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1999 XVS1100
Yamaha 1999 XVS1100 Manuals
Manuals and User Guides for Yamaha 1999 XVS1100. We have
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Yamaha 1999 XVS1100 manual available for free PDF download: Service Manual
Yamaha 1999 XVS1100 Service Manual (355 pages)
1999 Motorcycle
Brand:
Yamaha
| Category:
Motorcycle
| Size: 7.63 MB
Table of Contents
Gen Info
8
How to Use this Manual
4
Table of Contents
8
Chapter 1
9
General Information
9
Motorcycle Identification
9
Vehicle Identification Number
9
Model Label
9
Important Information
10
Preparation for Removal Procedures
10
Replacement Parts
10
Gaskets, Oil Seals and O-Rings
10
Lock Washers/Plates and Cotter Pins
11
Bearings and Oil Seals
11
Circlips
11
Checking of Connections
12
Special Tools
13
2 Spec
18
Chapter 2. Specifications
19
General Specifications
19
Maintenance Specifications
22
Engine
22
Chassis
32
Electrical
36
Conversion Table
38
General Torque Specifications
38
Lubrication Points and Lubricant Types
39
Engine
39
Chassis
40
Lubrication Diagrams
41
Cable Routing
45
Insp Adj
55
Chapter 3 Periodic Inspections and Adjustments
57
Introduction
57
Periodic Maintenance/Lubrication Intervals
57
Fuel Tank and Seats
59
Removal
60
Installation
60
Engine
61
Adjusting the Valve Clearance
61
Synchronizing the Carburetors
64
Adjusting the Engine Idling Speed
66
Adjusting the Throttle Cable Free Play
67
Checking the Spark Plugs
68
Checking the Ignition Timing
69
Measuring the Compression Pressure
70
Checking the Engine Oil Level
72
Changing the Engine Oil
73
Adjusting the Clutch Cable Free Play
74
Cleaning the Air Filter Element
75
Checking the Carburetor Joint and Intake Manifold
76
Checking the Breather Hose
76
Checking the Exhaust System
77
Chassis
78
Adjusting the Front Brake
78
Adjusting the Rear Brake
79
Checking the Brake Fluid Level
80
Adjusting the Rear Brake Light Switch
81
Checking the Brake Hoses
81
Bleeding the Hydraulic Brake System
82
Adjusting the Shift Pedal
83
Checking the Final Drive Oil Level
84
Changing the Final Drive Oil
84
Checking and Adjusting the Steering Head
85
Checking the Front Fork
87
Adjusting the Rear Shock Absorber Assembly
87
Checking the Tires
88
Checking and Tightening the Spokes
91
Checking and Lubricating the Cables
92
Lubricating the Levers and Pedals
92
Lubricating the Sidestand
92
Lubricating the Rear Suspension
92
Electrical System
93
Checking and Charging the Battery
93
Checking the Fuses
99
Replacing the Headlight Bulb
100
Adjusting the Headlight Beam
101
Table of Contents
103
Chapter 4 Engine
106
Engine Removal
106
Mufflers, Brake Pedal and Side Cover
106
Leads, Shift Pedal and Clutch Cable
108
Engine Mounting Bolts
109
Installing the Engine
110
Cylinder Heads
111
Rear Cylinder Head
111
Front Cylinder Head
113
Removing the Cylinder Heads
115
Checking the Cylinder Heads
117
Checking the Timing Chain Tensioner
118
Installing the Cylinder Heads
118
Rocker Arms and Camshaft
121
Removing the Rocker Arms and Camshaft
122
Checking the Camshafts
122
Checking the Rocker Arms and Rocker Arm
123
Installing the Camshaft and Rocker Arms
124
Valves and Valve Springs
126
Removing the Valves
127
Checking the Valves and Valve Guides
127
Checking the Valve Seats
129
Checking the Valve Springs
131
Installing the Valves
131
Cylinders and Pistons
133
Removing the Cylinders and Pistons
133
Checking the Cylinders and Pistons
134
Checking the Piston Rings
136
Checking the Piston Pins
137
Installing the Pistons and Cylinders
137
Timing Gears
139
Removing the Timing Drive Gears
140
Checking the Timing Chains, Camshaft
140
Checking the Primary Drive
141
Installing the Timing Drive Gears
141
Right Crankcase Cover
143
Clutch Assembly
145
Removing the Clutch
147
Checking the Friction Plates
147
Checking the Pressure Plate
148
Checking the Clutch Boss
148
Checking the Clutch Push Rods
148
Checking the Clutch Plates
149
Checking the Clutch Spring and Clutch Spring Seat Plate
149
Checking the Clutch Housing
149
Installing the Clutch
150
Generator and Starter Clutch
152
Stator Coil and Pickup Coil
152
Generator and Starter Clutch
153
Removing the Generator
154
Checking the Starter Clutch
155
Installing the Generator
156
Shift Shaft
158
Checking the Shift Shaft
159
Checking the Stopper Lever
159
Installing the Shift Shaft
159
Oil Pump
160
Checking the Oil Pump
162
Checking the Oil Delivery Pipes
162
Checking the Oil Strainer
162
Crankshaft and Connecting Rods
164
Crankshaft and Connecting Rods Crankcase
164
Disassembling the Crankcase
166
Removing the Connecting Rods
167
Checking the Crankshaft and Connecting Rods
167
Checking the Bearing and Oil Seals
170
Installing the Crankshaft
170
Assembling the Crankcase
171
Transmission
173
Checking the Shift Forks
174
Checking the Shift Drum Assembly
174
Checking the Transmission
175
Installing the Transmission
176
Middle Gear
177
Middle Drive Pinion Gear
177
Middle Driven Pinion Gear
178
