Downloaded from www.Manualslib.

com manuals search engine

 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.

XVS1100L/XVS1100LC SERVICE MANUAL: LIT-11616-12-63 (5EL-28197-E0)

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.

Downloaded from www.Manualslib.com manuals search engine

 EAS00003

NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu-
al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha Vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
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.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
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.

This Service Manual contains information regarding periodic maintenance to the emission control sys-
tem. Please read this material carefully.

NOTE:
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!

Failure to follow WARNING instructions could result in severe injury or death to

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

CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.

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

Downloaded from www.Manualslib.com manuals search engine

 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 4 is provided for removal and disassembly jobs.
2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed by
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. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition to
the exploded diagram and the job instruction chart.

2 1 6

Downloaded from www.Manualslib.com manuals search engine

 EB003000

1 2 ILLUSTRATED SYMBOLS
The following symbols are not relevant to every
GEN
SPEC vehicle.
INFO Symbols 1 to 8 indicate the subject of each
chapter.
3 4 1 General information
CHK 2 Specifications
ADJ ENG 3 Periodic checks and adjustments
4 Engine
5 6 5 Carburetor
6 Chassis
7 Electrical system
CARB CHAS 8 Troubleshooting

7 8

ELEC TRBL
SHTG
Symbols 9 to 16 indicate the following.
9 10
9 Serviceable with engine mounted
10 Filling fluid
11 Lubricant
12 Special tool
13 Tightening torque
11 12
14 Wear limit, clearance
15 Engine speed
16 Electrical data

13 14

15 16

Symbols 17 to 22 in the exploded diagrams indi-

17 18 19 cate the types of lubricants and lubrication
points.
17 Engine oil
18 Gear oil
19 Molybdenum disulfide oil
20 21 22
20 Wheel bearing grease
21 Lithium soap base grease
22 Molybdenum disulfide grease

23 24 Symbols 23 to 24 in the exploded diagrams indi-

cate the following:
23 Apply locking agent (LOCTITER)
24 Replace the part

Downloaded from www.Manualslib.com manuals search engine

 CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
GENERAL MAINTENANCE AND LUBRICATION CHART . . . . . . . . . 15

CHASSIS
FRONT WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CHECKING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CHECKING THE BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REAR WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
MUFFLER AND BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CHECKING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CHECKING THE REAR WHEEL DRIVE HUB . . . . . . . . . . . . . . . . . 28
INSTALLING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

ELECTRICAL
CHECKING THE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

XVS1100AWR(C)/XVS1100ATR(C) WIRING DIAGRAM

Downloaded from www.Manualslib.com manuals search engine

 GENERAL SPECIFICATIONS SPEC

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 1645 mm (64.8 in)
Minimum ground clearance 140 mm (5.5 in)
Minimum turning radius 3400 mm (133.9 in)
Basic weight
With oil and a full fuel tank 285 kg (628 lb)
Tire
Type Tubeless
Size front 130/90-16M/C 67S
rear 170/80-15M/C 77S
Manufacturer front BRIDGESTONE/DUNLOP
rear BRIDGESTONE/DUNLOP
Type front EXEDRA G703/D404F
rear EXEDRA G702/D404G
Tire pressure (cold tire)
0 X 90 kg (0 X 198 lb) load*
front 225 kPa (2.25 kg/cm2, 32.6 psi)
rear 250 kPa (2.5 kg/cm2, 36.3 psi)
90 kg (198 lb) X Maximum load*
front 225 kPa (2.25 kg/cm2, 32.6 psi)
rear 250 kPa (2.5 kg/cm2, 36.3 psi)
* Load is the total weight of the cargo, rider,
passenger and accessories.

–1–
Downloaded from www.Manualslib.com manuals search engine
 MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONS
ENGINE

