2003 YAMAHA XVS1100A brake pads

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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_

The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.


From 50,000 km, repeat the maintenance intervals starting from 10,000 km.


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 lineCheck fuel hoses for cracks or damage.√√√√ √
2*Fuel filterCheck condition.√√
3 Spark plugsCheck condition.
Clean and regap.√√
Replace.√√
4*ValvesCheck valve clearance.
Adjust.√√√√
5 Air filter elementClean.√√
Replace.√√
6ClutchCheck operation.
Adjust.√√√√√
7*Front brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
8
*Rear brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
9*Brake hosesCheck for cracks or damage.√√√√ √
Replace. (See NOTE on page 6-4.) Every 4 years
10*WheelsCheck runout, spoke tightness and for damage.
Tighten spokes if necessary.√√√√
11*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
12*Wheel bearingsCheck bearing for looseness or damage.√√√√
13*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50,000 km
14*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20,000 km
15*Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.√√√√ √
16 SidestandCheck operation.
Lubricate.√√√√ √
17*Sidestand switchCheck operation.√√√√√ √
18*Front forkCheck operation and for oil leakage.√√√√
19*Shock absorber
assemblyCheck operation and shock absorber for oil leakage.√√√√
20*CarburetorsCheck starter (choke) operation.
Adjust engine idling speed and synchronization.√√√√√ √
21 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
U5KSE4.book Page 3 Wednesday, September 11, 2002 11:55 AM

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
U5KSE4.book Page 19 Wednesday, September 11, 2002 11:55 AM

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
U5KSE4.book Page 20 Wednesday, September 11, 2002 11:55 AM

10-INDEXAAir filter element, cleaning ...................... 6-11
Anti-theft alarm (optional) .........................3-6BBattery ................................................... 6-25
Brake and clutch levers,
checking and lubricating ...................... 6-22
Brake and shift pedals,
checking and lubricating ...................... 6-21
Brake fluid, changing ............................. 6-20
Brake fluid level, checking...................... 6-19
Brake lever...............................................3-9
Brake lever free play, adjusting .............. 6-17
Brake light switch, adjusting ................... 6-18
Brake pads, checking............................. 6-19
Brake pedal..............................................3-9
Brake pedal position, adjusting .............. 6-18CCables, checking and lubricating............ 6-21
Carburetors, adjusting............................ 6-12
Care.........................................................7-1
Clutch lever ..............................................3-8
Clutch lever free play, adjusting ............. 6-16
Conversion table ......................................8-5DDimmer switch .........................................3-7EEngine break-in........................................5-5
Engine idling speed................................ 6-12
Engine oil .................................................6-7
Engine stop switch ...................................3-7
Engine trouble warning light .................... 3-4FFinal gear oil ............................................ 6-9
Front fork, checking ............................... 6-23
Fuel ....................................................... 3-10
Fuel cock ............................................... 3-11
Fuel consumption, tips for reducing ......... 5-4
Fuel tank cap ........................................... 3-9
Fuses, replacing .................................... 6-27HHandlebar switches ................................. 3-7
Hazard switch .......................................... 3-8
Headlight bulb, replacing ....................... 6-29
Helmet holder ........................................ 3-14
High beam indicator light ......................... 3-5
Horn switch ............................................. 3-7IIdentification numbers ............................. 9-1
Ignition circuit cut-off system.................. 3-19
Immobilizer system .................................. 3-1
Immobilizer system indicator light ............ 3-5
Indicator and warning lights ..................... 3-4KKey identification number ........................ 9-1LLuggage strap holders ........................... 3-18MMain switch/steering lock ......................... 3-2
Model label .............................................. 9-2
NNeutral indicator light ...............................3-4OOil level warning light ...............................3-4PPanel, removing and installing..................6-5
Parking.....................................................5-5
Part locations ...........................................2-1
Pass switch ..............................................3-7
Periodic maintenance and
lubrication chart .....................................6-2
Pre-operation check list ............................4-1SSafety information ....................................1-1
Seats .....................................................3-13
Passenger seat.................................3-13
Rider seat .........................................3-13
Shifting .....................................................5-3
Shift pedal ................................................3-8
Shift points (for Switzerland only) .............5-4
Shock absorber assembly, adjusting ......3-16
Sidestand ...............................................3-19
Sidestand, checking and lubricating .......6-22
Spark plugs, checking ..............................6-6
Specifications ...........................................8-1
Speedometer unit.....................................3-6
Starter (choke) lever...............................3-12
Starting a cold engine ..............................5-1
Starting a warm engine ............................5-3
Start switch ..............................................3-8
Steering, checking..................................6-23
U5KSE4.book Page 1 Wednesday, September 11, 2002 11:55 AM