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PRINTED ON RECYCLED PAPER
YAMAHA MOTOR CO., LTD.
PRINTED IN JAPAN
2004.04-2.1
×1 CR
(E)
LIT-11626-18-16
OWNER’S MANUAL
XVS1100AWT(C)
XVS1100ATT(C)
5YS-28199-11
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EAU10041
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INTRODUCTION
EAU10080
Congratulations on your purchase of the Yamaha XVS1100AW(C)/XVS1100AT(C). This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer.
The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture. Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual.
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IMPORTANT MANUAL INFORMATION
EAU10130
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
CAUTION:
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.
NOTE:
● This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle
● is subsequently sold.
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.
EWA10010
WARNING
PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY
AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTOR-
CYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES
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IMPORTANT MANUAL INFORMATION
AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS
AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY
THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.
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IMPORTANT MANUAL INFORMATION
AFFIX DEALER
LABEL HERE
XVS1100AWT(C)/XVS1100ATT(C)
OWNER’S MANUAL
©2004 by Yamaha Motor Corporation, U.S.A.
1st edition, March 2004
All rights reserved.
Any reprinting or unauthorized use without the written permission of
Yamaha Motor Corporation, U.S.A. is expressly prohibited.
Printed in Japan.
P/N LIT-11626-18-16
EAU10192
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SAFETY INFORMATION ..................1-1
Location of important labels ...........1-5
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments ................2-3
FUNCTIONS .......................................3-1
Main switch/steering lock ................3-1
Indicator and warning lights ............3-2
Speedometer unit ...........................3-3
Handlebar switches ........................3-3
Clutch lever ....................................3-4
Shift pedal ......................................3-5
Brake lever .....................................3-5
Brake pedal ....................................3-5
Fuel tank cap ..................................3-6
Fuel ................................................3-6
(for California only) ......................3-7
Fuel cock ........................................3-8
Starter (choke) lever ........................3-9
Seats ..............................................3-9
Helmet holder ...............................3-10
Storage compartment ...................3-10
Adjusting the shock absorber assembly ...................................3-11
Luggage strap holders ..................3-13
Sidestand .....................................3-13
Ignition circuit cut-off system ....... 3-14
PRE-OPERATION CHECKS ............. 4-1
Pre-operation check list ................. 4-2
RIDING POINTS ................................ 5-1
Starting and warming up a cold engine ......................................... 5-1
Starting a warm engine .................. 5-2
Shifting ........................................... 5-3
Engine break-in .............................. 5-4
Parking ........................................... 5-5
MINOR REPAIR................................. 6-1
PERIODIC MAINTENANCE .......... 6-1
Owner’s tool kit .............................. 6-1
Periodic maintenance chart for the emission control system ............. 6-3
General maintenance and lubrication chart .......................... 6-4
Removing and installing the panel ........................................... 6-8
Checking the spark plugs .............. 6-8
Canister (for California only) ........ 6-10
Engine oil ..................................... 6-10
Final gear oil ................................ 6-12
Cleaning the air filter element ...... 6-13
Adjusting the carburetors ............. 6-14
TABLE OF CONTENTS
Adjusting the throttle cable free play ........................................... 6-15
Adjusting the valve clearance ...... 6-15
Tires ............................................. 6-15
Cast wheels .................................. 6-17
Accessories and replacement parts .......................................... 6-18
Adjusting the clutch lever free play ........................................... 6-19
Adjusting the brake lever free play ........................................... 6-19
Adjusting the rear brake light switch ........................................ 6-20
Checking the front and rear brake pads .......................................... 6-21
Checking the brake fluid level ...... 6-21
Changing the brake fluid .............. 6-22
Checking and lubricating the cables ....................................... 6-23
Checking and lubricating the throttle grip and cable ............... 6-23
Checking and lubricating the brake and shift pedals ............... 6-23
Checking and lubricating the brake and clutch levers ............. 6-24
Checking and lubricating the sidestand .................................. 6-24
Lubricating the rear suspension ... 6-25
Checking the front fork ................. 6-25
Checking the steering .................. 6-26
Checking the wheel bearings ....... 6-26
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TABLE OF CONTENTS
Battery ..........................................6-27
Replacing the fuses ......................6-28
Replacing the headlight bulb ........6-30
Replacing a turn signal light bulb or the tail/brake light bulb ..........6-31
Supporting the motorcycle ............6-31
Troubleshooting ............................6-32
Troubleshooting chart ...................6-33
STORAGE ..........................................7-1
Care ................................................7-1
Storage ...........................................7-3
SPECIFICATIONS .............................8-1
CONSUMER INFORMATION.............9-1
Identification numbers ....................9-1
Reporting safety defects .................9-3
Motorcycle noise regulation ............9-4
Maintenance record ........................9-5
WARRANTY ................................9-7
(Y.E.S.) ........................................9-9
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EAU10250
MOTORCYCLES ARE SINGLE
TRACK VEHICLES. THEIR SAFE
USE AND OPERATION ARE DEPEN-
DENT UPON THE USE OF PROPER
RIDING TECHNIQUES AS WELL AS
THE EXPERTISE OF THE OPERA-
TOR. EVERY OPERATOR SHOULD
KNOW THE FOLLOWING REQUIRE-
MENTS BEFORE RIDING THIS
MOTORCYCLE.
HE OR SHE SHOULD:
● OBTAIN THOROUGH INSTRUC-
TIONS FROM A COMPETENT
●
SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.
OBSERVE THE WARNINGS
AND MAINTENANCE REQUIRE-
●
●
MENTS IN THE OWNER’S MAN-
UAL.
OBTAIN QUALIFIED TRAINING
IN SAFE AND PROPER RIDING
TECHNIQUES.
OBTAIN PROFESSIONAL TECH-
NICAL SERVICE AS INDICATED
BY THE OWNER’S MANUAL
AND/OR WHEN MADE NECES-
SARY BY MECHANICAL CONDI-
TIONS.
Safe riding
● Always make pre-operation checks. Careful checks may help
● prevent an accident.
This motorcycle is designed to carry the operator and a passenger.
● The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile/motorcycle accidents.
Many accidents have been caused by an automobile driver who did not see the motorcycle.
Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident.
Therefore:
• Wear a brightly colored jacket.
• Use extra caution when approaching and passing through intersections, since intersec-
SAFETY INFORMATION
●
● tions are the most likely places for motorcycle accidents to occur.
• Ride where other motorists can see you. Avoid riding in another motorist’s blind spot.
Many motorcycle accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license.
• Make sure that you are qualified and that you only lend your motorcycle to other qualified operators.
• Know your skills and limits.
Staying within your limits may help you to avoid an accident.
• We recommend that you practice riding your motorcycle where there is no traffic until you have become thoroughly familiar with the motorcycle and all of its controls.
Many motorcycle accidents have been caused by error of the motorcycle operator. A typical error made by the operator is veering
1-1
1
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1
SAFETY INFORMATION
●
● wide on a turn due to EXCESSIVE
SPEED or undercornering (insufficient lean angle for the speed).
• Always obey the speed limit and never travel faster than warranted by road and traffic conditions.
• Always signal before turning or changing lanes. Make sure that other motorists can see you.
The posture of the operator and passenger is important for proper control.
• The operator should keep both hands on the handlebar and both feet on the operator footrests during operation to maintain control of the motorcycle.
• The passenger should always hold onto the operator, seat strap, or grab bar, if equipped, with both hands and keep both feet on the passenger footrests.
• Never carry a passenger unless he or she can firmly place both feet on the passenger footrests.
Never ride under the influence of alcohol or other drugs.
● This motorcycle is designed for onroad use only, therefore, it is not suitable for off-road use.
Protective apparel
The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries.
●
●
Always wear an approved helmet.
Wear a face shield or goggles.
Wind in your unprotected eyes could contribute to an impairment
●
●
● of vision which could delay seeing a hazard.
The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations.
Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or wheels and cause injury or an accident.
Never touch the engine or exhaust system during or after operation.
They become very hot and can
● cause burns. Always wear protective clothing that covers your legs, ankles, and feet.
Passengers should also observe the precautions mentioned above.
Modifications
Modifications made to this motorcycle not approved by Yamaha, or the removal of original equipment, may render the motorcycle unsafe for use and may cause severe personal injury.
Modifications may also make your motorcycle illegal to use.
Loading and accessories
Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight distribution of the motorcycle is changed. To avoid the possibility of an accident, use extreme caution when adding cargo or accessories to your motorcycle. Use extra care when riding a motorcycle that has added cargo or accessories.
Here are some general guidelines to follow if loading cargo or adding accessories to your motorcycle:
1-2
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Loading
The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of
XVS1100AW 200 kg (441 lb) (CAL)
XVS1100AW 203 kg (448 lb) (U49)
XVS1100AT 200 kg (441 lb) (CAL)
XVS1100AT 203 kg (448 lb) (U49).
When loading within this weight limit, keep the following in mind:
● Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbal-
●
● ance or instability.
Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely attached to the motorcycle before riding. Check accessory mounts and cargo restraints frequently.
Never attach any large or heavy items to the handlebar, front fork, or front fender. These items, including such cargo as sleeping bags, duffel bags, or tents, can create unstable handling or slow steering response.
Accessories
Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since Yamaha cannot test all other accessories that may be available, you must personally be responsible for the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when selecting and installing any accessories.
Keep the following guidelines in mind, as well as those provided under “Loading” when mounting accessories.
● Never install accessories or carry cargo that would impair the performance of your motorcycle. Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance,
SAFETY INFORMATION limit suspension travel, steering travel or control operation, or obscure lights or reflectors.
• Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum.
• Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross winds. These accessories may also cause instability when passing or being passed by large vehicles.
• Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the opera-
1
1-3
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1
SAFETY INFORMATION
● tor and may limit control ability, therefore, such accessories are not recommended.
Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the motorcycle’s electrical system, an electric failure could result, which could cause a dangerous loss of lights or engine power.
Gasoline and exhaust gas
● GASOLINE IS HIGHLY FLAMMA-
BLE:
• Always turn the engine off when refueling.
• Take care not to spill any gasoline on the engine or exhaust system when refueling.
• Never refuel while smoking or in
● the vicinity of an open flame.
Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your motorcycle in an area that has adequate ventilation.
●
●
●
Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch. When parking the motorcycle, note the following:
• The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas.
• Do not park the motorcycle on a slope or soft ground, otherwise it may fall over.
• Do not park the motorcycle near a flammable source (e.g. a kerosene heater, or near an open flame), otherwise it could catch fire.
When transporting the motorcycle in another vehicle, make sure that it is kept upright and that the fuel cock is turned to “ON” or “RES” (for vacuum type) / “OFF” (for manual type). If it should lean over, gasoline may leak out of the carburetor or fuel tank.
If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your
1-4 eyes, see your doctor immediately.
If any gasoline spills on your skin or clothing, immediately wash the affected area with soap and water and change your clothes.
