Yamaha XVS1100 2001 Manual

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
XVS1100 (N). For complete service information procedures it is necessary to use this Supplementary
Service Manual together with the following manual.
XVS1100 (L) SERVICE MANUAL: 5EL1-AE1
EB000000
XVS1100 (N)
SUPPLEMENTARY SERVICE MANUAL
2000 by Yamaha Motor Co.,Ltd.
First edition, September 2000
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.

NOTE:
CAUTION:
EB001000 NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and
their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual,
so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha mo-
torcycleshasabasicunderstandingofthemechanicalideasandtheproceduresofmotorcyclerepair.
Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe and
unfit for use.
YamahaMotorCompany,Ltd.iscontinuallystrivingtoimprove all itsmodels.Modifications andsignifi-
cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
FailuretofollowWARNINGinstructions couldresultin severeinjuryor deathto
the motorcycle operator, a bystander or a person inspecting or repairing the
motorcycle.
ACAUTIONindicatesspecialprecautions that must be taken to avoid damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

1
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 7accompaniestheexploded diagram,providingthe orderofjobs,namesof
parts, notes in jobs, etc.
5. Forjobsrequiringmoreinformation,thestep-by-stepformatsupplements 8aregiveninadditionto
the exploded diagram and the job instruction chart.

24
21
18
15 16 17
10
12
13
11
14
1
3
5
7
9
2
4
8
6
19 20
22 23
25
CHK
ADJ
EB003000
ILLUSTRATED SYMBOLS
Illustrated symbols 1to 9are printed on the
toprightofeachpageandindicatethesubjectof
each chapter.
1General information
2Specifications
3Periodic inspections and adjustments
4Engine
5Cooling system
6Carburetion
7Chassis
8Electrical
9Troubleshooting
Illustrated symbols 10 to 17 are used to identify
the specifications appearing in the text.
10 Can be serviced with engine mounted
11 Filling fluid
12 Lubricant
13 Special tool
14 Torque
15 Wear limit, clearance
16 Engine speed
17 Ω, V, A
Illustratedsymbols 18 to 23 inthe exploded dia-
grams indicate the types of lubricants and lu-
brication points.
18 Apply engine oil
19 Apply gear oil
20 Apply molybdenum disulfide oil
21 Apply wheel bearing grease
22 Apply lightweight lithium-soap base grease
23 Apply molybdenum disulfide grease
Illustratedsymbols 24 to 25 inthe exploded dia-
grams indicate where to apply locking agent 24
and when to install new parts 25 .
24 Apply locking agent (LOCTITE)
25 Replace

CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE/LUBRICATION INTERVALS 16. . . . . . . . . . .
ELECTRICAL SYSTEM 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE HEADLIGHT BULB 18. . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE HEADLIGHT BEAM 19. . . . . . . . . . . . . . . . . . . . . . . . .
CARBURETION
AIR INDUCTION SYSTEM 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INDUCTION SYSTEM DIAGRAMS 20. . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE AIR INDUCTION SYSTEM 22. . . . . . . . . . . . . . . . . . .
CHASSIS
FRONT AND REAR BRAKES 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE CALIPERS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING HEAD 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

–1–
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard
Model code: XVS1100: 5PB2
Basic weight:
With oil and a full fuel tank 275 kg
Tire:
Type
Size front
rear
Manufacturer front
rear
Type front
rear
With tube
110/90-18 61S
170/80-15M/C 77S
DUNLOP
DUNLOP
K555F
K555
Maximum load-except motorcycle: 200 kg

–2–
MAINTENANCE SPECIFICATIONS SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Camshaft:
Drive method
Cam cap inside diameter
Camshaft outside diameter
Shaft-to-cap clearance
Cam dimensions
Intake “A”
“B”
“C”
Exhaust “A”
“B”
“C”
Camshaft runout limit
Chain drive (left & right)
25.000 25.021 mm
24.96 24.98 mm
0.020 0.061 mm
39.112 39.212 mm
32.093 32.193 mm
7.162 mm
39.112 39.212 mm
32.127 32.227 mm
7.162 mm





39.012 mm
31.993 mm
7.012 mm
39.012 mm
32.027 mm
7.012 mm
0.03 mm

–3–
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
356.9 mm
319.4 mm
183 mm
4.41 N/mm (0.9 kg/mm)
6.37 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






Tightening torques
Part to be tightened Thread size Tightening
torque Remarks
g
Nm mkg ftlb
Brake caliper and bracket M10 27 2.7 20

