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. First edition, November 2002 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
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.
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.
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...
SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Rear suspension Shock absorber travel 51 mm (2.01 in) Spring free length 181 mm (7.13 in) Fitting length 169 mm (6.65 in) Spring rate (K1) 132.3 N/mm (13.49 kg/mm, 755.43 lb/in) 0 X 51 mm (0 X 2.01 in) Stroke (K1) Optional spring...
SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Electric starter system Type Constant mesh type Starter motor: Model/manufacturer SM-13/MITSUBA Output 0.6 kW 0.025 X 0.035 Ω at 20_C (68_F) Armature coil resistance Brush overall length 12.5 mm (0.49 in) 4 mm (0.16 in) 7.65 X 10.01 N Brush spring pressure (780 X 1021 g, 27.51 X 36.01 OZ)
SPEC CABLE ROUTING EB206000 CABLE ROUTING Clutch cable Sidestand switch lead Heat protector Starter cable Neutral switch lead Speedometer lead Handlebar switch lead (left) Pickup coil lead Wire harness Handlebar switch lead (right) To engine Purge hose (carburetor to sole- Spark plug lead A.C.
SPEC CABLE ROUTING A Fasten the handlebar switch C Clamp the wire harness with the H Push the wire harness inside of lead (left and right) to the handle- hook of frame side. the side cover. bar with plastic locking tie and D When installing the pipe of I Push the sensing hose inside of cut the end of tie.
SPEC CABLE ROUTING M Fasten the lead with locking tie R When installing the fitting plate, near the side cover. do not pinch the each hoses and N Position the all connectors inside wireharness. of the connector cover. S When install the AI system push O Route the clutch cable through the wire harness to space of rear- the cable guide.
SPEC CABLE ROUTING Battery Breather hose Down tube Battery positive (+) lead Purge hose (carburetor to sole- Rear brake hose Starter motor positive (+) lead noid valve) (For CAL) Frame Speedometer lead Rear brake switch Stay 2 Fuel hose (fuel pump to carbure- Reserve hose Turn signal relay tor)
SPEC CABLE ROUTING Rectifire/ regulator and light (re- A Clamp the battery positive (+) D Route the harness and starter duce relay) lead lead to the battery with battery motor (+) lead, that are con- band. nected to the rectifier regulator B Connect the battery negative (–) and other equipment, by the out- lead and push it in to the space...
SPEC CABLE ROUTING 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 bat- regulator coupler sufficiently un- with joint, knob is out side of frame. tery negative (–) lead to the til the sound is heard.
SPEC CABLE ROUTING T Fasten the oil level sensor lead V Arrange the throttle position sen- X Push the light reduce lead and with a locking tie to battery box. sor connector, carburetor heater the terminal-coupler lead for the Fix to the battery box with the connector and thermo switch carburetor heater into the deep- band.
SPEC CABLE ROUTING Front brake hose Battery Fuel hose (fuel cock to fuel filter) Throttle cable Battery positive (+) lead Throttle position sensor lead Master cylinder reservoir hose Tail/ brake light lead Carburetor heater lead Spark plug lead Starter relay Tappet cover Purge hose (carburetor to sole- Starter motor positive (+) lead...
SPEC CABLE ROUTING 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 bat- band to forward. clip downword. tery box.
SPEC CABLE ROUTING O Route the igniter lead through the igniter plate hole to the wire- harness. 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 Check control system for damage. Evaporative emission S Replace if necessary. control system** * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. ** California only GENERAL MAINTENANCE AND LUBRICATION CHART...
S Lubricate the throttle grip housing and cable. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi (7,000 km) or 6 months.
CHAS FRONT WHEEL AND BRAKE DISCS 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 Removing the front wheel and brake...
CHAS FRONT WHEEL AND BRAKE DISCS Order Job name/Part name Q’ty Remarks Disassembling the front wheel Disassemble the parts in the order listed. Oil seals Bearings Collar For assembly, reverse the disassembly procedure. –18–...
CHAS FRONT WHEEL AND BRAKE DISCS 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.
CHAS FRONT WHEEL AND BRAKE DISCS 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.
CHAS FRONT WHEEL AND BRAKE DISCS 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.
CHAS FRONT WHEEL AND BRAKE DISCS 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.
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.
CHAS REAR WHEEL AND BRAKE DISC 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...
CHAS REAR WHEEL AND BRAKE DISC 62 Nm (6.2mSkg, 45 ftSlb) Order Job name/Part name Q’ty Remarks Rear wheel disassembly Remove the parts in the order listed. Disassembling the rear wheel Lock washers Clutch hub Dampers O-rings Oil seal Bearing Spacer Bearings For assembly, reverse the disassembly...
CHAS REAR WHEEL AND BRAKE DISC 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.
ELEC CHECKING THE SWITCHES ELECTRICAL EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the termi- nals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear ! Repair or replace the switch. Improperly connected ! Properly connect. Incorrect continuity reading ! Replace the switch.
ELEC CHECKING THE SWITCHES Clutch switch Engine stop switch Horn switch Start switch Dimmer switch Fuse Turn signal switch Rear brake switch Main switch Sidestand switch Front brake switch Neutral switch –31–...