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Yamaha XVS1100AWR Service Manual

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  • Page 2 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.
  • Page 3: Important Information

    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 4: How To Use This Manual

    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 5 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 6: Table Of Contents

    CHECKING THE SWITCHES ........XVS1100AWR(C)/XVS1100ATR(C) WIRING DIAGRAM...
  • Page 7: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code XVS1100: 5KSJ (For U.S.A.) 5KSK (For CAL) 5KSU (For U.S.A.) 5KSV (For CAL) Dimensions Overall length 2460 mm (96.9 in) Overall width 945 mm (37.2 in) Overall height 1,095 mm (43.1 in) Seat height 710 mm (28 in) Wheelbase...
  • Page 8: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Carburetor I.D. mark 5EL5 40 (U.S.A.) 5EL6 50 (CAL) Main jet (M.J) #1: #110, #2: #112.5 Main air jet (M.A.J) Jet needle (J.N) 5DL 43-53-1 Needle jet (N.J) P-0M Pilot air jet (P.A.J.1) #63.8 (P.A.J.2)
  • Page 9: Electrical

    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...
  • Page 10 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)
  • Page 11: Cable Routing

    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.
  • Page 12 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.
  • Page 13 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.
  • Page 14 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)
  • Page 15 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...
  • Page 16 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.
  • Page 17 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.
  • Page 18 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...
  • Page 19 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.
  • Page 20 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.
  • Page 21: Periodic Checks And Adjustments

    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...
  • Page 22 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.
  • Page 23: Chassis

    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...
  • Page 24 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–...
  • Page 25: Removing The Front Wheel

    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.
  • Page 26 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.
  • Page 27: Checking The Brake Discs

    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.
  • Page 28 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.
  • Page 29: Installing The Front Wheel

    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.
  • Page 30: Rear Wheel And Brake Disc

    CHAS REAR WHEEL AND BRAKE DISC REAR WHEEL AND BRAKE DISC MUFFLER AND BRAKE CALIPER 20 Nm (2.0mSkg, 14 ftSlb) 30 Nm (3.0mSkg, 22 ftSlb) 40 Nm (4.0mSkg, 29 ftSlb) 20 Nm (2.0mSkg, 14 ftSlb) 25 Nm (2.5mS kg, 18 ftSlb) Order Job name/Part name Q’ty...
  • Page 31: Rear 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...
  • Page 32 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...
  • Page 33: Removing The Rear Wheel

    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.
  • Page 34: Checking The Rear Wheel Drive Hub

    CHAS REAR WHEEL AND BRAKE DISC EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1. Check: S rear wheel drive hub Cracks/damage ! Replace. S rear wheel drive hub dampers Damage/wear ! Replace. EAS00572 INSTALLING THE REAR WHEEL 1. Lubricate: S drive shaft splines Recommended lubricant Molybdenum disulfide grease 2.
  • Page 35 CHAS REAR WHEEL AND BRAKE DISC f. Tighten the rear axle holder with specified torque. Rear axle end nut 23 Nm (2.3 mSkg, 17 ftSlb) g. Tighten the rear brake caliper bracket bolt with specified tightening torque. Brake caliper bracket bolt 40 Nm (4.0 mSkg, 29 ftSlb) h.
  • Page 36: Electrical

    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.
  • Page 37 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–...
  • Page 38 PRINTED IN U.S.A.
  • Page 39: Xvs1100Awr(C)/Xvs1100Atr(C) Wiring Diagram

    XVS1100AWR(C)/XVS1100ATR(C) WIRING DIAGRAM Pickup coil Neutral indicator light A.C. magneto High beam indicator light Rectifier/ regulator Neutral switch Main switch Trip switch Solenoid Turn signal relay Battery Horn Main fuse Rear brake light switch Starter relay Left handlebar switch Starter motor...

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