Yamaha V-Star XVS1100AWR User 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.
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.

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

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26
3
5
4
7
8
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 5are 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 7accompanies 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 8are given in addition to
the exploded diagram and the job instruction chart.

22
1
3
5
7
9
2
4
8
6
24
23
21
1918
1615
1413
11 12
10
GEN
INFO SPEC
ENG
CARB
ELEC
CHAS
CHK
ADJ
TRBL
SHTG
20
17
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 in the exploded diagrams indi-
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 in the exploded diagrams indi-
cate the following:
23 Apply locking agent (LOCTITER)
24 Replace the part

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

–1–
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
Overall width
Overall height
2460 mm (96.9 in)
945 mm (37.2 in)
1,095 mm (43.1 in)
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
710 mm (28 in)
1645 mm (64.8 in)
140 mm (5.5 in)
3400 mm (133.9 in)
Basic weight
With oil and a full fuel tank 285 kg (628 lb)
Tire
Type
Size front
rear
Manufacturer front
rear
Type front
rear
Tubeless
130/90-16M/C 67S
170/80-15M/C 77S
BRIDGESTONE/DUNLOP
BRIDGESTONE/DUNLOP
EXEDRA G703/D404F
EXEDRA G702/D404G
Tire pressure (cold tire)
0 X90 kg (0 X198 lb) load*
front
rear
90 kg (198 lb) XMaximum load*
front
rear
225 kPa (2.25 kg/cm2, 32.6 psi)
250 kPa (2.5 kg/cm2, 36.3 psi)
225 kPa (2.25 kg/cm2, 32.6 psi)
250 kPa (2.5 kg/cm2, 36.3 psi)
* 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)
Valve seat size (V.S)
Starter jet (G.S.1)
Starter jet (G.S.2)
Throttle valve size (Th.V)
Fuel level (above the line on
the float chamber) (F.L)
Engine idle speed
Intake vacuum
Engine oil temperature
5EL5 40 (U.S.A.)
5EL6 50 (CAL)
#1: #110, #2: #112.5
#55
5DL 43-53-1
P-0M
#63.8
#145
1.0
#17.5
0.8
0.8
0.8
1.2
#42.5
0.8
#125
4 X5 mm (0.16 X0.20 in)
950 X1,050 r/min
34.7 X37.3 kPa (260 X280 mmHg)
75 X85_C (167 X185_F)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
Fuel pump
Type
Model/manufacturer
Consumption amperage <max>
Output pressure
Electrical type
UC-Z61B/MITSUBISHI
0.8 A
12 kPa (0.12 kg/cm2,1.7 psi)
SSS
SSS
SSS
SSS
CHASSIS
Item Standard Limit
Front suspension
Front fork travel
Fork spring free length
Fitting length
Collar length
Spring rate (K1)
(K2)
Stroke (K1)
(K2)
Optional spring
Oil capacity
Oil level
Oil grade
140 mm (5.51 in)
371.9 mm (14.64 in)
334.4 mm (13.17 in)
183 mm (7.20 in)
4.41 N/mm (0.45 kg/mm, 25.18 lb/in)
6.37 N/mm (0.65 kg/mm, 36.37 lb/in)
0 X77.5 mm (0 X3.05 in)
77.5 X140 mm (3.05 X5.51 in)
No
0.483 L (483 cm3, 17.01 Imp OZ,
16.34 US OZ)
104 mm (4.09 in)
Fork oil 10WT or equivalent
SSS
350 mm
(13.78 in)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS

