![Yamaha DRAG STAR XVS1100 (1999) [13/355] Gen info](/img/pdf.png)
Yamaha DRAG STAR XVS1100 (1999) [13/355] Gen info
![Yamaha DRAG STAR XVS1100 (1999) [13/355] Gen info](/views2/1121370/page13/bgd.png)
1-5
SPECIAL TOOLS
GEN
INFO
EB102001
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or
improvised techniques. Special tools may differ by shape and part number from country to country. In
such a case, two types are provided.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No.
Tool name/How to use Illustration
Weight
90890-01084
Bolt
90890-01085
Slide hammer bolt/weight
These tools are used to remove the rocker
arm shaft.
90890-01135
Crankcase separating tool
This tool is used to remove the crankshaft.
90890-01229
Coupling gear/Middle shaft tool
This tool is needed when removing or
installing the final pinion shaft nut.
Final gear
backlash band
90890-01230
Middle gear
backlash band
90890-01231
Final gear backlash band
This tool is needed when measuring final gear
/middle gear backlash.
Installer pot
90890-01274
Bolt
90890-01275
Crankshaft installer pot/bolt/adapter/spacer
90890 01275
Adaptor
90890-04130
Spacer
90890-04060
These tools are used to install the crankshaft.
90890-01304
Piston pin puller
This tool is used to remove the piston pin.
90890-01312
Fuel level gauge
This gauge is used to measure the fuel level
in the float chamber.
Содержание
- Caution 3
- Important information 3
- Notice 3
- How to use this manual 4
- And when to install new parts 5
- Apply engine oil 5
- Apply gear oil 5
- Apply lightweight lithium soap base grease 5
- Apply locking agent loctit 5
- Apply molybdenum disulfide grease 5
- Apply molybdenum disulfide oil 5
- Apply wheel bearing grease 5
- Are printed on the top right of each page and indicate the subject of each chapter 5
- Are used to identify the specifications appearing in the text 5
- Can be serviced with engine mounted 5
- Carburetion 5
- Chassis 5
- Cooling system 5
- Electrical 5
- Engine 5
- Engine speed 5
- Filling fluid 5
- General information 5
- Illustrated symbols 5
- In the exploded dia grams indicate the types of lubricants and lu brication points 5
- In the exploded dia grams indicate where to apply locking agent 5
- Lubricant 5
- Periodic inspections and adjustments 5
- Replace 5
- Special tool 5
- Specifications 5
- Torque 5
- Troubleshooting 5
- Wear limit clearance 5
- Ω v a 5
- Carburetion 6
- Chapter titles 6
- Chassis 6
- Electrical 6
- Engine overhaul 6
- General information 6
- Periodic inspection and adjustments 6
- Specifications 6
- Troubleshooting 6
- Chapter 1 general information 8
- Gen info 8
- General information 8
- Gen info 9
- General information 9
- Motorcycle identification 9
- Gen info 10
- Important information 10
- Caution 11
- Gen info 11
- Important information 11
- Checking of connections 12
- Gen info 12
- Gen info 13
- Special tools 13
- Gen info 14
- Special tools 14
- Gen info 15
- Special tools 15
- Gen info 16
- Special tools 16
- Chapter 2 specifications 18
- Specifications 18
- General specifications 19
- Specifications 19
- General specifications 20
- General specifications 21
- Maintenance specifications 22
- Maintenance specifications 23
- Maintenance specifications 24
- Maintenance specifications 25
- Maintenance specifications 26
- Maintenance specifications 27
- Maintenance specifications 28
- Crankcase tightening sequence 29
- Cylinder head tightening sequence 29
- Maintenance specifications 29
- Maintenance specifications 30
- Maintenance specifications 31
- Maintenance specifications 32
- Maintenance specifications 33
- Maintenance specifications 34
- Maintenance specifications 35
- Maintenance specifications 36
- Maintenance specifications 37
- A nut b bolt 38
- All specification data in this manual are listed in si and metric units use this table to convert metric unit data to imperial unit data 38
- Conversion table 38
- General torque specifications 38
- General torque specifications conversion table 38
- Metric multiplier imp 38
- Mm x 0 3937 0 8 in 38
- Mm x 0 3937 in 38
- This chart specifies torque for standard fasten ers with standard i s o pitch threads torque specifications for special components or as semblies are provided for each chapter of this manual to avoid warpage tighten multi fasten er assemblies in a crisscross fashion in pro gressive stages until the specified torque is reached unless otherwise specified torque specifications require clean dry threads com ponents should be at room temperature 38