Removing the Middle Drive Shaft Assembly
180
Disassembling the Middle Drive Shaft Assembly
180
Removing the Middle Driven Shaft Assembly
181
Checking the Middle Drive Shaft Assembly
181
Checking the Middle Driven Shaft Assembly
181
Assembling the Middle Drive Shaft Assembly
182
Assembling the Middle Driven Shaft Assembly
183
Installing the Middle Gear Assembly and Adjusting the Backlash
183
Installing the Universal Joint
185
Aligning the Middle Gear
186
5 Carb
189
Carburetor
190
Chapter 5
193
Checking the Carburetors
193
Assembling the Carburetors
195
Installing the Carburetors
195
Measuring and Adjusting the Fuel Level
196
Checking and Adjusting the Throttle Position Sensor
197
Air Induction System (Ais)
199
Air Induction
199
Air Cut-Off Valve
199
Air Induction System Inspection
200
6 Chas
203
Front Wheel and Brake Discs
205
Chapter 6
207
Checking the Front Wheel
207
Removing the Front Wheel
207
Checking the Brake Discs
209
Installing the Front Wheel
211
Adjusting the Front Wheel Static Balance
212
Rear Wheel and Brake Disc
214
Muffler and Brake Caliper
214
Rear Wheel
215
Removing the Rear Wheel
217
Checking the Rear Wheel
217
Checking the Rear Wheel Drive Hub
218
Installing the Rear Wheel
218
Adjusting the Rear Wheel Static Balance
219
Front and Rear Brakes
220
Front Brake Pads
220
Rear Brake Pads
221
Replacing the Front Brake Pads
222
Replacing the Rear Brake Pads
224
Front Brake Master Cylinder
226
Rear Brake Master Cylinder
228
Removing the Front Brake Master Cylinder
230
Removing the Rear Brake Master Cylinder
230
Checking the Front and Rear Brake Master Cylinder
231
Installing the Front Brake Master Cylinder
232
Installing the Rear Brake Master Cylinder
234
Front Brake Calipers
236
Rear Brake Caliper
238
Removing the Front Brake Calipers
240
Removing the Rear Brake Caliper
240
Checking the Front and Rear Brake Calipers
241
Installing the Front Brake Calipers
242
Installing the Rear Brake Caliper
244
Front Fork
247
Removing the Front Fork Legs
250
Disassembly the Front Fork Legs
250
Checking the Front Fork Legs
251
Assembling the Front Fork Legs
252
Handlebar
256
Removing the Handlebar
258
Checking the Handlebar
258
Installing the Handlebar
259
Steering Head
262
Removing the Lower Bracket
264
Checking the Steering Head
264
Installing the Steering Head
265
Rear Shock Absorber and Swingarm
267
Right Side Cover and Battery Box
267
Left Side Cover and Tool Box
268
Rear Shock Absorber and Swingarm
268
Disposing of a Rear Shock Absorber and Gas Cylinder
270
Removing the Rear Shock Absorber
271
Removing the Swingarm
272
Cylinder
273
Checking the Swingarm
273
Installing the Rear Shock Absorber
274
Installing the Swingarm
274
Shaft Drive
276
Troubleshooting
276
Checking the Final Drive Oil for Contamination and Inspecting the Shaft Drive for Leaks
279
Measuring the Ring Gear Backlash
280
Adjusting the Ring Gear Backlash
281
Final Drive Assembly and Drive Shaft
283
Final Gear
284
Disassembling the Final Drive Assembly
285
Removing and Installing the Ring Gear Bearings
286
Aligning the Final Drive Pinion Gear and Ring Gear
287
Checking the Drive Shaft
291
Installing the Drive Shaft
291
7 Elec
294
Chapter 7 Electrical
296
Electrical Components
296
Switches
297
Checking Switch Continuity
297
Checking the Switches
298
Checking the Bulbs and Bulb Sockets
300
Types of Bulbs
300
Checking the Condition of the Bulbs
300
Checking the Condition of the Bulb Sockets
302
Ignition System
303
Circuit Diagram
303
Troubleshooting
304
Electric Starting System
308
Circuit Diagram
308
Starting Circuit Operation
309
Troubleshooting
310
Starter Motor
314
Charging System
318
Circuit Diagram
318
Troubleshooting
319
Lighting System
321
Circuit Diagram
321
Troubleshooting
322
Checking the Lighting System
323
Signal System
326
Circuit Diagram
326
Troubleshooting
328
Checking the Signaling System
329
Signaling System
330
Fuel Pump System
334
Circuit Diagram
334
Fuel Pump Circuit Operation
335
Troubleshooting
336
Fuel Pump Test
338
Carburetor Heater System
339
Circuit Diagram
339
Troubleshooting
340
Self-Diagnosis
343
Trbl Shtg
347
Troubleshooting
347
Chapter 8
348
Electrical System
348
Fuel System
348
Starting Failure/Hard Starting
348
Compression System
349
Poor Idle Speed Performance
349
Poor Idle Speed Performance Poor Idle Speed Performance
349
Poor Medium-And High-Speed Performance
349
Clutch Slipping/Dragging
350
Clutch Slipping
350
Clutch Dragging
350
Faulty Gear Shifting
350
Hard Shifting
350
Shift Pedal Does Not Move
350
Jumps-Out-Of Gear
350
Faulty Brake
351
Faulty Brake Poor Braking Performance
351
Front Fork Oil Leakage and Front Fork Malfunction
351
Malfunction
351
Oil Leakage
351
Unstable Handling
352
Overheating Overheating
351
Faulty Lighting and Signal Systems
352
Headlight Does Not Light
352
Bulb Burnt out
352
Flasher Does Not Light
352
Flasher Blinks Slowly
352
Flasher Remains Lit
352
Horn Does Not Sound
352
Unstable Handling Unstable Handling
352
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