Yamaha 5PB2, Supplementary Service Manual

Page 1: ......

Page 2: ......

Page 3: ...is necessary to use this Supplementary Service Manual together with the following manual XVS1100 L SERVICE MANUAL 5EL1 AE1 EB000000 XVS1100 N SUPPLEMENTARY SERVICE MANUAL 2000 by Yamaha Motor Co Ltd First edition September 2000 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...ll its models Modifications and signifi cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert ...

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: ...ions appearing in the text 10 Can be serviced with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Torque 15 Wear limit clearance 16 Engine speed 17 Ω V A Illustrated symbols 18 to 23 in the exploded dia grams indicate the types of lubricants and lu brication points 18 Apply engine oil 19 Apply gear oil 20 Apply molybdenum disulfide oil 21 Apply wheel bearing grease 22 Apply lightw...

Page 7: ... AND ADJUSTMENTS INTRODUCTION 16 PERIODIC MAINTENANCE LUBRICATION INTERVALS 16 ELECTRICAL SYSTEM 18 REPLACING THE HEADLIGHT BULB 18 ADJUSTING THE HEADLIGHT BEAM 19 CARBURETION AIR INDUCTION SYSTEM 20 AIR INDUCTION SYSTEM DIAGRAMS 20 CHECKING THE AIR INDUCTION SYSTEM 22 CHASSIS FRONT AND REAR BRAKES 23 FRONT BRAKE CALIPERS 23 STEERING HEAD 24 ...

Page 8: ......

Page 9: ...ATIONS Item Standard Model code XVS1100 5PB2 Basic weight With oil and a full fuel tank 275 kg Tire Type Size front rear Manufacturer front rear Type front rear With tube 110 90 18 61S 170 80 15M C 77S DUNLOP DUNLOP K555F K555 Maximum load except motorcycle 200 kg ...

Page 10: ... Camshaft outside diameter Shaft to cap clearance Cam dimensions Intake A B C Exhaust A B C Camshaft runout limit Chain drive left right 25 000 25 021 mm 24 96 24 98 mm 0 020 0 061 mm 39 112 39 212 mm 32 093 32 193 mm 7 162 mm 39 112 39 212 mm 32 127 32 227 mm 7 162 mm 39 012 mm 31 993 mm 7 012 mm 39 012 mm 32 027 mm 7 012 mm 0 03 mm ...

Page 11: ... 356 9 mm 319 4 mm 183 mm 4 41 N mm 0 9 kg mm 6 37 N mm 1 3 kg mm 0 77 5 mm 77 5 140 mm No 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 Tightening torques Part to be tightened Thread size Tightening torque Remarks g Nm m kg ft lb ...

Page 12: ...ce color A C magneto F4T654 MITSUBISHI 14 V 305 W at 5 000 r min 0 36 0 44 Ω at 20_C White White SSS SSS SSS SSS Electric starter system Type Starter motor Model manufacturer Output Armature coil resistance Brush overall length Brush spring pressure Commutator diameter 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...

Page 13: ...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 EB206000 CABLE ROUTING 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...

Page 14: ...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 sensing hose inside of the LID and not bend the sensing hose I Push the wireharne...

Page 15: ...e side cover O Route the clutch cable through the cable guide P Position the throtlle cable and starter cable as shown and clamp them with holder Q 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 R Route the each hoses through the frame guide and do not pinch it S When installing the fitting plate d...

Page 16: ... 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 box 31 Carburetor hea...

Page 17: ...t 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 mm from the top of...

Page 18: ...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 19: ...s 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 cu...

Page 20: ...tive lead 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 Fram...

Page 21: ...ward 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 ignitar unit through the hole of LID 2 J Route the fuel tank breather hose under the fuel filter and connect it fuel tank sideroll over valve side wit...

Page 22: ...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 tie upward U T...

Page 23: ...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 24: ...000 km ANNUAL NO ITEM CHECK OR MAINTENANCE JOB 1 10 20 30 40 CHECK 1 Fuel line Check fuel hoses for cracks or damage 2 Fuel filter Check condition Check condition 3 Spark plugs Clean and regap Replace 4 Valves Check valve clearance Adjust 5 Air filter element Clean 5 Air filter element Replace 6 Clutch Check operation Adjust 7 Front brake Check operation fluid level and vehicle for fluid leakage S...

Page 25: ...dling speed and synchronization 20 Engine oil Change 21 Engine oil filter element Replace 22 Final gear oil Check oil level and vehicle for oil leakage 22 Final gear oil Change 23 Moving parts and cables Lubricate 24 Lights signals and switches Check operation Adjust headlight beam EAU03541 The air filter needs more frequent service if you are riding in unusually wet or dusty areas Hydraulic brake...

Page 26: ...s away from the bulb until it has cooled down 5 Install headlight bulb New Secure the new headlight bulb with the head light bulb holder Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistene...

Page 27: ...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 28: ... 1 Reed valve 2 Air filter 3 Orifice 4 Carburetor joint near cylinder A To the front cylinder head B To the rear cylinder head C To the orifice D To the carburetor joint rear cylinder E To the air cut off valve The orifice 3 should be installed with the arrow mark facing the air cut off valve side ...

Page 29: ...Air filter Air filter to air cut valve hose Air cut valve Vacuume hose 2 Orifice Vacuum hose 1 Reed valve case to rear cylinder head pipe Reed valve case to rear cylinder head pipe 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure AIR INDUCTION SYSTEM CARB ...

Page 30: ...pes Cracks damage Replace 2 Check reed valve 1 reed valve stopper reed valve seat Cracks damage Replace the reed valve 3 Measure reed valve bending a Out of specification Replace the reed valve Maximum reed valve bending 0 4 mm 1 Surface plate 4 Check air cutoff valve Cracks damage Replace 5 Check air cleaner Cracks damage Replace Clogged Clean ...

Page 31: ...r washers Brake hose Retaining bolt Brake caliper assembly 1 1 2 1 2 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 27 Nm 2 7 m kg 30 Nm 3 0 m kg FRONT AND REAR BRAKES CHAS CHASSIS FRONT AND REAR BRAKES FRONT BRAKE CALIPERS ...

Page 32: ...light body Brake hose joint holder Upper bracket Lock washer Upper ring nut 1 1 1 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 WARNING 1st 2nd 52 Nm 5 2 m kg 18 Nm 1 8 m kg 110 Nm 11 0 m kg 7 Nm 0 7 m kg STEERING HEAD CHAS STEER...

Page 33: ...g nut Bearing cover Lower bracket Bearing upper Rubber seal Bearing lower 1 1 1 1 1 1 1 For installaiton reverse the removal procedure Refer to REMOVING THE LOWER BRACKET INSTALLING THE STEERING HEAD 1st 2nd 52 Nm 5 2 m kg 18 Nm 1 8 m kg 110 Nm 11 0 m kg 7 Nm 0 7 m kg STEERING HEAD CHAS ...

Page 34: ......