2003 YAMAHA XVS1100A spark plugs

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
U5KSE4.book Page 2 Wednesday, September 11, 2002 11:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6
EAU01673
Checking the spark plugs The spark plugs are important engine
components, which are easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plugs should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
To remove a spark plug
1. Remove the appropriate spark
plug cover (rear right or front left)
by pulling it off as shown.
2. Remove the spark plug cap.3. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.
To check the spark plugs
1. Check that the porcelain insulator
around the center electrode on
each spark plug is a medi-
um-to-light tan (the ideal color
when the motorcycle is ridden nor-
mally).
2. Check that all spark plugs installed
in the engine have the same color.
NOTE:@ If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle. @3. Check each spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and replace
it if necessary.
1. Spark plug cover
1. Spark plug wrench
Specified spark plug:
BPR7ES (NGK) or
W22EPR-U (DENSO)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
6
EAU01297
Troubleshooting chart
EW000125
WARNING
@ Keep away open flames and do not smoke while checking or working on the fuel system.@
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plugs
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
DryWet
Open the throttle halfway and operate
the electric starter.
U5KSE4.book Page 33 Wednesday, September 11, 2002 11:55 AM

MOTORCYCLE CARE AND STORAGE
7-4
7
ECA00013
CAUTION:_

Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess.


Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.


Avoid using abrasive polishing
compounds as they will wear
away the paint.
_NOTE:_ Consult a Yamaha dealer for advice on
what products to use. _
Storage Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA00014
CAUTION:_

Storing the motorcycle in a
poorly ventilated room or cover-
ing it with a tarp, while it is still
wet, will allow water and humid-
ity to seep in and cause rust.


To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
_
Long-term
Before storing your motorcycle for
several months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. For motorcycles equipped with a
fuel cock that has an “OFF” posi-
tion: Turn the fuel cock lever to
“OFF”.
3. Drain the carburetor float cham-
bers by loosening the drain bolts;
this will prevent fuel deposits from
building up. Pour the drained fuel
into the fuel tank.
4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
5. Perform the following steps to pro-
tect the cylinders, piston rings, etc.
from corrosion.
a. Remove the spark plug caps
and spark plugs.
b. Pour a teaspoonful of engine
oil into each spark plug bore.
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MOTORCYCLE CARE AND STORAGE
7-5
7c. Install the spark plug caps onto
the spark plugs, and then place
the spark plugs on the cylinder
head so that the electrodes are
grounded. (This will limit spark-
ing during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder walls with oil.)
e. Remove the spark plug caps
from the spark plugs, and then
install the spark plugs and the
spark plug caps.
EWA00003
WARNING
_ To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over. _6. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
8. Cover the muffler outlets with plas-
tic bags to prevent moisture from
entering them.
9. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place (less
than 0 °C or more than 30 °C). For
more information on storing the
battery, see page 6-26.
NOTE:_ Make any necessary repairs before
storing the motorcycle. _
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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