Item Standard Limit

Carburetor
I.D. mark 5EL5 40 (U.S.A.) SSS
5EL6 50 (CAL) SSS
Main jet (M.J) #1: #110, #2: #112.5 SSS
Main air jet (M.A.J) #55 SSS
Jet needle (J.N) 5DL 43-53-1 SSS
Needle jet (N.J) P-0M SSS
Pilot air jet (P.A.J.1) #63.8 SSS
(P.A.J.2) #145 SSS
Pilot outlet (P.O) 1.0 SSS
Pilot jet (P.J) #17.5 SSS
Bypass 1 (B.P.1) 0.8 SSS
Bypass 2 (B.P.2) 0.8 SSS
Bypass 3 (B.P.3) 0.8 SSS
Valve seat size (V.S) 1.2 SSS
Starter jet (G.S.1) #42.5 SSS
Starter jet (G.S.2) 0.8 SSS
Throttle valve size (Th.V) #125 SSS
Fuel level (above the line on 4 X 5 mm (0.16 X 0.20 in) SSS
the float chamber) (F.L)
Engine idle speed 950 X 1,050 r/min SSS
Intake vacuum 34.7 X 37.3 kPa (260 X 280 mmHg) SSS
Engine oil temperature 75 X 85_C (167 X 185_F) SSS
Fuel pump
Type Electrical type SSS
Model/manufacturer UC-Z61B/MITSUBISHI SSS
Consumption amperage <max> 0.8 A SSS
Output pressure 12 kPa (0.12 kg/cm2,1.7 psi) SSS
CHASSIS

Item Standard Limit

Front suspension
Front fork travel 140 mm (5.51 in) SSS
Fork spring free length 371.9 mm (14.64 in) 350 mm
(13.78 in)
Fitting length 334.4 mm (13.17 in) SSS
Collar length 183 mm (7.20 in) SSS
Spring rate (K1) 4.41 N/mm (0.45 kg/mm, 25.18 lb/in) SSS
(K2) 6.37 N/mm (0.65 kg/mm, 36.37 lb/in) SSS
Stroke (K1) 0 X 77.5 mm (0 X 3.05 in) SSS
(K2) 77.5 X 140 mm (3.05 X 5.51 in) SSS
Optional spring No SSS
Oil capacity 0.483 L (483 cm3, 17.01 Imp OZ, SSS
16.34 US OZ)
Oil level 104 mm (4.09 in) SSS
Oil grade Fork oil 10WT or equivalent SSS

–2–
Downloaded from www.Manualslib.com manuals search engine
 MAINTENANCE SPECIFICATIONS SPEC

Item Standard Limit

Rear suspension
Shock absorber travel 51 mm (2.01 in) SSS
Spring free length 181 mm (7.13 in) SSS
Fitting length 169 mm (6.65 in) SSS
Spring rate (K1) 132.3 N/mm (13.49 kg/mm, 755.43 lb/in) SSS
Stroke (K1) 0 X 51 mm (0 X 2.01 in) SSS
Optional spring No SSS
Front wheel
Type Cast wheel SSS
Rim size 16M/C MT 3.00 SSS
Rim material Aluminum SSS
Rim runout limit radial SSS 1.0 mm
(0.04 in)
lateral SSS 0.5 mm
(0.02 in)
Rear wheel
Type Cast wheel SSS
Rim size 15M/C MT4.50 SSS
Rim material Aluminum SSS
Rim runout limit radial SSS 1.0 mm
(0.04 in)
lateral SSS 0.5 mm
(0.02 in)
ELECTRICAL

Item Standard Limit

T.C.I.
Pickup coil resistance/color 189 X 231 Ω at 20_C (68_F)/Gray – Black SSS
T.C.I. unit model/manufacturer J4T142/MITSUBISHI SSS
Rectifier/regulator
Regulator type Semi-conductor, short-circuit type SSS
Model/manufacturer SH678-11/SHINDENGEN SSS
No load regulated voltage 14.1 X 14.9 V SSS
Rectifier capacity 22 A SSS
Withstand voltage 200 V SSS

–3–
Downloaded from www.Manualslib.com manuals search engine
 MAINTENANCE SPECIFICATIONS SPEC

Item Standard Limit

Electric starter system
Type Constant mesh type SSS
Starter motor:
Model/manufacturer SM-13/MITSUBA SSS
Output 0.6 kW SSS
Armature coil resistance 0.025 X 0.035 Ω at 20_C (68_F) SSS
Brush overall length 12.5 mm (0.49 in) 4 mm
(0.16 in)
Brush spring pressure 7.65 X 10.01 N SSS
(780 X 1021 g, 27.51 X 36.01 OZ)
Commutator diameter 28 mm (1.10 in) 27 mm
(1.06 in)
Mica undercut 0.7 mm (0.03 in) SSS
Starter relay:
Model/manufacturer MS5F-421/JIDECO SSS
Amperage rating 180 A SSS
Starting circuit cut-off relay
Model/manufacturer G8R-30Y-U/OMRON SSS
Coil resistance 202.5 X 247.5 Ω at 20_C (68_F)
Thermostat switch
Model/manufacturer 5FU/NIPPON THERMOSTAT SSS