- Lubrication points and lubricant types 39
- Lubrication points and lubricant types 40
- Lubrication diagrams 41
- Lubrication diagrams 42
- Lubrication diagrams 43
- Cable routing 44
- Cable routing 45
- Cable routing 46
- Cable routing 47
- Cable routing 48
- Cable routing 49
- Cable routing 50
- Cable routing 51
- Cable routing 52
- Cable routing 53
- Chapter 3 periodic inspections and adjustments 55
- Insp adj 55
- Periodic inspections and adjustments 55
- Insp adj 56
- Insp adj 57
- Introduction 57
- Introduction periodic maintenance lubrication intervals 57
- Periodic inspections and adjustments 57
- Periodic maintenance lubrication intervals 57
- This chapter includes all information necessary to perform recommended inspections and adjust ments these preventive maintenance procedures if followed will ensure more reliable vehicle opera tion and a longer service life the need for costly overhaul work will be greatly reduced this informa tion applies to vehicles already in service as well as to new vehicles that are being prepared for sale all service technicians should be familiar with this entire chapter 57
- Insp adj 58
- Periodic maintenance lubrication intervals 58
- The air filter needs more frequent service if you are riding in unusually wet or dusty areas hydraulic brake system when disassembling the master cylinder or caliper cylinder always replace the brake fluid check the brake fluid level regularly and fill as required replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years replace the brake hoses every four years or if cracked or damaged 58
- Fuel tank and seats 59
- Insp adj 59
- Fuel tank and seats 60
- Insp adj 60
- Adjusting the valve clearance 61
- Engine 61
- Insp adj 61
- Adjusting the valve clearance 62
- Insp adj 62
- Adjusting the valve clearance 63
- Insp adj 63
- Adjusting the valve clearance synchronizing the carburetors 64
- Insp adj 64
- Insp adj 65
- Synchronizing the carburetors 65
- Insp adj 66
- Synchronizing the carburetors adjusting the engine idling speed 66
- Adjusting the engine idling speed adjusting the throttle cable free play 67
- Insp adj 67
- Adjusting the throttle cable free play checking the spark plugs 68
- Caution 68
- Insp adj 68
- Warning 68
- Checking the spark plugs checking the ignition timing 69
- Insp adj 69
- Checking the ignition timing measuring the compression pressure 70
- Insp adj 70
- Caution 71
- Insp adj 71
- Measuring the compression pressure 71
- Warning 71
- Caution 72
- Insp adj 72
- Measuring the compression pressure checking the engine oil level 72
- Checking the engine oil level changing the engine oil 73
- Insp adj 73
- Warning 73
- Changing the engine oil adjusting the clutch cable free play 74
- Insp adj 74
- Adjusting the clutch cable free play cleaning the air filter element 75
- Insp adj 75
- Caution 76
- Insp adj 76
- Checking the exhaust system 77
- Insp adj 77
- Adjusting the front brake 78
- Caution 78
- Chassis 78
- Insp adj 78
- Warning 78
- Adjusting the rear brake 79
- Caution 79
- Insp adj 79
- Warning 79
- Caution 80
- Checking the brake fluid level 80
- Insp adj 80
- Warning 80
- Adjusting the rear brake light switch checking the brake hoses 81
- Insp adj 81
- Bleeding the hydraulic brake system 82
- Insp adj 82
- Warning 82
- Bleeding the hydraulic brake system adjusting the shift pedal 83
- Insp adj 83
- Warning 83
- Checking the final drive oil level changing the final drive oil 84
- Insp adj 84
- Changing the final drive oil checking and adjusting the steering head 85
- Insp adj 85
- Warning 85
- Checking and adjusting the steering head 86
- Insp adj 86
- Warning 86
- Caution 87
- Checking the front fork adjusting the rear shock absorber assembly 87
- Insp adj 87
- Warning 87
- Adjusting the rear shock absorber assembly checking the tires 88
- Insp adj 88
- Warning 88
- Checking the tires 89
- Insp adj 89
- Warning 89
- Checking the tires 90
- Insp adj 90
- Warning 90
- Checking the tires checking and tightening the spokes 91
- Insp adj 91
- Insp adj 92
- Warning 92
- Caution 93
- Checking and charging the battery 93
- Electrical system 93
- Insp adj 93
- Warning 93
- Caution 94
- Checking and charging the battery 94
- Insp adj 94
- Caution 95
- Checking and charging the battery 95
- Insp adj 95