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Location of important labels
Please read the following important labels carefully before operating this vehicle.
SAFETY INFORMATION
EAU10381
1
1-5
1
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SAFETY INFORMATION
1
2
3
4 California only
1-6
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Left view
3. Shock absorber assembly spring preload adjusting ring (page 3-11)
5. Storage compartment (page 3-10)
6. Owner’s tool kit (page 6-1)
8. Engine oil level check window (page 6-10)
2-1
DESCRIPTION
EAU10410
2
2
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DESCRIPTION
Right view
3. Main switch/steering lock (page 3-1)
4. Air filter element (page 6-13)
2-2
EAU10420
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Controls and instruments
2. Left handlebar switches (page 3-3)
3. Starter (choke) lever (page 3-9)
4. Speedometer unit (page 3-3)
6. Right handlebar switches (page 3-3)
2-3
DESCRIPTION
EAU10430
2
3
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INSTRUMENT AND CONTROL FUNCTIONS
Main switch/steering lock
EAU10460 EAU10680
LOCK
The steering is locked, and all electrical systems are off. The key can be removed.
To unlock the steering
To lock the steering
The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below.
EAU10510
ON
All electrical systems are supplied with power, and the headlight, meter lighting, taillight and position lights come on, and the engine can be started. The key cannot be removed.
EAU10660
OFF
All electrical systems are off. The key can be removed.
1. Push.
2. Turn.
1. Turn the handlebars all the way to the left.
2. Push the key in from the “OFF” position, and then turn it to “LOCK” while still pushing it.
3. Remove the key.
1. Push.
2. Turn.
Push the key in, and then turn it to
“OFF” while still pushing it.
EWA10060
WARNING
Never turn the key to “OFF” or
“LOCK” while the vehicle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident. Make sure that the vehicle is stopped before turning the key to “OFF” or
“LOCK”.
3-1
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INSTRUMENT AND CONTROL FUNCTIONS
EAU11001
Indicator and warning lights
High beam indicator light “ ”
EAU11080
This indicator light comes on when the high beam of the headlight is switched on.
1. Oil level warning light “
2. Neutral indicator light “ ”
”
3. Turn signal indicator light “
4. Engine trouble warning light “
5. High beam indicator light “ ”
”
”
Turn signal indicator light “
EAU11020
”
This indicator light flashes when the turn signal switch is pushed to the left or right.
EAU11060
Neutral indicator light “ ”
This indicator light comes on when the transmission is in the neutral position.
EAU11120
Oil level warning light “ ”
This warning light comes on when the engine oil level is low.
The electrical circuit of the warning light can be checked by turning the key to
“ON”.
If the warning light does not come on for a few seconds, then go off, have a
Yamaha dealer check the electrical circuit.
NOTE:
Even if the oil level is sufficient, the warning light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is not a malfunction.
EAU11500
Engine trouble warning light “ ”
This warning light comes on or flashes when an electrical circuit monitoring the engine is defective. When this occurs, have a Yamaha dealer check the selfdiagnosis system.
The electrical circuit of the warning light can be checked by turning the key to
“ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical circuit.
3
3-2
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INSTRUMENT AND CONTROL FUNCTIONS
Speedometer unit
EAU11731 tance that can be traveled with a full tank of fuel. This information will enable you to plan future fuel stops.
Handlebar switches
Left
EAU12343
3
1. “TRIP” button
2. Odometer/tripmeter
The speedometer unit is equipped with a digital odometer and a tripmeter. The speedometer shows riding speed. The odometer shows the total distance traveled. The tripmeter shows the distance traveled since it was last set to zero.
Pushing the “TRIP” button switches the display between the odometer mode
“ODO” and the tripmeter mode “TRIP”.
To reset the tripmeter, select it by pushing the “TRIP” button, and then push the “TRIP” button again and hold it down for at least one second. The tripmeter can be used to estimate the dis-
NOTE:
This model is not equipped with a tachometer; however, it has a built-in speed limiter, which prevents the engine speed from exceeding approximately 6800 r/min and the vehicle speed from exceeding approximately
175 km/h (110 mi/h).
1. Dimmer switch “ /
2. Horn switch “ ”
”
3. Turn signal switch “ / ”
Right
1. Engine stop switch “ / ”
2. Start switch “ ”
3-3
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INSTRUMENT AND CONTROL FUNCTIONS
EAU12400
Dimmer switch “ / ”
Set this switch to “ ” for the high beam and to “ ” for the low beam.
EAU12500
Horn switch “ ”
Press this switch to sound the horn.
EAU12430
Turn signal switch “ / ”
To signal a right-hand turn, push this switch to “ ”. To signal a left-hand turn, push this switch to “ ”. When released, the switch returns to the center position.
Since this model is equipped with a self-canceling system, the turn signal lights will self-cancel after the vehicle has traveled both about 150 m (490 ft) and for approximately 15 seconds.
However, the turn signal lights can also be canceled manually by pushing the switch in after it has returned to the center position.
NOTE:
The self-canceling system only operates when the vehicle is moving, so that the turn signal lights will not self-cancel while you are stopped at an intersection.
EAU12660
Engine stop switch “ / ”
Set this switch to “ ” before starting the engine. Set this switch to “ ” to stop the engine in case of an emergency, such as when the vehicle overturns or when the throttle cable is stuck.
EAU12710
Start switch “ ”
Push this switch to crank the engine with the starter.
CAUTION:
ECA10050
See page 5-1 for starting instruc-
tions prior to starting the engine.
Clutch lever
EAU12820
1. Clutch lever
The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar grip. To engage the clutch, release the lever. The lever should be pulled rapidly and released slowly for smooth clutch operation.
The clutch lever is equipped with a clutch switch, which is part of the igni-
tion circuit cut-off system. (See page
3
3-4
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INSTRUMENT AND CONTROL FUNCTIONS
Shift pedal
EAU12880
Brake lever
EAU12890
Brake pedal
EAU12941
3
1. Shift pedal
The shift pedal is located on the left side of the engine and is used in combination with the clutch lever when shifting the gears of the 5-speed constant-mesh transmission equipped on this motorcycle.
NOTE:
Use your toes or heel to shift up and your toes to shift down.
1. Brake lever
The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip.
1. Brake pedal
The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal.
3-5
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INSTRUMENT AND CONTROL FUNCTIONS
Fuel tank cap
1. Fuel tank cap lock cover
2. “ ” mark
3. Unlock.
4. Lock.
To remove the fuel tank cap
Slide the lock cover open, insert the key into the lock, and then turn it 1/4 turn clockwise. The lock will be released and the fuel tank cap can be removed.
To install the fuel tank cap
EAU13120 2. Turn the key counterclockwise to the original position, remove it, and then close the lock cover.
NOTE:
The fuel tank cap cannot be installed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked.
EWA10130
WARNING
Make sure that the fuel tank cap is properly installed before riding.
1. Insert the fuel tank cap into the tank opening with the key inserted in the lock and with the “ ” mark facing forward.
Fuel
EAU13210
1. Fuel tank filler tube
2. Fuel level
Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown.
EWA10880
WARNING
●
●
Do not overfill the fuel tank, otherwise it may overflow when the fuel warms up and expands.
Avoid spilling fuel on the hot engine.
3
3-6
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3
INSTRUMENT AND CONTROL FUNCTIONS
ECA10070
CAUTION:
Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts.
Recommended fuel:
UNLEADED GASOLINE ONLY
Fuel tank capacity:
17.0 L (4.49 US gal) (3.74 Imp.gal)
Fuel reserve amount:
4.5 L (1.19 US gal) (0.99 Imp.gal)
EAU13300 knocking (or pinging) occurs, use a gasoline of a different brand or premium unleaded fuel. Use of unleaded fuel will extend spark plug life and reduce maintenance costs.
Gasohol
There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if the ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems.
ECA11400
CAUTION:
Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system.
Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number
[(R+M)/2] of 86 or higher, or a research octane number of 91 or higher. If
EAU13440
Catalytic converter (for
California only)
This vehicle is equipped with a catalytic converter in the muffler.
EWA10860
WARNING
The exhaust system is hot after operation. Make sure that the exhaust system has cooled down before doing any maintenance work.
ECA10700
CAUTION:
The following precautions must be observed to prevent a fire hazard or other damages.
● Use only unleaded gasoline.
●
The use of leaded gasoline will cause unrepairable damage to the catalytic converter.
Never park the vehicle near pos-
● sible fire hazards such as grass or other materials that easily burn.
Do not allow the engine to idle too long.
3-7
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INSTRUMENT AND CONTROL FUNCTIONS
EAU13550
Fuel cock
The fuel cock supplies fuel from the tank to the carburetors while also filtering it.
The fuel cock lever positions are explained as follows and shown in the illustrations.
ON
OFF
1. Pointed end positioned over “ON”
With the fuel cock lever in this position, fuel flows to the carburetors. Turn the fuel cock lever to this position when starting the engine and riding.
RES
This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the fuel cock lever to this position if you run out of fuel while riding. When this occurs, refuel as soon as possible and be sure to turn the fuel cock lever back to “ON”!
3
1. Pointed end positioned over “OFF”
With the fuel cock lever in this position, fuel will not flow. Always turn the fuel cock lever to this position when the engine is not running.
1. Pointed end positioned over “RES”
3-8
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3
INSTRUMENT AND CONTROL FUNCTIONS
Starter (choke) lever “ ”
EAU13610
Seats
EAU14200
Passenger seat
To remove the passenger seat
Remove the bolt, and then pull the passenger seat up.
1. Projection
2. Seat holder
1. Starter (choke) lever “ ”
Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke).
Move the lever in direction (a) to turn on the starter (choke).
Move the lever in direction (b) to turn off the starter (choke).
ECA10990
CAUTION:
Do not use the starter (choke) for more than 3 minutes as the exhaust pipe may discolor from excessive heat. In addition, extended use of the starter (choke) will cause afterburning. If this occurs, turn off the starter (choke).
1. Bolt
To install the passenger seat
Insert the projection on the front of the passenger seat into the holder as shown, place the seat in the original position, and then install the bolt.
3-9
Rider seat
To remove the rider seat
1. Remove the passenger seat.
2. Remove the bolt, and then pull the rider seat up.
1. Bolt
U5YS11E0.book Page 10 Wednesday, April 7, 2004 10:47 AM
INSTRUMENT AND CONTROL FUNCTIONS
To install the rider seat
1. Insert the projections on the front of the rider seat into the holders as shown, place the seat in the original position, and then install the bolt.
Helmet holder
2
1
EAU14281 EAU14481
Storage compartment
The storage compartment is located on the left side of the vehicle.
To open the storage compartment
1. Slide the lock cover open, insert the key into the lock, and then turn it clockwise.
3
1. Projection
2. Seat holder
2. Install the passenger seat.
NOTE:
Make sure that the seats are properly secured before riding.