–4–
Downloaded from www.Manualslib.com manuals search engine
 CABLE ROUTING SPEC
EB206000

CABLE ROUTING
1 Clutch cable 13 Sidestand switch lead 23 Heat protector
2 Starter cable 14 Neutral switch lead 24 Speedometer lead
3 Handlebar switch lead (left) 15 Pickup coil lead 25 Wire harness
4 Handlebar switch lead (right) 16 To engine 26 Purge hose (carburetor to sole-
5 Spark plug lead 17 A.C. magneto lead noid valve) (for CAL)
6 Throttle cable 18 Ventilation hose 27 Fitting plate
7 Fuel hose (fuel cock to filter) 19 Sensing hose (AI system to car- 28 Fuel hose (inlet) (fuel filter to fuel
8 Fuel breather hose (fuel tank roll buretor joint) pump)
over valve) (for CAL) 20 Fuel hose (fuel pump to carbure- 29 Fuel hose (outlet) (fuel pump to
9 Fuse box tor) carburetor)
10 Alarm connector 21 Clip 30 Alarm connector lead
11 Fuel pump lead 22 Brake hose 31 Wire harness
12 Speed sensor lead

–5–
Downloaded from www.Manualslib.com manuals search engine
 CABLE ROUTING SPEC
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. throttle cable press it inside. the tool box plate and not bend
B Lay out the throttle and starter E Clamp the fuel hoses to the the sensing hose.
cables in three rows and secure frame with the clamp. J Through the wire harness of so-
them with a clip. (Two points at F Cross the fuel hose (fuel cock lenoid valve between AIS duct
the front and rear.) Care should side) and fuel hose (carburetor and fuel hose (for CAL).
be taken at this time so that the side) between guide of frame K Fasten the alarm lead with a plas-
clip does not fall to the outside and clamp. (carburetor side is tic band on the tool box plate.
against the vertical face of the upper) L Fasten the sidestand switch lead
vehicle. Point the opening part of G When connecting the sensing to the bracket of tool box plate
the clip to the inside of the ve- hose (carburetor joint to AI sys- with plastic locking tie.
hicle. tem) with a nozzle.

–6–
Downloaded from www.Manualslib.com manuals search engine
 CABLE ROUTING SPEC
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. side.
P Fasten the handlebar switch
leads (left and right) under the
handle crown with a plastic
band. Set the band at four
notches and install it no slacking.
Q Route the each hoses through the
frame guide and do not pinch it.

–7–
Downloaded from www.Manualslib.com manuals search engine
 CABLE ROUTING SPEC
1 Battery 13 Breather hose 25 Down tube
2 Battery positive (+) lead 14 Purge hose (carburetor to sole- 26 Rear brake hose
3 Starter motor positive (+) lead noid valve) (For CAL) 27 Frame
4 Speedometer lead 15 Rear brake switch 28 Stay 2
5 Fuel hose (fuel pump to carbure- 16 Reserve hose 29 Turn signal relay
tor) 17 Air filter drain hose 30 Handlebar switch lead (left)
6 Spark plug lead 18 Delay relay 31 Silencer
7 Main switch lead 19 Battery negative (–) lead 32 Throttle position sensor lead
8 Throttle cable 20 Oil level switch lead 33 Carburetor heater lead
9 Front brake hose 21 Rear brake light switch lead 34 Thermo switch lead
10 Handlebar switch lead (right) 22 Light reduce relay 35 Horn
11 Headlight lead 23 Rectifier/ regulator
12 Ignition coil 24 Stay 1

–8–
Downloaded from www.Manualslib.com manuals search engine
 CABLE ROUTING SPEC
36 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 side of the frame side bracket
between battery box and battery. and then secure it by passing the
C Push the wireharness into the band through the weight saving
space between frame and start- hole of the bracket. (The secur-
er motor relay. ing point should be within 0 to 10
mm (0 to 0.39 in) right above the
junction point of harness side
leads that are connected with the
battery (–) lead.)

