Except for California (06 Model)

XVS11AWV

XVS11ATV

For California (04 Model)

XVS1100ASC

XVS1100ATSC

SUPPLEMENTARY

SERVICE MANUAL

5KS-28197-E2

LIT-11616-19-82

XVS11AWV/XVS11ATV

XVS1100ASC/XVS1100ATSC

SUPPLEMENTARY

SERVICE MANUAL

© 2005 by Yamaha Motor

Corporation, U.S.A.

First Edition, October 2005

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-11616-19-82

XVS1100L/XVS1100LC SERVICE MANUAL: LIT-11616-12-63 (5EL-28197-E0)

XVS1100AM/XVS1100AMC SUPPLEMENTARY SERVICE

MANUAL: LIT-11616-13-36 (5KS-28197-E0)

XVS1100AWR(C)/XVS1100ATR(C) SUPPLEMENTARY SERVICE

MANUAL: LIT-11616-16-46 (5KS-28197-E1)

EAS00001

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the

XVS1100A. For complete service information procedures it is necessary to use this Supplementary

Service Manual together with the following manual.

EAS00003

NOTICE

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

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

one manual. 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 vehicle 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

vehicle 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

significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-

ers and will appear in future editions of this manual where applicable.

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

system. Please read this material carefully.

NOTE:

Designs and specifications are subject to change without notice.

EAS00005

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

Q

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

w

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

to the motorcycle operator, a bystander or a person checking or repairing

the motorcycle.

cC

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.

EAS00007

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are

laid out with the individual steps in sequential order.

1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of

each page indicate the current chapter.

Refer to "SYMBOLS".

2 Each chapter is divided into sections. The current section title is shown at the top of each page,

except in Chapter 3 ("PERIODIC CHECKS AND ADJUSTMENTS"), where the sub-section title(s)

appears.

3 Sub-section titles appear in smaller print than the section title.

4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of

each removal and disassembly section.

5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates

a disassembly step.

6 Symbols indicate parts to be lubricated or replaced.

Refer to "SYMBOLS".

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

parts, notes in jobs, etc.

8 Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

1

2

6

3

5

4

7

8

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 Carburetor

6 Chassis

7 Electrical system

8 Troubleshooting

Symbols 9 to y indicate the following.

9 Serviceable with engine mounted

0 Filling fluid

q Lubricant

w Special tool

e Tightening torque

r Wear limit, clearance

t Engine speed

y Electrical data

Symbols u to s in the exploded diagrams indi-

cate the types of lubricants and lubrication

points.

u Engine oil

i Gear oil

o Molybdenum-disulfide oil

p Wheel-bearing grease

a Lithium-soap-based grease

s Molybdenum-disulfide grease

Symbols d to f in the exploded diagrams indi-

cate the following.

d Apply locking agent (LOCTITE^®)

f Replace the part

CONTENTS

SPECIFICATIONS

GENERAL SPECIFICATIONS

…………………………………………… 1

MAINTENANCE SPECIFICATIONS ……………………………………… 2

ENGINE …………………………………………………………………… 2

CHASSIS ………………………………………………………………… 3

ELECTRICAL

…………………………………………………………… 4

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION

…………………………………………………………… 6

PERIODIC MAINTENANCE CHART FOR EMISSION CONTROL

SYSTEM ……………………………………………………………………… 6

GENERAL MAINTENANCE AND LUBRICATION CHART …………… 6

CARBURETOR

CARBURETOR ……………………………………………………………… 9

CHECKING THE FUEL CUT SOLENOID …………………………… 11

ELECTRICAL

CARBURETOR HEATER SYSTEM ……………………………………… 12

CIRCUIT DIAGRAM

…………………………………………………… 12

TROUBLE SHOOTING ………………………………………………… 13

SELF-DIAGNOSIS

………………………………………………………… 16

TROUBLE SHOOTING ………………………………………………… 18

XVS11AWV/XVS11ATV/XVS1100ASC/XVS1100ATSC

WIRING DIAGRAM (for US and CAL)

SPEC

–1–

GENERAL SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item

Standard

Model code:

XVS1100ASC :

5YS1 (For CAL)

XVS1100ATSC : 5YS4 (For CAL)

XVS1100ATTC : 5YSD (For CAL)

XVS1100AWTC : 5YS9 (For CAL)

XVS11ATV :

5YSM (For U.S.A.)

