YAMAHA XVS1100A 2003 Manual PDF

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
EAU03164
Checking and lubricating the
brake and clutch levers The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
EAU03165
Checking and lubricating the
sidestand 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.
EW000113
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)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
EAU02939
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @Check the inner tubes for scratches,
damage and excessive oil leakage.To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
EC000098
CAUTION:@ If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it. @
EAU00794
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6 2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steer-
ing.
EAU01144
Checking the wheel bearings The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion 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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PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EAU04242
Battery The battery is located behind panel A.
(See page 6-5 for panel removal and
installation procedures.)
This motorcycle is equipped with a
sealed-type (MF) battery, which does
not require any maintenance. There is
no need to check the electrolyte or to
add distilled water.
EC000101
CAUTION:_ Never attempt to remove the battery
cell seals, as this would permanent-
ly damage the battery. _
EW000116
WARNING
_

Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al-
ways shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
EXTERNAL: Flush with plenty
of water.
INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a physician.
EYES: Flush with water for
15 minutes and seek prompt
medical attention.


Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed
space.


KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
_
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6 To charge the battery
Have a Yamaha dealer charge the bat-
tery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quickly
if the motorcycle is equipped with op-
tional electrical accessories.
To store the battery
1. If the motorcycle 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 in-
stallation.4. After installation, make sure that
the battery leads are properly con-
nected to the battery terminals.
EC000102
CAUTION:_

Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.


To charge a sealed-type (MF)
battery, a special (con-
stant-voltage) battery charger is
required. Using a conventional
battery charger will damage the
battery. If you do not have ac-
cess to a sealed-type (MF) bat-
tery charger, have a Yamaha
dealer charge your battery.
_
1. Positive battery terminal
2. Negative battery terminal
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
EAU04993
Replacing the fuses The main fuse is located under the igni-
tor unit panel.The fuse box, which contains the fuses
for the individual circuits, is located in-
side the storage compartment. (See
page 3-15 for storage compartment
cover removal and installation proce-
dures.)
If a fuse is blown, replace it as follows.
NOTE:_ Include steps 1–3 and 9–10 only for the
main fuse. _1. Remove the rider seat. (See page
3-13 for rider seat removal and in-
stallation procedures.)
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
7. Odometer and immobilizer system fuse
(backup fuse)
8. Spare fuse (× 3)
9. Turn signal light, taillight, auxiliary light and
hazard fuse
1. Quick fastener (× 3)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6 3. Pull the ignitor unit panel outward
to the right.
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.
EC000103
CAUTION:_ Do not use a fuse of a higher amper-
age 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.
1. Ignitor unit panel
2. Spare main fuse
3. Main fuse
Specified fuses:
Main fuse: 30 A
Odometer and
immobilizer system fuse
(backup fuse): 10 A
Ignition fuse: 10 A
Headlight fuse: 15 A
Carburetor heater fuse: 15 A
Signaling system fuse: 10 A
Ignitor unit fuse: 5 A
Turn signal light, taillight,
auxiliary light and
hazard fuse: 10 A
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
69. 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. _10. Install the rider seat.
EAU04187
Replacing the headlight bulb This motorcycle is equipped with a
quartz bulb headlight. If the headlight
bulb burns out, replace it as follows.
1. Remove the headlight unit by re-
moving the screws.2. Disconnect the headlight coupler,
and then remove the bulb cover.
1. Quick fastener
2. Pin
After removal
Before installation
1. Screw (× 2)
1. Headlight bulb cover
2. Headlight coupler
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6 3. Remove the headlight bulb holder
by turning it counterclockwise, and
then remove the defective bulb.
EW000119
WARNING
_ Headlight bulbs get very hot. There-
fore, 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.
EC000105
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-
fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with
alcohol or thinner. _5. Install the headlight bulb cover,
and then connect the coupler.
6. Install the headlight unit by install-
ing the screws.7. Have a Yamaha dealer adjust the
headlight beam if necessary.
1. Headlight bulb holder
1. Do not touch the glass part of the bulb.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6
EAU00855
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 counter-
clockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screws.
EC000108
CAUTION:@ Do not overtighten the screws, oth-
erwise the lens may break. @
EAU01579
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 mainte-
nance requiring the motorcycle to
stand upright. Check that the motor-
cycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed un-
der the engine for added stability.
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 un-
der the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
1. Screw (× 2)
1. Screw (× 3)
U5KSE4.book Page 31 Wednesday, September 11, 2002 11:55 AM