Yamaha XVS1100(L) User manual

EB000000

XVS1100 (L)

SERVICE MANUAL

1998 by Yamaha Motor Co.,Ltd.

First edition, October 1998

unauthorized use without the written

permission of Yamaha Motor Co., Ltd.

is expressly prohibited.

NOTE:

CAUTION:

EB001000 NOTICE

This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and

their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual,

so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha mo-

torcycleshasabasicunderstandingofthemechanicalideasandtheproceduresofmotorcyclerepair.

Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe and

unfit for use.

YamahaMotorCompany,Ltd.iscontinuallystrivingtoimproveall its models.Modificationsandsignifi-

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

will appear in future editions of this manual where applicable.

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!

Failuretofollow WARNINGinstructions couldresultin severeinjuryordeathto

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

motorcycle.

ACAUTIONindicatesspecialprecautionsthatmust be taken 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 7accompanies theexplodeddiagram, providingtheorder ofjobs,names of

parts, notes in jobs, etc.

5. Forjobsrequiringmoreinformation,thestep-by-stepformatsupplements 8aregiveninadditionto

the exploded diagram and the job instruction chart.

15 16 17

19 20

22 23

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols 1to 9are printed on the

toprightofeachpageandindicatethesubjectof

each chapter.

1General information

2Specifications

3Periodic inspections and adjustments

4Engine

5Cooling system

6Carburetion

7Chassis

8Electrical

9Troubleshooting

Illustrated symbols 10 to 17 are used to identify

the specifications appearing in the text.

10 Can be serviced with engine mounted

11 Filling fluid

12 Lubricant

13 Special tool

14 Torque

15 Wear limit, clearance

16 Engine speed

17 Ω, V, A

Illustratedsymbols 18 to 23 intheexplodeddia-

grams indicate the types of lubricants and lu-

brication points.

18 Apply engine oil

19 Apply gear oil

20 Apply molybdenum disulfide oil

21 Apply wheel bearing grease

22 Apply lightweight lithium-soap base grease

23 Apply molybdenum disulfide grease

Illustratedsymbols 24 to 25 intheexplodeddia-

grams indicate where to apply locking agent 24

and when to install new parts 25 .

24 Apply locking agent (LOCTITE)

25 Replace

E004000

INSP

ADJ

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTION AND

ADJUSTMENTS

ENGINE OVERHAUL

CARBURETION

CHASSIS

ELECTRICAL

TROUBLESHOOTING

GEN

INFO 1

SPEC 2

ENG 4

CARB 5

CHAS 6

ELEC 7

TRBL

SHTG 8

CHAPTER TITLES

GEN

INFO

GEN

INFO

CHAPTER 1.

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . .

MODEL LABEL 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IMPORTANT INFORMATION 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREPARATION FOR REMOVAL PROCEDURES 1-2. . . . . . . . . . . . . . .

REPLACEMENT PARTS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GASKETS, OIL SEALS AND O-RINGS 1-2. . . . . . . . . . . . . . . . . . . . . . . .

LOCK WASHERS/PLATES AND COTTER PINS 1-3. . . . . . . . . . . . . . . .

BEARINGS AND OIL SEALS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCLIPS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING OF CONNECTIONS 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

MOTORCYCLE IDENTIFICATION GEN

INFO

EB100000

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

EB100010

VEHICLE IDENTIFICATION NUMBER

Thevehicleidentificationnumber 1isstamped

into the right side of the steering head.

MODEL LABEL

The model label 1is affixed to the frame. This

information will be needed to order spare parts.

1-2

IMPORTANT INFORMATION GEN

INFO

EB101000

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL PROCE-

DURES

1. Remove all dirt, mud, dust and foreign mate-

rial before removal and disassembly.

2. Use proper tools and cleaning equipment.

Refer to the “SPECIAL TOOLS” section.

3. When disassembling the machine, always

keep mated parts together. This includes

gears,cylinders, pistons and other partsthat

have been “mated” through normal wear.

Mated parts must always be reused or re-

placed as an assembly.

4. During machine disassembly, clean all parts

and place them in trays in the order of disas-

sembly. This will speed up assembly and al-

low for the correct installation of all parts.

5. Keep all parts away from any source of fire.

EB101010

REPLACEMENT PARTS

1. Use only genuine Yamaha parts for all re-

placements. Use oil and grease recom-

mended by Yamaha for all lubrication jobs.

Other brands may be similar in function and

appearance, but inferior in quality.

EB101020

GASKETS, OIL SEALS AND O-RINGS

1. Replaceallgaskets,seals and O-rings when

overhauling the engine. All gasket surfaces,

oil seal lips and O-rings must be cleaned.

2. Properly oil all mating parts and bearings

during reassembly. Apply grease to the oil

seal lips.

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