–3–
MAINTENANCE SPECIFICATIONS SPEC
Item Standard Limit
Rear suspension
Shock absorber travel
Spring free length
Fitting length
Spring rate (K1)
Stroke (K1)
Optional spring
51 mm (2.01 in)
181 mm (7.13 in)
169 mm (6.65 in)
132.3 N/mm (13.49 kg/mm, 755.43 lb/in)
0 X51 mm (0 X2.01 in)
No
SSS
SSS
SSS
SSS
SSS
SSS
Front wheel
Type
Rim size
Rim material
Rim runout limit radial
lateral
Cast wheel
16M/C MT 3.00
Aluminum
SSS
SSS
SSS
SSS
SSS
1.0 mm
(0.04 in)
0.5 mm
(0.02 in)
Rear wheel
Type
Rim size
Rim material
Rim runout limit radial
lateral
Cast wheel
15M/C MT4.50
Aluminum
SSS
SSS
SSS
SSS
SSS
1.0 mm
(0.04 in)
0.5 mm
(0.02 in)
ELECTRICAL
Item Standard Limit
T.C.I.
Pickup coil resistance/color
T.C.I. unit model/manufacturer
189 X231 Ωat 20_C (68_F)/Gray – Black
J4T142/MITSUBISHI
SSS
SSS
Rectifier/regulator
Regulator type
Model/manufacturer
Semi-conductor, short-circuit type
SH678-11/SHINDENGEN
SSS
SSS
No load regulated voltage
Rectifier capacity
Withstand voltage
14.1 X14.9 V
22 A
200 V
SSS
SSS
SSS

–4–
MAINTENANCE SPECIFICATIONS SPEC
Item Standard Limit
Electric starter system
Type
Starter motor:
Model/manufacturer
Output
Armature coil resistance
Brush overall length
Brush spring pressure
Commutator diameter
Mica undercut
Starter relay:
Model/manufacturer
Amperage rating
Constant mesh type
SM-13/MITSUBA
0.6 kW
0.025 X0.035 Ωat 20_C (68_F)
12.5 mm (0.49 in)
7.65 X10.01 N
(780 X1021 g, 27.51 X36.01 OZ)
28 mm (1.10 in)
0.7 mm (0.03 in)
MS5F-421/JIDECO
180 A
SSS
SSS
SSS
SSS
4 mm
(0.16 in)
SSS
27 mm
(1.06 in)
SSS
SSS
SSS
Starting circuit cut-off relay
Model/manufacturer
Coil resistance
G8R-30Y-U/OMRON
202.5 X247.5 Ω at 20_C (68_F)
SSS
Thermostat switch
Model/manufacturer 5FU/NIPPON THERMOSTAT SSS

–5–
CABLE ROUTING SPEC
1Clutch cable
2Starter cable
3Handlebar switch lead (left)
4Handlebar switch lead (right)
5Spark plug lead
6Throttle cable
7Fuel hose (fuel cock to filter)
8Fuel breather hose (fuel tank roll
over valve) (for CAL)
9Fuse box
10 Alarm connector
11 Fuel pump lead
12 Speed sensor lead
13 Sidestand switch lead
14 Neutral switch lead
15 Pickup coil lead
16 To engine
17 A.C. magneto lead
18 Ventilation hose
19 Sensing hose (AI system to car-
buretor joint)
20 Fuel hose (fuel pump to carbure-
tor)
21 Clip
22 Brake hose
23 Heat protector
24 Speedometer lead
25 Wire harness
26 Purge hose (carburetor to sole-
noid valve) (for CAL)
27 Fitting plate
28 Fuel hose (inlet) (fuel filter to fuel
pump)
29 Fuel hose (outlet) (fuel pump to
carburetor)
30 Alarm connector lead
31 Wire harness
EB206000
CABLE ROUTING

–6–
CABLE ROUTING SPEC
A Fasten the handlebar switch
lead (left and right) to the handle-
bar with plastic locking tie and
cut the end of tie.
B Lay out the throttle and starter
cables in three rows and secure
them with a clip. (Two points at
the front and rear.) Care should
be taken at this time so that the
clip does not fall to the outside
against the vertical face of the
vehicle. Point the opening part of
the clip to the inside of the ve-
hicle.
C Clamp the wire harness with the
hook of frame side.
D When installing the pipe of
throttle cable press it inside.
E Clamp the fuel hoses to the
frame with the clamp.
F Cross the fuel hose (fuel cock
side) and fuel hose (carburetor
side) between guide of frame
and clamp. (carburetor side is
upper)
G When connecting the sensing
hose (carburetor joint to AI sys-
tem) with a nozzle.
H Push the wire harness inside of
the side cover.
I Push the sensing hose inside of
the tool box plate and not bend
the sensing hose.
J Through the wire harness of so-
lenoid valve between AIS duct
and fuel hose (for CAL).
K Fasten the alarm lead with a plas-
tic band on the tool box plate.
L Fasten the sidestand switch lead
to the bracket of tool box plate
with plastic locking tie.