- Warning 95
- Checking and charging the battery 96
- Insp adj 96
- Checking and charging the battery 97
- Insp adj 97
- Caution 98
- Checking and charging the battery 98
- Insp adj 98
- Caution 99
- Checking the fuses 99
- Insp adj 99
- Checking the fuses replacing the headlight bulb 100
- Insp adj 100
- Warning 100
- Caution 101
- Insp adj 101
- Replacing the headlight bulb adjusting the headlight beam 101
- Chapter 4 engine 103
- Engine 103
- Engine 106
- Engine removal 106
- Warning 106
- Engine removal 107
- Engine removal 108
- Engine removal 109
- Engine 110
- Cylinder heads 111
- Cylinder heads 112
- Cylinder heads 113
- Cylinder heads 114
- Cylinder heads 115
- Cylinder heads 116
- Cylinder heads 117
- Cylinder heads 118
- Cylinder heads 119
- Warning 119
- Cylinder heads 120
- Rocker arms and camshaft 121
- Rocker arms and camshaft 122
- Rocker arms and camshafts 123
- Rocker arms and camshafts 124
- Rocker arms and camshafts 125
- Valves and valve springs 126
- Valve and valve springs 127
- Valve and valve springs 128
- Valve and valve springs 129
- Caution 130
- Valve and valve springs 130
- Valve and valve springs 131
- Caution 132
- Valve and valve springs 132
- Cylinders and pistons 133
- Caution 134
- Cylinders and pistons 134
- Cylinder and pistons 135
- Cylinder and pistons 136
- Cylinders and pistons 137
- Cylinders and pistons 138
- Timing gears 139
- Timing gears 140
- Timing gears 141
- Timing gears 142
- Clutch 143
- Warning 143
- Clutch 144
- Clutch 145
- Clutch 146
- Clutch 147
- Clutch 148
- Clutch 149
- Clutch 150
- Clutch 151
- Generator and starter clutch 152
- Generator and starter clutch 153
- Generator and starter clutch 154
- Generator and starter clutch 155
- Generator and starter clutch 156
- Generator and starter clutch 157
- Shift shaft 158
- Shift shaft 159
- Oil pump 160
- Oil pump 161
- Oil pump 162
- Caution 163
- Oil pump 163
- Crankshaft and connecting rods 164
- Crankshaft and connecting rods 165
- Caution 166
- Crankshaft and connecting rods 166
- Crankshaft and connecting rods 167
- Caution 168
- Crankshaft and connecting rods 168
- Crankshaft and connecting rods 169
- Crankshaft and connecting rods 170
- Caution 171
- Crankshaft and connecting rods 171
- Crankshaft and connecting rods 172
- Transmission 173
- Transmission 174
- Warning 174
- Transmission 175
- Transmission 176
- Warning 176
- Middle gear 177
- Middle gear 178
- Middle gear 179
- Middle gear 180
- Middle gear 181
- Middle gear 182
- Middle gear 183
- Warning 183
- Middle gear 184
- Caution 185
- Middle gear 185
- Middle gear 186
- Middle gear 187
- Carburetion 189
- Chapter 5 carburetion 189
- Carburetion 190
- Carburetor 190
- Carburetor 191
- Carburetor 192
- Carburetors 193
- Carburetor 194
- Carburetor 195
- Caution 195
- Carburetor 196
- Carburetor 197
- Carburetor 198
- Air induction system ais 199
- Air induction system ais 200
- Chapter 6 chassis 203
- Chassis 203
- Chassis 205
- Front wheel and brake discs 205
- Warning 205
- Front wheel and brake discs 206
- Front wheel and brake discs 207
- Warning 207
- Front wheel and brake discs 208
- Warning 208
- Caution 209
- Front wheel and brake discs 209
- Front wheel and brake discs 210
- Caution 211
- Front wheel and brake discs 211
- Warning 211
- Front wheel and brake discs 212
- Front wheel and brake discs 213
- Rear wheel and brake disc 214
- Rear wheel and brake disc 215
- Warning 215
- Rear wheel and brake disc 216
- Rear wheel and brake disc 217
- Warning 217
- Rear wheel and brake disc 218
- Rear wheel and brake disc 219
- Front and rear brakes 220
- Front and rear brakes 221
- Caution 222
- Front and rear brakes 222
- Front and rear brakes 223
- Front and rear brakes 224
- Front and rear brakes 225
- Front and rear brakes 226
- Front and rear brakes 227
- Front and rear brakes 228
- Front and rear brakes 229
- Front and rear brakes 230
- Front and rear brakes 231
- Front and rear brakes 232
- Warning 232
- Caution 233
- Front and rear brakes 233
- Warning 233
- Caution 234
- Front and rear brakes 234
- Warning 234
- Front and rear brakes 235
- Front and rear brakes 236
- Front and rear brakes 237
- Front and rear brakes 238
- Front and rear brakes 239
- Front and rear brakes 240
- Warning 240
- Front and rear brakes 241
- Warning 241
- Front and rear brakes 242
- Warning 242
- Caution 243
- Front and rear brakes 243
- Warning 243