1. Helmet holder
2. Unlock.
To open the helmet holder, insert the key into the lock, and then turn the key as shown.
To lock the helmet holder, place it in the original position, and then remove the key.
EWA10160
WARNING
Never ride with a helmet attached to the helmet holder, since the helmet may hit objects, causing loss of control and possibly an accident.
1. Storage compartment cover
2. Storage compartment lock cover
3-10
U5YS11E0.book Page 11 Wednesday, April 7, 2004 10:47 AM
3
INSTRUMENT AND CONTROL FUNCTIONS
1. Storage compartment lock
2. Pull the storage compartment cover out as shown.
1. Storage compartment cover
2. Turn the key counterclockwise, remove it, and then close the lock cover.
EAU14871
Adjusting the shock absorber assembly
The shock absorber assembly is located under the rider seat and is equipped with a spring preload adjusting ring.
ECA10100
CAUTION:
Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings.
Adjust the spring preload as follows.
1. Remove the rider seat. (See page
2. Remove each quick fastener from the ignitor unit panel by pushing the center in with a screwdriver, then pulling the fastener out.
1. Storage compartment cover
To close the storage compartment
1. Place the storage compartment cover in its original position as shown.
1. Quick fastener
3-11
U5YS11E0.book Page 12 Wednesday, April 7, 2004 10:47 AM
INSTRUMENT AND CONTROL FUNCTIONS
3. Pull the ignitor unit panel out to the right.
1. Ignitor unit panel
4. Remove the mudguard by removing each quick fastener.
1
5. To increase the spring preload and thereby harden the suspension, turn the adjusting ring in direction
(a). To decrease the spring preload and thereby soften the suspension, turn the adjusting ring in direction (b).
NOTE:
● Align the appropriate notch in the adjusting ring with the position in-
● dicator on the shock absorber.
Use the special wrench included in the owner’s tool kit to make the adjustment.
Spring preload setting:
Minimum (soft):
1
Standard:
4
Maximum (hard):
9
6. Install the mudguard and ignitor unit panel by installing the quick fasteners.
NOTE:
To install a quick fastener, push the pin back so that it will protrude from the fastener head, and then insert the fastener and push the protruding pin in until it is flush with the fastener head.
3
1. Quick fastener
2. Mudguard
2
1. Position indicator
2. Spring preload adjusting ring
3. Special wrench
3-12
1. Quick fastener (after removal)
2. Quick fastener (before installation)
U5YS11E0.book Page 13 Wednesday, April 7, 2004 10:47 AM
3
INSTRUMENT AND CONTROL FUNCTIONS
7. Install the rider seat.
EWA10220
WARNING
This shock absorber contains highly pressurized nitrogen gas. For proper handling, read and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling.
● Do not tamper with or attempt to open the gas cylinder.
● Do not subject the shock absorber to an open flame or other
● high heat sources, otherwise it may explode due to excessive gas pressure.
Do not deform or damage the
● gas cylinder in any way, as this will result in poor damping performance.
Always have a Yamaha dealer service the shock absorber.
Luggage strap holders
EAU15150
1. Luggage strap holder
There is a luggage strap holder on each passenger footrest.
EAU15300
Sidestand
The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the vehicle upright.
NOTE:
The built-in sidestand switch is part of the ignition circuit cut-off system, which cuts the ignition in certain situations.
(See further down for an explanation of the ignition circuit cut-off system.)
EWA10240
WARNING
The vehicle must not be ridden with the sidestand down, or if the sidestand cannot be properly moved up
(or does not stay up), otherwise the sidestand could contact the ground and distract the operator, resulting in a possible loss of control.
Yamaha’s ignition circuit cut-off system has been designed to assist the operator in fulfilling the responsibility of raising the sidestand before starting off. Therefore, check this system regularly as described
3-13
U5YS11E0.book Page 14 Wednesday, April 7, 2004 10:47 AM
INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer repair it if it does not function properly.
EAU15311
Ignition circuit cut-off system
The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions.
● It prevents starting when the transmission is in gear and the side-
● stand is up, but the clutch lever is not pulled.
It prevents starting when the transmission is in gear and the clutch le-
● ver is pulled, but the sidestand is still down.
It cuts the running engine when the transmission is in gear and the sidestand is moved down.
Periodically check the operation of the ignition circuit cut-off system according to the following procedure.
EWA10250
WARNING
If a malfunction is noted, have a
Yamaha dealer check the system before riding.
3
3-14
U5YS11E0.book Page 15 Wednesday, April 7, 2004 10:47 AM
3
INSTRUMENT AND CONTROL FUNCTIONS
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is turned on.
3. Turn the key on.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
YES
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
YES
NO
NO
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
YES NO
The system is OK. The motorcycle can be ridden.
NOTE:
This check is most reliable if performed with a warmed-up engine.
The neutral switch may be defective.
The motorcycle should not be ridden until checked by a Yamaha dealer.
The sidestand switch may be defective.
The motorcycle should not be ridden until checked by a Yamaha dealer.
The clutch switch may be defective.
The motorcycle should not be ridden until checked by a Yamaha dealer.
3-15
U5YS11E0.book Page 1 Wednesday, April 7, 2004 10:47 AM
PRE-OPERATION CHECKS
EAU15591
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.
NOTE:
Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved.
EWA11150
WARNING
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating the vehicle.
4
4-1
U5YS11E0.book Page 2 Wednesday, April 7, 2004 10:47 AM
PRE-OPERATION CHECKS
4
Pre-operation check list
ITEM
Fuel
Engine oil
Final gear oil
Front brake
Rear brake
Clutch
CHECKS
• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
• Check oil level in engine.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.
• Check vehicle for oil leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check lever free play.
• Adjust if necessary.
• Check brake pads for wear.
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
• Lubricate cable if necessary.
• Check lever free play.
• Adjust if necessary.
4-2
PAGE
EAU15602
U5YS11E0.book Page 3 Wednesday, April 7, 2004 10:47 AM
PRE-OPERATION CHECKS
PAGE
Throttle grip
ITEM
Control cables
Wheels and tires
Brake and shift pedals
Brake and clutch levers
Sidestand
Chassis fasteners
Instruments, lights, signals and switches
Sidestand switch
CHECKS
• Make sure that operation is smooth.
• Check cable free play.
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing.
• Make sure that operation is smooth.
• Lubricate if necessary.
• Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary.
• Make sure that operation is smooth.
• Lubricate pedal pivoting points if necessary.
• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.
• Make sure that operation is smooth.
• Lubricate pivot if necessary.
• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.
• Check operation.
• Correct if necessary.
• Check operation of ignition circuit cut-off system.
• If system is defective, have Yamaha dealer check vehicle.
—
—
4
4-3
U5YS11E0.book Page 1 Wednesday, April 7, 2004 10:47 AM
5
OPERATION AND IMPORTANT RIDING POINTS
EAU15950
●
●
●
EWA10270
WARNING
Become thoroughly familiar with all operating controls and their functions before riding.
Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand.
Never start the engine or operate it in a closed area for any length of time. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time. Always make sure that there is adequate ventilation.
Before starting out, make sure that the sidestand is up. If the sidestand is not raised completely, it could contact the ground and distract the operator, resulting in a possible loss of control.
EAU16420
Starting and warming up a cold engine
In order for the ignition circuit cut-off system to enable starting, one of the following conditions must be met:
● The transmission is in the neutral
● position.
The transmission is in gear with the clutch lever pulled and the sidestand up.
EWA10290
WARNING
●
●
Before starting the engine, check the function of the ignition circuit cut-off system according to the procedure
Never ride with the sidestand down.
1. Turn the fuel cock lever to “ON”.
2. Turn the key to “ON” and make sure that the engine stop switch is set to “ ”.
3. Shift the transmission into the neutral position.
NOTE:
When the transmission is in the neutral position, the neutral indicator light should be on, otherwise have a
Yamaha dealer check the electrical circuit.
4. Turn the starter (choke) on and
completely close the throttle. (See page 3-9.)
5. Start the engine by pushing the start switch.
NOTE:
If the engine fails to start, release the start switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt.
ECA11390
CAUTION:
● The oil level warning light should come on when the key is turned to “ON”, and then go off after two to three seconds. If the oil level warning light flickers or remains on after starting, imme-
5-1
U5YS11E0.book Page 2 Wednesday, April 7, 2004 10:47 AM
OPERATION AND IMPORTANT RIDING POINTS
● diately stop the engine, and then check the engine oil level and the vehicle for oil leakage. If necessary, add engine oil, and then check the warning light again. If the warning light does not come on when turning the key to “ON”, or if it does not go off after starting the engine with sufficient engine oil, have a
Yamaha dealer check the electrical circuit.
The engine trouble warning light should also come on when the key is turned to “ON”. If the warning light does not come on when the key is turned to “ON”, flashes or remains on after starting the engine, have a
Yamaha dealer check the electrical circuit.
6. After starting the engine, move the starter (choke) back halfway.
ECA11130
CAUTION:
For maximum engine life, always warm the engine up before starting off. Never accelerate hard when the engine is cold!
7. When the engine is warm, turn the starter (choke) off.
NOTE:
The engine is warm when it responds normally to the throttle with the starter
(choke) turned off. To avoid the possibility of excessive exhaust emissions, never leave the starter (choke) on longer than necessary. The time necessary for starter (choke) use depends upon the ambient temperature. Temperatures above 10 °C (50 °F) require about
7 seconds of starter (choke) use and temperatures below 10 °C (50 °F) require about 35 seconds with the starter
(choke) turned on, then about 2.5 minutes with the starter (choke) in the halfway position.
EAU16640
Starting a warm engine
Follow the same procedure as for starting a cold engine with the exception that the starter (choke) is not required when the engine is warm.
5
5-2
U5YS11E0.book Page 3 Wednesday, April 7, 2004 10:47 AM
5
OPERATION AND IMPORTANT RIDING POINTS
Shifting
1. Shift pedal
2. Neutral position
Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc.
The gear positions are shown in the illustration.
NOTE:
To shift the transmission into the neutral position, press the shift pedal down repeatedly until it reaches the end of its travel, and then slightly raise it.
EAU16671 ECA10260
CAUTION:
●
●
Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission.
Always use the clutch while changing gears to avoid damaging the engine, transmission, and drive train, which are not designed to withstand the shock of forced shifting.
4. At the recommended shift points shown in the following table, close the throttle, and at the same time, quickly pull the clutch lever in.
5. Shift the transmission into second gear. (Make sure not to shift the transmission into the neutral position.)
6. Open the throttle part way and gradually release the clutch lever.
7. Follow the same procedure when shifting to the next higher gear.
NOTE:
Always shift gears at the recommended shift points.
EAU16700
To decelerate
1. Apply both the front and the rear brakes to slow the motorcycle.
2. Shift the transmission into first gear when the motorcycle reaches
25 km/h (15.5 mi/h). If the engine is about to stall or runs very roughly, pull the clutch lever in and use the brakes to stop the motorcycle.