–9–
Downloaded from www.Manualslib.com manuals search engine
 CABLE ROUTING SPEC
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.
F Route the front turn signal / posi- frame with a plastic locking tie. P To rear brake.
tion light lead and headlight lead K 70 mm (2.76 in) Q Fasten the rear brake switch
through the rear of headlight L Fasten the rear brake switch lead lead with a band to down tube.
body hole. and master cylinder reservoir (four point)
G Connect the ignition coil lead at hose to the down tube with a plas- R Cutting part at the edge of the
red tape to the right side. tic locking tie, and cut the end of band.
H Knob of clip is rearside of body. locking tie and position is inside of S 30_ X 45_
I Fasten the rear brake switch frame.
lead to the rear brake switch M 20 mm (0.79 in) (from bead end.)
bracket with a plastic locking tie N Locate the band to forward of
and cut of the end, inside of frame. down tube.

–10–
Downloaded from www.Manualslib.com manuals search engine
 CABLE ROUTING SPEC
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. To fix, align the band to the connector between the starting est position in the groove of the
bottom of the box’s hole while fix- circuit cut off relay and high ten- battery box.
ing the lead to the back of the box sion code.
(inside the body). The cutting part W Secure to the battery box with
at the edge of the band comes to the band, cut the surplus section
the front side of the body. and then point the locking sec-
U Clamp the handlebar switch lead tion to the regulator side.
(right) to the frame with a holder.
The part to open and shut is out-
side of the body.

–11–
Downloaded from www.Manualslib.com manuals search engine
 CABLE ROUTING SPEC
1 Front brake hose 12 Battery 23 Fuel hose (fuel cock to fuel filter)
2 Throttle cable 13 Battery positive (+) lead 24 Throttle position sensor lead
3 Master cylinder reservoir hose 14 Tail / brake light lead 25 Carburetor heater lead
4 Spark plug lead 15 Starter relay 26 Tappet cover
5 Purge hose (carburetor to sole- 16 Starter motor positive (+) lead 27 Clutch cable
noid valve) (for CAL) 17 Fuel tank breather hose (fuel 28 Thermo switch lead
6 Rear brake light switch lead tank to roll over valve) (for CAL) 29 Wire harness
7 Rear brake hose 18 Fuel pump outlet hose 30 Frame
8 Fuel hose (fuel pump to carbure- 19 Fuel pump inlet hose 31 Igniter unit
tor) 20 Ventilation hose 32 Igniter plate
9 Delay relay 21 Starter cable 33 Fuel filter
10 Battery negative (–) lead 22 Sensing hose (AI system to car- 34 Tool box plate
11 Battery negative (–) lead con- buretor joint) 35 Speedometer lead connecter
nector

–12–
Downloaded from www.Manualslib.com manuals search engine
 CABLE ROUTING SPEC
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. K Fasten the wire harness with a
B Route the rear brake switch lead G Secure the igniter unit lead and band on the tool box plate.
under the master cylinder reser- tail brake light lead to the frame L Fasten the wire harness to the
vor hose. with a clamp. Point the frame with a plastic locking tie.
C Position the band end of right open / close section to the upper Position the locking tie front of
side bracket. side of the vehicle. the holder.
D Position the steel band end to H To the rear fender. M Route the wire harness outside
forward. I Connect the wire harness to the of the guide on the frame.
E Position the steel band end to igniter unit through the hole of ig- N Clamp the clutch cable and start-
right side. niter plate. er cable with a holder.
Position the end of holder down
side.

–13–
Downloaded from www.Manualslib.com manuals search engine
 CABLE ROUTING SPEC
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 Position the locking tie upward.
T Forward.

–14–
Downloaded from www.Manualslib.com manuals search engine
 INTRODUCTION/PERIODIC MAINTENANCE CHART FOR
THE EMISSION CONTROL SYSTEM / GENERAL MAINTENANCE AND CHK
LUBRICATION CHART ADJ
EAS00036

