Yamaha XVS1100(L) Manuals

Manuals and User Guides for Yamaha XVS1100(L). We have 2 Yamaha XVS1100(L) manuals available for free PDF download: Service Manual

Yamaha XVS1100(L) Service Manual (397 pages)

Brand: Yamaha | Category: Motorcycle | Size: 23.6 MB

Exploded Diagrams
3
Illustrated Symbols
4
Table of Contents
5
General Information
6
Motorcycle Identification
7
Vehicle Identification Number
7
Model Label
7
Important Information
8
Preparation for Removal Procedures
8
Replacement Parts
8
Gaskets, Oil Seals and O-Rings
8
Lock Washers/Plates and Cotter Pins
9
Bearings and Oil Seals
9
Circlips
9
Checking of Connections
10
Special Tools
11
Specifications
15
Maintenance Specifications
19
Cylinder Head Tightening Sequence
26
Crankcase Tightening Sequence
26
Tightening Torques
27
Chassis
29
Conversion Table
35
Lubrication Points and Lubricant Types
36
Lubrication Diagrams
38
Cable Routing
41
Periodic Checks and Adjustments
52
Periodic Maintenance Chart for Emission Control System
54
General Maintenance and Lubrication Chart
54
Fuel Tank and Seats
56
Engine
58
Adjusting the Valve Clearance
58
Adjusting the Valve Clearance/Synchronizing the Carburetors
61
Adjusting the Engine Idling Speed
63
Adjusting the Throttle Cable Free Play
64
Checking the Spark Plugs
65
Checking the Ignition Timing
66
Measuring the Compression Pressure
67
Checking the Engine Oil Level
69
Changing the Engine Oil
70
Adjusting the Clutch Cable Free Play
71
Cleaning the Air Filter Element
72
Checking the Carburetor Joint and Intake Manifold
73
Checking the Breather Hose
73
Checking the Exhaust System
74
Adjusting the Front Brake
75
Adjusting the Rear Brake
76
Checking the Brake Fluid Level
77
Adjusting the Rear Brake Light Switch
78
Checking the Brake Hoses
78
Bleeding the Hydraulic Brake System
79
Adjusting the Shift Pedal
80
Checking the Final Drive Oil Level
81
Changing the Final Drive Oil
81
Checking and Adjusting the Steering Head
82
Checking the Front Fork
84
Adjusting the Rear Shock Absorber Assembly
84
Checking the Tires
85
Front Tire
87
Rear Tire
87
Checking and Tightening the Spokes
88
Checking and Lubricating the Cables
89
Lubricating the Levers and Pedals
89
Lubricating the Sidestand
89
Lubricating the Rear Suspension
89
Electrical System
90
Checking and Charging the Battery
90
Charging Method Using a Variable-Current (Voltage) Type Charger
93
Charging Method Using a Constant-Voltage Type Charger
94
Checking the Fuses
96
Replacing the Headlight Bulb
97
Adjusting the Headlight Beam
98
Engine Removal
102
Mufflers, Brake Pedal and Side Cover
102
Leads, Shift Pedal and Clutch Cable
104
Engine Mounting Bolts
105
Installing the Engine
106
Cylinder Heads
107
Rear Cylinder Head
107
Front Cylinder Head
109
Removing the Cylinder Heads
111
Checking the Cylinder Heads
113
Checking the Timing Chain Tensioner
114
Installing the Cylinder Heads
114
Rocker Arms and Camshaft
117
Removing the Rocker Arms and Camshaft
118
Checking the Camshafts
118
Checking the Rocker Arms and Rocker Arm Shafts
119
Installing the Camshaft and Rocker Arms
120
Valves and Valve Springs
122
Removing the Valves
123
Checking the Valve Seats
125
Checking the Valve Springs
127
Installing the Valves
127
Cylinders and Pistons
129
Removing the Pistons
130
Checking the Cylinders and Pistons
130
Checking the Piston Rings
132
Installing the Pistons and Cylinders
133
Timing Gears
135
Removing the Timing Drive Gears
136
Checking Timing Chains, Camshaft Sprockets, and Timing Chain Guides
136
Front Cylinder
136
Rear Cylinder
136
Checking the Primary Drive
137
Installing the Timing Drive Gears
137
Right Crankcase Cover
139
Clutch Assembly
141
Removing the Clutch
143
Checking the Friction Plates
143
Checking the Pressure Plate
144
Checking the Clutch Boss
144
Checking the Clutch Push Rods
144
Checking the Clutch Plates
145
Checking the Clutch Spring and Clutch Spring Seat Plate
145
Checking the Clutch Housing
145
Installing the Clutch
146
Generator and Starter Clutch
148
Stator Coil and Pickup Coil
148
Removing the Generator
150
Checking the Starter Clutch
151
Installing the Generator
152
Shift Shaft
154
Checking the Shift Shaft
155
Checking the Stopper Lever
155
Installing the Shift Shaft
155
Oil Pump
156
Checking the Oil Pump
158
Checking the Oil Delivery Pipes
158
Checking the Oil Strainer
158
Assembling the Oil Pump
159
Crankshaft and Connecting Rods
160
Crankcase
160
Disassembling the Crankcase
162
Removing the Crankshaft Assembly
163
Removing the Connecting Rods
163
Checking the Crankshaft and Connecting Rods
163
Checking the Bearings and Oil Seals
166
Installing the Crankshaft
166
Assembling the Crankcase
167
Transmission
169
Checking the Shift Forks