3. Open the throttle gradually, and at the same time, release the clutch lever slowly.
5-3
EAU16680
To start out and accelerate
1. Pull the clutch lever to disengage the clutch.
2. Shift the transmission into first gear. The neutral indicator light should go out.
U5YS11E0.book Page 4 Wednesday, April 7, 2004 10:47 AM
OPERATION AND IMPORTANT RIDING POINTS
3. Shift the transmission into the neutral position when the motorcycle is almost completely stopped. The neutral indicator light should come on.
EAU16720
Recommended shift points
The recommended shift points during acceleration and deceleration are shown in the table below.
Shift up points:
1st → 2nd: 20 km/h (12.4 mi/h)
2nd → 3rd: 30 km/h (18.6 mi/h)
3rd
→ 4th: 40 km/h (24.9 mi/h)
4th → 5th: 50 km/h (31.1 mi/h)
Shift down points:
5th
→ 4th: 25 km/h (15.5 mi/h)
4th → 3rd: 25 km/h (15.5 mi/h)
3rd → 2nd: 25 km/h (15.5 mi/h)
2nd
→ 1st: 25 km/h (15.5 mi/h)
EAU16841
Engine break-in
There is never a more important period in the life of your engine than the period between 0 and 1600 km (1000 mi). For this reason, you should read the following material carefully.
Since the engine is brand new, do not put an excessive load on it for the first
1600 km (1000 mi). The various parts in the engine wear and polish themselves to the correct operating clearances.
During this period, prolonged full-throttle operation or any condition that might result in engine overheating must be avoided.
EAU17041
0–1000 km (0–600 mi)
Avoid prolonged operation above 1/3 throttle.
1000–1600 km (600–1000 mi)
Avoid prolonged operation above 1/2 throttle.
ECA10331
CAUTION:
After 1000 km (600 mi) of operation, the engine oil and final gear oil must be changed, and the oil filter cartridge or element replaced.
1600 km (1000 mi) and beyond
The vehicle can now be operated normally.
ECA10270
CAUTION:
If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the vehicle.
5
5-4
U5YS11E0.book Page 5 Wednesday, April 7, 2004 10:47 AM
5
OPERATION AND IMPORTANT RIDING POINTS
EAU17180
Parking
When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to “OFF”.
EWA10310
WARNING
●
●
Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them.
Do not park on a slope or on soft ground, otherwise the vehicle may overturn.
ECA10380
CAUTION:
Never park in an area where there are fire hazards such as grass or other flammable materials.
5-5
U5YS11E0.book Page 1 Wednesday, April 7, 2004 10:47 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of motorcycle inspection, adjustment, and lubrication are explained on the following pages.
Maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual that is certified (if applicable).
EWA10320
WARNING
If you are not familiar with maintenance work, have a Yamaha dealer do it for you.
EAU17231 EAU17301
PERIODIC MAINTENANCE
PROPER PERIODIC MAINTENANCE
OF YOUR VEHICLE IS IMPORTANT
IN ORDER TO ENJOY LONG, PLEA-
SURABLE SERVICE. ESPECIALLY
IMPORTANT ARE THE MAINTE-
NANCE SERVICES RELATED TO
EMISSIONS CONTROL. THESE
CONTROLS NOT ONLY FUNCTION
TO ENSURE CLEANER AIR, BUT
ARE ALSO VITAL TO PROPER EN-
GINE OPERATION AND MAXIMUM
PERFORMANCE. IN THE FOLLOW-
ING PERIODIC MAINTENANCE
CHARTS, THE SERVICES RELATED
TO EMISSIONS CONTROL ARE
GROUPED SEPARATELY. THESE
SERVICES REQUIRE SPECIALIZED
DATA, KNOWLEDGE, AND EQUIP-
MENT. YAMAHA DEALERS ARE
TRAINED AND EQUIPPED TO PER-
FORM THESE PARTICULAR SER-
VICES.
Owner’s tool kit
EAU17440
1. Owner’s tool kit
The owner’s tool kit is located inside the
storage compartment. (See page
The service information included in this manual and the tools provided in the owner’s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly.
NOTE:
If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.
6
6-1
6
U5YS11E0.book Page 2 Wednesday, April 7, 2004 10:47 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EWA10340
WARNING
Modifications not approved by
Yamaha may cause loss of performance, excessive emissions, and render the vehicle unsafe for use.
Consult a Yamaha dealer before attempting any changes.
6-2
U5YS11E0.book Page 3 Wednesday, April 7, 2004 10:47 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17600
Periodic maintenance chart for the emission control system
INITIAL
No.
ITEM ROUTINE
600 mi
(1000 km) or
1 month
ODOMETER READINGS
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
2
3
4
5
*
*
*
*
Fuel line
Fuel filter
Spark plugs
Valve clearance
Crankcase breather system
• Check fuel hoses for cracks or damage.
• Replace if necessary.
• Replace.
• Check condition.
• Adjust gap and clean.
• Replace every 8000 mi (13000 km) or 12 months.
• Check and adjust valve clearance when engine is cold.
• Check breather hose for cracks or damage.
• Replace if necessary.
√
√
√
√
√
√
Replace.
√
√
6
7
8
*
*
*
Carburetor synchronization
Idle speed
Exhaust system
• Adjust synchronization of carburetors.
• Check and adjust engine idle speed.
• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if necessary.
√ √
√
√
√
√
√
9 *
Evaporative emission control system
(For California only)
• Check control system for damage.
• Replace if necessary.
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
√
√
√
√
√
√
√
√
√
Replace.
√
√
√
√
√
√
Replace.
√
√
√
√
√
√
6-3
6
U5YS11E0.book Page 4 Wednesday, April 7, 2004 10:47 AM
6
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU32182
General maintenance and lubrication chart
No.
1 * Air filter element
2 * Clutch
3 * Front brake
4 * Rear brake
5 * Brake hoses
6 * Wheels
7 * Tires
ITEM
8 * Wheel bearings
ROUTINE
• Clean with compressed air.
• Replace if necessary.
• Check operation.
• Adjust or replace cable.
• Check operation, fluid level, and for fluid leakage.
• Replace brake pads if necessary.
• Check operation, fluid level, and for fluid leakage.
• Replace brake pads if necessary.
• Check for cracks or damage.
• Replace.
• Check runout and for damage.
• Replace if necessary.
• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
• Check bearings for smooth operation.
• Replace if necessary.
INITIAL
600 mi
(1000 km) or
1 month
ODOMETER READINGS
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
√ √ √ √ √
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
Every 4 years
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
6-4
U5YS11E0.book Page 5 Wednesday, April 7, 2004 10:47 AM
No.
ITEM
PERIODIC MAINTENANCE AND MINOR REPAIR
ROUTINE
INITIAL
600 mi
(1000 km) or
1 month
ODOMETER READINGS
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
9
10 *
11 *
12
13
14
*
15 *
16 *
17 *
Swingarm pivot bearings
Steering bearings
Chassis fasteners
Brake and clutch lever pivot shafts
Brake and shift pedal pivot shafts
Sidestand pivot
Sidestand switch
Front fork
Shock absorber assembly
• Check bearing assemblies for looseness.
• Moderately repack with lithiumsoap-based grease.
• Check bearing assemblies for looseness.
• Moderately repack with lithiumsoap-based grease every 16000 mi (25000 km) or 24 months.
• Check all chassis fitting and fasteners.
• Correct if necessary.
• Apply lithium-soap-based grease
(all-purpose grease) lightly.
• Apply lithium-soap-based grease
(all-purpose grease) lightly.
• Check operation.
• Apply lithium-soap-based grease
(all-purpose grease) lightly.
• Check operation and replace if necessary.
• Check operation and for oil leakage.
• Replace if necessary.
• Check operation and for oil leakage.
• Replace if necessary.
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
Repack.
Repack.
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
6-5
6
U5YS11E0.book Page 6 Wednesday, April 7, 2004 10:47 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
6
No.
ITEM ROUTINE
INITIAL
600 mi
(1000 km) or
1 month
ODOMETER READINGS
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
18 *
19
Rear suspension link pivots
Engine oil
• Apply lithium-soap-based grease lightly.
• Change (warm engine before draining).
√ √ √
20 *
Engine oil filter element
• Replace.
√ √
21
22 *
Final gear oil
Control cables
• 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.
• Apply Yamaha chain and cable lube or engine oil SAE 10W-30 thoroughly.
Change.
√
√
√
√
√
23 *
Throttle grip housing and cable
• Check operation and free play.
• Adjust the throttle cable free play if necessary.
• Lubricate the throttle grip housing and cable.
√ √
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
√
√
√
√
√
√
√
Change.
√
√
√
√
√
√
NOTE:
From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.
6-6
U5YS11E0.book Page 7 Wednesday, April 7, 2004 10:47 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17630
NOTE:
●
●
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service
• After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required.
• Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
6
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU18751
Removing and installing the panel
The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the panel needs to be removed and installed.
1. Bolt
Checking the spark plugs
EAU19551
The spark plugs are important engine components, which are easy to check.
Since heat and deposits will cause any spark plug to slowly erode, the spark plugs should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plugs can reveal the condition of the engine.
To install the panel
Place the panel in the original position, and then install the bolt.
To remove a spark plug
1. Remove the appropriate spark plug cover (rear right or front left) by pulling it off as shown.
1. Panel A
EAU19151
Panel A
To remove the panel
Remove the bolt, and then pull the panel off as shown.
1. Spark plug cover
2. Remove the spark plug cap.
6-8
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PERIODIC MAINTENANCE AND MINOR REPAIR
3. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit.
NOTE:
If any spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such problems yourself. Instead, have a
Yamaha dealer check the vehicle.
3. Check each spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.
1. Spark plug gap
1. Spark plug wrench
Specified spark plug:
NGK/BPR7ES
DENSO/W22EPR-U
To check the spark plugs
1. Check that the porcelain insulator around the center electrode on each spark plug is a medium-tolight tan (the ideal color when the vehicle is ridden normally).
2. Check that all spark plugs installed in the engine have the same color.
To install a spark plug
1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification.
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
2. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads.
3. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque.
Tightening torque:
Spark plug:
20 Nm (2.0 m·kgf, 14.5 ft·lbf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible.
4. Install the spark plug cap.
5. Place the spark plug cover in the original position.
EAU19672
Canister (for California only)
EAU19822
Engine oil
The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element replaced at the intervals specified in the periodic maintenance and lubrication chart.
This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere.
●
●
Check each hose connection.
Check each hose and canister for
● cracks or damage. Replace if damaged.
Make sure the vent hose is not blocked. Clean it if necessary.
To check the engine oil level
1. Place the vehicle on a level surface and hold it in an upright position.
NOTE:
Make sure that the vehicle is positioned straight up when checking the oil level.
A slight tilt to the side can result in a false reading.
