation221
Pilot Screw Inspection/Adjustment222
Throttle Position Sensor Testing223
Tps Connector223
Carburetor Heater Relay Test224
Carburetor Heater Relay Removal/Installation224
Throttle Position Sensor Adjustment224
Thermo Switch Test225
Throttle Cable Replacement226
Carburetor Heater Test226
Choke Cable Replacement227
Fuel Filter Removal/Installation228
Fuel Pump Removal/Installation229
Fuel Pump Operational Test229
Air Induction System Removal/Installation230
Fuel Pump Resistance Test230
Fuel Pump Relay Resistance Test230
Air Induction System231
Air Induction System Inspection232
Evaporative Emission Control Inspection233
Rollover Valve Removal/Installation233
Evaporative Emission Control System234
Canister Removal/Installation235
Solenoid Valve Testing235
Exhaust System Removal/Installation236
Carburetor Specifications238
Fuel And Emission System Electrical Specifications239
Air/Fuel And Exhaust System Specifications239
Air/Fuel And Exhaust System Torque Specifications239
Current Draw Test240
Stator Resistance Test241
Charging Voltage Test241
Voltage Regulator/Rectifier Removal/Installation242
Stator/Pickup Coil Assembly Removal/Installation242
Spark Plug Cap Resistance244
Ignition Coil244
Pickup Coil Resistance Test245
Spark Plug Removal/Installation245
Diode Continuity Test246
Ignitor Unit Testing246
Ignitor Unit Removal/Installation246
Starter Operational Test247
Starter Removal/Installation248
Starter Disassembly248
Starter Assembly251
Starter Inspection253
Starting Circuit Cutoff Relay254
Sccr Removal/Installation254
Sccr Continuity Test255
Sccr Diode Test (Starting Circuit)255
Sccr Diode Test (Ignition Circuit)255
Starter Relay Removal/Installation256
Starter Relay Continuity Test256
Headlight Bulb Replacement257
Headlight Housing Removal/Installation258
Headlight Adjustment258
1999-2000 Xvs1100 Models258
2001-On Xvs1100 Models258
Xvs1100A Models259
Headlight Voltage Test259
Meter Assembly Removal/Installation260
Meter Indicator Light Test261
Taillight/Brake Light Replacement262
Taillight/Brake Light Assembly Removal/Installation262
Meter Assembly263
Taillight (Xvs1100 Models)264
Taillight Test265
Brake Light Test266
Taillight Sub-Harness Connector266
Auxiliary Light Test266
Horn Removal/Installation267
Horn Circuit Test267
Turn Signal Bulb Replacement268
Turn Signals (Xvs1100 Models)268
Turn Signal Assembly Removal/Installation269
Front Turn Signal269
Turn Signals (Xvs1100A Models)269
Rear Turn Signal270
Turn Signal Flash Test270
Flasher Relay Removal/Installation271
Neutral Indicator Light Circuit Test272
Oil Lever Indicator Light272
Indicator Test272
Speed Sensor Removal/Installation273
Speed Sensor Test273
Oil Level Relay Removal/Installation273
Switches274
Left Handlebar Switch Replacement274
Horn Switch274
Right Handlebar Switch Replacement275
Main Switch Replacement276
Neutral Switch Replacement277
Sidestand Switch Replacement277
Clutch Switch Replacement277
Self-Diagnostic System278
Fuses278
Front Brake Switch Replacement278
Rear Brake Switch Replacement278
Wiring Connectors279
Main Fuse Removal279
Fuse Removal279
Fuse Testing279
Electrical System Specifications280
Replacement Bulbs280
Electrical System Torque Specifications281
Wheel And Tires282
Motorcycle Stand282
Brake Rotor Protection282
Wheel Inspection283
Bearing Removal285
Bearing Installation285
Front Wheel Removal287
Front Wheel Installation289
Front Hub Disassembly/Inspection/Assembly289
Rear Wheel Removal290
Rear Wheel Installation291
Rear Hub Preliminary Inspection293
Rear Hub Disassembly/Assembly294