170
Checking the Shift Drum Assembly
170
Checking the Transmission
171
Installing the Transmission
172
Middle Gear
173
Middle Drive Pinion Gear
173
Middle Driven Pinion Gear
174
Removing the Middle Drive Shaft Assembly
176
Disassembling the Middle Drive Shaft Assembly
176
Removing the Middle Driven Shaft Assembly
177
Checking the Middle Drive Shaft Assembly
177
Checking the Middle Driven Shaft Assembly
177
Assembling the Middle Drive Shaft Assembly
178
Assembling the Middle Driven Shaft Assembly
179
Installing the Middle Gear Assembly and Adjusting the Backlash
179
Installing the Universal Joint
181
Aligning the Middle Gear
182
Carburetion
184
Checking the Carburetors
188
Assembling the Carburetors
190
Installing the Carburetors
190
Measuring and Adjusting the Fuel Level
191
Checking and Adjusting the Throttle Position Sensor
192
Air Induction System
194
Air Cut-Off Valve
194
Air Induction System Inspection
195
Front Wheel and Brake Discs
198
Removing the Front Wheel
200
Checking the Front Wheel
200
Checking the Brake Discs
202
Installing the Front Wheel
204
Adjusting the Front Wheel Static Balance
205
Rear Wheel and Brake Disc
207
Muffler and Brake Caliper
207
Rear Wheel
208
Removing the Rear Wheel
210
Checking the Rear Wheel
210
Checking the Rear Wheel Drive Hub
211
Installing the Rear Wheel
211
Adjusting the Rear Wheel Static Balance
212
Front and Rear Brakes
213
Front Brake Pads
213
Rear Brake Pads
214
Replacing the Front Brake Pads
215
Replacing the Rear Brake Pads
217
Front Brake Master Cylinder
219
Rear Brake Master Cylinder
221
Removing the Front Brake Master Cylinder
223
Removing the Rear Brake Master Cylinder
223
Checking the Front and Rear Brake Master Cylinder
224
Installing the Front Brake Master Cylinder
225
Installing the Rear Brake Master Cylinder
227
Front Brake Calipers
229
Rear Brake Caliper
231
Removing the Front Brake Calipers
233
Removign the Rear Brake Caliper
233
Checking the Front and Rear Brake Calipers
234
Installing the Front Brake Calipers
235
Installing the Rear Brake Caliper
237
Front Fork
240
Removing the Front Fork Legs
243
Disassembling the Front Fork Legs
243
Checking the Front Fork Legs
244
Assembling the Front Fork Legs
245
Installing the Front Fork Legs
248
Handlebar
249
Removing the Handlebar
251
Checking the Handlebar
251
Installing the Handlebar
252
Steering Head
255
Removing the Lower Bracket
257
Checking the Steering Head
257
Installing the Steering Head
258
Rear Shock Absorber and Swingarm
260
Ride Side Cover and Battery Box
260
Left Side Cover and Tool Box
261
Handling the Rear Shock Absorber and Gas Cylinder
263
Disposing of a Rear Shock Absorber and Gas Cylinder
263
Removing the Rear Shock Absorber
264
Removing the Swingarm
265
Checking the Rear Shock Absorber and Gas Cylinder
266
Checking the Swingarm
266
Installing the Rear Shock Absorber
267
Installing the Swingarm
267
Shaft Drive Troubleshooting
269
Shaft Drive Troubleshooting Chart
271
Measuring the Ring Gear Backlash
273
Adjusting the Ring Gear Backlash
274
Final Drive Assembly and Drive Shaft
276
Final Gear
277
Disassembling the Final Drive Assembly
278
Removing and Installing the Ring Gear Bearings
279
Aligning the Final Drive Pinion Gear and Ping Gear
280
Checking the Drive Shaft
284
Installing the Drive Shaft
284
Electrical
286
Electrical Components
288
Switches
289
Checking Switch Continuity
289
Checking the Switches
290
Checking the Bulbs and Bulb Sockets
292
Types of Bulbs
292
Checking the Condition of the Bulbs
292
Checking the Condition of the Bulb Sockets
294
Ignition System
295
Circuit Diagram
295
Ignition System Troubleshooting
296
Electric Starting System
300
Starting Circuit Operation
301
Starting Starting System Troubleshooting
302
The Starter Motor Fails to Turn
302
Starter Motor
306
Checking the Starter Motor
307
Assembling the Starter Motor
308
Charging System Circuit Diagram
310
The Battery Is Not Being Charged
311
Lighting System Circuit Diagram
313
Checking the Lighting System
315
Signal System Circuit Diagram
318
Checking the Signaling System
321
Fuel Pump System Circuit Diagram
326
Fuel Pump Circuit Operation
327
The Fuel Pump Fails to Operate
328
Fuel Pump Test
330
Carburetor Heater System Circuit Diagram
331
The Carburetor Heater Fails to Operate
332
The Solenoid Valve Fails to Operate
335
Self-Diagnosis
337
Wiring Diagram
340
Troubleshooting
342
Starting Failure/Hard Starting
343
Poor Idle Speed Performance
344
Poor Medium-And-High Speed Performance
344
Faulty Gear Shifting
345
Clutch Slipping/Dragging
345
Overheating
346
Faulty Brake
346
Front Fork Oil Leakage and Front Fork Malfunction
346
Unstable Handling
347
Faulty Lighting and Signal Systems
347