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Wait a few minutes until the oil settles, and then check the oil level through the check window located at the bottom-left side of the crankcase.
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NOTE:
The engine oil should be between the minimum and maximum level marks.
PERIODIC MAINTENANCE AND MINOR REPAIR
3. Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase.
NOTE:
Check the washer for damage and replace it if necessary.
1. Engine oil filler cap
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
4. If the engine oil is at or below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level.
To change the engine oil
1. Start the engine, warm it up for several minutes, and then turn it off.
2. Place an oil pan under the engine to collect the used oil.
1. Engine oil drain bolt
4. Install the engine oil drain bolt, and then tighten it to the specified torque.
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31 ft·lbf)
5. Add the specified amount of the recommended engine oil, and then install and tighten the oil filler cap.
Recommended engine oil:
Oil change quantity:
3.00 L (3.17 US qt) (2.64 Imp.qt)
ECA11620
CAUTION:
● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In addition, do not use oils labeled
“ENERGY CONSERVING II” or higher.
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PERIODIC MAINTENANCE AND MINOR REPAIR
● Make sure that no foreign material enters the crankcase.
6. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause.
NOTE:
After the engine is started, the engine oil level warning light should go off if the oil level is sufficient.
ECA10400
CAUTION:
If the oil level warning light flickers or remains on, immediately turn the engine off and have a Yamaha dealer check the vehicle.
7. Turn the engine off, and then check the oil level and correct it if necessary.
NOTE:
Have a Yamaha dealer replace the oil filter element at the intervals specified in the periodic maintenance and lubrication chart.
EAU20022
Final gear oil
The final gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the vehicle. In addition, the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart.
EWA10370
●
●
WARNING
Make sure that no foreign material enters the final gear case.
Make sure that no oil gets on the tire or wheel.
To check the final gear oil level
1. Place the vehicle on a level surface and hold it in an upright position.
NOTE:
● The final gear oil level must be
● checked on a cold engine.
Make sure that the vehicle is positioned straight up when checking the oil level. A slight tilt to the side can result in a false reading.
6-12
2. Remove the oil filler bolt, and then check the oil level in the final gear case.
NOTE:
The oil level should be at the brim of the filler hole.
1. Final gear oil drain bolt
2. Final gear oil filler bolt
3. Correct oil level
3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct level.
To change the final gear oil
1. Place an oil pan under the final gear case to collect the used oil.
U5YS11E0.book Page 13 Wednesday, April 7, 2004 10:47 AM
2. Remove the oil filler bolt and drain bolt to drain the oil from the final gear case.
3. Install the final gear oil drain bolt, and then tighten it to the specified torque.
Tightening torque:
Final gear oil drain bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
4. Add the recommended final gear oil to the brim of the filler hole.
PERIODIC MAINTENANCE AND MINOR REPAIR
6. Check the final gear case for oil leakage. If oil is leaking, check for the cause.
EAU20670
Cleaning the air filter element
The air filter element should be cleaned as follows at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas.
1. Remove the air filter case cover by removing the screws.
Recommended final gear oil:
SAE80 API GL-4 Hypoid gear oil
Oil quantity:
0.19 L (0.20 US qt) (0.17 Imp.qt)
6
NOTE:
GL4 is a quality rating. Hypoid gear oils rated GL5 or GL6 may also be used.
5. Install the oil filler bolt, and then tighten it to the specified torque.
Tightening torque:
Final gear oil filler bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
1. Air filter case cover
2. Screw
2. Pull the air filter element out.
3. Lightly tap the air filter element to remove most of the dust and dirt, and then blow the remaining dirt out with compressed air as shown.
If the air filter element is damaged, replace it.
6-13
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PERIODIC MAINTENANCE AND MINOR REPAIR
4. Insert the air filter element into the air filter case as shown.
ECA10480
CAUTION:
●
●
Make sure that the air filter element is properly seated in the air filter case.
The engine should never be operated without the air filter element installed, otherwise the piston(s) and/or cylinder(s) may become excessively worn.
5. Install the air filter case cover by installing the screws.
Adjusting the carburetors
EAU21270
The carburetors are important parts of the engine and emission control system, which require very sophisticated adjustment. Therefore, all carburetor adjustments should be left to a Yamaha dealer, who has the necessary professional knowledge and experience.
1. Air filter element
2. Projection
3. Slot
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU21380
Adjusting the throttle cable free play
EAU21400
Adjusting the valve clearance
The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.
1. Throttle cable free play
The throttle cable free play should measure 4.0–6.0 mm (0.16–0.24 in) at the throttle grip. Periodically check the throttle cable free play and, if necessary, have a Yamaha dealer adjust it.
EAU32541
Tires
To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified tires.
Tire air pressure
The tire air pressure should be checked and, if necessary, adjusted before each ride.
EWA10500
WARNING
●
●
The tire air pressure must be checked and adjusted on cold tires (i.e., when the temperature of the tires equals the ambient temperature).
The tire air pressure must be adjusted in accordance with the riding speed and with the total weight of rider, passenger, cargo, and accessories approved for this model.
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PERIODIC MAINTENANCE AND MINOR REPAIR
Tire air pressure (measured on cold tires):
0–90 kg (0–198 lb):
Front:
225 kPa (33 psi) (2.25 kgf/cm²)
Rear:
250 kPa (36 psi) (2.50 kgf/cm²)
XVS1100AW 90–200 kg (198–441 lb) (CAL)
XVS1100AW 90–203 kg (198–448 lb) (U49)
XVS1100AT 90–200 kg (198–441 lb)
(CAL)
XVS1100AT 90–203 kg (198–448 lb)
(U49):
Front:
225 kPa (33 psi) (2.25 kgf/cm²)
Rear:
250 kPa (36 psi) (2.50 kgf/cm²)
Maximum load*:
XVS1100AW 200 kg (441 lb) (CAL)
XVS1100AW 203 kg (448 lb) (U49)
XVS1100AT 200 kg (441 lb) (CAL)
XVS1100AT 203 kg (448 lb) (U49)
* Total weight of rider, passenger, cargo and accessories not carry loosely packed items that can shift. Securely pack your heaviest items close to the center of the vehicle, and distribute the weight evenly from side to side. Properly adjust the suspension for your load, and check the condition and pressure of your tires. NEVER OVER-
LOAD YOUR VEHICLE. Make sure that the total weight of the cargo, rider, passenger, and accessories
(cowling, saddlebags, etc. if approved for this model) does not exceed the maximum load of the vehicle. Operation of an overloaded vehicle could cause tire damage, an accident, or even injury.
Tire inspection
1. Tire sidewall
2. Tire wear indicator
3. Tire tread depth
Always check the tires before operating the motorcycle. If a tire tread shows crosswise lines (minimum tread depth), if the tire has a nail or glass fragments in it, or if the sidewall is cracked, contact a Yamaha dealer immediately and have the tire replaced.
Minimum tire tread depth (front and rear):
1.0 mm (0.04 in)
EWA10510
WARNING
Proper loading of your vehicle is important for several characteristics of your vehicle, such as handling, braking, performance and safety. Do
6-16
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EWA10520
WARNING
It is dangerous to ride with a wornout tire. When a tire tread begins to show lines, have a Yamaha dealer replace the tire immediately. Brakes, tires and related wheel parts replacement should also be left to a
Yamaha dealer.
Tire information
This motorcycle is equipped with cast wheels and tubeless tires.
EWA10460
WARNING
●
●
The front and rear tires should be of the same make and design, otherwise the handling characteristics of the vehicle cannot be guaranteed.
After extensive tests, only the tires listed below have been approved for this model by
Yamaha Motor Co., Ltd.
PERIODIC MAINTENANCE AND MINOR REPAIR
Front tire:
Size:
130/90-16M/C 67S
Manufacturer/model:
DUNLOP/D404F
BRIDGESTONE/EXEDRA G703
Rear tire:
Size:
170/80-15M/C 77S
Manufacturer/model:
DUNLOP/D404G
BRIDGESTONE/EXEDRA G702
EAU21990
Cast wheels
To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified wheels.
● The wheel rims should be checked for cracks, bends, warpage or damage before each ride. If any damage is found, have a Yamaha dealer replace the wheel. Do not attempt even the smallest repair to
● the wheel. A deformed or cracked wheel must be replaced.
The wheel should be balanced whenever either the tire or wheel has been changed or replaced. An unbalanced wheel can result in poor performance, adverse handling characteristics, and a short-
●
● ened tire life.
Ride at moderate speeds after changing a tire since the tire surface must first be “broken in” for it to develop its optimal characteristics.
After repairing or replacing the rear tire, tighten the valve stem nut and locknut to the specified torques.
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PERIODIC MAINTENANCE AND MINOR REPAIR
Tightening torques:
Valve stem nut:
1.5 Nm (0.15 m·kgf, 1.08 ft·lbf)
Valve stem locknut:
3.0 Nm (0.30 m·kgf, 2.17 ft·lbf)
EAU22011
Accessories and replacement parts
EWA10621
WARNING
This vehicle is not designed to pull a trailer or to be attached to a sidecar.
The accessories or replacement parts you choose for your vehicle should be designed specifically for this model, and they must be securely mounted to maintain the inherent stability of the original design. Genuine Yamaha Parts and
Accessories are designed and tested to be compatible with your vehicle. Please consider Genuine
Yamaha Parts and Accessories before making a purchase. Use of non-
Yamaha-approved accessories or replacement parts may cause loss of handling stability and riding safety.
Since Yamaha cannot control the quality of accessories or parts manufactured by other companies,
Yamaha cannot be held liable for any consequences caused by the use of items which have not been approved by Yamaha.
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU22020
Adjusting the clutch lever free play
NOTE:
If the specified free play cannot be obtained as described above or if the clutch does not operate correctly, have a Yamaha dealer check the internal clutch mechanism.
EAU22092
Adjusting the brake lever free play
1. Locknut
2. Clutch lever free play adjusting bolt
3. Clutch lever free play
The clutch lever free play should measure 5.0–10.0 mm (0.20–0.39 in) as shown. Periodically check the clutch lever free play and, if necessary, adjust it as follows.
1. Loosen the locknut at the clutch lever.
2. To increase the clutch lever free play, turn the adjusting bolt in direction (a). To decrease the clutch lever free play, turn the adjusting bolt in direction (b).
3. Tighten the locknut.
1. Brake lever free play
The brake lever free play should measure 5.0–8.0 mm (0.20–0.31 in) as shown. Periodically check the brake lever free play and, if necessary, adjust it as follows.
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PERIODIC MAINTENANCE AND MINOR REPAIR system. If there is air in the hydraulic system, have a Yamaha dealer bleed the system before operating the motorcycle. Air in the hydraulic system will diminish the braking performance, which may result in loss of control and an accident.
EAU22270
Adjusting the rear brake light switch
6
1. Locknut
2. Brake lever free play adjusting screw
1. Loosen the locknut at the brake lever.
2. To increase the brake lever free play, turn the adjusting screw in direction (a). To decrease the brake lever free play, turn the adjusting screw in direction (b).
