Yamaha 5KS4, Supplementary Service Manual

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Page 3: ... is necessary to use this Supplementary Service Manual together with the following manual XVS1100 SERVICE MANUAL 5EL1 AE1 EB000000 XVS1100A SUPPLEMENTARY SERVICE MANUAL 1999 by Yamaha Motor Co Ltd First edition December 1999 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform with federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manu...

Page 5: ...help identify parts and clarify procedure steps there are exploded diagrams at the start of each re moval and disassembly section 1 An easy to see exploded diagram 4 is provided for removal and disassembly jobs 2 Numbers 5 are given in the order of the jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in ...

Page 6: ...tem 8 Troubleshooting Symbols 9 to 16 indicate the following 9 Serviceable with engine mounted 10 Filling fluid 11 Lubricant 12 Special tool 13 Tightening torque 14 Wear limit clearance 15 Engine speed 16 Electrical data Symbols 17 to 22 in the exploded diagrams indi cate the types of lubricants and lubrication points 17 Engine oil 18 Gear oil 19 Molybdenum disulfide oil 20 Wheel bearing grease 21...

Page 7: ...ON CHART 19 FUEL TANK AND SEATS 21 CHASSIS 22 ADJUSTING THE REAR BRAKE 22 ADJUSTING THE SHIFT PEDAL 23 CHECKING THE TIRES 23 ELECTRICAL SYSTEM 26 ADJUSTING THE HEADLIGHT BEAM 26 CHASSIS FRONT AND REAR BRAKES 27 FRONT BRAKE PADS 27 REAR BRAKE MASTER CYLINDER 28 FRONT BRAKE CALIPERS 29 FRONT FORK 31 REMOVING THE FRONT FORK LEGS 35 DISASSEMBLING THE FRONT FORK LEGS 35 CHECKING THE FRONT FORK LEGS 36 ...

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Page 9: ...rd SAE 20W40 SE or SAE 10W 30 SE ACEA standard G4 or G5 Chassis Frame type Caster angle Trail Double cradle 33 132 mm Tire Type Size front rear Manufacturer front rear Type front rear With tube 130 90 16 67S 170 80 15M C 77S DUNLOP DUNLOP D404F D404G Maximum load except motorcycle 200 kg Tire pressure cold tire 0 90 kg 0 198 lb load front rear 90 kg 198 lb Maximum load front rear 225 kPa 2 25 kg c...

Page 10: ...J 2 Pilot outlet P O Pilot jet P J Bypass 1 B P 1 Bypass 2 B P 2 Bypass 3 B P 3 Pilot screw P S Valve seat size V S Starter jet G S 1 Starter jet G S 2 Throttle valve size Th V Fuel level F L Engine idle speed Intake vacuum Engine oil temperature 5KS4 00 1 110 2 112 5 55 1 2 5DL44 53 3 P 0M 63 8 145 1 0 17 5 0 8 0 8 0 8 3 1 2 42 5 0 8 125 4 5 mm 950 1 050 r min 34 7 37 3 kPa 260 280 mmHg 75 85 C ...

Page 11: ...cting rod big end Crank shaft Main axle Drive axle Pinion drive Middle driveshaft Rocker arm EX Camshaft EX Rocker arm EX Rocker arm IN Camshaft IN Rocker arm IN Oil filter Relief valve Oil pump Oil pan Pressure feed Splashed Orifice Item Standard Lubrication chart ...

Page 12: ...o 0 464 L 108 mm Fork oil 10W or equivalent 350 mm Rear suspension Shock absorber travel Spring free length Fitting length Spring rate K1 Stroke K1 Optional spring 50 mm 179 5 mm 163 mm 117 7 N mm 12 kg mm 0 50 mm No Front wheel Type Rim size Rim material Rim runout limit radial lateral Spoke wheel 16 MT3 00 Steel 1 0 mm 0 5 mm Brake lever brake pedal Brake lever free play at lever end Brake pedal...

Page 13: ...ter Mica undercut Starter relay Model manufacturer Amperage rating Constant mesh type SM 13 MITSUBA 0 6 kW 0 026 0 034 Ω at 20_C 10 mm 7 65 10 01 N 780 1021 g 28 mm 0 7 mm MS5F 421 JIDECO 180 A SSS SSS SSS SSS 5 mm SSS 27 mm SSS SSS SSS Tightening torques Part to be tightened Thread size Tightening torque Remarks g Nm mSkg Brake hose holder and lower bracket Headlight stay and lower bracket Headli...

Page 14: ... 6 LUBRICATION POINTS AND LUBRICANT TYPES SPEC LUBRICATION POINTS AND LUBRICANT TYPES EB203010 CHASSIS Lubrication point Symbol Drive shaft coupling gear oil seal ...