Yamaha XVS1100(L) Service Manual (355 pages)

1999 Motorcycle

Brand: Yamaha | Category: Motorcycle | Size: 7.63 MB

Gen Info

8
- How to Use this Manual
  4
- Table of Contents
  8
- Chapter 1
  9
- General Information
  9
- Motorcycle Identification
  9
  - Vehicle Identification Number
    9
  - Model Label
    9
- Important Information
  10
  - Preparation for Removal Procedures
    10
  - Replacement Parts
    10
  - Gaskets, Oil Seals and O-Rings
    10
  - Lock Washers/Plates and Cotter Pins
    11
  - Bearings and Oil Seals
    11
  - Circlips
    11
- Checking of Connections
  12
- Special Tools
  13
2 Spec

18
- Chapter 2. Specifications
  19
- General Specifications
  19
- Maintenance Specifications
  22
  - Engine
    22
  - Chassis
    32
  - Electrical
    36
- Conversion Table
  38
- General Torque Specifications
  38
- Lubrication Points and Lubricant Types
  39
  - Engine
    39
  - Chassis
    40
- Lubrication Diagrams
  41
- Cable Routing
  45
Insp Adj

55
- Chapter 3 Periodic Inspections and Adjustments
  57
- Introduction
  57
- Periodic Maintenance/Lubrication Intervals
  57
- Fuel Tank and Seats
  59
  - Removal
    60
  - Installation
    60
- Engine
  61
- Chassis
  78
- Electrical System
  93
  - Checking and Charging the Battery
    93
  - Checking the Fuses
    99
  - Replacing the Headlight Bulb
    100
  - Adjusting the Headlight Beam
    101
Table of Contents