–7–
CABLE ROUTING SPEC
M Fasten the lead with locking tie
near the side cover.
N Position the all connectors inside
of the connector cover.
O Route the clutch cable through
the cable guide.
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.
R When installing the fitting plate,
do not pinch the each hoses and
wireharness.
S When install the AI system push
the wire harness to space of rear-
side.

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

–9–
36 Rectifire/regulator and light (re-
duce relay) lead
CABLE ROUTING SPEC
A Clamp the battery positive (+)
lead to the battery with battery
band.
B Connect the battery negative (–)
lead and push it in to the space
between battery box and battery.
C Push the wireharness into the
space between frame and start-
er motor relay.
D Route the harness and starter
motor (+) lead, that are con-
nected to the rectifier regulator
and other equipment, by the out-
side of the frame side bracket
and then secure it by passing the
band through the weight saving
hole of the bracket. (The secur-
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.)

–10–
O Make sure to insert the rectifier
regulator coupler sufficiently un-
til the sound is heard.
P To rear brake.
Q Fasten the rear brake switch
lead with a band to down tube.
(four point)
R Cutting part at the edge of the
band.
S30_X45_
CABLE ROUTING SPEC
J Fasten the wire harness, starter
motor positive (+) lead and bat-
tery negative (–) lead to the
frame with a plastic locking tie.
K 70 mm (2.76 in)
L Fasten the rear brake switch lead
and master cylinder reservoir
hose to the down tube with a plas-
tic locking tie, and cut the end of
locking tie and position is inside of
frame.
M 20 mm (0.79 in) (from bead end.)
N Locate the band to forward of
down tube.
E Connect the purge hose (carbu-
retor side-solenoid valve side)
with joint, knob is out side of frame.
F Route the front turn signal/posi-
tion light lead and headlight lead
through the rear of headlight
body hole.
G Connect the ignition coil lead at
red tape to the right side.
H Knob of clip is rearside of body.
I Fasten the rear brake switch
lead to the rear brake switch
bracket with a plastic locking tie
and cut of the end, inside of frame.

–11–
T Fasten the oil level sensor lead
with a locking tie to battery box.
Fix to the battery box with the
band. To fix, align the band to the
bottom of the box’s hole while fix-
ing the lead to the back of the box
(inside the body). The cutting part
at the edge of the band comes to
the front side of the body.
U Clamp the handlebar switch lead
(right) to the frame with a holder.
The part to open and shut is out-
side of the body.
CABLE ROUTING SPEC
V Arrange the throttle position sen-
sor connector, carburetor heater
connector and thermo switch
connector between the starting
circuit cut off relay and high ten-
sion code.
W Secure to the battery box with
the band, cut the surplus section
and then point the locking sec-
tion to the regulator side.
X Push the light reduce lead and
the terminal-coupler lead for the
carburetor heater into the deep-
est position in the groove of the
battery box.

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

–13–
A Clamp the throttle cables with
the holder. Position the end of
clip downword.
B Route the rear brake switch lead
under the master cylinder reser-
vor hose.
C Position the band end of right
side bracket.
D Position the steel band end to
forward.
E Position the steel band end to
right side.
CABLE ROUTING SPEC
F Route the battery positive (+)
lead through the slit of the bat-
tery box.
G Secure the igniter unit lead and
tail brake light lead to the frame
with a clamp. Point the
open/close section to the upper
side of the vehicle.
H To the rear fender.
I Connect the wire harness to the
igniter unit through the hole of ig-
niter plate.
J Position the mark on the steel
band to forward.
K Fasten the wire harness with a
band on the tool box plate.
L Fasten the wire harness to the
frame with a plastic locking tie.
Position the locking tie front of
the holder.
M Route the wire harness outside
of the guide on the frame.
N Clamp the clutch cable and start-
er cable with a holder.
Position the end of holder down
side.

–14–
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.
CABLE ROUTING SPEC