light YAMAHA XVS1100A 2003 User Guide

OPERATION AND IMPORTANT RIDING POINTS
5-2
5 4. Turn the starter (choke) on and
completely close the throttle. (See
page 3-12 for starter (choke) oper-
ation.)
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 pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any one
attempt. _
ECA00149
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-
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 elec-
trical 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 elec-
trical circuit.


The immobilizer system indica-
tor light should come on when
the key is turned to “ON”, and
then go off after a few seconds.
If the indicator light does not
come on when the key is turned
to “ON”, then go off, have a
Yamaha dealer check the elec-
trical circuit.
_6. After starting the engine, move the
starter (choke) back halfway.
U5KSE4.book Page 2 Wednesday, September 11, 2002 11:55 AM

OPERATION AND IMPORTANT RIDING POINTS
5-3
5
ECA00045
CAUTION:_ For maximum engine life, never ac-
celerate 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. _
EAU01258
Starting a warm engine Follow the same procedure as for start-
ing a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.
EAU00423
Shifting 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 il-
lustration.NOTE:@ To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it. @1. Shift pedal
N. Neutral position
U5KSE4.book Page 3 Wednesday, September 11, 2002 11:55 AM

OPERATION AND IMPORTANT RIDING POINTS
5-4
5
EC000048
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 dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.


Always use the clutch while
changing gears to avoid dam-
aging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
@
EAU02941
Recommended shift points
(for Switzerland only) The recommended shift points during
acceleration are shown in the table be-
low.CF-01ENOTE:@ When shifting down two gears at a
time, reduce the speed accordingly
(e.g., down to 35 km/h when shifting
from 4th to 2nd gear). @
EAU04577
Tips for reducing fuel
consumption Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:

Turn the starter (choke) off as
soon as possible.


Shift up swiftly, and avoid high en-
gine speeds during acceleration.


Do not rev the engine while shift-
ing down, and avoid high engine
speeds with no load on the engine.


Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at traf-
fic lights or at railroad crossings).
Shift point
(km/h)
1st→2nd
2nd→3rd
3rd→4th
4th→5th23
36
50
60
U5KSE4.book Page 4 Wednesday, September 11, 2002 11:55 AM

6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-2
Removing and installing the panel ....................... 6-5
Checking the spark plugs .................................... 6-6
Engine oil ............................................................. 6-7
Final gear oil ........................................................ 6-9
Cleaning the air filter element ............................ 6-11
Adjusting the carburetors ................................... 6-12
Adjusting the engine idling speed ...................... 6-12
Adjusting the throttle cable free play .................. 6-13
Adjusting the valve clearance ............................ 6-13
Tires ................................................................... 6-13
Spoke wheels .................................................... 6-16
Adjusting the clutch lever free play .................... 6-16
Adjusting the brake lever free play ..................... 6-17
Adjusting the brake pedal position ..................... 6-18
Adjusting the rear brake light switch .................. 6-18
Checking the front and rear brake pads ............. 6-19
Checking the brake fluid level ............................ 6-19
Changing the brake fluid .................................... 6-20Checking and lubricating the cables ................. 6-21
Checking and lubricating the throttle grip and
cable ............................................................... 6-21
Checking and lubricating the brake and
shift pedals ...................................................... 6-21
Checking and lubricating the brake and
clutch levers .................................................... 6-22
Checking and lubricating the sidestand ............ 6-22
Checking the front fork ...................................... 6-23
Checking the steering ....................................... 6-23
Checking the wheel bearings ............................ 6-24
Battery ............................................................... 6-25
Replacing the fuses .......................................... 6-27
Replacing the headlight bulb ............................. 6-29
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
U5KSE4.book Page 1 Wednesday, September 11, 2002 11:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU03884
NOTE:_