- Caution 244
- Front and rear brakes 244
- Warning 244
- Caution 245
- Front and rear brakes 245
- Warning 245
- Caution 246
- Front and rear brakes 246
- Front fork 247
- Front fork 248
- Front fork 249
- Caution 250
- Front fork 250
- Warning 250
- Front fork 251
- Warning 251
- Caution 252
- Front fork 252
- Warning 252
- Caution 253
- Front fork 253
- Caution 254
- Front fork 254
- Front fork 255
- Warning 255
- Handlebar 256
- Warning 256
- Handlebar 257
- Handlebar 258
- Warning 258
- Caution 259
- Handlebar 259
- Warning 259
- Handlebar 260
- Warning 260
- Handlebar 261
- Steering head 262
- Warning 262
- Steering head 263
- Steering head 264
- Warning 264
- Caution 265
- Steering head 265
- Steering head 266
- Rear shock absorber and swingarm 267
- Rear shock absorber and swingarm 268
- Rear shock absorber and swingarm 269
- Rear shock absorber and swingarm 270
- Warning 270
- Caution 271
- Rear shock absorber and swingarm 271
- Warning 271
- Rear shock absorber and swingarm 272
- Warning 272
- Rear shock absorber and swingarm 273
- Caution 274
- Rear shock absorber and swingarm 274
- Rear shock absorber and swingarm 275
- Shaft drive 276
- Shaft drive 277
- Warning 277
- Shaft drive 278
- Shaft drive 279
- Shaft drive 280
- Shaft drive 281
- Shaft drive 282
- Shaft drive 283
- Warning 283
- Shaft drive 284
- Caution 285
- Shaft drive 285
- Warning 285
- Shaft drive 286
- Shaft drive 287
- Shaft drive 288
- Caution 289
- Shaft drive 289
- Caution 290
- Shaft drive 290
- Shaft drive 291
- Shaft drive 292
- Chapter 7 electrical 294
- Electrical 294
- Electrical 296
- Electrical components 296
- Caution 297
- Switches 297
- Checking the switches 298
- Cecking the switches 299
- For aus 299
- For europe 299
- Checking the bulbs and bulb sockets 300
- Caution 301
- Checking the bulbs and bulb sockets 301
- Warning 301
- Checking the bulbs and bulb sockets 302
- Circuit diagram 303
- Ignition system 303
- Ignition system 304
- Ignition system 305
- Ignition system 306
- Ignition system 307
- Circuit diagram 308
- Electric starting system 308
- Electric starting system 309
- Electric starting system 310
- Warning 310
- Electric starting system 311
- Electric starting system 312
- Electric starting system 313
- Electric starting system 314
- Electric starting system 315
- Electric starting system 316
- Electric starting system 317
- Charging system 318
- Circuit diagram 318
- Charging system 319
- Charging system 320
- Circuit diagram 321
- Lighting system 321
- Lighting system 322
- Lighting system 323
- Lighting system 324
- Lighting system 325
- Circuit diagram 326
- Signal system 326
- Signal system 327
- Signaling system 328
- Signaling system 329
- Signaling system 330
- Signaling system 331
- Signaling system 332
- Singnal system 333
- Circuit diagram 334
- Fuel pump system 334
- Fuel pump circuit operation the fuel pump circuit consists of the fuel pump relay fuel pump engine stop switch and ignitor unit the ignitor unit includes the control unit for the fuel pump 335
- Fuel pump system 335
- Fuel pump system 336
- Fuel pump system 337
- Fuel pump system 338
- Warning 338
- Carburetor heater system 339
- Circuit diagram 339
- Carburetor heater system 340
- Carburetor heater system 341
- Carburetor heater system 342
- Self diagnosis 343
- Self diagnosis 344
- Self diagnosis 345
- Chapter 8 troubleshooting 347
- Trbl shtg 347
- Troubleshooting 347
- Starting failure hard starting 348
- Trbl shtg 348
- Troubleshooting 348
- Poor idle speed performance 349
- Poor medium and high speed performance 349
- Starting failure hard starting poor idle speed performance poor medium and high speed performance 349
- Trbl shtg 349
- Clutch slipping dragging 350
- Faulty gear shifting 350
- Faulty gear shifting clutch slipping dragging 350
- Trbl shtg 350
- Faulty brake 351
- Front fork oil leakage and front fork malfunction 351
- Overheating 351
- Overheating faulty brake front fork oil leakage and front fork malfunction 351
- Trbl shtg 351
- Faulty lighting and signal systems 352
- Trbl shtg 352
- Unstable handling 352
- Unstable handling faulty lighting and signal systems 352
- Color code 353
- Wiring diagram for europe 353
- Xvs1100 wiring diagram for europe 353
- Color code 354
- Wiring diagram for aus 354
- Xvs1100l wiring diagram for aus 354
- Cable routing 355
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