Page 15: ... 7 LUBRICATION DIAGRAMS SPEC 1 Camshaft 2 Crankshaft 3 Main axle 4 Middle drive shaft 5 Drive axle 6 Connecting rod big end LUBRICATION DIAGRAMS ...

Page 16: ...d sensor lead 13 Sidestand switch lead 14 Neutral switch lead 15 Pickup coil lead 16 To engine 17 A C magneto lead 18 Ventilation hose 19 Sensing hose AIS carburetor joint 20 Fuel hose carburetor fuel pump 21 Clip 22 Brake hose 23 Heat protector 24 Speed meter lead 25 Wireharness 26 Purge hose carburetor sole noid valve for CAL 27 Fitting plate 28 Fuel hose inlet fuel filter fuel pump 29 Fuel hose...

Page 17: ...hook of frame side D When installing the pipe of throttle cable press it inside E Clamp the fuel hoses to the frame with the clamp F Change the fuel hose fuel cock side and fuel hose carburetor side between guide of frame and clamp carburetor side is upper G When connecting the sensing hose carburetor joint AIS with a nozzle H Push the wireharness inside of the side cover I Push the sensing hose i...

Page 18: ...ng tie near the side cover N Positionthe all connectors inside of the connector cover O Route the clutch cable through the cable guide P Fasten the handlebar switch leads left and right under the handle crown with a plastic band Set the band at four notches and install it no slacking Q Route the each hoses through the frame guide and do not pinch it R When installing the fitting plate do not pinch...

Page 19: ...ad 12 Ignition coil 13 Breather hose 14 Purge hose carburetor solenoid valve for CAL 15 Rear brake switch 16 Reserve hose 17 Air filter drain hose 18 Delay relay 19 Battery negative lead 20 Starter motor positive lead 21 Oil level switch lead 22 Rear brake switch lead 23 Carburetor heater connecter 24 Light reduce relay 25 Rectifier regulator 26 Stay 1 27 Down tube 28 Frame 29 Stay 2 30 Battery bo...

Page 20: ...ttery band B Connect the battery negative lead and push it in to the space between battery box and battery C Push the wireharness into the space between frame and start er motor relay D Route the rectifire regulator lead wireharness and starter motor positive lead through the out of frame bracket and fas ten them to the frame with a plas tic locking tie The place to fix must be between 0 mm and 10...

Page 21: ...G SPEC I Fasten the rear brake switch lead to the rear brake switch bracket with a plastic locking tie and cut of the end inside of frame J Fasten the wireharness starter motor positive lead and bat tery negative lead to the frame with a plastic locking tie K From the engine L About 70 mm E Connect the purge hose carbu retor side solenoid valve side with joint knob is out side of frame F Route the...

Page 22: ... hole while fix ing the lead to the back of the box inside the body The cutting part at the edge of the band comes to the front side of the body V Clamp the handlebar switch lead right to the frame with a holder The part to open and shut is out side of the body W Arrange the throttle position sen sor connector carburetor heater connector and thermo switch connector between the starting circuit cut...

Page 23: ... 13 Taillight lead 14 Starter relay 15 Starter motor positive lead 16 Fuel tank breather hose fuel tank roll over valve for CAL 17 Outlet 18 Inlet 19 Ventilation hose 20 Starter cable 21 Sensing hose AIS carburetor joint 22 Fuel hose fuel cock fuel filter 23 Throttle position sensor lead 24 Carburetor heater lead 25 Tappet cover 26 Clutch cable 27 Thermo switch lead 28 Wireharness 29 Frame 30 Igni...

Page 24: ... CABLE ROUTING SPEC E Position the steel band end to right side F Route the battery positive lead through the slit of the bat tery box G Clamp the igniter unit lead to the frame with a holder H To the rear fender I Connect the wireharness to the igniter unit through the hole of igniter plate J Route the fuel tank breather hose under the fuel filter and connect it fuel tank sideroll over valve side...

Page 25: ...er N Route the wireharness outside of the guide on the frame CABLE ROUTING SPEC O Clamp the clutch cable and start er cable with a holder Position the end of holder down side P Route the igniter lead through the igniter plate hole to the wire harness Q To the wireharness R Clamp the taillight lead with mud guard clamp S Clamp the taillight lead with a holder on the mud guard T Position the locking...

Page 26: ...NG SPEC 1 Throttle cable 2 Starter cable 3 Clutch cable 4 Handlebar switch lead left 5 Headlight lead 6 Brake hose 7 Handlebar switch lead right A Route the handlebar switch lead right rear side of the throttle cable ...