XVS11ATVC :

5YSN (For CAL)

XVS11AWV :

5YSH (For U.S.A.)

XVS11AWVC :

5YSJ (For CAL)

Basic weight

With oil and fuel

XVS1100ASC/XVS1100ATSC/XVS1100ATTC/

XVS1100AWTC/XVS11ATVC/XVS11AWVC :

288.0 kg (635 lb)

XVS11ATV/XVS11AWV :

285.0 kg (628 lb)

Maximum load

XVS1100ASC/XVS1100ATSC/XVS1100ATTC/

XVS1100AWTC/XVS11ATVC/XVS11AWVC :

200 kg (441 lb)

XVS11ATV/XVS11AWV :

203 kg (448 lb)

SPEC

–2–

MAINTENANCE SPECIFICATIONS

MAINTENANCE SPECIFICATIONS

ENGINE

Item

Standard

Limit

Final gear oil:

Type

SAE80 API GL-4 Hypoid gear oil

•••

Quantity

0.19 L (0.20 US qt) (0.17 Imp.qt)

•••

Carburetor:

Type × quantity

BSR37 × 2

•••

Manufacturer

MIKUNI

•••

ID mark

5YS1 00

•••

Main jet

#1:#112.5 #2:#115

•••

Main air jet

#55

•••

Jet needle

5DL43-53-1

•••

Needle jet

P-0M

•••

Pilot air jet 1

#63.8

•••

Pilot air jet 2

#145

•••

Pilot outlet

1

•••

Pilot jet

#17.5

•••

Bypass 1

0.8

•••

Bypass 2

0.8

•••

Bypass 3

0.8

•••

Valve seat size

1.2

•••

Starter jet 1

#42.5

•••

Starter jet 2

0.8

•••

Throttle valve size

#125

•••

Fuel level

4–5 mm (0.16–0.20 in)

•••

SPEC

MAINTENANCE SPECIFICATIONS

–3–

CHASSIS

Item

Standard

Limit

Front suspension:

Type

Telescopic fork

•••

Spring/shock absorber type

Coil spring/oil damper

•••

Shock absorber travel

140.0 mm (5.51 in)

•••

Fork spring free length

371.9 mm (14.64 in)

•••

Collar length

183.0 mm (7.20 in)

•••

Installed length

334.4 mm (13.17 in)

•••

Spring rate K1

4.40 N/mm (25.12 lb/in) (0.45 kgf/mm)

•••

Spring rate K2

6.30 N/mm (35.97 lb/in) (0.64 kgf/mm)

•••

Spring stroke K1

0.0–77.5 mm (0.00–3.05 in)

•••

Spring stroke K2

77.5–140.0 mm (3.05–5.51 in)

•••

Inner tube outer diameter

41.0 mm (1.61 in)

•••

Optional spring available

No

•••

Recommended oil

Yamaha fork oil 10WT

•••

Quantity

488.0 cm³ (16.50 US oz) (17.21 Imp.oz)

•••

Level

99.0 mm (3.90 in)

•••

SPEC

–4–

MAINTENANCE SPECIFICATIONS

ELECTRICAL

Item

Standard

Limit

TCI:

Pickup coil resistance

189–231 ΩGray–Black

•••

TCI unit model/manufacturer

J4T145/MITSUBISHI

•••

Battery:

Model

GT14B-4

•••

Voltage, capacity

12 V, 12.0 Ah

•••

Specific gravity

1.32

•••

Manufacturer

GS YUASA

•••

Ten hour rate amperage

1.20 A

•••

Bulb voltage, wattage × quantity:

Headlight

12 V, 60 W/55.0 W × 1

•••

Tail/brake light

12 V, 8.0 W/27.0 W × 1

•••

Front turn signal/position light

XVS1100ASC/XVS1100ATSC :

12 V, 27 W/8.0 W × 2

•••

XVS1100ATTC/XVS1100AWTC/

XVS11ATV/XVS11ATVC/XVS11AWV/

XVS11AWVC :

12 V, 23 W/8.0 W × 2

•••

Rear turn signal light

XVS1100ASC/XVS1100ATSC :

12 V, 27.0 W × 2

•••

XVS1100ATTC/XVS1100AWTC/

XVS11ATV/XVS11ATVC/XVS11AWV/

XVS11AWVC :

