EAS00001

XVS1100L/XVS1100LC

SERVICE MANUAL

1999 by Yamaha Motor

Corporation, U.S.A.

First Edition, March 1999

All rights reserved. Any reproduction or

unauthorized use without the written

permission of Yamaha Motor

Corporation, U.S.A. is expressly

prohidited. Printed in U.S.A.

P/N LIT-11616-12-63

NOTE:

CAUTION:

EAS00003

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers

and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu-

al. There fore, anyone who uses this book to perform maintenance and repairs on Yamaha Vehicles

should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

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.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-

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.

This Service Manual contains information regarding periodic maintenance to the emission control sys-

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!

Failure to follow WARNING instructions could result in severe injury or death to

the motorcycle operator, a bystander or a person inspecting or repairing the

motorcycle.

A CAUTION indicates special precautions that must be taken to avoid damage

to the motorcycle.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

1

2

6

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 4 is provided for removal and disassembly jobs.

2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed by

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. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition to

the exploded diagram and the job instruction chart.

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1

3

5

7

9

2

4

8

6

24

23

21

19

18

16

15

14

13

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 1 to 8 indicate the subject of each

chapter.

1 General information

2 Specifications

3 Periodic checks and adjustments

4 Engine

5 Caburetor

6 Chassis

7 Electrical system

8 Troubleshooting

Symbols 9 to ¹⁶ indicate the following.

9 Serviceable 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 in the exploded diagrams indi-

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 in the exploded diagrams indi-

cate the following:

23 Apply locking agent (LOCTITE
)

24 Replace the part

CHK

ADJ

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND

ADJUSTMENTS

ENGINE

CARBURETION

CHASSIS

ELECTRICAL SYSTEM

TROUBLESHOOTING

GEN

INFO 1

SPEC 2

3

ENG 4

CARB 5

CHAS 6

ELEC 7

TRBL

SHTG 8

E004000 TABLE OF CONTENTS

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEN

INFO

1-1

MOTORCYCLE IDENTIFICATION

GEN

INFO

EB100000

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

EB100010

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is stamped

into the right side of the steering head.

MODEL LABEL

The model label 1 is 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 parts that

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. Replace all gaskets, 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 1 and 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.

1 Oil seal

Do not use compressed air to spin the bear-

ings dry. This will damage the bearing sur-

faces.

1 Bearing

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 2 is positioned opposite the

thrust 3 it receives. See sectional view.

4 Shaft

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 1 and 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

the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or

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.

P/N. YM-, YU-

for US, CAN

YS-, YK-, ACC-

P/N 90890-

Except for US, CAN

Tool No.

Tool name/How to use

Illustration

Weight

YU-1083-3

90890-01084

Bolt

YU-1083-2

90890-01085

Slide hammer bolt/weight

These tools are used to remove the rocker

arm shaft.

YU-01135-A

90890-01135

Crankcase separating tool

This tool is used to remove the crankshaft.

YM-01229

90890-01229

Coupling gear/Middle shaft tool

This tool is needed when removing or

installing the final pinion shaft nut.

Final gear

backlash band

YM-01230

90890-01230

Middle gear ba-

clash band

YM-01231

90890-01231

Final gear backlash band

This tool is needed when measuring final gear

/middle gear backlash.

Installer pot

YU-90058

90890-01274

Bolt

YU-90060

90890-01275

Crankshaft installer pot/bolt/adapter/spacer

Adaptor

YM-4059

90890-04130

Spacer

YM-90070

90890-04060

These tools are used to install the crankshaft.