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


Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
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.
_22
*Engine oil filter elementReplace.√√√
23 Final gear oilCheck oil level and vehicle for oil leakage.√√ √
Change.√√√
24*Front and rear brake
switchesCheck operation.√√√√√ √
25 Moving parts and cablesLubricate.√√√√ √
26*Throttle grip housing
and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√√ √
27*Muffler and exhaust pipeCheck the screw clamp for looseness.√√√√√
28*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
U5KSE4.book Page 4 Wednesday, September 11, 2002 11:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6
EAU01673
Checking the spark plugs 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 mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
To remove a spark plug
1. Remove the appropriate spark
plug cover (rear right or front left)
by pulling it off as shown.
2. Remove the spark plug cap.3. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.
To check the spark plugs
1. Check that the porcelain insulator
around the center electrode on
each spark plug is a medi-
um-to-light tan (the ideal color
when the motorcycle is ridden nor-
mally).
2. Check that all spark plugs installed
in the engine have the same color.
NOTE:@ If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle. @3. Check each spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and replace
it if necessary.
1. Spark plug cover
1. Spark plug wrench
Specified spark plug:
BPR7ES (NGK) or
W22EPR-U (DENSO)
U5KSE4.book Page 6 Wednesday, September 11, 2002 11:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
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 speci-
fied torque as soon as possible. @4. Install the spark plug cap.
5. Place the spark plug cover in the
original position.
EAU04618
Engine oil The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:_ Make sure that the motorcycle is posi-
tioned 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.
a. Spark plug gapSpark plug gap:
0.7–0.8 mm
Tightening torque:
Spark plug:
20 Nm (2.0 m·kgf)
U5KSE4.book Page 7 Wednesday, September 11, 2002 11:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
ECA00133
CAUTION:_

In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.


Make sure that no foreign mate-
rial 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. _
EC000067
CAUTION:_ If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha deal-
er 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 when necessary. _
EAU04083
Final gear oil The final gear case must be checked
for oil leakage before each ride. If any
leakage is found, have a Yamaha deal-
er check and repair the motorcycle. 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.
EW000066
WARNING
_

Make sure that no foreign mate-
rial enters the final gear case.


Make sure that no oil gets on
the tire or wheel.
_
Recommended engine oil:
See page 8-1.
Oil quantity:
Periodic oil change:
3.0 L
Total amount (dry engine):
3.6 L
U5KSE4.book Page 9 Wednesday, September 11, 2002 11:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 To check the final gear oil level
1. Place the motorcycle 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 motorcycle is
positioned straight up when check-
ing the oil level. A slight tilt to the
side can result in a false reading.
_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. _3. If the oil is below the brim of the fill-
er hole, add sufficient oil of the rec-
ommended 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.
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.
4. Add the recommended final gear
oil to the brim of the filler hole.
NOTE:_ GL4 is a quality rating. Hypoid gear oils
rated GL5 or GL6 may also be used. _5. Install and tighten the oil filler bolt.
6. Check the final gear case for oil
leakage. If oil is leaking, check for
the cause.
1. Final gear oil drain bolt
2. Final gear oil filler bolt
3. Correct oil level
Tightening torque:
Final gear oil drain bolt:
23 Nm (2.3 m·kgf)
Recommended final gear oil:
Hypoid gear oil SAE 80
(API GL4)
or multi-grade hypoid gear oil
SAE 80W-90
Oil quantity:
0.2 L
U5KSE4.book Page 10 Wednesday, September 11, 2002 11:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
6
EAU03195*
Cleaning the air filter element The air filter element should be cleaned
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart. Clean the air filter element
more frequently if you are riding in un-
usually wet or dusty areas.
1. Remove the air filter case cover by
removing the screws.
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.4. Insert the air filter element into the
air filter case as shown.
EC000082*
CAUTION:@

Make sure that the air filter ele-
ment is properly seated in the
air filter case.


The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
pistons and/or cylinders may
become excessively worn.
@5. Install the air filter case cover by
installing the screws.
1. Air filter case cover
2. Screw (× 3)
1. Air filter element
2. Projection
3. Slot
U5KSE4.book Page 11 Wednesday, September 11, 2002 11:55 AM