103
- Chapter 4 Engine
  106
- Engine Removal
  106
  - Mufflers, Brake Pedal and Side Cover
    106
  - Leads, Shift Pedal and Clutch Cable
    108
  - Engine Mounting Bolts
    109
  - Installing the Engine
    110
- Cylinder Heads
  111
  - Rear Cylinder Head
    111
  - Front Cylinder Head
    113
  - Removing the Cylinder Heads
    115
  - Checking the Cylinder Heads
    117
  - Checking the Timing Chain Tensioner
    118
  - Installing the Cylinder Heads
    118
- Rocker Arms and Camshaft
  121
- Valves and Valve Springs
  126
  - Removing the Valves
    127
  - Checking the Valves and Valve Guides
    127
  - Checking the Valve Seats
    129
  - Checking the Valve Springs
    131
  - Installing the Valves
    131
- Cylinders and Pistons
  133
  - Removing the Cylinders and Pistons
    133
  - Checking the Cylinders and Pistons
    134
  - Checking the Piston Rings
    136
  - Checking the Piston Pins
    137
  - Installing the Pistons and Cylinders
    137
- Timing Gears
  139
  - Removing the Timing Drive Gears
    140
  - Checking the Timing Chains, Camshaft
    140
  - Checking the Primary Drive
    141
  - Installing the Timing Drive Gears
    141
  - Right Crankcase Cover
    143
  - Clutch Assembly
    145
  - Removing the Clutch
    147
  - Checking the Friction Plates
    147
  - Checking the Pressure Plate
    148
  - Checking the Clutch Boss
    148
  - Checking the Clutch Push Rods
    148
  - Checking the Clutch Plates
    149
  - Checking the Clutch Spring and Clutch Spring Seat Plate
    149
  - Checking the Clutch Housing
    149
  - Installing the Clutch
    150
- Generator and Starter Clutch
  152
  - Stator Coil and Pickup Coil
    152
  - Generator and Starter Clutch
    153
  - Removing the Generator
    154
  - Checking the Starter Clutch
    155
  - Installing the Generator
    156
- Shift Shaft
  158
  - Checking the Shift Shaft
    159
  - Checking the Stopper Lever
    159
  - Installing the Shift Shaft
    159
- Oil Pump
  160
  - Checking the Oil Pump
    162
  - Checking the Oil Delivery Pipes
    162
  - Checking the Oil Strainer
    162
  - Crankshaft and Connecting Rods
    164
- Crankshaft and Connecting Rods Crankcase
  164
  - Disassembling the Crankcase
    166
  - Removing the Connecting Rods
    167
  - Checking the Crankshaft and Connecting Rods
    167
  - Checking the Bearing and Oil Seals
    170
  - Installing the Crankshaft
    170
  - Assembling the Crankcase
    171
- Transmission
  173
  - Checking the Shift Forks
    174
  - Checking the Shift Drum Assembly
    174
  - Checking the Transmission
    175
  - Installing the Transmission
    176
- Middle Gear
  177
5 Carb

189
- Carburetor
  190
- Chapter 5
  193
- Checking the Carburetors
  193
- Assembling the Carburetors
  195
- Installing the Carburetors
  195
- Measuring and Adjusting the Fuel Level
  196
- Checking and Adjusting the Throttle Position Sensor
  197
- Air Induction System (Ais)
  199
  - Air Induction
    199
  - Air Cut-Off Valve
    199
  - Air Induction System Inspection
    200
6 Chas

