Yamaha XVS1100(L) User manual

EB000000
XVS1100 (L)
SERVICE MANUAL
1998 by Yamaha Motor Co.,Ltd.
First edition, October 1998
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.iscontinuallystrivingtoimproveall its models.Modificationsandsignifi-
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!
Failuretofollow WARNINGinstructions couldresultin severeinjuryordeathto
the motorcycle operator, a bystander or a person inspecting or repairing the
motorcycle.
ACAUTIONindicatesspecialprecautionsthatmust 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 7accompanies theexplodeddiagram, providingtheorder ofjobs,names of
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
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 intheexplodeddia-
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 intheexplodeddia-
grams indicate where to apply locking agent 24
and when to install new parts 25 .
24 Apply locking agent (LOCTITE)
25 Replace
E004000

INSP
ADJ
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION AND
ADJUSTMENTS
ENGINE OVERHAUL
CARBURETION
CHASSIS
ELECTRICAL
TROUBLESHOOTING
GEN
INFO 1
SPEC 2
3
ENG 4
CARB 5
CHAS 6
ELEC 7
TRBL
SHTG 8
CHAPTER TITLES

GEN
INFO
1

GEN
INFO
CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . .
MODEL LABEL 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPORTANT INFORMATION 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION FOR REMOVAL PROCEDURES 1-2. . . . . . . . . . . . . . .
REPLACEMENT PARTS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKETS, OIL SEALS AND O-RINGS 1-2. . . . . . . . . . . . . . . . . . . . . . . .
LOCK WASHERS/PLATES AND COTTER PINS 1-3. . . . . . . . . . . . . . . .
BEARINGS AND OIL SEALS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCLIPS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING OF CONNECTIONS 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1
MOTORCYCLE IDENTIFICATION GEN
INFO
EB100000
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EB100010
VEHICLE IDENTIFICATION NUMBER
Thevehicleidentificationnumber 1isstamped
into the right side of the steering head.
MODEL LABEL
The model label 1is affixed to the frame. This
information will be needed to order spare parts.

1-2
IMPORTANT INFORMATION GEN
INFO
EB101000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL PROCE-
DURES
1. Remove all dirt, mud, dust and foreign mate-
rial before removal and disassembly.
2. Use proper tools and cleaning equipment.
Refer to the “SPECIAL TOOLS” section.
3. When disassembling the machine, always
keep mated parts together. This includes
gears,cylinders, pistons and other partsthat
have been “mated” through normal wear.
Mated parts must always be reused or re-
placed as an assembly.
4. During machine disassembly, clean all parts
and place them in trays in the order of disas-
sembly. This will speed up assembly and al-
low for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EB101010
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all re-
placements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EB101020
GASKETS, OIL SEALS AND O-RINGS
1. Replaceallgaskets,seals and O-rings when
overhauling the engine. All gasket surfaces,
oil seal lips and O-rings must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.

1-3
IMPORTANT INFORMATION GEN
INFO
CAUTION:
EB101030
LOCK WASHERS/PLATES AND COTTER
PINS
1. Replace all lock washers/plates 1and cot-
ter pins after removal. Bend lock tabs along
the bolt or nut flats after the bolt or nut has
been tightened to specification.
EB101040
BEARINGS AND OIL SEALS
1. Install bearings and oil seals so that the
manufacturer’s marks or numbers are vis-
ible. When installing oil seals, apply a light
coating of lightweight lithium base grease to
the seal lips. Oil bearings liberally when
installing, if appropriate.
1Oil seal
Do not use compressed air to spin the bear-
ings dry. This will damage the bearing sur-
faces.
1Bearing
EB101050
CIRCLIPS
1. Check all circlips carefully before reassemb-
ly. Always replace piston pin clips after one
use. Replace distorted circlips. When instal-
ling a circlip 1, make sure that the sharp-
edged corner 2is positioned opposite the
thrust 3it receives. See sectional view.
4Shaft

