Yamaha XVS1100 2000 Manual

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the

XVS1100A. For complete service information procedures it is necessary to use this Supplementary

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

unauthorized use without the written

permission of Yamaha Motor Co., Ltd.

is expressly prohibited.

NOTE:

WARNING

CAUTION:

EAS00003 NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers

andtheirqualifiedmechanics.Itisnotpossibletoincludealltheknowledgeofamechanicinonemanu-

al. There fore, anyone who uses this book to perform maintenance and repairs on Yamaha Vehicles

shouldhaveabasicunderstandingofmechanicsandthetechniquestorepairthesetypesofvehicles.

Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-

hicle unsafe and unfit for use.

This model has been designed and manufactured to perform within certain specifications in regard to

performance and emissions. Proper service with the correct tools is necessary to ensure that the ve-

hicle will operate as designed. 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.

YamahaMotor Company, Ltd. is continuallystrivingtoimproveallofitsmodels.Modificationsandsig-

nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers

and will appear in future editions of this manual where applicable.

ThisServiceManualcontainsinformationregardingperiodicmaintenancetotheemissioncontrolsys-

tem. Please read this material carefully.

Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

FailuretofollowWARNINGinstructions couldresultinsevereinjury ordeathto

the motorcycle operator, a bystander or a person inspecting or repairing the

motorcycle.

ACAUTIONindicatesspecialprecautionsthatmustbetaken to avoid damage

to the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

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. It is located in the upper right corner of the page.

3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa-

nied by corresponding illustrations.

EXPLODED DIAGRAMS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each re-

moval and disassembly section.

1. An easy-to-see exploded diagram 4is provided for removal and disassembly jobs.

2. Numbers 5aregivenintheorderofthejobsintheexplodeddiagram.Anumberthatisenclosedby

a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks

6. The meanings of the symbol marks are given on the next page.

4. Ajobinstructionchart 7accompaniestheexplodeddiagram, providingtheorderofjobs, namesof

parts, notes in jobs, etc.

5. Forjobsrequiringmoreinformation,thestep-by-stepformatsupplements 8aregiveninadditionto

the exploded diagram and the job instruction chart.

1918

1615

1413

11 12

GEN

INFO SPEC

ENG

CARB

ELEC

CHAS

CHK

ADJ

TRBL

SHTG

EB003000

ILLUSTRATED SYMBOLS

The following symbols are not relevant to every

vehicle.

Symbols 1to 8indicate the subject of each

chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Engine

5Carburetor

6Chassis

7Electrical system

8Troubleshooting

Symbols 9to 16 indicate the following.

9Serviceable with engine mounted

10 Filling fluid

11 Lubricant

12 Special tool

13 Tightening torque

14 Wear limit, clearance

15 Engine speed

16 Electrical data

Symbols 17 to 22 intheexplodeddiagramsindi-

cate the types of lubricants and lubrication

points.

17 Engine oil

18 Gear oil

19 Molybdenum disulfide oil

20 Wheel bearing grease

21 Lithium soap base grease

22 Molybdenum disulfide grease

Symbols 23 to 24 intheexplodeddiagramsindi-

cate the following:

23 Apply locking agent (LOCTITE)

24 Replace the part

CONTENTS

SPECIFICATIONS

GENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION POINTS AND LUBRICANT TYPES 6. . . . . . . . . . . . . . . .

CHASSIS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION DIAGRAMS 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC MAINTENANCE AND LUBRICATION CHART 19. . . . . . . . . .

FUEL TANK AND SEATS 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE REAR BRAKE 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE SHIFT PEDAL 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE TIRES 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SYSTEM 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE HEADLIGHT BEAM 26. . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS

FRONT AND REAR BRAKES 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT BRAKE PADS 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR BRAKE MASTER CYLINDER 28. . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT BRAKE CALIPERS 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT FORK 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVING THE FRONT FORK LEGS 35. . . . . . . . . . . . . . . . . . . . . . . .

DISASSEMBLING THE FRONT FORK LEGS 35. . . . . . . . . . . . . . . . . .

CHECKING THE FRONT FORK LEGS 36. . . . . . . . . . . . . . . . . . . . . . . .

ASSEMBLING THE FRONT FORK LEGS 37. . . . . . . . . . . . . . . . . . . . . .

INSTALLING THE FRONT FORK LEGS 40. . . . . . . . . . . . . . . . . . . . . . .

STEERING HEAD 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

–1–

Temp. C

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard

Model code: XVS1100:5KS4 (For Europe)

5KS5 (For Australia)

Dimensions:

Overall length

Overall width

Overall height

Seat height

Wheelbase

Minimum ground clearance

Minimum turning radius

2,465 mm

945 mm

1,095 mm

710 mm

1,645 mm

145 mm

3,300 mm

Oil type or grade:

Engine oil API standard:

SAE 20W40 SE or SAE 10W 30 SE

ACEA standard:

G4 or G5

Chassis:

Frame type

Caster angle

Trail

Double cradle

33

132 mm

Tire:

Type

Size front

rear

Manufacturer front

rear

Type front

rear

With tube

130/90-16 67S

170/80-15M/C 77S

DUNLOP

D404F

D404G

Maximum load-except motorcycle: 200 kg

Tire pressure (cold tire):

0 90 kg (0 198 lb) load *

front

rear

90 kg (198 lb) Maximum load *

front

rear

225 kPa (2.25 kg/cm2, 2.25 bar)

250 kPa (2.50 kg/cm2, 2.5 bar)

* Load is the total weight of the cargo, rider,

passenger and accessories.

–2–

MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Item Standard Limit

Carburetor:

I. D. mark

Main jet (M.J)

Main air jet (M.A.J)

Jet needle (J.N)

Needle jet (N.J)

Pilot air jet (P.A.J.1)

(P.A.J.2)

Pilot outlet (P.O)

Pilot jet (P.J)

Bypass 1 (B.P.1)

Bypass 2 (B.P.2)

Bypass 3 (B.P.3)

Pilot screw (P.S)

Valve seat size (V.S)

Starter jet (G.S.1)

Starter jet (G.S.2)

Throttle valve size (Th.V)

Fuel level (F.L)

Engine idle speed

Intake vacuum

Engine oil temperature

5KS4 00

#1: #110, #2: #112.5

#55

#1, #2: 5DL44-53-3

P-0M

#63.8

#145

1.0

#17.5

0.8

1.2

#42.5

0.8

#125

45 mm

950 1,050 r/min

34.7 37.3 kPa (260 280 mmHg)

75 85C



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