2003 YAMAHA XVS1100A oil filter

DESCRIPTION
2-2
2
Right view9. Engine oil filter element (page 6-7)
10. Battery (page 6-25)
11. Main fuse (page 6-28)
12. Main switch/steering lock (page 3-2)
13. Air filter element (page 6-11)
14. Brake pedal (page 3-9)
U5KSE4.book Page 2 Wednesday, September 11, 2002 11:55 AM

OPERATION AND IMPORTANT RIDING POINTS
5-5
5
EAU01128
Engine break-in There is never a more important period
in the life of your engine than the period
between 0 and 1,600 km. For this rea-
son, you should read the following ma-
terial carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1,600 km. The various parts in the en-
gine wear and polish themselves to the
correct operating clearances. During
this period, prolonged full-throttle oper-
ation or any condition that might result
in engine overheating must be avoided.
EAU01171*
0–1,000 km
Avoid prolonged operation above
1/3 throttle.
1,000–1,600 km
Avoid prolonged operation above
1/2 throttle.
EC000056*
CAUTION:@ After 1,000 km of operation, the en-
gine oil and final gear oil must be
changed, and the oil filter element
replaced. @1,600 km and beyond
The vehicle can now be operated nor-
mally.
EC000049
CAUTION:@ If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle. @
EAU00457
Parking When parking, stop the engine, re-
move the key from the main switch,
and then turn the fuel cock lever to
“OFF”.
EW000058
WARNING
@

Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.


Do not park on a slope or on
soft ground, otherwise the
motorcycle may overturn.
@
U5KSE4.book Page 5 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
6-7
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

8-1
8
EAU01038
8-SPECIFICATIONSSpecifications CS-01E
Model XVS1100A
Dimensions
Overall length 2,465 mm
Overall width 945 mm
Overall height 1,095 mm
Seat height 710 mm
Wheelbase 1,645 mm
Ground clearance 145 mm
Minimum turning radius 3,300 mm
Basic weight (with oil and full
fuel tank)
291 kg
Engine
Engine type Air-cooled 4-stroke, SOHC
Cylinder arrangement V type 2-cylinder
Displacement 1,063 cm
3
Bore × stroke 95.0 × 75.0 mm
Compression ratio 8.3:1
Starting system Electric starter
Lubrication system Wet sumpEngine oil
Ty p e
Recommended engine oil
classification API Service SE, SF, SG or
higher
Quantity
Without oil filter element
replacement 3.0 L
With oil filter element
replacement 3.1 L
Total amount (dry engine) 3.6 L
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40
CAUTION:In order to prevent clutch slippage (since the engine oil also
lubricates the clutch), do not mix any chemical additives. Do
not use oils with a diesel specification of “CD” or oils of a
higher quality than specified. In addition, do not use oils la-
beled “ENERGY CONSERVING II” or higher.
U5KSE4.book Page 1 Wednesday, September 11, 2002 11:55 AM

SPECIFICATIONS
8-2
8
Final gear oil
Type Hypoid gear oil SAE 80
(API GL4) or multi-grade hypoid
gear oil SAE 80W-90
Quantity 0.2 L
Air filterDry type element
Fuel
Type REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity 17 L
Fuel reserve amount 4.5 L
Carburetor
Manufacturer MIKUNI
Model × quantity BSR37 × 2
Spark plug
Manufacturer/model NGK / BPR7ES or
DENSO / W22EPR-U
Gap 0.7–0.8 mm
Clutch typeWet, multiple-disc
Transmission
Primary reduction system Spur gear
Primary reduction ratio 1.660
Secondary reduction system Shaft drive
Secondary reduction ratio 2.875
Transmission type Constant-mesh 5-speed
Operation Left footGear ratio
1st 2.353
2nd 1.667
3rd 1.286
4th 1.032
5th 0.853
Chassis
Frame type Double cradle
Caster angle 33°
Trail 132 mm
Tires
Front
Type Tube tire
Size 130/90-16 M/C 67S
Manufacturer/
model Dunlop / D404F
Rear
Type Tube tire
Size 170/80-15 M/C 77S
Manufacturer/
model Dunlop / D404G
Maximum load* 197 kg
U5KSE4.book Page 2 Wednesday, September 11, 2002 11:55 AM