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM
INITIAL ODOMETER READINGS
8,000 mi
600 mi 4,000mi 12,000 mi 16,000 mi 20,000 mi
NO. ITEM REMARKS (13,000
(1,000 km) (7,000 km) (19,000 km) (25,000 km) (31,000 km)
km)
or or or or or
or
1 month 6 months 18 months 24 months 30 months
12 months
S Check and adjust valve clearance when
1 * Valve clearance Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ
engine is cold.
S Check condition.
S Adjust gap and clean.
2 Spark plugs S Replace at 8,000 mi (13,000 km) or 12 Ǹ Replace. Ǹ Replace. Ǹ
months and thereafter every 8,000 mi
(13,000 km) or 12 months.
S Check ventilation hose for cracks or dam-
Crankcase ventilation
3 * age. Ǹ Ǹ Ǹ Ǹ Ǹ
system
S Replace if necessary.
S Check fuel hoses for cracks or damage.
4 * Fuel line Ǹ Ǹ Ǹ Ǹ Ǹ
S Replace if necessary.
S Replace initial 20,000 mi (31,000 km) and
5 * Fuel filter Ǹ
thereafter every 20,000 mi (31,000 km).
S Check for leakage.
6 * Exhaust system S Tighten if necessary. Ǹ Ǹ Ǹ Ǹ Ǹ
S Replace gasket(s) if necessary.
Carburetor
7 * S Adjust synchronization of carburetors. Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ
synchronization
S Check and adjust engine idle speed.
8 * Idle speed Ǹ Ǹ Ǹ Ǹ Ǹ
S Adjust cable free play.
Evaporative emission S Check control system for damage.
9 * Ǹ Ǹ
control system** S Replace if necessary.

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the
service.
** California only
GENERAL MAINTENANCE AND LUBRICATION CHART
INITIAL ODOMETER READINGS
600 mi 4,000mi 8,000 mi 12,000 mi 16,000 mi 20,000 mi
NO. ITEM REMARKS (1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or or or or or or
1 month 6 months 12 months 18 months 24 months 30 months
S Replace.
1 Engine oil Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ
S Warm engine before draining.
Engine oil filter
2 * S Replace. Ǹ Ǹ Ǹ
element
3 Air filter element S Clean or replace if necessary. Ǹ Ǹ Ǹ Ǹ Ǹ
S Check operation fluid level, and fluid leakage.
4 * Brake system S Correct accordingly. Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ
S Replace pads if necessary.
S Check operation.
5 * Clutch Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ
S Adjust or replace cable.
S Check oil level and leakage.
S Replace at initial 600 mi (1,000 km) or 1 month
6 * Final gear oil and thereafter every 18,000 mi (25,000 km) or Replace. Check. Ǹ
24 months.
S Hypoid gear oil SAE 80 (API GL4)
S Apply chain, lube thoroughly.
Control and me-
7 * S Yamaha Chain and Cable Lube or engine oil Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ
ter cables
SAE 10W-30 (API SE)

–15–
Downloaded from www.Manualslib.com manuals search engine
 CHK
GENERAL MAINTENANCE AND LUBRICATION CHART ADJ
INITIAL ODOMETER READINGS
600 mi 4,000mi 8,000 mi 12,000 mi 16,000 mi 20,000 mi
NO. ITEM REMARKS (1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or or or or or or
1 month 6 months 12 months 18 months 24 months 30 months
S Check swingarm pivot for play.
S Correct if necessary.
Swingarm pivot
8 * S Moderately repack every 16,000 mi (25,000 Repack.
shaft
km) or 24 months with lithium-soap-based
grease.
Rear suspension S Check operation.
9 * Ǹ Ǹ
link pivots S Correct if necessary.
Brake and clutch S Apply chain lube thoroughly.
10 Ǹ Ǹ Ǹ Ǹ Ǹ
lever pivot shafts S Lithium-soap-based grease.
Brake pedal and S Apply chain lube thoroughly.
11 Ǹ Ǹ Ǹ Ǹ Ǹ
shift pedal shafts S Lithium-soap-based grease.
S Check operation.
12 Sidestand pivot S Lubricate and repair if necessary. Ǹ Ǹ Ǹ Ǹ Ǹ
S Lithium-soap-based grease.
S Check operation and for oil leakage.
13 * Front fork Ǹ Ǹ Ǹ Ǹ Ǹ
S Correct accordingly.
S Check bearing play and steering for smooth
operation.
S Correct if necessary.
14 * Steering bearings Ǹ Ǹ Ǹ Repack. Ǹ
S Moderately repack every 18,000 mi (25,000
km) or 24 months with lithium-soap-based
grease.
S Check bearings for looseness and damage.
15 * Wheel bearings Ǹ Ǹ Ǹ Ǹ Ǹ
S Replace if necessary.
16 * Wheels S Check runout and for damage. Ǹ Ǹ Ǹ Ǹ Ǹ
S Check operation.
17 * Sidestand switch Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ
S Replace if necessary.
S Check tire tread wear and for damage.
18 * Tires Ǹ Ǹ Ǹ Ǹ Ǹ
S Replace if necessary.
Shock absorber S Check operation and for oil leakage.
19 * Ǹ Ǹ Ǹ Ǹ Ǹ
assembly S Replace if necessary.
S Make sure that all nuts, bolts and screws
20 * Chassis fasteners are properly tightened. Ǹ Ǹ Ǹ Ǹ Ǹ
S Tighten if necessary.
S Check operation and free play.
S Adjust the throttle cable free play if neces-
Throttle grip hous-
21 * sary. Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ
ing and cable
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.