12 V, 21.0 W × 2

•••

Meter lighting

14 V, 1.4 W × 2

•••

Starting circuit cut-off relay:

Model/manufacturer

G8R-30Y-U0/OMRON

•••

Coil resistance

162–198 Ω

•••

Fuel pump relay:

Model/manufacturer

G8R-30Y-U0/OMRON

•••

Coil resistance

162–198 Ω

•••

SPEC

MAINTENANCE SPECIFICATIONS

–5–

Item

Standard

Limit

Fuses:

Main fuse

30.0 A

•••

Headlight fuse

15.0 A

•••

Signaling system fuse

10.0 A

•••

Ignition fuse

10.0 A

•••

Backup fuse

5.0 A

•••

Carburetor heater fuse

15.0 A

•••

Ignitor unit fuse

5.0 A

•••

Reserve fuse

30.0 A

•••

Reserve fuse

15.0 A

•••

Reserve fuse

10.0 A

•••

Reserve fuse

5.0 A

•••

CHK

ADJ

–6–

INTRODUCTION/ PERIODIC MANTENANCE CHART FOR

EMISSION CONTROL SYSTEM/ GENERAL MAINTENANCE

AND LUBRICATION CHART

EB300000

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION

This chapter includes all information necessary to perform recommended checks and adjustments.

If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a

longer service life and reduce the need for costly overhaul work. This information applies to vehi-

cles already in service as well as to new vehicles that are being prepared for sale. All service tech-

nicians should be familiar with this entire chapter.

EB301000

PERIODIC MAINTENANCE CHART FOR EMISSION CONTROL SYSTEM

*

Since these items require special tools, data and technical skills, they should be serviced by a

Yamaha dealer.

GENERAL MAINTENANCE AND LUBRICATION CHART

No.

ITEM

ROUTINE

INITIAL

ODOMETER READINGS

600 mi

(1000 km)

or

1 month

4000 mi

(7000 km)

or

6 months

8000 mi

(13000 km)

or

12 months

12000 mi

(19000 km)

or

18 months

16000 mi

(25000 km)

or

24 months

20000 mi

(31000 km)

or

30 months

1

*

Fuel line

Check fuel hoses for cracks or

damage.

Replace if necessary.

Ö

Ö

Ö

Ö

Ö







2

*

Fuel filter

Replace.

Replace.

3

Spark plugs

Check condition.

Adjust gap and clean.

Replace every 8000 mi (13000

km) or 12 months.

Ö

Replace.

Ö

Replace.

Ö

4

*

Valve clearance

Check and adjust valve clearance

when engine is cold.

Ö

Ö

Ö



Ö



Ö



Ö

5

*

Crankcase breather

system

Check breather hose for cracks or

damage.

Replace if necessary.

Ö

Ö

Ö

Ö

Ö







6

*

Carburetor synchro-

nization

Adjust synchronization of carbu-

retors.

Ö

Ö

Ö

Ö

Ö

Ö







7

*

Idle speed

Check and adjust engine idle

speed.

Ö

Ö

Ö

Ö

Ö







8

*

Exhaust system

Check for leakage.

Tighten if necessary.

Replace gasket(s) if necessary.

Ö

Ö

Ö

Ö

Ö







9

*

Evaporative emis-

sion control system

(For California only)

Check control system for dam-

age.

Replace if necessary.

Ö

No.

ITEM

ROUTINE

INITIAL

ODOMETER READINGS

600 mi

(1000 km)

or

1 month

4000 mi

(7000 km)

or

6 months

8000 mi

(13000 km)

or

12 months

12000 mi

(19000 km)

or

18 months

16000 mi

(25000 km)

or

24 months

20000 mi

(31000 km)

or

30 months

1

*

Air filter element

Clean with compressed air.

Replace if necessary.

Ö

Ö

Ö

Ö

Ö







2

*

Clutch

Check operation.

Adjust or replace cable.

Ö

Ö

Ö

Ö

Ö

Ö









3

*

Front brake

Check operation, fluid level, and

for fluid leakage.

Replace brake pads if necessary.

Ö

Ö

Ö

Ö

Ö

Ö









4

*

Rear brake

Check operation, fluid level, and

for fluid leakage.

Replace brake pads if necessary.

