2001 YAMAHA XVS1100A clutch

PRE-OPERATION CHECKS
4-2
4
Throttle grip• Make sure that operation is smooth.
• Lubricate throttle grip, housing and cables if necessary.
• Check free play.
• If necessary, have Yamaha dealer make adjustment.6-13
Control cables• Make sure that operation is smooth.
• Lubricate if necessary.6-22
Wheels and tires• Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary.6-13–6-16
Brake and shift pedals• Make sure that operation is smooth.
• Lubricate pedal pivoting points if necessary.6-23
Brake and clutch levers• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.6-23
Sidestand• Make sure that operation is smooth.
• Lubricate pivot if necessary.6-24
Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.—
Instruments, lights, signals
and switches• Check operation.
• Correct if necessary.—
Engine stop switch• Check operation.3-5
Sidestand switch• Check operation of ignition circuit cut-off system.
• If system is defective, have Yamaha dealer check vehicle.3-18 ITEM CHECKS PAGE
E_5pb.book Page 2 Thursday, October 5, 2000 10:10 AM

5-1
5
EAU00372
5-OPERATION AND IMPORTANT RIDING POINTS
EAU00373
WARNING
@ l
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.
l
Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
l
Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
@
EAU01714*
Starting the engine In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:l
The transmission is in the neutral
position.
l
The transmission is in gear with
the clutch lever pulled and the sid-
estand up.
EW000054
WARNING
@ l
Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-20.
l
Never ride with the sidestand
down.
@
1. Turn the fuel cock lever to “ON”.
2. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.
3. Shift the transmission into the neu-
tral position.NOTE:@ When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical cir-
cuit. @
E_5pb.book Page 1 Thursday, October 5, 2000 10:10 AM

OPERATION AND IMPORTANT RIDING POINTS
5-4
5
EC000048
CAUTION:@ l
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.
l
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). @
EAU00424
Tips for reducing fuel
consumption Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:l
Thoroughly warm up the engine.
l
Turn the starter (choke) off as
soon as possible.
l
Shift up swiftly, and avoid high en-
gine speeds during acceleration.
l
Do not rev the engine while shift-
ing down, and avoid high engine
speeds with no load on the engine.
l
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
E_5pb.book Page 4 Thursday, October 5, 2000 10:10 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 and oil filter element ............................ 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 .................... 6-17
Adjusting the brake lever free play ..................... 6-17
Adjusting the brake pedal position ..................... 6-19
Adjusting the rear brake light switch .................. 6-19
Checking the front and rear brake pads ............. 6-20
Checking the brake fluid level ............................ 6-21Changing the brake fluid ................................... 6-22
Checking and lubricating the cables ................. 6-22
Checking and lubricating the throttle grip
and cable ........................................................ 6-22
Checking and lubricating the brake and
shift pedals ...................................................... 6-23
Checking and lubricating the brake and
clutch levers .................................................... 6-23
Checking and lubricating the sidestand ............ 6-24
Checking the front fork ...................................... 6-24
Checking the steering ....................................... 6-25
Checking the wheel bearings ............................ 6-25
Battery ............................................................... 6-26
Replacing the fuses .......................................... 6-28
Replacing the headlight bulb ............................. 6-30
Replacing a turn signal light bulb or
the tail/brake light bulb .................................... 6-31
Troubleshooting ................................................. 6-32
Troubleshooting chart ........................................ 6-33
E_5pb.book Page 1 Thursday, October 5, 2000 10:10 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_ l
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
l
From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
l
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_CP-02ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´ 1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line• Check fuel hoses for cracks or damage.ÖÖÖÖ Ö
2*Fuel filter• Check condition.ÖÖ
3 Spark plugs• Check condition.
• Clean and regap.ÖÖ
• Replace.ÖÖ
4*Valves• Check valve clearance.
•Adjust.ÖÖÖÖ
5 Air filter element•Clean.ÖÖ
• Replace.ÖÖ
6Clutch• Check operation.
•Adjust.ÖÖÖÖÖ
7*Front brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
8*Rear brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
E_5pb_Periodic.fm Page 2 Thursday, December 14, 2000 4:31 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
EC000072
CAUTION:@ l
In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives
with the oil or use oils of a
higher grade than “CD”. In ad-
dition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
l
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. @
EAU02943*
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
@ l
Make sure that no foreign mate-
rial enters the final gear case.
l
Make sure that no oil gets on
the tire or wheel.
@
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element
replacement:
3.0 L
With oil filter element
replacement:
3.1 L
Total amount (dry engine):
3.6 L
E_5pb.book Page 9 Thursday, October 5, 2000 10:10 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
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. @
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. Locknut
2. Clutch lever free play adjusting bolt
c. Clutch lever free play
a. Brake lever free play
E_5pb.book Page 17 Thursday, October 5, 2000 10:10 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
64. Grease the metal-to-metal contact
surface of the throttle grip, and
then install the grip by installing
the screws.
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.
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. Recommended lubricant:
Throttle cable:
Engine oil
Throttle grip housing and grip:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
E_5pb.book Page 23 Thursday, October 5, 2000 10:10 AM