YAMAHA XVS1100A 2003 Repair Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6
EAU00630
Adjusting the carburetors The carburetors are important parts of
the engine and require very sophisti-
cated adjustment. Therefore, most car-
buretor adjustments should be left to a
Yamaha dealer, who has the neces-
sary professional knowledge and expe-
rience. The adjustment described in
the following section, however, may be
serviced by the owner as part of routine
maintenance.
EC000095
CAUTION:@ The carburetors have been set and
extensively tested at the Yamaha
factory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-
mance of or damage to the engine. @
EAU04757
Adjusting the engine idling
speed The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
The engine should be warm before
making this adjustment.NOTE:_

The engine is warm when it quick-
ly responds to the throttle.


A diagnostic tachometer is needed
to make this adjustment.
_1. Attach the tachometer to the spark
plug lead.2. Check the engine idling speed
and, if necessary, adjust it to spec-
ification by turning the throttle stop
screw. To increase the engine
idling speed, turn the screw in di-
rection
a. To decrease the engine
idling speed, turn the screw in di-
rection
b.
NOTE:_ If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment. _1. Throttle stop screwEngine idling speed:
950–1,050 r/min
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6
EAU00635
Adjusting the throttle cable
free play The throttle cable free play should
measure 4–6 mm at the throttle grip.
Periodically check the throttle cable
free play and, if necessary, have a
Yamaha dealer adjust it.
EAU00637
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.
EAU04463
Tires To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, 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.
EW000082
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, car-
go, and accessories approved
for this model.
_
a. Throttle cable free playU5KSE4.book Page 13 Wednesday, September 11, 2002 11:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6
CE-21E
CE-07EEWA00012
WARNING
_ Because loading has an enormous
impact on the handling, braking,
performance and safety characteris-
tics of your motorcycle, you should
keep the following precautions in
mind.

NEVER OVERLOAD THE
MOTORCYCLE! Operation of an
overloaded motorcycle may re-
sult in tire damage, loss of con-
trol, or severe injury. Make sure
that the total weight of rider,
passenger, cargo, and accesso-
ries does not exceed the speci-
fied maximum load for the
vehicle.


Do not carry along loosely
packed items, which can shift
during a ride.


Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.


Adjust the suspension and tire
air pressure with regard to the
load.


Check the tire condition and air
pressure before each ride.
_
Tire air pressure
(measured on cold tires)
Load* Front Rear
Up to 90 kg225 kPa
(2.25 kgf/cm
2,
2.25 bar)225 kPa
(2.25 kgf/cm
2,
2.25 bar)
90 kg–maximum225 kPa
(2.25 kgf/cm
2,
2.25 bar)250 kPa
(2.50 kgf/cm
2,
2.50 bar)
Maximum load* 197 kg
* Total weight of rider, passenger, cargo and
accessories
U5KSE4.book Page 14 Wednesday, September 11, 2002 11:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
6Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail
or glass fragments in it, or if the side-
wall is cracked, have a Yamaha dealer
replace the tire immediately.
CE-08ENOTE:_ The tire tread depth limits may differ
from country to country. Always comply
with the local regulations. _
Tire information
This motorcycle is equipped with tube
tires.
EW000078
WARNING
_

The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the motor-
cycle cannot be guaranteed.


After extensive tests, only the
tires listed below have been ap-
proved for this model by
Yamaha Motor Co., Ltd.
_CE-10EEAU00681
WARNING
@

Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta-
bility and can lead to loss of
control.


The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.


It is not recommended to patch
a punctured tube. If unavoid-
able, however, patch the tube
very carefully and replace it as
soon as possible with a
high-quality product.
@
1. Tire sidewall
a. Tire tread depthMinimum tire tread depth
(front and rear)1.6 mm
FRONT
Manufacturer Size Model
Dunlop 130/90-16 M/C 67S D404F
REAR
Manufacturer Size Model
Dunlop 170/80-15 M/C 77S D404G
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6
EAU00685
Spoke wheels To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.

The wheel rims should be checked
for cracks, bends or warpage, and
the spokes for looseness or dam-
age before each ride. If any dam-
age 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 han-
dling characteristics, and a short-
ened tire life.


Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
EAU00692
Adjusting the clutch lever free
play The clutch lever free play should mea-
sure 5–10 mm as shown. Periodically
check the clutch lever free play and, if
necessary, adjust it as follows.
1. Loosen the locknut at the clutch le-
ver.
2. To increase the clutch lever free
play, turn the adjusting bolt in di-
rection
a. To decrease the clutch
lever free play, turn the adjusting
bolt in direction
b.
3. Tighten the locknut.
NOTE:@ If the specified free play cannot be ob-
tained as described above or if the
clutch does not operate correctly, have
a Yamaha dealer check the internal
clutch mechanism. @
1. Locknut
2. Clutch lever free play adjusting bolt
c. Clutch lever free play
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
EAU00696
Adjusting the brake lever free
play The brake lever free play should mea-
sure 5–8 mm as shown. Periodically
check the brake lever free play and, if
necessary, adjust it as follows.1. Loosen the locknut at the brake le-
ver.
2. To increase the brake lever free
play, turn the adjusting bolt in di-
rection
a. To decrease the brake
lever free play, turn the adjusting
bolt in direction
b.
3. Tighten the locknut.
EW000099
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
system. If there is air in the hy-
draulic system, have a Yamaha
dealer bleed the system before
operating the motorcycle. Air in
the hydraulic system will dimin-
ish the braking performance,
which may result in loss of con-
trol and an accident.
@
a. Brake lever free play
1. Locknut
2. Brake lever free play adjusting bolt
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6
EAU01746
Adjusting the brake pedal
position The top of the brake pedal should be
positioned approximately 98.5 mm
above the top of the footrest as shown.
Periodically check the brake pedal po-
sition and, if necessary, have a
Yamaha dealer adjust it.
EW000109
WARNING
@ A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the hydraulic system. If there
is air in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the motorcycle. Air in
the hydraulic system will diminish
the braking performance, which
may result in loss of control and an
accident. @
EAU00713
Adjusting the rear brake light
switch The rear brake light switch, which is ac-
tivated 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.
a. Distance between brake pedal and footrest
1. Rear brake light switch
2. Rear brake light switch adjusting nut
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6
EAU01314
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified 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 disassem-
ble 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 disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU04856
Checking the brake fluid level Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake flu-
id 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.
1. Brake pad wear indicator grooveFront
1. Brake pad wear indicator grooveRear
1. Brake fluid reservoir
2. Minimum level markFront
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6 Observe these precautions:


When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.


Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.


Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.


Be careful that water does not en-
ter 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 paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU03976
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the master cylin-
ders 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.
1. Brake fluid reservoir
2. Minimum level mark
Recommended brake fluid: DOT 4Rear
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
EAU02962
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 ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
EW000112
WARNING
@ Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions. @
EAU04034
Checking and lubricating the
throttle grip and cable The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated or
replaced at the intervals specified in
the periodic maintenance chart.
EAU03370
Checking and lubricating the
brake and shift pedals The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary. Recommended lubricant:
Engine oil
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
U5KSE4.book Page 21 Wednesday, September 11, 2002 11:55 AM