1999-2005 Yamaha XVS1100S SC V-Star Custom Service Manual

Description

This Official 1999 2000 2001 2002 2003 2004 2005 Yamaha XVS1100S SC V-Star Custom Factory Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1999-2005 Yamaha XVS1100S/SC V-Star Custom motorcycles. This is the same book used by the service department at your local Yamaha dealer. It has everything in it you need to know in order to repair and service your motorcycle.

Note:  Cover states 2001-2005, but it contains the base manual LIT-11616-12-63 that covers 1999-2000.

1999 Yamaha XVS1100L/LC 1100 V-Star Custom
2000 Yamaha XVS1100M/MC 1100 V-Star Custom
2000 Yamaha XVS1100AM/AMC  1100 V-Star Classic

Also includes supplement LIT-11616-14-23, covering models:

2001 Yamaha XVS1100N/NC V-Star Custom
2002 Yamaha XVS1100P/PC V-Star Custom

Table of Contents

CHAPTER 1 GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION, VEHICLE IDENTIFICATION NUMBER, MODEL LABEL, IMPORTANT INFORMATION, PREPARATION FOR REMOVAL PROCEDURES, REPLACEMENT PARTS, GASKETS, OIL SEALS AND O-RINGS, LOCK WASHERS/PLATES AND COTTER PINS, BEARINGS AND OIL SEALS, CIRCLIPS, CHECKING OF CONNECTIONS, SPECIAL TOOLS.

CHAPTER 2 SPECIFICATIONS
GENERAL SPECIFICATIONS, MAINTENANCE SPECIFICATIONS (ENGINE, CHASSIS, ELECTRICAL), CONVERSION TABLE/GENERAL TIGHTENING TORQUE SPECIFICATIONS, LUBRICATION POINTS AND LUBRICANT TYPES (ENGINE, CHASSIS), LUBRICATION DIAGRAMS, CABLE ROUTING

CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION, PERIODIC MAINTENANCE CHART FOR EMISSION CONTROL SYSTEM, GENERAL MAINTENANCE AND LUBRICATION CHART, FUEL TANK AND SEATS (REMOVAL, INSTALLATION), ENGINE (ADJUSTING THE VALVE CLEARANCE, SYNCHRONIZING THE CARBURETORS, ADJUSTING THE ENGINE IDLING SPEED, ADJUSTING THE THROTTLE CABLE FREE PLAY, CHECKING THE SPARK PLUGS, CHECKING THE IGNITION TIMING, MEASURING THE COMPRESSION PRESSURE, CHECKING THE ENGINE OIL LEVEL, CHANGING THE ENGINE OIL, ADJUSTING THE CLUTCH CABLE FREE PLAY, CLEANING THE AIR FILTER ELEMENT, CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD, CHECKING THE BREATHER HOSE, CHECKING THE EXHAUST SYSTEM), CHASSIS (ADJUSTING THE FRONT BRAKE, ADJUSTING THE REAR BRAKE, CHECKING THE BRAKE FLUID LEVEL, ADJUSTING THE REAR BRAKE LIGHT SWITCH, CHECKING THE BRAKE HOSES, BLEEDING THE HYDRAULIC BRAKE SYSTEM, ADJUSTING THE SHIFT PEDAL, CHECKING THE FINAL DRIVE OIL LEVEL, CHANGING THE FINAL DRIVE OIL, CHECKING AND ADJUSTING THE STEERING HEAD, CHECKING THE FRONT FORK, ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY, CHECKING THE TIRES, CHECKING AND TIGHTENING THE SPOKES, CHECKING AND LUBRICATING THE CABLES, LUBRICATING THE LEVERS AND PEDALS, LUBRICATING THE SIDESTAND, LUBRICATING THE REAR SUSPENSION), ELECTRICAL SYSTEM (CHECKING AND CHARGING THE BATTERY, CHECKING THE FUSES, REPLACING THE HEADLIGHT BULB, ADJUSTING THE HEADLIGHT BEAM).