NOTE:
F Air filter
S This model’s air filter is equipped with a disposable oil-coated paper element, which must not be
cleaned with compressed air to avoid damaging it.
S The air filter element needs to be replaced more frequently when riding in unusually wet or dusty
areas.
F Hydraulic brake service
S After disassembling the brake master cylinders and calipers, always change the fluid. Regularly
check the brake fluid levels and fill the reservoirs as required.
S Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
S Replace the brake hoses every four years and if cracked or damaged.
F Engine oil type
S Yamalube 4 ( 20W-40) or engine oil SAE 20W-40 (API SE) for temperatures of 5_C (40_F) or above.
S Yamalube 4 (10W-30) or engine oil SAE 10W-30 (API SE) for temperatures of 15_C (60_F) or below.

–16–
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL AND BRAKE DISCS CHAS

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 Remove the parts in the order listed.
discs Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so
there is no danger of it falling over.

1 Reflector 2
2 Brake calipers 2
3 Front wheel axle pinch bolt 1 Refer to “REMOVING/INSTALLING
4 Front wheel axle 1 THE FRONT WHEEL”.
5 Front wheel assembly 1
6 Collars 2 Refer to “INSTALLING THE FRONT
7 Brake discs 2 WHEEL”.
For installation, reverse the removal
procedure.

–17–
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL AND BRAKE DISCS CHAS

Order Job name/Part name Q’ty Remarks

Disassembling the front wheel Disassemble the parts in the order listed.
1 Oil seals 2
2 Bearings 2
3 Collar 1
For assembly, reverse the disassembly
procedure.

–18–
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL AND BRAKE DISCS CHAS
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.

2. Remove:
S reflectors 1 (left and right)
S brake calipers 2 (left and right)
NOTE:
Do not squeeze the brake lever when removing
the brake calipers.

3. Loosen:
S pinch bolt (front wheel axle) 1
S front wheel axle 2
4. Elevate:
S front wheel
NOTE:
Place the motorcycle on a suitable stand so that
the front wheel is elevated.

EAS00526

CHECKING THE FRONT WHEEL

1. Check:
S wheel axle
Roll the wheel axle on a flat surface.
Bends ! Replace.
WARNING
Do not attempt to straighten a bent wheel axle.

2. Check:
S tire
S front wheel
Damage/wear ! Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.

–19–
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL AND BRAKE DISCS CHAS
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. Check:
S collars
Damage/wear ! Replace.
WARNING
S New tires have a relatively low grip on the
road surface until they have been slightly
worn.
Therefore, approximately 100 km (62 mi)
should be traveled at normal speed before
any highspeed riding is done.

5. Check
S wheel bearings
Front wheel turns roughly or is loose ! Re-
place the wheel bearings.
S oil seals
Damage/wear ! Replace.
6. Replace:
S wheel bearings New
S oil seals New

a. Clean the outside of the front wheel hub.

b. Remove the oil seals 1 with a flat-head
screwdriver.
NOTE:
To prevent damaging the wheel, place a rag be-
tween the screwdriver and the wheel surface.

c. Remove the wheel bearings with a general

bearing puller 2 .
d. Install the new wheel bearings and oil seals
in the reverse order of disassembly.

–20–
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL AND BRAKE DISCS CHAS

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.

EAS00531

CHECKING THE BRAKE DISCS

The following procedure applies to all of the
brake discs.
1. Check:
S brake disc
Damage/galling ! Replace.
2. Measure:
S brake disc deflection 1
Out of specification ! Correct the brake disc
deflection or replace the brake disc.