3. Tighten the locknut.
EWA10630
WARNING
●
●
After adjusting the brake lever free play, check the free play and make sure that the brake is working properly.
A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic
1. Rear brake light switch
2. Rear brake light switch adjusting nut
The rear brake light switch, which is activated by the brake pedal, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows.
Turn the adjusting nut while holding the rear brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction (a). To make the brake light come on later, turn the adjusting nut in direction (b).
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU22321
Checking the front and rear brake pads
Front brake
The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. Each brake pad is provided with a wear indicator groove, which allows you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator grooves. If a brake pad has worn to the point that the wear indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set.
1. Brake pad wear indicator groove
Rear brake
EAU22580
Checking the brake fluid level
Front brake
1. Minimum level mark
Rear brake
6
1. Brake pad wear indicator groove
1. Minimum level mark
Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become ineffective.
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6
PERIODIC MAINTENANCE AND MINOR REPAIR
Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage.
Observe these precautions:
● When checking the fluid level, make sure that the top of the brake
● fluid reservoir is level.
Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance.
●
●
●
Be careful that water does not enter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock.
Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately.
As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause.
EAU22730
Changing the brake fluid
Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic maintenance and lubrication chart. In addition, have the oil seals of the master cylinders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking.
● Oil seals: Replace every two years.
● Brake hoses: Replace every four years.
Recommended brake fluid:
DOT 4
● Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance.
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23090
Checking and lubricating the cables
The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a
Yamaha dealer check or replace it.
EAU23110
Checking and lubricating the throttle grip and cable
The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart.
EAU23131
Checking and lubricating the brake and shift pedals
Recommended lubricant:
Yamaha Chain and Cable Lube or engine oil SAE 10W-30 (API SE)
EWA10710
WARNING
Damage to the outer housing of cables may result in internal rusting and cause interference with cable movement. Replace damaged cables as soon as possible to prevent unsafe conditions.
The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary.
6
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PERIODIC MAINTENANCE AND MINOR REPAIR
Recommended lubricant:
Lithium-soap-based grease (all-purpose grease)
EAU23140
Checking and lubricating the brake and clutch levers
EAU23200
Checking and lubricating the sidestand
The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary.
Recommended lubricant:
Lithium-soap-based grease (all-purpose grease)
The operation of the sidestand should be checked before each ride, and the sidestand pivot and metal-to-metal contact surfaces should be lubricated if necessary.
EWA10730
WARNING
If the sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it.
Recommended lubricant:
Lithium-soap-based grease (all-purpose grease)
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Lubricating the rear suspension
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23250 EAU23271
Checking the front fork
The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.
To check the condition
EWA10750
WARNING
Securely support the vehicle so that there is no danger of it falling over.
Check the inner tubes for scratches, damage and excessive oil leakage.
The pivoting points of the rear suspension must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease
To check the operation
1. Place the vehicle on a level surface and hold it in an upright position.
2. While applying the front brake, push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly.
ECA10590
CAUTION:
If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or repair it.
6
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23280
Checking the steering
Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.
1. Place a stand under the engine to raise the front wheel off the ground.
EWA10750
WARNING
Securely support the vehicle so that there is no danger of it falling over.
2. Hold the lower ends of the front fork legs and try to move them forward and backward. If any free play can be felt, have a Yamaha dealer check or repair the steering.
EAU23290
Checking the wheel bearings
The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings.
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Battery
EAU23380
1. Positive battery terminal
2. Negative battery terminal
The battery is located behind panel A.
This model is equipped with a sealedtype (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water.
ECA10620
CAUTION:
Never attempt to remove the battery cell seals, as this would permanently damage the battery.
PERIODIC MAINTENANCE AND MINOR REPAIR
●
●
EWA10760
WARNING
Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns. Avoid any contact with skin, eyes or clothing and always shield your eyes when working near batteries. In case of contact, administer the following FIRST AID.
• EXTERNAL: Flush with plenty of water.
• INTERNAL: Drink large quantities of water or milk and immediately call a physician.
• EYES: Flush with water for 15 minutes and seek prompt medical attention.
Batteries produce explosive hydrogen gas. Therefore, keep sparks, flames, cigarettes, etc., away from the battery and provide sufficient ventilation when charging it in an enclosed space.
● KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
To charge the battery
Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories.
To store the battery
1. If the vehicle will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place.
2. If the battery will be stored for more than two months, check it at least once a month and fully charge it if necessary.
3. Fully charge the battery before installation.
4. After installation, make sure that the battery leads are properly connected to the battery terminals.
6
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PERIODIC MAINTENANCE AND MINOR REPAIR
ECA10630
CAUTION:
●
●
Always keep the battery charged. Storing a discharged battery can cause permanent battery damage.
To charge a sealed-type (MF) battery, a special (constant-voltage) battery charger is required.
Using a conventional battery charger will damage the battery.
If you do not have access to a sealed-type (MF) battery charger, have a Yamaha dealer charge your battery.
EAU27101
Replacing the fuses
The main fuse is located under the ignitor unit panel.
The fuse box, which contains the fuses for the individual circuits, is located in-
side the storage compartment. (See page 3-10.)
NOTE:
Include steps 1–3 and 9–10 only for the main fuse.
1. Remove the rider seat. (See page
2. Remove the quick fasteners shown by pushing the center in with a screwdriver, then pulling the fastener out.
1. Fuse box
2. Headlight fuse
3. Signaling system fuse
4. Ignition fuse
5. Carburetor heater fuse
6. Ignitor unit fuse (for California only)
7. Backup fuse (for odometer)
8. Spare fuse
If a fuse is blown, replace it as follows.
1. Quick fastener
3. Pull the ignitor unit panel outward to the right.
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PERIODIC MAINTENANCE AND MINOR REPAIR
1. Ignitor unit panel
2. Spare main fuse
3. Main fuse
4. Turn the key to “OFF” and turn off the electrical circuit in question.
5. Remove the blown fuse, and then install a new fuse of the specified amperage.
Specified fuses:
Main fuse:
30.0 A
Backup fuse:
5.0 A
Ignition fuse:
10.0 A
Headlight fuse:
15.0 A
Carburetor heater fuse:
15.0 A
Signaling system fuse:
10.0 A
Ignitor unit fuse:
XVS1100AW 5.0 A (CAL)
XVS1100AT 5.0 A (CAL)
ECA10640
CAUTION:
Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire.
6. Turn the key to “ON” and turn on the electrical circuit in question to check if the device operates.
7. If the fuse immediately blows again, have a Yamaha dealer check the electrical system.
8. Install the storage compartment cover.
9. Place the ignitor unit panel in the original position and install the quick fasteners.
NOTE:
To install a quick fastener, push its pin back so that it will protrude from the fastener head, then insert the fastener and push the protruding pin in until it is flush with the fastener head.
1. Quick fastener (after removal)
2. Quick fastener (before installation)
10. Install the rider seat.
6
6-29
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23792
Replacing the headlight bulb
This model is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows.
1. Remove the headlight unit by removing the screws.
fected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner.
6
1. Screw
2. Disconnect the headlight coupler, and then remove the bulb cover.
3. Unhook the headlight bulb holder, and then remove the defective bulb.
1. Headlight bulb holder
EWA10790
WARNING
Headlight bulbs get very hot. Therefore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down.
4. Place a new headlight bulb into position, and then secure it with the bulb holder.
ECA10660
CAUTION:
Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely af-
1. Do not touch the glass part of the bulb.
5. Install the headlight bulb cover, and then connect the coupler.
6. Install the headlight unit by installing the screws.
7. Have a Yamaha dealer adjust the headlight beam if necessary.
6-30
U5YS11E0.book Page 31 Wednesday, April 7, 2004 10:47 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU24281
Replacing a turn signal light bulb or the tail/brake light bulb
1. Remove the lens by removing the screws.
2. Remove the defective bulb by pushing it in and turning it counterclockwise.
3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops.
4. Install the lens by installing the screws.
ECA10680
CAUTION:
Do not overtighten the screws, otherwise the lens may break.
EAU24350
Supporting the motorcycle
Since this model is not equipped with a centerstand, follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand upright. Check that the motorcycle is in a stable and level position before starting any maintenance. A strong wooden box can be placed under the engine for added stability.
1. Screw
To service the front wheel
1. Stabilize the rear of the motorcycle by using a motorcycle stand or, if an additional motorcycle stand is not available, by placing a jack under the frame in front of the rear wheel.
2. Raise the front wheel off the ground by using a motorcycle stand.
1. Screw
To service the rear wheel
Raise the rear wheel off the ground by using a motorcycle stand or, if a motorcycle stand is not available, by placing
6
6-31
U5YS11E0.book Page 32 Wednesday, April 7, 2004 10:47 AM
6
PERIODIC MAINTENANCE AND MINOR REPAIR a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm.
EAU25850
Troubleshooting
Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power.
The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself. However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the motorcycle properly.
Use only genuine Yamaha replacement parts. Imitation parts may look like
Yamaha parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills.
6-32
U5YS11E0.book Page 33 Wednesday, April 7, 2004 10:47 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU25891
Troubleshooting chart
WARNING
Keep away open flames and do not smoke while checking or working on the fuel system.
1. Fuel
Check the fuel level in the fuel tank.
There is enough fuel.
Check the compression.
There is no fuel.
Supply fuel.
The engine does not start.
Check the compression.
EWA10840
2. Compression
Operate the electric starter.
There is compression.
Check the ignition.
There is no compression.
Have a Yamaha dealer check the vehicle.
6
3. Ignition
Remove the spark plugs and check the electrodes.
Wet
Wipe off with a dry cloth and correct the spark plug gaps, or replace the spark plugs.
Open the throttle halfway and operate the electric starter.
Dry Have a Yamaha dealer check the vehicle.
The engine does not start.
Check the battery.
4. Battery
Operate the electric starter.
The engine turns over quickly.
The engine turns over slowly.
The battery is good.
Check the battery lead connections, and charge the battery if necessary.
The engine does not start.
Have a Yamaha dealer check the vehicle.
6-33
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7
MOTORCYCLE CARE AND STORAGE
Care
EAU26060
While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appearance of a motorcycle. Frequent and proper care does not only comply with the terms of the warranty, but it will also keep your motorcycle looking good, extend its life and optimize its performance.
ucts onto seals, gaskets and wheel axles. Always rinse the dirt and degreaser off with water.
Before cleaning
1. Cover the muffler outlets with plastic bags after the engine has cooled down.
2. Make sure that all caps and covers as well as all electrical couplers and connectors, including the spark plug caps, are tightly installed.