CHAPTER 4 ENGINE
ENGINE REMOVAL (MUFFLERS, BRAKE PEDAL AND SIDE COVER, LEADS, SHIFT PEDAL AND CLUTCH CABLE, ENGINE MOUNTING BOLTS, INSTALLING THE ENGINE), CYLINDER HEADS (REAR CYLINDER HEAD, FRONT CYLINDER HEAD, REMOVING THE CYLINDER HEADS, CHECKING THE CYLINDER HEADS, CHECKING THE TIMING CHAIN TENSIONER, INSTALLING THE CYLINDER HEADS), ROCKER ARMS AND CAMSHAFT (REMOVING THE ROCKER ARMS AND CAMSHAFT, CHECKING THE CAMSHAFTS, CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS, INSTALLING THE CAMSHAFT AND ROCKER ARMS), VALVES AND VALVE SPRINGS (REMOVING THE VALVES, CHECKING THE VALVES AND VALVE GUIDES, CHECKING THE VALVE SEATS, CHECKING THE VALVE SPRINGS, INSTALLING THE VALVES), CYLINDERS AND PISTONS (REMOVING THE PISTONS, CHECKING THE CYLINDERS AND PISTONS, CHECKING THE PISTON RINGS, CHECKING THE PISTON PINS, INSTALLING THE PISTONS AND CYLINDERS), TIMING GEARS (REMOVING THE TIMING DRIVE GEARS, CHECKING THE TIMING CHAINS, CAMSHAFT SPROCKETS AND TIMING CHAIN GUIDES, CHECKING THE PRIMARY DRIVE, INSTALLING THE TIMING DRIVE GEARS), CLUTCH (RIGHT CRANKCASE COVER CLUTCH ASSEMBLY, REMOVING THE CLUTCH, CHECKING THE FRICTION PLATES, CHECKING THE PRESSURE PLATE, CHECKING THE CLUTCH BOSS, CHECKING THE CLUTCH PUSH RODS, CHECKING THE CLUTCH PLATES, CHECKING THE CLUTCH SPRING AND CLUTCH SPRING SEAT PLATE, CHECKING THE CLUTCH HOUSING, INSTALLING THE CLUTCH), GENERATOR AND STARTER CLUTCH (STATOR COIL AND PICKUP COIL, GENERATOR AND STARTER CLUTCH, REMOVING THE GENERATOR, CHECKING THE STARTER CLUTCH, INSTALLING THE GENERATOR), SHIFT SHAFT (SHIFT SHAFT AND STOPPER LEVER, CHECKING THE SHIFT SHAFT, CHECKING THE STOPPER LEVER, INSTALLING THE SHIFT SHAFT), OIL PUMP (CHECKING THE OIL PUMP, CHECKING THE OIL DELIVERY PIPES, CHECKING THE OIL STRAINER, ASSEMBLING THE OIL PUMP), CRANKSHAFT AND CONNECTING RODS (CRANKCASE, CRANKSHAFT AND CONNECTING RODS, DISASSEMBLING THE CRANKCASE, REMOVING THE CRANKSHAFT ASSEMBLY, REMOVING THE CONNECTING RODS, CHECKING THE CRANKSHAFT AND CONNECTING RODS, CHECKING THE BEARINGS AND OIL SEALS, INSTALLING THE CRANKSHAFT, ASSEMBLING THE CRANKCASE), TRANSMISSION (CHECKING THE SHIFT FORKS, CHECKING THE SHIFT DRUM ASSEMBLY, CHECKING THE TRANSMISSION, INSTALLING THE TRANSMISSION), MIDDLE GEAR (MIDDLE DRIVE PINION GEAR, MIDDLE DRIVEN PINION GEAR, REMOVING THE MIDDLE DRIVE SHAFT ASSEMBLY, DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY, REMOVING THE MIDDLE DRIVEN SHAFT ASSEMBLY, CHECKING THE MIDDLE DRIVE SHAFT ASSEMBLY, CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY, ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY, ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY, INSTALLING THE MIDDLE GEAR ASSEMBLY AND ADJUSTING THE BACKLASH, INSTALLING THE UNIVERSAL JOINT, ALIGNING THE MIDDLE GEAR).