–4–
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
Charging system:
Type
Model/manufacturer
Nominal output
Stator coil resistance/color
A.C. magneto
F4T654/MITSUBISHI
14 V 305 W at 5,000 r/min
0.36 0.44 Ωat 20_C/White – White
SSS
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

–5–
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
EB206000
CABLE ROUTING
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

–6–
A Fasten the handlebar switch
lead (left and rihgt) to the hand-
lebar with plastic locking tie and
cut the end of tie.
B Fasten the mainharness with a
plastic clamp at the back of the
cable guide.
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 sensing hose inside of
theLIDandnotbendthesensing
hose.
I Push the wireharness inside of
the side cover.
CABLE ROUTING SPEC
27

–7–
J Positiontheallconnectorsinside
of the connector cover.
K Through the wireharness of so-
lenoid valve between AIS duct
and fuel hose (for CAL).
L Fasten the alarm lead with a
plastic band on the LID.
M Fasten the sidestand switch lead
to the bracket of LID with plastic
locking tie.
N Fasten the lead with locking tie
near the side cover.
O Route the clutch cable through
the cable guide.
P Position the throtlle cable and
starter cable as shown and
clamp them with holder.
Q Fasten the handlebar switch
leads (left and right) under the
handle crown with a plastic
band. Set the band at four
notchesandinstallitnoslacking.
R Routetheeachhosesthroughthe
frame guide and do not pinch it.
S When installing the fitting plate,
do not pinch the each hoses and
wireharness.
T Wher install the AIS push the
wireharnesstospace of rearside.
CABLE ROUTING SPEC

–8–
1Battery
2Battery positive (+) lead
3Starter motor positive lead
4Speedmeter lead
5Fuelhose(carburetor-fuel pump)
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 lelay lead
CABLE ROUTING SPEC

–9–
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
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
10 mm from the top of the
divergingpoint of thelead on the
harness side whitch connected
the battery negative (–) lead.
CABLE ROUTING SPEC

–10–
M Fasten the rear brake switch lead
and master cylinder reservoir
hoseto the downtube with aplas-
tic locking tie, and cut the end of
locking tie and position is inside of
frame.
N About 20 mm from bead end.
O Locate the band to forward of
down tube.
P Route the rectifire/regulator lead
and carburetor heater lead
through inside of battery box hole
to outside it and connect them.
CABLE ROUTING SPEC
I Fasten the rear brake switch
lead to the rear brake switch
bracket with a plastic locking tie
andcutoftheend,insideofframe.
J Fasten the wireharness, starter
motor positive (+) lead and bat-
tery negative (–) lead to the
frame with a plastic locking tie.
K From the engine.
L About 70 mm
E Connect the purge hose (carbu-
retor side-solenoid valve side)
withjoint,knob is outside 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.

–11–
Q To rear brake.
R Fasten the rear brake switch
lead with a band to down tube.
(four point)
S Cutting part at the edge of the
band.
T About 30_45_
CABLE ROUTING SPEC
U Fasten the oil level sensor lead
with a locking tie to battery box.
Fix to the battery box with the
band.Tofix,alginthebandtothe
bottomofthebox’sholewhilefix-
ingtheleadtothebackofthebox
(insidethebody).Thecuttingpart
attheedgeofthe band comes to
the front side of the body.
V Clampthehandlebarswitchlead
(right) to the frame with a holder.
The part to open and shut is out-
side of the body.
W Arrangethethrottlepositionsen-
sor connector, carburetor heater
connector and thermo switch
connector between the starting
circuit cut off relay and high ten-
sion code.
X Put the light reduce relay lead,
carburetor heater lead into the
bottom of the groove.

–12–
1Brake hose
2Throttle cable
3Master cylinder reservoir hose
4High tension code
5Purge hose (carburetor-solenoid
valve) (for CAL)
6Rear brake switch lead
7Fuel hose (carburetor-fuel pump)
8Delay relay
9Battery negative (–) lead
10 Battery negative (–) lead con-
nector
11 Battery
CABLE ROUTING SPEC
12 Battery positive (+) lead
13 Taillight lead
14 Starter relay
15 Starter motor positive (+) lead
16 Fuel tank breather hose (fuel
tank-roll over valve) (for CAL)
17 Outlet
18 Inlet
19 Ventilation hose
20 Starter cable
21 Sensing hose (AIS-carburetor
joint)
22 Fuel hose (fuel cock-fuel filter)
23 Throttle position sensor lead
24 Carburetor heater lead
25 Tappet cover
26 Clutch cable
27 Thermo switch lead
28 Wireharness
29 Frame
30 Igniter unit
31 LID. 2
32 Mud guard
33 Fuel filter
34 LID.
35 Ignitor unit lead
36 Speed meter lead connecter