3. Remove extremely stubborn dirt, like oil burnt onto the crankcase, with a degreasing agent and a brush, but never apply such prod-
Cleaning
ECA10770
CAUTION:
●
●
●
Avoid using strong acidic wheel cleaners, especially on spoked wheels. If such products are used on hard-to-remove dirt, do not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse the area off with water, immediately dry it, and then apply a corrosion protection spray.
Improper cleaning can damage windshields, cowlings, panels and other plastic parts. Use only a soft, clean cloth or sponge with mild detergent and water to clean plastic.
Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products, solvent or
7-1
●
● thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
Do not use high-pressure washers or steam-jet cleaners since they cause water seepage and deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes), electric components (couplers, connectors, instruments, switches and lights), breather hoses and vents.
For motorcycles equipped with a windshield: Do not use strong cleaners or hard sponges as they will cause dulling or scratching. Some cleaning compounds for plastic may leave scratches on the windshield.
Test the product on a small hidden part of the windshield to make sure that it does not leave any marks. If the windshield is scratched, use a quality plastic polishing compound after washing.
U5YS11E0.book Page 2 Wednesday, April 7, 2004 10:47 AM
After normal use
Remove dirt with warm water, a mild detergent, and a soft, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bottlebrush for hard-to-reach areas. Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning.
ECA10790
CAUTION:
Do not use warm water since it increases the corrosive action of the salt.
2. After drying the motorcycle, apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces to prevent corrosion.
After riding in the rain, near the sea or on salt-sprayed roads
Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water, carry out the following steps after each ride in the rain, near the sea or on salt-sprayed roads.
NOTE:
Salt sprayed on roads in the winter may remain well into spring.
1. Clean the motorcycle with cold water and a mild detergent, after the engine has cooled down.
After cleaning
1. Dry the motorcycle with a chamois or an absorbing cloth.
2. Use a chrome polish to shine chrome, aluminum and stainlesssteel parts, including the exhaust system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.)
3. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces.
4. Use spray oil as a universal cleaner to remove any remaining dirt.
7-2
MOTORCYCLE CARE AND STORAGE
5. Touch up minor paint damage caused by stones, etc.
6. Wax all painted surfaces.
7. Let the motorcycle dry completely before storing or covering it.
EWA11130
WARNING
●
●
Make sure that there is no oil or wax on the brakes or tires.
If necessary, clean the brake discs and brake linings with a regular brake disc cleaner or acetone, and wash the tires with warm water and a mild detergent. Before riding at higher speeds, test the motorcycle’s braking performance and cornering behavior.
ECA10800
CAUTION:
●
●
Apply spray oil and wax sparingly and make sure to wipe off any excess.
Never apply oil or wax to any rubber and plastic parts, but treat them with a suitable care product.
7
U5YS11E0.book Page 3 Wednesday, April 7, 2004 10:47 AM
7
MOTORCYCLE CARE AND STORAGE
● Avoid using abrasive polishing compounds as they will wear away the paint.
NOTE:
Consult a Yamaha dealer for advice on what products to use.
Storage
EAU26230
Short-term
Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover.
ECA10810
CAUTION:
●
●
Storing the motorcycle in a poorly ventilated room or covering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust.
To prevent corrosion, avoid damp cellars, stables (because of the presence of ammonia) and areas where strong chemicals are stored.
Long-term
Before storing your motorcycle for several months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. For motorcycles equipped with a fuel cock that has an “OFF” position: Turn the fuel cock lever to
“OFF”.
7-3
3. Drain the carburetor float chambers by loosening the drain bolts; this will prevent fuel deposits from building up. Pour the drained fuel into the fuel tank.
4. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating.
5. Perform the following steps to protect the cylinders, piston rings, etc.
from corrosion.
a. Remove the spark plug caps and spark plugs.
b. Pour a teaspoonful of engine oil into each spark plug bore.
c. Install the spark plug caps onto the spark plugs, and then place the spark plugs on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d. Turn the engine over several times with the starter. (This will coat the cylinder walls with oil.) e. Remove the spark plug caps from the spark plugs, and then install the spark plugs and the spark plug caps.
U5YS11E0.book Page 4 Wednesday, April 7, 2004 10:47 AM
MOTORCYCLE CARE AND STORAGE
EWA10950
WARNING
To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over.
6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/centerstand.
7. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot.
8. Cover the muffler outlets with plastic bags to prevent moisture from entering them.
9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month.
Do not store the battery in an excessively cold or warm place [less than 0 °C (30 °F) or more than 30
°C (90 °F)]. For more information on storing the battery, see page
NOTE:
Make any necessary repairs before storing the motorcycle.
7
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8
SPECIFICATIONS
Dimensions:
Overall length:
2460 mm (96.9 in)
Overall width:
945 mm (37.2 in)
Overall height:
1095 mm (43.1 in)
Seat height:
710 mm (28.0 in)
Wheelbase:
1645 mm (64.8 in)
Ground clearance:
140 mm (5.51 in)
Minimum turning radius:
3400 mm (133.9 in)
Weight:
With oil and fuel:
XVS1100AW 285.0 kg (628 lb) (U49)
XVS1100AW 288.0 kg (635 lb) (CAL)
XVS1100AT 285.0 kg (628 lb) (U49)
XVS1100AT 288.0 kg (635 lb) (CAL)
Engine:
Engine type:
Air cooled 4-stroke, SOHC
Cylinder arrangement:
V-type 2-cylinder
Displacement:
1063.0 cm³ (64.86 cu.in)
Bore
× stroke:
95.0
× 75.0 mm (3.74 × 2.95 in)
Compression ratio:
8.30 :1
Starting system:
Electric starter
Lubrication system:
Wet sump
Engine oil:
Type:
YAMALUBE 4, SAE10W30 or SAE20W40
0
°
10
° 30° 50° 70° 90° 110°
130
°F
YAMALUBE 4 (10W30) or SAE 10W30
YAMALUBE 4 (20W40) or SAE 20W40
–20
°
–10
° 0° 10° 20° 30° 40°
50
°C
Recommended engine oil grade:
API service SE, SF, SG type or higher
Engine oil quantity:
Without oil filter element replacement:
3.00 L (3.17 US qt) (2.64 Imp.qt)
With oil filter element replacement:
3.10 L (3.28 US qt) (2.73 Imp.qt)
Final gear oil:
Type:
SAE80 API GL-4 Hypoid gear oil
Quantity:
0.19 L (0.20 US qt) (0.17 Imp.qt)
Air filter:
Air filter element:
Dry element
Fuel:
Recommended fuel:
Unleaded gasoline only
Fuel tank capacity:
17.0 L (4.49 US gal) (3.74 Imp.gal)
Fuel reserve amount:
4.5 L (1.19 US gal) (0.99 Imp.gal)
Carburetor:
Manufacturer:
MIKUNI
Type x quantity:
BSR37 x 2
Spark plug(s):
Manufacturer/model:
NGK/BPR7ES
Manufacturer/model:
DENSO/W22EPR-U
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Clutch:
Clutch type:
Wet, multiple-disc
Transmission:
Primary reduction system:
Spur gear
Primary reduction ratio:
78/47 (1.660)
Secondary reduction system:
Shaft drive
Secondary reduction ratio:
44/47
× 19/18 × 32/11 (2.875)
Transmission type:
Constant mesh 5-speed
8-1
U5YS11E0.book Page 2 Wednesday, April 7, 2004 10:47 AM
Operation:
Left foot operation
Gear ratio:
1st:
40/17 (2.353)
2nd:
40/24 (1.667)
3rd:
36/28 (1.286)
4th:
32/31 (1.032)
5th:
29/34 (0.853)
Chassis:
Frame type:
Double cradle
Caster angle:
33.00 °
Trail:
132.0 mm (5.20 in)
Front tire:
Type:
Tubeless
Size:
130/90-16M/C 67S
Manufacturer/model:
DUNLOP/D404F
Manufacturer/model:
BRIDGESTONE/EXEDRA G703
Rear tire:
Type:
Tubeless
Size:
170/80-15M/C 77S
SPECIFICATIONS
Manufacturer/model:
DUNLOP/D404G
Manufacturer/model:
BRIDGESTONE/EXEDRA G702
Loading:
Maximum load:
XVS1100AW 200 kg (441 lb) (CAL)
XVS1100AW 203 kg (448 lb) (U49)
XVS1100AT 200 kg (441 lb) (CAL)
XVS1100AT 203 kg (448 lb) (U49)
(Total weight of rider, passenger, cargo and accessories)
Tire air pressure (measured on cold tires):
Loading condition:
0–90 kg (0–198 lb)
Front:
225 kPa (33 psi) (2.25 kgf/cm²)
Rear:
250 kPa (36 psi) (2.50 kgf/cm²)
Loading condition:
XVS1100AW 90–200 kg (198–441 lb)
(CAL)
XVS1100AW 90–203 kg (198–448 lb)
(U49)
XVS1100AT 90–200 kg (198–441 lb) (CAL)
XVS1100AT 90–203 kg (198–448 lb) (U49)
Front:
225 kPa (33 psi) (2.25 kgf/cm²)
Rear:
250 kPa (36 psi) (2.50 kgf/cm²)
Front wheel:
Wheel type:
Cast wheel
8-2
Rim size:
16M/C x MT3.00
Rear wheel:
Wheel type:
Cast wheel
Rim size:
15M/C x MT4.50
Front brake:
Type:
Dual disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 4
Rear brake:
Type:
Single disc brake
Operation:
Right foot operation
Recommended fluid:
DOT 4
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
140.0 mm (5.51 in)
Rear suspension:
Type:
Swingarm (link suspension)
Spring/shock absorber type:
Coil spring/gas-oil damper
8
U5YS11E0.book Page 3 Wednesday, April 7, 2004 10:47 AM
8
SPECIFICATIONS
Wheel travel:
113.0 mm (4.45 in)
Electrical system:
Ignition system:
Transistorized coil ignition (digital)
Charging system:
A.C. magneto
Battery:
Model:
GT14B-4
Voltage, capacity:
12 V, 12.0 Ah
Headlight:
Bulb type:
Halogen bulb
Bulb voltage, wattage x quantity:
Headlight:
12 V, 60 W/55.0 W × 1
Tail/brake light:
12 V, 8.0/27.0 W × 1
Front turn signal/position light:
12 V, 23 W/8.0 W × 2
Rear turn signal light:
12 V, 21.0 W × 2
Meter lighting:
14 V, 1.4 W × 2
Neutral indicator light:
12 V, 1.7 W × 1
High beam indicator light:
12 V, 1.7 W × 1
Oil level warning light:
12 V, 1.7 W × 1
Turn signal indicator light:
12 V, 1.7 W × 1
Engine trouble warning light:
12 V, 1.7 W × 1
Fuses:
Main fuse:
30.0 A
Headlight fuse:
15.0 A
Signaling system fuse:
10.0 A
Ignition fuse:
10.0 A
Carburetor heater fuse:
15.0 A
Ignitor unit fuse:
XVS1100AW 5.0 A (CAL)
XVS1100AT 5.0 A (CAL)
Backup fuse:
5.0 A
8-3
U5YS11E0.book Page 1 Wednesday, April 7, 2004 10:47 AM
EAU26351
Identification numbers
Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen.
