Yamaha XVS1100LC Manuals

Manuals and User Guides for Yamaha XVS1100LC. We have 1 Yamaha XVS1100LC manual available for free PDF download: Service Manual

Yamaha XVS1100LC Service Manual (397 pages)

Brand: Yamaha | Category: Motorcycle | Size: 23.6 MB

Exploded Diagrams
3
Illustrated Symbols
4
Table of Contents
5
General Information
6
Motorcycle Identification
7
Vehicle Identification Number
7
Model Label
7
Important Information
8
Preparation for Removal Procedures
8
Replacement Parts
8
Gaskets, Oil Seals and O-Rings
8
Lock Washers/Plates and Cotter Pins
9
Bearings and Oil Seals
9
Circlips
9
Checking of Connections
10
Special Tools
11
Specifications
15
Maintenance Specifications
19
Cylinder Head Tightening Sequence
26
Crankcase Tightening Sequence
26
Tightening Torques
27
Chassis
29
Conversion Table
35
Lubrication Points and Lubricant Types
36
Lubrication Diagrams
38
Cable Routing
41
Periodic Checks and Adjustments
52
Periodic Maintenance Chart for Emission Control System
54
General Maintenance and Lubrication Chart
54
Fuel Tank and Seats
56
Engine
58
Adjusting the Valve Clearance
58
Adjusting the Valve Clearance/Synchronizing the Carburetors
61
Adjusting the Engine Idling Speed
63
Adjusting the Throttle Cable Free Play
64
Checking the Spark Plugs
65
Checking the Ignition Timing
66
Measuring the Compression Pressure
67
Checking the Engine Oil Level
69
Changing the Engine Oil
70
Adjusting the Clutch Cable Free Play
71
Cleaning the Air Filter Element
72
Checking the Carburetor Joint and Intake Manifold
73
Checking the Breather Hose
73
Checking the Exhaust System
74
Adjusting the Front Brake
75
Adjusting the Rear Brake
76
Checking the Brake Fluid Level
77
Adjusting the Rear Brake Light Switch
78
Checking the Brake Hoses
78
Bleeding the Hydraulic Brake System
79
Adjusting the Shift Pedal
80
Checking the Final Drive Oil Level
81
Changing the Final Drive Oil
81
Checking and Adjusting the Steering Head
82
Checking the Front Fork
84
Adjusting the Rear Shock Absorber Assembly
84
Checking the Tires
85
Front Tire
87
Rear Tire
87
Checking and Tightening the Spokes
88
Checking and Lubricating the Cables
89
Lubricating the Levers and Pedals
89
Lubricating the Sidestand
89
Lubricating the Rear Suspension
89
Electrical System
90
Checking and Charging the Battery
90
Charging Method Using a Variable-Current (Voltage) Type Charger
93
Charging Method Using a Constant-Voltage Type Charger
94
Checking the Fuses
96
Replacing the Headlight Bulb
97
Adjusting the Headlight Beam
98
Engine Removal
102
Mufflers, Brake Pedal and Side Cover
102
Leads, Shift Pedal and Clutch Cable
104
Engine Mounting Bolts
105
Installing the Engine
106
Cylinder Heads
107
Rear Cylinder Head
107
Front Cylinder Head
109
Removing the Cylinder Heads
111
Checking the Cylinder Heads
113
Checking the Timing Chain Tensioner
114
Installing the Cylinder Heads
114
Rocker Arms and Camshaft
117
Removing the Rocker Arms and Camshaft
118
Checking the Camshafts
118
Checking the Rocker Arms and Rocker Arm Shafts
119
Installing the Camshaft and Rocker Arms
120
Valves and Valve Springs
122
Removing the Valves
123
Checking the Valve Seats
125
Checking the Valve Springs
127
Installing the Valves
127
Cylinders and Pistons
129
Removing the Pistons
130
Checking the Cylinders and Pistons
130
Checking the Piston Rings
132
Installing the Pistons and Cylinders
133
Timing Gears
135
Removing the Timing Drive Gears
136
Checking Timing Chains, Camshaft Sprockets, and Timing Chain Guides
136
Front Cylinder
136
Rear Cylinder
136
Checking the Primary Drive
137
Installing the Timing Drive Gears
137
Right Crankcase Cover
139
Clutch Assembly
141
Removing the Clutch
143
Checking the Friction Plates
143
Checking the Pressure Plate
144
Checking the Clutch Boss
144
Checking the Clutch Push Rods
144
Checking the Clutch Plates
145
Checking the Clutch Spring and Clutch Spring Seat Plate
145
Checking the Clutch Housing
145
Installing the Clutch
146
Generator and Starter Clutch
148
Stator Coil and Pickup Coil
148
Removing the Generator
150
Checking the Starter Clutch
151
Installing the Generator
152
Shift Shaft
154
Checking the Shift Shaft
155
Checking the Stopper Lever
155
Installing the Shift Shaft
155
Oil Pump
156
Checking the Oil Pump
158
Checking the Oil Delivery Pipes
158
Checking the Oil Strainer
158
Assembling the Oil Pump
159
Crankshaft and Connecting Rods
160
Crankcase
160
Disassembling the Crankcase
162
Removing the Crankshaft Assembly
163
Removing the Connecting Rods
163
Checking the Crankshaft and Connecting Rods
163
Checking the Bearings and Oil Seals
166
Installing the Crankshaft
166
Assembling the Crankcase
167
Transmission
169
Checking the Shift Forks
170
Checking the Shift Drum Assembly