1-4
CHECKING OF CONNECTIONS GEN
INFO
NOTE:
NOTE:
EB801000
CHECKING OF CONNECTIONS
Check the connectors for stains, rust, moisture,
etc.
1. Disconnect:
Connector
2. Check:
Connector
Moisture Dry each terminal with an air
blower.
Stains/rust Connect and disconnect the
terminals several times.
3. Check:
Connector leads
Looseness Bend up the pin 1and con-
nect the terminals.
4. Connect:
Connector terminals
The two terminals “click” together.
5. Check:
Continuity (using a pocket tester)
If there is no continuity, clean the terminals.
When checking the wire harness be sure to
perform steps 1 to 3.
As a quick remedy, use a contact revitalizer
available at most part stores.
Check the connector with a pocket tester as
shown.

1-5
SPECIAL TOOLS GEN
INFO
EB102001
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
theappropriate specialtools;thiswill helppreventdamagecaused bytheuse of inappropriatetoolsor
improvised techniques. Special tools may differ by shape and part number from country to country. In
such a case, two types are provided.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name/How to use Illustration
Weight
90890-01084
Bolt
90890-01085
Slide hammer bolt/weight
These tools are used to remove the rocker
arm shaft.
90890-01135
Crankcase separating tool
This tool is used to remove the crankshaft.
90890-01229
Coupling gear/Middle shaft tool
This tool is needed when removing or
installing the final pinion shaft nut.
Final gear
backlash band
90890-01230
Middle gear
backlash band
90890-01231
Final gear backlash band
Thistoolisneededwhenmeasuringfinalgear
/middle gear backlash.
Installer pot
90890-01274
Bolt
90890-01275
Crankshaft installer pot/bolt/adapter/spacer
90890 01275
Adaptor
90890-04130
Spacer
90890-04060
These tools are used to install the crankshaft.
90890-01304
Piston pin puller
This tool is used to remove the piston pin.
90890-01312
Fuel level gauge
This gauge is used to measure the fuel level
in the float chamber.

1-6
SPECIAL TOOLS GEN
INFO
Tool No. Tool name/How to use Illustration
T-handle
90890-01326
Holder
90890-01460
T-handle/damper rod holder
These tools are needed to loosen and tighten
the damper rod holding bolt.
Puller
90890-01362
Adapter
90890-04131
Flywheel puller/adapter
These tools are needed to remove the rotor.
Weight
90890-01367
Adapter
90890-01381
Fork seal driver weight/adapter
These tools are needed when installing the
slidemetal, oil sealanddustseal intothefork.
Ring nut wrench
90890-01403
Exhaust nut
wrench
90890-01268
Ring nut wrench/ehaust and steering nut
wrench
This tool is needed to loosen and tighten the
steering stem ring nut.
90890-01701
Sheave holder
This tool is needed to hold the rotor when re-
moving or installing the rotor bolt.
90890-03081
Compression gauge set
These tools are needed to measure engine
compression.
90890-03094
Vacuum gauge
This gauge is needed for carburetor synchro-
nization.
90890-03112
Pocket tester
This instrument is needed for checking the
electrical system.
90890-03113
Engine tachometer
This tool is needed for observing engine r/min.

1-7
SPECIAL TOOLS GEN
INFO
Tool No. Tool name/How to use Illustration
90890-03141
Timing light
This tool is necessary for checking ignition
timing.
90890-04014
Valve guide remover & installer
This tool is needed to remove and install the
valve guide.
90890-04019
Valve spring compressor
This tool is needed to remove and install the
valve assemblies.
Adapter
90890-01277
Shock puller
90890-01290
Weight
90890-01291
Crankshaft installer bolt adapter/armature
shock puller/weight
These tools are needed when removing the
final pinion shaft.
90890-04137
Bearing retainer wrench
This tool is needed when removing or instal-
ling the middle drive shaft assembly.
Wrench
90890-04138
Holder
90890-04055
Middle drive shaft nut wrench/Middle drive
shaft holder
These tools are needed when removing or
installing the middle drive shaft bearing.
90890-04062
Universal joint holder
This tool is needed when removing or instal-
ling the driven pinion gear nut.
90890-04077
Bearing retainer wrench
This tool is needed when removing or instal-
ling the final drive pinion gear assembly.
90890-04086
Clutch holding tool
Thistoolisneeded to hold the clutch when re-
moving or installing the clutch boss nut.

