Yamaha XVS1100 (L) DragStar 99 Service Manual ENG By …

1 EB000000 XVS1100 (L) Service Manual 1998 by Yamaha motor Co., edition, October 1998 All rights reserved. Any reproduction orunauthorized use without the writtenpermission of Yamaha motor Co., expressly :CAUTION:EB001000 NOTICEThis Manual was produced by the Yamaha motor company primarily for use by Yamaha dealers andtheir qualified mechanics. It is not possible to include all the knowledge of a mechanic in one Manual ,so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha mo-torcycles has a basic understanding of the mechanical ideas and the procedures of motorcycle attempted by anyone without this knowledge are likely to render the motorcycle unsafe andunfit for motor company , continually striving to improve all its models.

2 Modifications and signifi-cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers andwill appear in future editions of this Manual where and specifications are subject to change without INFORMATIONP articularly important information is distinguished in this Manual by the following Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!Failure to follow WARNING instructions could result in severe injury or death tothe motorcycle operator, a bystander or a person inspecting or repairing CAUTION indicates special precautions that must be taken to avoid damageto the :A NOTE provides key information to make procedures easier or TO USE THIS MANUALMANUAL ORGANIZATIONThis Manual consists of chapters for the main categories of subjects.

3 (See Illustrated symbols )1st title 1:This is the title of the chapter with its symbol in the upper right corner of each title 2:This title indicates the section of the chapter and only appears on the first page of eachsection. It is located in the upper right corner of the title 3:This title indicates a sub-section that is followed by step-by-step procedures accompa-nied by corresponding DIAGRAMSTo help identify parts and clarify procedure steps, there are exploded diagrams at the start of each re-moval and disassembly An easy-to-see exploded diagram 4 is provided for removal and disassembly Numbers 5 are given in the order of the jobs in the exploded diagram.

4 A number that is enclosed bya circle indicates a disassembly An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks6. The meanings of the symbol marks are given on the next A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names ofparts, notes in jobs, For jobs requiring more information, the step-by-step format supplements 8 are given in addition tothe exploded diagram and the job instruction SYMBOLSI llustrated symbols 1 to 9 are printed on thetop right of each page and indicate the subject ofeach information2 Specifications3 Periodic inspections and adjustments4 Engine5 Cooling system6 Carburetion7 Chassis8 Electrical9 TroubleshootingIllustrated symbols 10 to 17 are used to identifythe specifications appearing in the be serviced with engine mounted11 Filling fluid12 Lubricant13 Special tool14 Torque15 Wear limit.

5 Clearance16 Engine speed17 , V, AIllustrated symbols 18 to 23 in the exploded dia-grams indicate the types of lubricants and lu-brication engine oil19 Apply gear oil20 Apply molybdenum disulfide oil21 Apply wheel bearing grease22 Apply lightweight lithium-soap base grease23 Apply molybdenum disulfide greaseIllustrated symbols 24 to 25 in the exploded dia-grams indicate where to apply locking agent 24and when to install new parts locking agent (LOCTITE )25 ReplaceE004000 INSPADJGENERAL INFORMATIONSPECIFICATIONSPERIODIC INSPECTION AND ADJUSTMENTSENGINE OVERHAULCARBURETIONCHASSISELECTRICALTROU BLESHOOTINGGENINFO1 SPEC23 ENG4 CARB5 CHAS6 ELEC7 TRBLSHTG8 CHAPTER TITLES GENINFO 1 GENINFOCHAPTER INFORMATIONMOTORCYCLE IDENTIFICATION1-1.

6 VEHICLE IDENTIFICATION NUMBER1-1.. MODEL LABEL1-1.. IMPORTANT INFORMATION1-2.. PREPARATION FOR REMOVAL PROCEDURES1-2.. REPLACEMENT PARTS1-2.. GASKETS, OIL SEALS AND O-RINGS1-2.. LOCK WASHERS / PLATES AND COTTER PINS1-3.. BEARINGS AND OIL SEALS1-3.. CIRCLIPS1-3.. CHECKING OF CONNECTIONS1-4.. SPECIAL TOOLS1-5.. 1-1 MOTORCYCLE IDENTIFICATIONGENINFOEB100000 GENERAL INFORMATIONMOTORCYCLE IDENTIFICATIONEB100010 VEHICLE IDENTIFICATION NUMBERThe vehicle identification number 1 is stampedinto the right side of the steering LABELThe model label 1 is affixed to the frame.

7 Thisinformation will be needed to order spare INFORMATIONGENINFOEB101000 IMPORTANT INFORMATIONPREPARATION FOR REMOVAL PROCE-DURES1. Remove all dirt, mud, dust and foreign mate-rial before removal and Use proper tools and cleaning to the SPECIAL TOOLS When disassembling the machine, alwayskeep mated parts together. This includesgears, cylinders, pistons and other parts thathave been mated through normal parts must always be reused or re-placed as an During machine disassembly, clean all partsand place them in trays in the order of disas-sembly.

8 This will speed up assembly and al-low for the correct installation of all Keep all parts away from any source of PARTS1. Use only genuine Yamaha parts for all re-placements. Use oil and grease recom-mended by Yamaha for all lubrication brands may be similar in function andappearance, but inferior in , OIL SEALS AND O-RINGS1. Replace all gaskets, seals and O-rings whenoverhauling the engine. All gasket surfaces,oil seal lips and O-rings must be Properly oil all mating parts and bearingsduring reassembly. Apply grease to the oilseal INFORMATIONGENINFOCAUTION:EB101030 LOCK WASHERS / PLATES AND COTTERPINS1.

9 Replace all lock washers / plates 1 and cot-ter pins after removal. Bend lock tabs alongthe bolt or nut flats after the bolt or nut hasbeen tightened to AND OIL SEALS1. Install bearings and oil seals so that themanufacturer s marks or numbers are vis-ible. When installing oil seals, apply a lightcoating of lightweight lithium base grease tothe seal lips. Oil bearings liberally wheninstalling, if sealDo not use compressed air to spin the bear-ings dry. This will damage the bearing Check all circlips carefully before reassemb-ly.

10 Always replace piston pin clips after oneuse. Replace distorted circlips. When instal-ling a circlip 1, make sure that the sharp-edged corner 2 is positioned opposite thethrust 3 it receives. See sectional OF CONNECTIONSGENINFONOTE:NOTE:EB801000 CHECKING OF CONNECTIONSC heck the connectors for stains, rust, moisture, Disconnect: Connector2. Check: ConnectorMoisture Dry each terminal with an / rust Connect and disconnect theterminals several Check: Connector leadsLooseness Bend up the pin 1 and con-nect the Connect: Connector terminalsThe two terminals click Check: Continuity (using a pocket tester) If there is no continuity, clean the terminals.