Brake disc deflection limit

(maximum)
Front: 0.15 mm (0.006 in)
Rear: 0.15 mm (0.006 in)

a. Place the motorcycle on a suitable stand so

that the wheel is elevated.
b. Before measuring the front brake disc deflec-
tion, turn the handlebar to the left or right to
ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 2 X 3 mm (0.078 X
0.12 in) below the edge of the brake disc.

–21–
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL AND BRAKE DISCS CHAS
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. Adjust:
S brake disc deflection

a. Remove the brake disc.

b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE:
Tighten the brake disc bolts in stages and in a
crisscross pattern.

Brake disc bolt

23 Nm (2.3 mSkg, 17 ftSlb)
LOCTITE

d. Measure the brake disc deflection.

e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be brought
within specification, replace the brake disc.

–22–
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL AND BRAKE DISCS CHAS
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.

3. Tighten:
S wheel axle 1 59 Nm (5.9 mSkg, 29 ftSlb)
S wheel axle pinch bolt 2
20 Nm (2.0 mSkg, 14 ftSlb)

CAUTION:
Before tightening the wheel axle nut, push
down hard on the handlebar several times and
check if the front fork rebounds smoothly.

4. Install:
S brake calipers 40 Nm (4.0 mSkg, 29 ftSlb)
S reflectors

WARNING
Make sure that the brake hose is routed
properly.

–23–
Downloaded from www.Manualslib.com manuals search engine
 REAR WHEEL AND BRAKE DISC CHAS

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 Remarks

Removing the muffler and brake Remove the parts in the order listed.
caliper
1 Muffler 1
2 Muffler stay 1
3 Brake hose holder 1
4 Brake caliper 1 Refer to “REMOVING THE REAR WHEEL”.
For installation, reverse the removal
procedure.

–24–
Downloaded from www.Manualslib.com manuals search engine
 REAR WHEEL AND BRAKE DISC CHAS

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

Removing the rear wheel Remove the parts in the order listed.
WARNING
Securely support the motorcycle so
there is no danger of it falling over.

Final gear oil Drain

Refer to “FINAL GEAR OIL REPLACE-
MENT” in CHAPTER 3.
Fuel tank and seats Refer to “FUEL TANK AND SEATS” in
CHAPTER 3.
Rear fender assembly Loosen
1 Brake caliper bracket bolt 1
2 Bolts 4
3 Rear axle nut/washer 1/1
4 Rear axle end nuts/axle holder 2/1 Refer to “REMOVING/INSTALLING
5 Rear wheel assembly 1 THE REAR WHEEL”.
6 Washer 1
7 Collar 1
For installation, reverse the removal
procedure.

–25–
Downloaded from www.Manualslib.com manuals search engine
 REAR WHEEL AND BRAKE DISC CHAS

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
1 Lock washers 2
2 Clutch hub 1
3 Dampers 6
4 O-rings 2
5 Oil seal 1
6 Bearing 1
7 Spacer 1
8 Bearings 2
For assembly, reverse the disassembly
procedure.

–26–
Downloaded from www.Manualslib.com manuals search engine
 REAR WHEEL AND BRAKE DISC CHAS
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.

2. Remove:
S rear gear case fitting bolts
3. Remove:
S brake caliper 1
S brake caliper bracket bolt
NOTE:
Do not depress the brake pedal when removing
the brake caliper.

4. Remove:
S wheel axle nut
S washer
5. Remove:
S rear axle end nut 2
6. Remove:
S rear axle holder 3
7. Remove:
S rear wheel
EAS00566

CHECKING THE REAR WHEEL

1. Check:
S wheel axle
S rear wheel
S wheel bearings
S oil seals
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
2. Check:
S tire
Damage/wear ! Replace.
Refer to “CHECKING THE TIRES” in chapter
3.
3. Measure:
S rear wheel radial runout
S rear wheel lateral runout
Refer to “FRONT WHEEL AND BRAKE
DISCS”.

–27–
Downloaded from www.Manualslib.com manuals search engine
 REAR WHEEL AND BRAKE DISC CHAS
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. Lubricate:
S wheel axle
S wheel bearings
S oil seal lips

Recommended lubricant
Lithium soap base grease

3. Install:
S rear wheel assembly

a. Install the rear wheel assembly 1 with the

rear brake caliper bracket 2 and hold the
bracket to keep the specified position.
b. After installation of the rear axle shaft 3 ,
slide the wheel assembly to forward direc-
tion.
c. To make sure the caliper bracket mounts on
the swingarm and then, fix the holder of swin-
garm temporally.
NOTE:
The holder should installed with the punch mark
a facing upper.

d. Tighten the rear gear housing bolts, with spe-

cified tightening torque.