1-8
SPECIAL TOOLS GEN
INFO
Tool No. Tool name/How to use Illustration
90890-04090
Damper spring compressor
This tool is needed when removing or instal-
ling the damper spring.
90890-06754
Dynamic spark tester
Ignition checker
This instrument is necessary for checking the
ignition system components.
90890-85505
Yamaha bond No.1215
Thissealant(bond)isusedoncrankcasemat-
ing surfaces, etc.

SPEC
2

E
SPEC
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SPECIFICATIONS 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL TORQUE SPECIFICATIONS 2-20. . . . . . . . . . . . . . . . . . . . . . . . . .
CONVERSION TABLE 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION POINTS AND LUBRICANT TYPES 2-21. . . . . . . . . . . . . . . .
ENGINE 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION DIAGRAMS 2-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1
GENERAL SPECIFICATIONS SPEC
Temp. C
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard
Model code: XVS1100: 5EL1 (For Europe)
5EL2 (For D, A, FIN)
5EL3 (For Australia)
Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
2,405 mm
895 mm
1,095 mm
690 mm
1,640 mm
145 mm
3,200 mm
Basic weight:
With oil and a full fuel tank 274 kg (5EL2 : 275kg)
Engine:
Engine type
Cylinder arrangement
Displacement
Bore stroke
Compression ratio
Compression pressure (STD)
Starting system
Air cooled 4-stroke, SOHC
V-type 2-cylinder
1.063 L
95 75mm
8.3 : 1
1,000 kPa (10 kg/cm2, 10 bar) at 400 r/min
Electric starter
Lubrication system: Wet sump
Oil type or grade:
Engine oil API standard:
“SE” or higher grade
ACEA standard:
G4 or G5
Final gear oil: SAE80API “GL-4” Hypoid Gear Oil
Oil quantity:
Engine oil
Periodic oil change
With oil filter replacement
Total amount
Final gear case oil
Total amount
3.0 L
3.1 L
3.6 L
0.2 L
Air filter: Dry type element
Fuel:
Type
Fuel tank capacity
Fuel reserve amount
Regular unleaded gasoline
17 L
4.5 L

2-2
GENERAL SPECIFICATIONS SPEC
Item Standard
Carburetor:
Type/quantity
Manufacturer BSR37/2
MIKUNI
Spark plug:
Type
Manufacturer
Spark plug gap
BPR7ES/W22EPR–U
NGK/DENSO
0.7 X0.8 mm
Clutch type: Wet, multiple-disc
Transmission:
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Transmission type
Operation
Gear ratio 1st
2nd
3rd
4th
5th
Spur gear
78/47 (1.660)
Shaft drive
44/47 19/18 32/11 (2.875)
Constant mesh 5-speed
Left foot operation
40/17 (2.353)
40/24 (1.667)
36/28 (1.286)
32/31 (1.032)
29/34 (0.853)
Chassis:
Frame type
Caster angle
Trail
Double cradle
33
136 mm
Tire:
Type
Size front
rear
Manufacturer front
rear
Type front
rear
With tube
110/90-18 61S
170/80-15M/C 77S
BRIDGESTONE/DUNLOP
BRIDGESTONE/DUNLOP
EXEDRA L309/K555F
EXEDRA G546/K555
Maximum load-except motorcycle: 201 kg (5EL2 : 200kg)
Tire pressure (cold tire):
0 X90 kg (0 X198 lb) load *
front
rear
90 kg (198 lb) XMaximum load *
front
rear
200 kPa (2.00 kg/cm2)
225 kPa (2.25 kg/cm2)
225 kPa (2.25 kg/cm2)
250 kPa (2.50 kg/cm2)
* Load is the total weight of the cargo, rider,
passenger and accessories.
Brake:
Front brake type
operation
Rear brake type
operation
Dual disc brake
Right hand operation
Single disc brake
Right foot operation