Rear Hub Inspection295
Laced Wheel Service Component Condition295
Wheel Truing Preliminaries296
Wheel Truing Procedure296
Wheel Runout296
Wheel Balance297
Lateral Adjustment297
Radial Adjustment298
Tire Changing (Laced Wheels)299
Tire Changing (Case Wheels)302
Wheel Specifications305
Tire Inflation Pressure305
Wheel Torque Specifications306
Front Fork Removal307
Fork Assembly (Xvs 1100)308
Fork Assembly (Xvs1100A)309
Fork Leg312
Handlebar Removal/Installation320
Steering Head Removal322
Handlebar Inspection322
Steering Head Bearing Races326
Lower Bearing Replacement327
Front Suspension Specifications328
Front Suspension And Steering Torque Specifications328
Rear Suspension And Final Drive329
Shock Absorber Removal/Installation329
Shock Absorber And Swing Arm330
Suspension Linkage Removal/Installation331
Shock Absorber And Swing Arm Inspection331
Shock Absorber Disposal331
Suspension Linkage Inspection332
Swing Arm Removal333
Needle Bearing Replacement333
Installing Swing Arm Bearings333
Final Drive Assembly Removal/Installation336
Final Drive Assembly Inspection336
Final Drive Assembly337
Drive Shaft Removal/Installation337
Gear Lash Measurement339
Gear Lash Adjustment339
Shims And Thrust Washers340
Final Gearcase Disassembly340
Final Gearcase Assembly341
Gearcase Bearing Replacement Removal343
Calculated Shim Value Rounded Off344
Pinion Gear/Ring Gear Alignment344
Pinion Gear Shim Selection344
Ring Gear Shim Thickness Selection345
Rear Suspension And Final Drive Specifications345
Rear Suspension And Final Drive Torque Specifications346
Brakes347
Brake Service347
Preventing Brake Fluid Damage348
Brake Bleeding348
Manual Bleeding349
Vacuum Bleeding350
Brake Fluid Draining351
Brake Pads352
Front Brake Pad Replacement352
Rear Brake Pad Replacement354
Front Caliper Removal357
Front Brake Caliper358
Front Brake Caliper Installation359
Front Brake Caliper Disassembly/Assembly359
Front Brake Caliper Inspection360
Front Master Cylinder Removal/Installation361
Master Cylinder363
Rear Brake Caliper Removal366
Rear Brake Caliper367
Rear Brake Caliper Installation368
Rear Brake Caliper Disassembly368
Rear Brake Caliper Asasembly369
Rear Brake Master Cylinder Removal370
Rear Brake Master Cylinder Installation370
Rear Brake Master Cylinder Disassembly370
Rear Brake Master Cylinder Assembly370
Rear Master Cylinder371
Rear Master Cylinder Inspection373
Brake Pedal/Footrest Assembly Removal374
Brake Pedal/Footrest Assembly Installation375
Brake Disc Inspection375
Brake Disc Removal/Installation376
Front Brake Hose377
Brake Hose Replacement378
Front Brake Specifications379
Rear Brake Specifications379
Brake System Torque Specifications379
Frame380
Seats Removal/Installation380
Ignitor Panel Removal/Installation380
Left Side Cover Removal/Installation382
Toolbox Cover Removal/Installation382
Toolbox Panel Removal/Installation383
Battery Cover Removal/Installation383
Right Side Cover Removal/Installation385
Battery Box Removal/Installation385
Frame Neck Cover Removal/Installation386
Rider Floorboards Disassembly/Assembly387
Passenger Footpegs Removal/Installation388
Sidestand Removal/Installation388
Sidestand Disassembly/Assembly388
Passenger Footpegs388
Front Fender Removal/Installation389
Rear Fender Removal390
Front Fender390
Rear Fender391
Windshield (Silverado Models) Removal/Installation392
Frame And Body Torque Specifications393
Index394
1999-On Usa, California And Canada Models395
Wiring Diagrams396
1999-On Europe Models401
1999-On Australia Models403
Quick Reference Data405