170
Checking the Transmission
171
Installing the Transmission
172
Middle Gear
173
Middle Drive Pinion Gear
173
Middle Driven Pinion Gear
174
Removing the Middle Drive Shaft Assembly
176
Disassembling the Middle Drive Shaft Assembly
176
Removing the Middle Driven Shaft Assembly
177
Checking the Middle Drive Shaft Assembly
177
Checking the Middle Driven Shaft Assembly
177
Assembling the Middle Drive Shaft Assembly
178
Assembling the Middle Driven Shaft Assembly
179
Installing the Middle Gear Assembly and Adjusting the Backlash
179
Installing the Universal Joint
181
Aligning the Middle Gear
182
Carburetion
184
Checking the Carburetors
188
Assembling the Carburetors
190
Installing the Carburetors
190
Measuring and Adjusting the Fuel Level
191
Checking and Adjusting the Throttle Position Sensor
192
Air Induction System
194
Air Cut-Off Valve
194
Air Induction System Inspection
195
Front Wheel and Brake Discs
198
Removing the Front Wheel
200
Checking the Front Wheel
200
Checking the Brake Discs
202
Installing the Front Wheel
204
Adjusting the Front Wheel Static Balance
205
Rear Wheel and Brake Disc
207
Muffler and Brake Caliper
207
Rear Wheel
208
Removing the Rear Wheel
210
Checking the Rear Wheel
210
Checking the Rear Wheel Drive Hub
211
Installing the Rear Wheel
211
Adjusting the Rear Wheel Static Balance
212
Front and Rear Brakes
213
Front Brake Pads
213
Rear Brake Pads
214
Replacing the Front Brake Pads
215
Replacing the Rear Brake Pads
217
Front Brake Master Cylinder
219
Rear Brake Master Cylinder
221
Removing the Front Brake Master Cylinder
223
Removing the Rear Brake Master Cylinder
223
Checking the Front and Rear Brake Master Cylinder
224
Installing the Front Brake Master Cylinder
225
Installing the Rear Brake Master Cylinder
227
Front Brake Calipers
229
Rear Brake Caliper
231
Removing the Front Brake Calipers
233
Removign the Rear Brake Caliper
233
Checking the Front and Rear Brake Calipers
234
Installing the Front Brake Calipers
235
Installing the Rear Brake Caliper
237
Front Fork
240
Removing the Front Fork Legs
243
Disassembling the Front Fork Legs
243
Checking the Front Fork Legs
244
Assembling the Front Fork Legs
245
Installing the Front Fork Legs
248
Handlebar
249
Removing the Handlebar
251
Checking the Handlebar
251
Installing the Handlebar
252
Steering Head
255
Removing the Lower Bracket
257
Checking the Steering Head
257
Installing the Steering Head
258
Rear Shock Absorber and Swingarm
260
Ride Side Cover and Battery Box
260
Left Side Cover and Tool Box
261
Handling the Rear Shock Absorber and Gas Cylinder
263
Disposing of a Rear Shock Absorber and Gas Cylinder
263
Removing the Rear Shock Absorber
264
Removing the Swingarm
265
Checking the Rear Shock Absorber and Gas Cylinder
266
Checking the Swingarm
266
Installing the Rear Shock Absorber
267
Installing the Swingarm
267
Shaft Drive Troubleshooting
269
Shaft Drive Troubleshooting Chart
271
Measuring the Ring Gear Backlash
273
Adjusting the Ring Gear Backlash
274
Final Drive Assembly and Drive Shaft
276
Final Gear
277
Disassembling the Final Drive Assembly
278
Removing and Installing the Ring Gear Bearings
279
Aligning the Final Drive Pinion Gear and Ping Gear
280
Checking the Drive Shaft
284
Installing the Drive Shaft
284
Electrical
286
Electrical Components
288
Switches
289
Checking Switch Continuity
289
Checking the Switches
290
Checking the Bulbs and Bulb Sockets
292
Types of Bulbs
292
Checking the Condition of the Bulbs
292
Checking the Condition of the Bulb Sockets
294
Ignition System
295
Circuit Diagram
295
Ignition System Troubleshooting
296
Electric Starting System
300
Starting Circuit Operation
301
Starting Starting System Troubleshooting
302
The Starter Motor Fails to Turn
302
Starter Motor
306
Checking the Starter Motor
307
Assembling the Starter Motor
308
Charging System Circuit Diagram
310
The Battery Is Not Being Charged
311
Lighting System Circuit Diagram
313
Checking the Lighting System
315
Signal System Circuit Diagram
318
Checking the Signaling System
321
Fuel Pump System Circuit Diagram
326
Fuel Pump Circuit Operation
327
The Fuel Pump Fails to Operate
328
Fuel Pump Test
330
Carburetor Heater System Circuit Diagram
331
The Carburetor Heater Fails to Operate
332
The Solenoid Valve Fails to Operate
335
Self-Diagnosis
337
Wiring Diagram
340
Troubleshooting
342
Starting Failure/Hard Starting
343
Poor Idle Speed Performance
344
Poor Medium-And-High Speed Performance
344
Faulty Gear Shifting
345
Clutch Slipping/Dragging
345
Overheating
346
Faulty Brake
346
Front Fork Oil Leakage and Front Fork Malfunction
346
Unstable Handling
347
Faulty Lighting and Signal Systems
347

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