Rear gear housing bolt

70 Nm (7.0 mSkg, 51 ftSlb)

e. Tighten the nut of rear axle shaft with speci-

fied torque.

Wheel axle nut

107 Nm (10.7 mSkg, 77 ftSlb)

–28–
Downloaded from www.Manualslib.com manuals search engine
 REAR WHEEL AND BRAKE DISC CHAS
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. Install the rear brake caliper on the bracket

and tighten the bolts with specified tightening
torque.

Brake caliper bolt

40 Nm (4.0 mSkg, 29 ftSlb)

–29–
Downloaded from www.Manualslib.com manuals search engine
 CHECKING THE SWITCHES ELEC

EAS00731
ELECTRICAL
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.

–30–
Downloaded from www.Manualslib.com manuals search engine
 CHECKING THE SWITCHES ELEC
1 Clutch switch 7 Engine stop switch
2 Horn switch 8 Start switch
3 Dimmer switch 9 Fuse
4 Turn signal switch 10 Rear brake switch
5 Main switch 11 Sidestand switch
6 Front brake switch 12 Neutral switch

–31–
Downloaded from www.Manualslib.com manuals search engine
 PRINTED IN U.S.A.

Downloaded from www.Manualslib.com manuals search engine

 XVS1100AWR(C)/XVS1100ATR(C) WIRING DIAGRAM

1 Pickup coil 30 Neutral indicator light

2 A.C. magneto 31 High beam indicator light
3 Rectifier/ regulator 32 Neutral switch
4 Main switch 33 Trip switch
5 Solenoid 34 Turn signal relay
6 Battery 35 Horn
7 Main fuse 36 Rear brake light switch
8 Starter relay 37 Left handlebar switch
9 Starter motor 38 Dimmer switch
10 Starting circuit cut-off relay 39 Horn switch
11 Oil level warning light relay 40 Clutch switch
12 Right handlebar switch 41 Turn signal switch
13 Front brake light switch 42 Headlight
14 Engine stop switch 43 Front turn signal light (left)
15 Start switch 44 Front turn signal light (right)
16 Oil level gauge 45 Rear turn signal light (left)
17 Sidestand switch 46 Rear turn signal light (right)
18 Fuel pump 47 Tail/ brake light
19 Throttle position sensor 48 Ignition fuse
20 Igniter unit 49 Backup fuse
21 Ignition coil 50 Headlight fuse
22 Spark plug 51 Signal fuse
23 Speed sensor 52 Carburetor heater fuse
24 Meter assembly 53 Thermo switch
25 Oil level warning light 54 Carburetor heater 1
26 Engine trouble warning light 55 Carburetor heater 2
27 Speedometer 56 Carburetor heater earth
28 Meter light
29 Turn signal indicator light

COLOR CODE
B ......... Black Br/ B . . . . . . Brown/ Black
Br . . . . . . . . Brown Br/ L . . . . . . Brown/ Blue
Ch . . . . . . . Chocolate Br/ W . . . . . Brown/ White
Dg . . . . . . . Dark green Br/ Y . . . . . . Brown/ Yellow
G ........ Green L /B . . . . . . . Blue/ Black
Gy . . . . . . . Gray L/G . . . . . . Blue/ Green
L ......... Blue L/R . . . . . . Blue/ Red
Lg . . . . . . . . Light green L/W . . . . . . Blue/ White
O ........ Orange L/Y . . . . . . . Blue/ Yellow
P ......... Pink R/ B . . . . . . Red/ Black
R......... Red R/ G . . . . . . Red/ Green
Sb . . . . . . . . Sky blue R/ W . . . . . . Red/ White
W ........ White R/ Y . . . . . . Red/ Yellow
Y ......... Yellow Sb/ W . . . . . Sky blue / White
B/ L . . . . . . . Black/ Blue W/ B . . . . . . White/ Black
B/ R . . . . . . Black/ Red W/ G . . . . . . White/ Green
B/ W . . . . . . Black/ White Y/ L . . . . . . . Yellow/ Blue
B/ Y . . . . . . Black/ Yellow Y/ R . . . . . . Yellow/ Red

Downloaded from www.Manualslib.com manuals search engine