KEY IDENTIFICATION NUMBER:
Key identification number
VEHICLE IDENTIFICATION
NUMBER:
MODEL LABEL INFORMATION:
CONSUMER INFORMATION
EAU26381
Vehicle identification number
EAU26400
1. Key identification number
The key identification number is stamped into the key tag. Record this number in the space provided and use it for reference when ordering a new key.
1. Vehicle identification number
The vehicle identification number is stamped into the steering head pipe.
Record this number in the space provided.
NOTE:
The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your area.
9
9-1
U5YS11E0.book Page 2 Wednesday, April 7, 2004 10:47 AM
CONSUMER INFORMATION
EAU26470
Model label
9
1. Model label
The model label is affixed to the frame
under the rider seat. (See page 3-9.)
Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
9-2
U5YS11E0.book Page 3 Wednesday, April 7, 2004 10:47 AM
CONSUMER INFORMATION
EAU26550
Reporting safety defects
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation,
U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Yamaha Motor Corporation, U.S.A.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C.
area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain other information about motor vehicle safety from the Hotline.
9
9-3
9
U5YS11E0.book Page 4 Wednesday, April 7, 2004 10:47 AM
CONSUMER INFORMATION
EAU26560
Motorcycle noise regulation
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW”.
These acts include tampering with the following systems; i.e., modification, removal, etc.
Exhaust system
• Muffler
• Exhaust pipe
• Silencer
Intake system
• Air cleaner case
• Air cleaner element
• Intake duct
9-4
U5YS11E0.book Page 5 Wednesday, April 7, 2004 10:47 AM
CONSUMER INFORMATION
EAU26631
Maintenance record
Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required. It is not acceptable proof of maintenance work.
Date of service
Mileage
Servicing dealer name and address
Remarks
Maintenance interval
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
24000 mi
(37000 km) or
36 months
28000 mi
(43000 km) or
42 months
32000 mi
(49000 km) or
48 months
9-5
9
9
U5YS11E0.book Page 6 Wednesday, April 7, 2004 10:47 AM
CONSUMER INFORMATION
Maintenance interval
36000 mi
(55000 km) or
54 months
40000 mi
(61000 km) or
60 months
Date of service
Mileage
Servicing dealer name and address
Remarks
9-6
U5YS11E0.book Page 7 Wednesday, April 7, 2004 10:47 AM
CONSUMER INFORMATION
YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED
EAU26661
WARRANTY
9
9-7
9
U5YS11E0.book Page 8 Wednesday, April 7, 2004 10:47 AM
CONSUMER INFORMATION
9-8
U5YS11E0.book Page 9 Wednesday, April 7, 2004 10:47 AM
CONSUMER INFORMATION
EAU26750
YAMAHA EXTENDED SERVICE (Y.E.S.)
Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.).
Y.E.S. is designed and administered by Yamaha Motor
Corporation to provide maximum owner satisfaction. You get uninterrupted factory-backed coverage for extra peace of mind.
Y.E.S. is flexible. You choose the plan that’s right for you: 12 months, 24 months, 36 months or, on certain models, even 48 months beyond your warranty period.
Y.E.S. is designed and administered by the same
Yamaha people who handle your warranty – and it shows in the comprehensive coverage benefits. There are no mileage limitations. Coverage isn’t limited to
“moving parts” or the “drive train” like many other plans.
And Y.E.S. covers manufacturing defects just like the warranty. See the sample contract at your Yamaha dealer to see how comforting uninterrupted factorybacked protection can be.
You don’t have to pay anything for covered repairs.
There’s no deductible to pay, and repairs aren’t
“pro-rated.” You don’t have any “out-of-pocket” expenses for covered repairs.
In addition, Travel and Recreation Interruption Protection
(TRIP) is included at no extra cost. TRIP gives you up to
$150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service: replacement vehicle rental, emergency towing, phone calls, even food and lodging when you are away from home. This superb coverage goes into effect when you purchase Y.E.S., so it applies to any warranty repairs as well as covered repairs during your entire
Y.E.S. plan period.
Y.E.S. coverage is honored at any authorized Yamaha dealer nationwide.
Y.E.S. coverage is transferable to a new owner if you sell or trade-in. That can make your Yamaha much more valuable!
This excellent Y.E.S. plan coverage is only available to
Yamaha owners like you, and only while your Yamaha is still within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts. He can show you how easy it is to protect your investment with Yamaha
Extended Service.
9
9-9
9
U5YS11E0.book Page 10 Wednesday, April 7, 2004 10:47 AM
CONSUMER INFORMATION
We urge you to act now. You’ll get the excellent benefits of
TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your
Yamaha Limited Warranty expires.
A special note:
If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.
Yamaha Service Marketing
P.O. Box 6555
Cypress, CA 90630
1-(866)-YES-EXTD (1-866-937-3983)
9-10
U5YS11E0.book Page 1 Wednesday, April 7, 2004 10:47 AM
A
B
Accessories and replacement parts ..... 6-18
Air filter element, cleaning .................... 6-13
C
Battery .................................................. 6-27
Brake and clutch levers, checking and lubricating ........................................... 6-24
Brake and shift pedals, checking and lubricating ........................................... 6-23
Brake fluid, changing ............................ 6-22
Brake fluid level, checking .................... 6-21
Brake lever ............................................. 3-5
Brake lever free play, adjusting ............ 6-19
Brake pedal ............................................ 3-5
D
Dimmer switch ........................................ 3-4
E
Cables, checking and lubricating .......... 6-23
Canister (for California only)................. 6-10
Carburetors, adjustment ....................... 6-14
Care ........................................................ 7-1
(for California only) ............................... 3-7
Clutch lever............................................. 3-4
Clutch lever free play, adjusting ........... 6-19
Engine break-in ...................................... 5-4
Engine oil .............................................. 6-10
Engine, starting a warm.......................... 5-2
Engine stop switch.................................. 3-4
Engine trouble warning light ................... 3-2
F
Final gear oil ......................................... 6-12
Front and rear brake pads, checking .... 6-21
H
Front fork, checking...............................6-25
Fuel .........................................................3-6
Fuel cock.................................................3-8
Fuel tank cap...........................................3-6
Fuses, replacing ....................................6-28
Handlebar switches .................................3-3
Headlight bulb, replacing.......................6-30
Helmet holder........................................3-10
High beam indicator light.........................3-2
Horn switch .............................................3-4
I
K
Identification numbers .............................9-1
Ignition circuit cut-off system .................3-14
Indicator and warning lights ....................3-2
Key identification number........................9-1
L
M
Labels, location of ...................................1-5
Luggage strap holders ..........................3-13
Main switch/steering lock ........................3-1
Maintenance and lubrication, periodic.....6-4
Maintenance, emission control system ...6-3
Maintenance, periodic .............................6-1
Maintenance record ................................9-5
Model label ..............................................9-2
N
O
Neutral indicator light ..............................3-2
Noise regulation ......................................9-4
P
Oil level warning light ..............................3-2
Panel, removing and installing ................6-8
INDEX
R
Parking.................................................... 5-5
Part locations .......................................... 2-1
Pre-operation check list .......................... 4-2
S
Rear brake light switch, adjusting ......... 6-20
Rear suspension, lubricating ................ 6-25
T
Safety defects, reporting......................... 9-3
Safety information ................................... 1-1
Seats....................................................... 3-9
Shifting.................................................... 5-3
Shift pedal ............................................... 3-5
Shock absorber assembly, adjusting .... 3-11
Sidestand.............................................. 3-13
Sidestand, checking and lubricating ..... 6-24
Spark plugs, checking............................. 6-8
Specifications.......................................... 8-1
Speedometer unit ................................... 3-3
Starter (choke) lever ............................... 3-9
Starting and warming up a cold engine................................................... 5-1
Start switch ............................................. 3-4
Steering, checking ................................ 6-26
Storage ................................................... 7-3
Storage compartment ........................... 3-10
Supporting the motorcycle .................... 6-31
Throttle cable free play, adjusting ......... 6-15
Throttle grip and cable, checking and lubricating ........................................... 6-23
Tires...................................................... 6-15
Tool kit .................................................... 6-1
Troubleshooting .................................... 6-32
Troubleshooting chart ........................... 6-33
U5YS11E0.book Page 2 Wednesday, April 7, 2004 10:47 AM
INDEX
V
Turn signal indicator light ........................ 3-2
Turn signal light bulb or tail/brake light bulb, replacing .................................... 6-31
Turn signal switch ................................... 3-4
Valve clearance, adjusting .................... 6-15
Vehicle identification number .................. 9-1
W
Warranty, extended................................. 9-9
Warranty, limited ..................................... 9-7
Wheel bearings, checking..................... 6-26
Wheels .................................................. 6-17
PRINTED ON RECYCLED PAPER
YAMAHA MOTOR CO., LTD.
PRINTED IN JAPAN
2004.04-2.1
×1 CR
(E)
LIT-11626-18-16
OWNER’S MANUAL
XVS1100AWT(C)
XVS1100ATT(C)
5YS-28199-11
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Table of contents
- 3 Introduction
- 7 Table of Contents
- 9 Safety Information
- 15 Description
- 17 Controls and instruments
- 18 Instrument and Control Function
- 18 Main switch/steering lock
- 19 Indicator and warning lights
- 20 Handlebar switches
- 21 Clutch lever
- 22 Shift pedal
- 22 Brake lever and pedal
- 23 Fuel
- 26 Starter (choke)
- 28 Adjusting the shock absorber
- 34 Pre-Operation Checks
- 34 Pre-operation check list
- 36 Operation and Important Riding Points
- 36 Starting and warming up a cold engine
- 38 Shifting
- 39 Engine break-in
- 41 Periodic Maintenance and Minor Repair
- 41 Owner's tool kit
- 43 Periodic maintenance chart for the emission control system
- 44 General maintenance and lubrication chart
- 48 Checking the spark plugs
- 50 Engine oil
- 55 Adjusting the throttle cable free play
- 55 Tires
- 59 Adjusting the clutch lever free play
- 59 Adjusting the brake lever free play
- 61 Checking the front and rear brake pads
- 61 Checking the brake fluid level
- 63 Checking and lubrication the cables
- 66 Checking the steering
- 67 Battery
- 68 Replacing the fuses
- 70 Replacing the headlight bulb
- 72 Troubleshooting
- 74 Motorcycle Care and Storage
- 74 Care
- 76 Storage
- 78 Specifications
- 81 Consumer Information
- 81 Identification numbers
- 81 Vehicle identification number
- 83 Reporting safety defects
- 87 Yamaha Motor Corporation, USA Street and Enduro Motorcycle Limited Warranty
- 89 Yamaha Extended Service (Y.E.S.)
- 91 Index