CHAPTER 5 CARBURETION
CARBURETOR (CHECKING THE CARBURETORS, ASSEMBLING THE CARBURETORS, INSTALLING THE CARBURETORS, MEASURING AND ADJUSTING THE FUEL LEVEL, CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR), AIR INDUCTION SYSTEM (AIS) (AIR INDUCTION, AIR CUT-OFF VALVE, AIR INDUCTION SYSTEM INSPECTION).

CHAPTER 6 CHASSIS
FRONT WHEEL AND BRAKE DISCS (REMOVING THE FRONT WHEEL, CHECKING THE FRONT WHEEL, CHECKING THE BRAKE DISCS, INSTALLING THE FRONT WHEEL, ADJUSTING THE FRONT WHEEL STATIC BALANCE), REAR WHEEL AND BRAKE DISC (MUFFLER AND BRAKE CALIPER, REAR WHEEL, REMOVING THE REAR WHEEL, CHECKING THE REAR WHEEL, CHECKING THE REAR WHEEL DRIVE HUB, INSTALLING THE REAR WHEEL, ADJUSTING THE REAR WHEEL STATIC BALANCE), FRONT AND REAR BRAKES (FRONT BRAKE PADS, REAR BRAKE PADS, REPLACING THE FRONT BRAKE PADS, REPLACING THE REAR BRAKE PADS, FRONT BRAKE MASTER CYLINDER, REAR BRAKE MASTER CYLINDER , REMOVING THE FRONT BRAKE MASTER CYLINDER REMOVING THE REAR BRAKE MASTER CYLINDER CHECKING THE FRONT AND REAR BRAKE MASTER, CYLINDER , INSTALLING THE FRONT BRAKE MASTER CYLINDER INSTALLING THE REAR BRAKE MASTER CYLINDER, FRONT BRAKE CALIPERS, REAR BRAKE CALIPER, REMOVING THE FRONT BRAKE CALIPERS, REMOVING THE REAR BRAKE CALIPER, CHECKING THE FRONT AND REAR BRAKE CALIPERS, INSTALLING THE FRONT BRAKE CALIPERS, INSTALLING THE REAR BRAKE CALIPER), FRONT FORK (REMOVING THE FRONT FORK LEGS, DISASSEMBLING THE FRONT FORK LEGS, CHECKING THE FRONT FORK LEGS, ASSEMBLING THE FRONT FORK LEGS, INSTALLING THE FRONT FORK LEGS), HANDLEBAR (REMOVING THE HANDLEBAR, CHECKING THE HANDLEBAR, INSTALLING THE HANDLEBAR), STEERING HEAD (REMOVING THE LOWER BRACKET, CHECKING THE STEERING HEAD, INSTALLING THE STEERING HEAD), REAR SHOCK ABSORBER AND SWINGARM (RIGHT SIDE COVER AND BATTERY BOX, LEFT SIDE COVER AND TOOL BOX, REAR SHOCK ABSORBER AND SWINGARM, HANDLING THE REAR SHOCK ABSORBER AND GAS, CYLINDER, DISPOSING OF A REAR SHOCK ABSORBER AND GAS, CYLINDER, REMOVING THE REAR SHOCK ABSORBER, REMOVING THE SWINGARM, CHECKING THE REAR SHOCK ABSORBER AND GAS, CYLINDER, CHECKING THE SWINGARM, INSTALLING THE REAR SHOCK ABSORBER, INSTALLING THE SWINGARM), SHAFT DRIVE (TROUBLESHOOTING, CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND INSPECTING THE SHAFT DRIVE FOR LEAKS, MEASURING THE RING GEAR BACKLASH, ADJUSTING THE RING GEAR BACKLASH, FINAL DRIVE ASSEMBLY AND DRIVE SHAFT, FINAL GEAR, DISASSEMBLING THE FINAL DRIVE ASSEMBLY, REMOVING AND INSTALLING THE RING GEAR BEARINGS, ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR, CHECKING THE DRIVE SHAFT, INSTALLING THE DRIVE SHAFT).