203
- Front Wheel and Brake Discs
  205
- Chapter 6
  207
- Checking the Front Wheel
  207
- Removing the Front Wheel
  207
- Checking the Brake Discs
  209
- Installing the Front Wheel
  211
- Adjusting the Front Wheel Static Balance
  212
- Rear Wheel and Brake Disc
  214
  - Muffler and Brake Caliper
    214
  - Rear Wheel
    215
  - Removing the Rear Wheel
    217
  - Checking the Rear Wheel
    217
  - Checking the Rear Wheel Drive Hub
    218
  - Installing the Rear Wheel
    218
  - Adjusting the Rear Wheel Static Balance
    219
- Front and Rear Brakes
  220
  - Front Brake Pads
    220
  - Rear Brake Pads
    221
  - Replacing the Front Brake Pads
    222
  - Replacing the Rear Brake Pads
    224
  - Front Brake Master Cylinder
    226
  - Rear Brake Master Cylinder
    228
  - Removing the Front Brake Master Cylinder
    230
  - Removing the Rear Brake Master Cylinder
    230
  - Checking the Front and Rear Brake Master Cylinder
    231
  - Installing the Front Brake Master Cylinder
    232
  - Installing the Rear Brake Master Cylinder
    234
  - Front Brake Calipers
    236
  - Rear Brake Caliper
    238
  - Removing the Front Brake Calipers
    240
  - Removing the Rear Brake Caliper
    240
  - Checking the Front and Rear Brake Calipers
    241
  - Installing the Front Brake Calipers
    242
  - Installing the Rear Brake Caliper
    244
- Front Fork
  247
  - Removing the Front Fork Legs
    250
  - Disassembly the Front Fork Legs
    250
  - Checking the Front Fork Legs
    251
  - Assembling the Front Fork Legs
    252
- Handlebar
  256
  - Removing the Handlebar
    258
  - Checking the Handlebar
    258
  - Installing the Handlebar
    259
- Steering Head
  262
  - Removing the Lower Bracket
    264
  - Checking the Steering Head
    264
  - Installing the Steering Head
    265
- Rear Shock Absorber and Swingarm
  267
  - Right Side Cover and Battery Box
    267
  - Left Side Cover and Tool Box
    268
  - Rear Shock Absorber and Swingarm
    268
    
    Disposing of a Rear Shock Absorber and Gas Cylinder
    270
  - Removing the Rear Shock Absorber
    271
  - Removing the Swingarm
    272
    
    Cylinder
    273
  - Checking the Swingarm
    273
  - Installing the Rear Shock Absorber
    274
  - Installing the Swingarm
    274
- Shaft Drive
  276
7 Elec

294
- Chapter 7 Electrical
  296
- Electrical Components
  296
- Switches
  297
  - Checking Switch Continuity
    297
- Checking the Switches
  298
- Checking the Bulbs and Bulb Sockets
  300
- Ignition System
  303
  - Circuit Diagram
    303
  - Troubleshooting
    304
- Electric Starting System
  308
  - Circuit Diagram
    308
  - Starting Circuit Operation
    309
  - Troubleshooting
    310
  - Starter Motor
    314
- Charging System
  318
  - Circuit Diagram
    318
  - Troubleshooting
    319
- Lighting System
  321
  - Circuit Diagram
    321
  - Troubleshooting
    322
  - Checking the Lighting System
    323
- Signal System
  326
  - Circuit Diagram
    326
  - Troubleshooting
    328
  - Checking the Signaling System
    329
  - Signaling System
    330
- Fuel Pump System
  334
  - Circuit Diagram
    334
  - Fuel Pump Circuit Operation
    335
  - Troubleshooting
    336
  - Fuel Pump Test
    338
- Carburetor Heater System
  339
  - Circuit Diagram
    339
  - Troubleshooting
    340
- Self-Diagnosis
  343
Trbl Shtg

347
- Troubleshooting
  347
- Chapter 8
  348
- Electrical System
  348
- Fuel System
  348
- Starting Failure/Hard Starting
  348
- Compression System
  349
- Poor Idle Speed Performance
  349
- Poor Idle Speed Performance Poor Idle Speed Performance
  349
- Poor Medium-And High-Speed Performance
  349
- Clutch Slipping/Dragging
  350
  - Clutch Slipping
    350
  - Clutch Dragging
    350
- Faulty Gear Shifting
  350
  - Hard Shifting
    350
  - Shift Pedal Does Not Move
    350
  - Jumps-Out-Of Gear
    350
- Faulty Brake
  351
- Faulty Brake Poor Braking Performance
  351
- Front Fork Oil Leakage and Front Fork Malfunction
  351
  - Malfunction
    351
  - Oil Leakage
    351
  - Unstable Handling
    352
- Overheating Overheating
  351
- Faulty Lighting and Signal Systems
  352
  - Headlight Does Not Light
    352
  - Bulb Burnt out
    352
  - Flasher Does Not Light
    352
  - Flasher Blinks Slowly
    352
  - Flasher Remains Lit
    352
  - Horn Does Not Sound
    352
- Unstable Handling Unstable Handling
  352

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Yamaha XVS1100(L) Service Manual (397 pages)

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Yamaha XVS1100(L) Service Manual (355 pages)

Table of Contents

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