Page 27: ... 6 Clutch Check operation Adjust or replace cable 7 Front brake Check operation fluid level and vehicle for fluid leakage Correct accordingly Replace brake pads if necessary 8 Rear brake Check operation fluid level and vehicle for fluid leakage Correct accordingly Replace brake pads if necessary 9 Wheels Check balance runout spoke tightness and for damage Tighten spokes and rebalance replace if ne...

Page 28: ... km or 24 months whichever comes first 23 Moving parts and cables S Lubricate if necessary 24 Air induction system S Check the air cut valve and reed valve for damage S Replace the entire air induction system if necessary 25 Lights signals and switches S Check operation S Correct if necessary S Adjust headlight beam if necessary Since these items require special tools data and technical skills hav...

Page 29: ...er seat bracket Rider s seat Fuel hose Ignitor plate Mud guard Meter lead couper Fuel tank assembly 1 1 1 1 1 1 1 1 Remove the parts in the order below Set the fuel cock to OFF before dis connecting the fuel hose For installation reverse the removal procedure NOTE 23 Nm 2 3 m kg 7 Nm 0 7 m kg 7 Nm 0 7 m kg FUEL TANK AND SEATS ...

Page 30: ...s lowered After adjusting the brake pedal position check that the end of the adjusting bolt 2 is visible through the hole d c Tighten the locknut 1 to specification Locknut 16 Nm 1 6 m kg A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will co...

Page 31: ...sition Direction shift pedal is raised Direction shift pedal is lowered EB304174 CHECKING THE TIRES The following procedure applies to both of the tires 1 Measure tire pressure Out of specification Regulate The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature The tire pressure and the suspension must be adjusted according to the total ...

Page 32: ...ssenger and acces sories It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit replace the tire immediately 2 Check tire surfaces Damage wear Replace the tire Minimum tire tread depth 1 6 mm 1 Tire tread depth 2 Side wall 3 Wear indicator Do not use a tubeless tire on a wheel de signed only for tube tires to avoid tire fail ure and personal injury from sudden defl...

Page 33: ...this model Then front and rear tires should always be by the same manufactur er and of the same design No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle Front tire Manufactur er Type Size DUNLOP 130 90 16 67S D404F Rear tire Manufactur er Type Size DUNLOP 170 80 15 M C 77S D404G New tires have a relatilv...

Page 34: ...eadlight beam vertically a Turn the adjusting screw 1 in direction a or b Direction Headlight beam is raised Direction Headlight beam is lowered 2 Adjust headlight beam horizontally a Turn the adjusting knob 2 in direction a or b Direction Headlight beam moves to the right Direction Headlight beam moves to the left ...

Page 35: ...oving the front brake pads Retaining bolt Brake caliper Brake pads Pad spring 1 1 2 1 Remove the parts in the order listed For installation reverse the removal procedure Refer to REPLACING THE FRONT BRAKE PADS 23 Nm 2 3 m kg CHASSIS FRONT AND REAR BRAKES FRONT BRAKE PADS ...

Page 36: ... Brake pedal assembly Union bolt Copper washers brake hose Clips reservoir hose Master cylinder assembly Reservoir tank 1 1 1 1 2 1 1 2 1 2 1 1 1 Remove the parts in the order listed Drain Disconnect For installation reverse removal procedure Refer to REMOVING INSTALLING THE REAR BRAKE MASTER CYLINDER 64 Nm 6 4 m kg 30 Nm 3 0 m kg 23 Nm 2 3 m kg EAS00586 REAR BRAKE MASTER CYLINDER ...

Page 37: ...id Brake hose holder Union bolt Copper washers Brake hose Retaining bolt Brake caliper assembly 1 1 2 1 1 1 Remove the parts in the order listed Drain For installation reverse the removal procedure Refer to REMOVING INSTALLING THE FRONT BRAKE CALIPERS 6 Nm 0 6 m kg 23 Nm 2 3 m kg 30 Nm 3 0 m kg FRONT BRAKE CALIPERS ...

Page 38: ...isassembling the front brake calipers Pad spring Brake caliper pistons Dust seals Caliper piston seals Bleed screw 1 2 2 2 1 Remove the parts in the order listed For assembly reverse the disassembly procedure Refer to REMOVING THE FRONT BRAKE CALIPERS 1 2 3 4 5 ...