CHAPTER 7 ELECTRICAL
ELECTRICAL COMPONENTS, SWITCHES (CHECKING SWITCH CONTINUITY), CHECKING THE SWITCHES, CHECKING THE BULBS AND BULB SOCKETS (TYPES OF BULBS, CHECKING THE CONDITION OF THE BULBS, CHECKING THE CONDITION OF THE BULB SOCKETS), IGNITION SYSTEM (CIRCUIT DIAGRAM, TROUBLESHOOTING), ELECTRIC STARTING SYSTEM (CIRCUIT DIAGRAM, STARTING CIRCUIT OPERATION, TROUBLESHOOTING, STARTER MOTOR), CHARGING SYSTEM (CIRCUIT DIAGRAM, TROUBLESHOOTING), LIGHTING SYSTEM (CIRCUIT DIAGRAM, TROUBLESHOOTING, CHECKING THE LIGHTING SYSTEM), SIGNAL SYSTEM (CIRCUIT DIAGRAM, TROUBLESHOOTING, CHECKING THE SIGNALING SYSTEM), FUEL PUMP SYSTEM (CIRCUIT DIAGRAM, FUEL PUMP CIRCUIT OPERATION, TROUBLESHOOTING, FUEL PUMP TEST), CARBURETOR HEATER SYSTEM (CIRCUIT DIAGRAM, TROUBLESHOOTING), EVAPORATIVE EMISSION CONTROL SYSTEM TROUBLESHOOTING, SELF-DIAGNOSIS TROUBLESHOOTING.

CHAPTER 8 TROUBLESHOOTING
STARTING FAILURE/HARD STARTING (FUEL SYSTEM, ELECTRICAL SYSTEM, COMPRESSION SYSTEM), POOR IDLE SPEED PERFORMANCE, POOR MEDIUM-AND-HIGH SPEED PERFORMANCE, FAULTY GEAR SHIFTING (HARD SHIFTING, SHIFT PEDAL DOES NOT MOVE, JUMPS-OUT-OF GEAR), CLUTCH SLIPPING/DRAGGING, OVERHEATING, FAULTY BRAKE, POOR BRAKING PERFORMANCE, FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION, UNSTABLE HANDLING, FAULTY LIGHTING AND SIGNAL SYSTEMS (HEADLIGHT DOES NOT LIGHT, BULB BURNT OUT, FLASHER DOES NOT LIGHT, FLASHER BLINKS SLOWLY, FLASHER REMAINS LIT, FLASHER BLINKS QUICKLY, HORN DOES NOT SOUND).

WIRING DIAGRAM
This book features a complete pull-out wiring diagram that details all circuits and the following components: Pickup coil, AC magneto (stator coil), Rectifier/regulator, Main switch, Ignition fuse, Battery, Main fuse, Starter relay, Starter motor, Oil level gauge, Oil lamp relay, Starting circuit cut-off relay, Fuel pump, Diode, Sidestand switch, Throttle position sensor, Ignitor unit, Ignition coil, Spark plug, Speed sensor, Neutral switch, Trip switch, Meter assembly, Oil level caution light, Engine warning light, Speedmeter, Turn signal indicator light, Meter light, Neutral indicator light, High beam indicator light, Right handlebar switch, Front brake switch, Engine stop switch, Start switch, Rear brake switch, Horn, Flasher relay, Left handlebar switch, Dimmer switch, Horn switch, Clutch switch, Turn signal switch, Headlight, Front turn signal/position light (left), Front turn signal/position light (right), Rear turn signal light (left), Rear turn signal light (right), Tail/brake light, Solenoid (for CAL), Backup fuse, Headlight fuse, Signal fuse, Carburetor heater fuse, Thermo switch, Carburetor heater relay, Carburetor heater 1, Carburetor heater 2, Carburetor heater ground.