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
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
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.

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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 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.

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 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
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)
225 kPa (2.25 kg/cm2, 2.25 bar)
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
0.8
0.8
3
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






















–3–
MAINTENANCE SPECIFICATIONS SPEC
Needle bearing (starter) Connecting rod big end
Crank shaft
Main axle
Drive axle
Pinion drive
Middle driveshaft
Rocker arm (EX) Camshaft (EX) Rocker arm (EX) Rocker arm (IN) Camshaft (IN) Rocker arm (IN)
Oil filter
Relief valve Oil pump
Oil pan
Pressure feed
Splashed
Orifice
Item Standard
Lubrication chart:

–4–
MAINTENANCE SPECIFICATIONS SPEC
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
361.9 mm
324.4 mm
183 mm
8.8 N/mm (0.9 kg/mm)
12.7 N/mm (1.3 kg/mm)
0 77.5 mm
77.5 140 mm
No
0.464 L
108 mm
Fork oil 10W or equivalent

350 mm










Rear suspension:
Shock absorber travel
Spring free length
Fitting length
Spring rate (K1)
Stroke (K1)
Optional spring
50 mm
179.5 mm
163 mm
117.7 N/mm (12 kg/mm)
0 50 mm
No






Front wheel:
Type
Rim size
Rim material
Rim runout limit radial
lateral
Spoke wheel
16 MT3.00
Steel





1.0 mm
0.5 mm
Brake lever & brake pedal:
Brake lever free play (at lever end)
Brake pedal position
Brake pedal free play
Clutch lever free play (at lever end)
Throttle grip free play
5 8 mm
98.5 mm
0 mm
5 10 mm
4 6 mm






–5–
MAINTENANCE SPECIFICATIONS SPEC
ELECTRICAL
Item Standard Limit
Ignition coil:
Model/manufacturer
Primary winding resistance
Secondary winding resistance
F6T541/MITSUBISHI
3.57 4.83 Ωat 20_C
10.7 14.5 kΩat 20_C
SSS
SSS
SSS
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
0.026 0.034 Ωat 20_C
10 mm
7.65 10.01 N (780 1021 g)
28 mm
0.7 mm
MS5F-421/JIDECO
180 A
SSS
SSS
SSS
SSS
5 mm
SSS
27 mm
SSS
SSS
SSS
Tightening torques
Part to be tightened Thread size Tightening
torque Remarks
g
Nm mSkg
Brake hose holder and lower bracket
Headlight stay and lower bracket
Headlight body and headlight unit
Headlight stay and headlight
Helmet hanger and frame
Passenger seat
Passenger seat braket
M6
M8
M5
M6
M6
M8
M6
7
23
4
7
7
7
7
0.7
2.3
0.4
0.7
0.7
0.7
0.7

–6–
LUBRICATION POINTS AND LUBRICANT TYPES SPEC
LUBRICATION POINTS AND LUBRICANT TYPES
EB203010
CHASSIS
Lubrication point Symbol
Drive shaft coupling gear oil seal

–7–
LUBRICATION DIAGRAMS SPEC
1Camshaft
2Crankshaft
3Main axle
4Middle drive shaft
5Drive axle
6Connecting rod big end
LUBRICATION DIAGRAMS

–8–
CABLE ROUTING SPEC
1Clutch cable
2Starter cable
3Handlebar switch lead (left)
4Handlebar switch lead (right)
5High tension code
6Throttle cable
7Fuel hose (fuel cock-filter)
8Fuelbreatherhose(fueltank-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 (AIS-carburetor
joint)
20 Fuel hose (carburetor-fuel pump)
21 Clip
22 Brake hose
23 Heat protector
24 Speed meter lead
25 Wireharness
26 Purge hose (carburetor-sole-
noid valve) (for CAL)
27 Fitting plate
28 Fuel hose (inlet) (fuel filter-fuel
pump)
29 Fuel hose (outlet) (carburetor-
fuel pump)
30 Alarm connector lead
31 Wireharness
EB206000
CABLE ROUTING

–9–
CABLE ROUTING SPEC
A Fasten the handlebar switch
lead (left and right) to the hand-
lebar with plastic locking tie and
cut the end of tie.
B Position the throttle cable and
starter cable as shown and
clamp them with holder.
C Clamp the wireharness 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 Change 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-AIS) with
a nozzle.
H Push the wireharness inside of
the side cover.
I Push the sensing hose inside of
the tool box plate and not bend
the sensing hose.

–10–
CABLE ROUTING SPEC
J Through the wireharness of so-
lenoid valve between AIS duct
and fuel hose (for CAL).
K Fastenthealarmleadwithaplas-
tic band on the tool box plate.
L Fastenthe sidestandswitch lead
to the bracket of tool box plate
with plastic locking tie.
M Fasten the lead with locking tie
near the side cover.
N Positiontheallconnectorsinside
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
notchesandinstallitnoslacking.
Q Routethe eachhosesthroughthe
frame guide and do not pinch it.
R When installing the fitting plate,
do not pinch the each hoses and
wireharness.
S Wher install the AIS push the
wireharnesstospace ofrearside.

–11–
CABLE ROUTING SPEC
1Battery
2Battery positive (+) lead
3Starter motor positive lead
4Speedmeter lead
5Fuelhose (carburetor-fuelpump)
6High tension code
7Main switch lead
8Throttle cable
9Brake hose
10 Handlebar switch lead (right)
11 Headlight lead
12 Ignition coil
13 Breather hose
14 Purge hose (carburetor-solenoid
valve) (for CAL)
15 Rear brake switch
16 Reserve hose
17 Air filter drain hose
18 Delay relay
19 Battery negative (–) lead
20 Starter motor positive (+) lead
21 Oil level switch lead
22 Rear brake switch lead
23 Carburetor heater connecter
24 Light reduce relay
25 Rectifier/regulator
26 Stay. 1
27 Down tube
28 Frame
29 Stay. 2
30 Battery box
31 Carburetor heater lead
32 Light reduce relay lead

–12–
33 Flasher relay
34 Handlebar switch lead (left)
35 Silencer
36 Throttle position sensor lead
37 Carburetor heater lead
38 Thermo switch lead
39 Starting circuit cut-off relay
40 Horn
41 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
betweenbatteryboxandbattery.
C Push the wireharness into the
space between frame and start-
er motor relay.
D Route the rectifire/regulator
lead, wireharness and starter
motor positive (+) lead through
the out of frame bracket and fas-
tenthemtotheframewithaplas-
tic locking tie. The place to fix
must be between 0 mm and
10mmfromthetopofthediverg-
ing point of the lead on the har-
ness side which connected the
battery negative (–) lead.