Ö

Ö

Ö

Ö

Ö

Ö









–7–

CHK

ADJ

*

Since these items require special tools, data and technical skills, they should be serviced by a

Yamaha dealer.

GENERAL MAINTENANCE AND LUBRICATION CHART

18 *

Shock absorber as-

sembly

Check operation and for oil leak-

age.

Replace if necessary.

Ö

Ö

Ö

Ö

Ö







19 *

Rear suspension

link pivots

Apply lithium-soap-based grease

lightly.

Ö



20

Engine oil

Change (warm engine before

draining).

Ö

Ö

Ö

Ö

Ö

Ö









21 *

Engine oil filter ele-

ment

Replace.

Ö

22

Final gear oil

Check oil level and for oil leakage.

Change at initial 600 mi (1000

km) or 1 month, and thereafter

every 16000 mi (25000 km) or 24

months.

Change.

Ö

Ö

Ö



Ö



Change.



23 *

Control cables

Apply Yamaha chain and cable

lube or engine oil SAE 10W-30

thoroughly.

Ö

Ö

Ö

Ö

Ö

Ö









24 *

Throttle grip hous-

ing and cable

Check operation and free play.

Adjust the throttle cable free play

if necessary.

Lubricate the throttle grip housing

and cable.

Ö

Ö

Ö

Ö

Ö







9

*

Wheel bearings

Check bearings for smooth oper-

ation.

Replace if necessary.

Ö

Ö

Ö

Ö

Ö







10 *

Swingarm pivot

bearings

Check bearing assemblies for

looseness.

Moderately repack with lithium-

soap-based grease.

Ö



Repack.

11 *

Steering bearings

Check bearing assemblies for

looseness.

Moderately repack with lithium-

soap-based grease every 16000

mi (25000 km) or 24 months.

Ö

Ö

Ö

Ö



Ö



Repack.



12 *

Chassis fasteners

Check all chassis fitting and fas-

teners.

Correct if necessary.

Ö

Ö

Ö

Ö

Ö







13

Brake and clutch le-

ver pivot shafts

Apply lithium-soap-based grease

(all-purpose grease) lightly.

Ö

Ö

Ö

Ö

Ö







14

Brake and shift ped-

al pivot shafts

Apply lithium-soap-based grease

(all-purpose grease) lightly.

Ö

Ö

Ö

Ö

Ö







15

Sidestand pivot

Check operation.

Apply lithium-soap-based grease

(all-purpose grease) lightly.

Ö

Ö

Ö

Ö

Ö







16 *

Sidestand switch

Check operation and replace if

necessary.

Ö

Ö

Ö

Ö

Ö

Ö







17 *

Front fork

Check operation and for oil leak-

age.

Replace if necessary.

Ö

Ö

Ö

Ö

Ö







No.

ITEM

ROUTINE

INITIAL

ODOMETER READINGS

600 mi

(1000 km)

or

1 month

4000 mi

(7000 km)

or

6 months

8000 mi

(13000 km)

or

12 months

12000 mi

(19000 km)

or

18 months

16000 mi

(25000 km)

or

24 months

20000 mi

(31000 km)

or

30 months

Ö

Ö

5

*

Brake hoses

Check for cracks or damage.

Ö

Ö

Ö

Ö

Ö







Replace.

Every 4 years

6

*

Wheels (XVS11V)

Check runout, spoke tightness

and for damage.

Tighten spokes if necessary.

Ö

Ö

Ö

Ö

Ö







7

*

Wheels (XVS11AWV

/XVS11ATV)

Check runout and for damage.

Replace if necessary.

Ö

Ö

Ö

Ö

Ö







8

*

Tires

Check tread depth and for dam-

age.

Replace if necessary.

Check air pressure.

Correct if necessary.

Ö

Ö

Ö

Ö

Ö







CHK

ADJ

–8–

GENERAL MAINTENANCE AND LUBRICATION CHART

NOTE:

From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi

(13000 km) or 12 months.

EAU00477

NOTE:

8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

8Hydraulic brake service

9 After disassembling the brake master cylinders and calipers, always change the fluid. Regularly

check the brake fluid levels and fill the reservoirs as required.

9 Every two years replace the internal components of the brake master cylinders and calipers,

and change the brake fluid.

9 Replace the brake hoses every four years and if cracked or damaged.