Page 39: ...der Upper bracket bolts Cap bolts Lower bracket bolts Steering stem nut Upper bracket with handle 2 2 1 2 2 2 1 1 Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISCS Refer to REMOVING INSTALLING THE FRONT FORK LEGS 40 Nm 4 0 m kg 10 Nm 1 0 m kg 7 Nm 0 7 m kg 110 Nm 11 0 m kg 20 Nm 2 0 m kg 23 Nm 2 3 m kg 30 Nm 3 0 m kg FRONT FORK ...

Page 40: ...Upper fork covers Upper fork cover spacers Upper fork cover washers Front fork legs Lower fork covers 2 2 2 2 2 For installation reverse the removal procedure 40 Nm 4 0 m kg 10 Nm 1 0 m kg 7 Nm 0 7 m kg 110 Nm 11 0 m kg 20 Nm 2 0 m kg 23 Nm 2 3 m kg 30 Nm 3 0 m kg ...

Page 41: ...Spacer Spring seat Fork spring Dust seal Oil seal clip Damper rod bolt Copper washer Damper rod rebound spring Oil seal 1 1 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed Refer to DISASSEMBLING ASSEM BLING THE FRONT FORK LEGS 1 2 3 4 5 9 6 7 8 10 11 23 Nm 2 3 m kg 30 Nm 3 0 m kg ...

Page 42: ...s Seal spacer Outer tube bushing Inner tube inner tube bushing Oil lock piece Outer tube 1 1 1 1 1 1 For assembly reverse the disassembly procedure Refer to DISASSEMBLING ASSEM BLING THE FRONT FORK LEGS 12 13 14 15 16 23 Nm 2 3 m kg 30 Nm 3 0 m kg ...

Page 43: ...stand so that the front wheel is elevated 2 Remove upper bracket Refer to STEERING HEAD 3 Loosen lower bracket pinch bolt 1 Before loosening the upper and lower bracket pinch bolts support the front fork leg 4 Remove front fork leg EAS00653 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove cap bolt O ring spacer spring seat fork spring 2 Drai...

Page 44: ...er tube into the outer tube and just before it bottoms out pull B the inner tube back quickly c Repeat this step until the inner tube sepa rates from the outer tube EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check inner tube 1 outer tube 2 Bends damage scratches Replace Do not attempt to straighten a bent inner tube as this may dangerousl...

Page 45: ...dure applies to both of the front fork legs Make sure that the oil levels both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability When assembling the front fork leg be sure to replace the following parts inner tube bushing outer tube bushing oil seal dust seal Before assembling the front fork leg make sure that all of the components are clean 1 Install...

Page 46: ...3 T handle 90890 01326 Damper rod holder 90890 01460 4 Install outer tube bushing 1 seal spacer with the fork seal driver weight 2 and adapt er 3 Fork seal driver weight 90890 01367 Adapter 90890 01381 5 Install oil seal 1 with the fork seal driver weight and adapter Make sure that the numbered side of the oil seal faces up Before installing the oil seal apply lithium soap base grease onto its lip...

Page 47: ...sembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork 9 After filling the front fork leg slowly stroke the inner tube up and down at least ten times to distribute the fork oil Be sure to stroke the inner tube slowly because the fork oil may spurt out 10 Measure front fork leg oil level a Out of specification Correct Front fork leg oil level from the ...

Page 48: ...GS 1 Install Lower fork covers 1 Front forks Temporarily tighten the lower bracket pinch bolts 2 Tighten Upper bracket Steering stem nut When aligning the fork tubes do not install the upper fork covers Make sure that the inner tube end is flush with the top of the handlebar crown 3 Tighten Lower bracket pinch bolts Cap bolts 4 Remove Steering stem nut Upper bracket 5 Install Upper fork cover wash...

Page 49: ... 41 FRONT FORK CHAS 110 Nm 11 0 m kg 20 Nm 2 0 m kg 6 Install Upper bracket 1 Steering stem nut 2 7 Tighten Upper bracket pinch bolts ...

Page 50: ...urn signal position light Headlight body Upper bracket Lock washer Upper ring nut 1 1 1 1 1 1 Remove the parts in the order listed Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over Refer to FRONT FORK Refer to HANDLEBAR Disconnect 52 Nm 5 2 m kg 18 Nm 1 8 m kg 110 Nm 11 0 m kg 23 Nm 2 3 m kg 1st 2nd STEERING HEAD ...

Page 51: ...her Lower ring nut Bearing cover Lower bracket Bearing upper Rubber seal Bearing lower 1 1 1 1 1 1 1 For installation reverse the removal procedure Refer to REMOVING THE LOWER BRACKET INSTALLING THE STEERING HEAD 52 Nm 5 2 m kg 18 Nm 1 8 m kg 110 Nm 11 0 m kg 23 Nm 2 3 m kg 1st 2nd ...

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