1978-1981 Yamaha XS1100 Four Cylinder Motorcycle Service Manual

Description

This 242 page, 1978-1981 Yamaha XS1100 Service Manual is a reproduction of the original out of print manual. This manual was originally written by Yamaha Motor Company for use by Authorized Yamaha Dealers and their qualified motorcycle mechanics. It has been assumed that certain basic mechanical procedures inherent to the 1978-1981 Yamaha XS1100 motorcycle are already known and understood by the reader. Without such basic knowledge, repairs or service to this model may render the motorcycle unsafe. For this reason, we advise that all repairs and/or service be performed by an Authorized Yamaha Dealer representative in possession of the requisite basic product knowledge. This 1978-1981 Yamaha XS1100 Service Manual is intended to acquaint the mechanic with the disassembly, reassembly, maintenance, and troubleshooting procedures required to provide optimum performance and longevity of the unit. The information enclosed should be closely studied to avoid unnecessary repairs and to provide the 1978-1981 Yamaha XS1100 motorcycle owner with a sound, safe, dependable machine.

This manual has replaced Clymer M411 in our catalog.

1978-1981 Yamaha XS1100 Service Manual Model Coverage

1978 Yamaha XS1100
1979 Yamaha XS1100
1980 Yamaha XS1100
1981 Yamaha XS1100

Table of Contents

General Information
Periodic Inspection
And Adjustment
Engine Overhaul
Carburetion
Chassis
Electrical
Appendices
XS1100F Supplement
XS1100SF Supplement
XS1100G/SG Supplement

Index of Topics

Machine Identification
For Tune-up
For Engine Service
For Shaft Drive Service
For Electrical Components
Introduction
Maintenance Intervals Charts
Engine
Valve Clearance Adjustment
Cam Chain Adjustment
Ignition Timing
Air Filter
Carburetor
Engine Oil
Middle Gear/Final Gear Oil
Compression Pressure Measurement
Clutch Adjustment
Chassis
Fuel Petcock Cleaning
Fuel Petcock Disassembly
Front and Rear Brake
Wheels and Tires
Front Fork Oil Change
Steering Head Adjustment
Throttle Cable and Grip Lubrication
Drive Shaft Joint Lubrication
Lubrication of Levers, Pedals, etc
Electrical
Battery
Spark Plug
Headlight
Engine Removal
Preparation for Removal
Seat and Fuel Tank Removal
Ignition Ballast Resister, Horn, Muffler, Footrest,
Brake Pedal
Air Cleaner Case
Wiring and Cables
Drive Shaft Joint
Removal
Engine Disassembly
Cylinder Head and Cylinder Removal
Cylinder Head Disassembly
Piston and Cam Chain Dampers Removal
Generator
Kick Shaft, Clutch and Primary Driven Gear
Pick-up Coil Assembly Removal
Starter Motor Removal
Shifter
Oil Pump Removal and Disassembly
Crankcase Disassembly
Primary Shaft Disassembly
Inspection and Repair
Cylinder Head Cover
Cylinder Head
Valve, Valve Guide and Valve Seat
Valve Spring and Lifters
Camshafts, Cam Chain and Cam Sprockets
Cylinder
Piston and Piston Rings
Piston Pin
Crankshaft
Connecting Rod
Oil Pump
Primary Shaft Damper Hi-Vo Chain
Primary Drive
Transmission
Starter Drives
Crankcases and Strainer Cover
Bearings and Oil Seals
Engine Assembly and Adjustment
Crankcase
Oil Pump and Strainer Cover
Shifter
Starter Motor/Breather Cover
Clutch/Kick Gear
Generator (ACG)
Pick-up Coil Assembly
Pistons and Cylinder
Cylinder Head and Cam Shafts
Cam Chain, Cam Sprockets and Chain Tensioner
Oil Delivery Pipe and Cylinder Head Cover
Remounting Engine
Remounting Engine
Carburetor
Description
Specifications
Disassembly
Inspection
Adjustments
Front Wheel
Removal
Front Axle Inspection
Front Wheel Inspection
Replacing Wheel Bearings
Installing Front Wheel
Rear Wheel
Removal
Rear Axle Inspection
Replacing Wheel Bearing
Rear Wheel Inspection
Installing Rear Wheel
Brakes
Caliper Pad Replacement
Caliper Disassembly
Master Cylinder Disassembly
Brake Inspection and Repair
Brake Reassembly
Wheels, Tires, Tubes,
Wheel Inspection
Tire, Tube Removal
Installation
Front Forks
Removal and Disassembly
Inspection
Assembly
Steering Head
Adjustment
Removal
Inspection
Reassembly
Swing Arm
Inspection
Adjustment
Removal
Inspection and Lubrication
Installation
Rear Shock Absorber
Removal
Inspection
Cables and Fittings
Cable Maintenance
Throttle maintenance
Final Drive Gear
Drive Shaft/Joint
Removal
Inspection
Reinstallation
Electric Starting System
Circuit Diagram
Starter Motor
Starter Relay Switch
Charging System
Circuit Diagram
AC Generator
Voltage Regulator
Ignition system
Circuit Diagram
Description
Operation
Troubleshooting/Inspection
Fuel Gauge
Circuit Diagram
Description
Troubleshooting/Inspection
Tachometer
Circuit Diagram
Description
Troubleshooting/Inspection
Lighting and Signal System
Circuit Diagram
Lighting Tests and Checks
Reserve Lighting System
Self-Cancelling Flasher System
Switches
Battery
Specifications
General Specifications
Maintenance Specifications
Torque Specifications
General Torque Specifications
Conversion Tables
Consumer Information
Stopping Distance
Acceleration and Passing Ability
Lubrication Chart
Cable Routing
Wiring Diagram