Yamaha V star 1100 Owner's Manual

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Summary of Contents:

[Page 1] Yamaha 1100

WARNINGS, CAUTIONS AND NOTES The terms WARNING, CAUTION and NOTE have specific meanings in this manual. A WARNING emphasizes areas where injury or even death could result from negligence. Mechani - cal damage may also occur. WARNINGS should be taken ...

[Page 2] Yamaha 1100

3. Do not add fuel to the fuel tank or service the fuel system while the vehicle is near open flames, around sparks or near someone who is smoking. Gasoline vapor is heavier than air; it collects in low areas and is more easily ignited than liquid ga...

[Page 3] Yamaha 1100

Record these numbers in the Quick Reference Data section at the front of the book. Have these numbers available when ordering parts. If neces - sary, use Table 1 and Table 2 to identify a particular motorcycle. FASTENERS Proper fastener selection and...

[Page 4] Yamaha 1100

WARNING Do not install fasteners with a strength classification lower than what was originally installed by the manufacturer. Doing so may cause equipment failure and/or damage. Torque Specifications The components of the motorcycle may be sub - ject...

[Page 5] Yamaha 1100

To use a cotter pin, first make sure the pin’s diam - eter is correct for the hole in the fastener. After cor - rectly tightening the fastener and aligning the holes, insert the cotter pin through the hole and bend the ends over the fastener (Figur...

[Page 6] Yamaha 1100

most often required. Make sure to follow the manu- facturer’s recommendations for lubricant types. Engine oils Generally, all liquid lubricants are called oil. They may be mineral-based (including petroleum bases), natural-based (vegetable and anim...

[Page 7] Yamaha 1100

Brake fluid will damage plastic, painted or plated surfaces. Use extreme care when working with brake fluid. Immediately clean up any spills with soap and water. Rinse the area with plenty of clean water. Hydraulic brake systems require clean and moi...

[Page 8] Yamaha 1100

Gasket Remover Aerosol gasket remover can help remove stub - born gaskets. This product can speed up the re - moval process and prevent damage to the mating surface that may be caused by a scraping tool. Most of these products are very caustic. Follo...

[Page 9] Yamaha 1100

The number stamped on the wrench refers to the distance between the work areas. This must match the distance across two parallel flats on the bolt head or nut. The box-end wrench is an excellent tool because it grips the fastener on all sides. This r...

[Page 10] Yamaha 1100

WARNING Do not use hand sockets with air or impact tools. They may shatter and cause injury. Always wear eye protec tion when using impact or air tools. Various handles are available for sockets. The speed handle is used for fast operation. Flexible ...

[Page 11] Yamaha 1100

specifications in this manual provide an indication of the range required. A torque wrench is a precision tool that must be properly cared for to remain accurate. Store torque wrenches in cases or separate padded drawers within a toolbox. Follow the ...

[Page 12] Yamaha 1100

GENERAL INFORMATION 13 1 21 HOW TO MEASURE TORQUE WRENCH EFFECTIVE LENGTH L L L L L + A = Effective length L = Effective length No calculation needed A A 22 23 ...

[Page 13] Yamaha 1100

pliers. The sharp jaws will damage the objects they hold. Snap Ring Pliers Snap ring pliers (Figure 24) are specialized pliers with tips that fit into the ends of snap rings to re - move and install them. Snap ring pliers are available with a fixed a...

[Page 14] Yamaha 1100

is easily felt. This feel for the equipment produces consistently accurate measurements and reduces the risk of damaging the tool or component. Refer to the following sections for a description of various measuring tools. Feeler Gauge The feeler or t...

[Page 15] Yamaha 1100

Micrometers A micrometer is an instrument designed for linear measurement using the decimal divisions of the inch or meter (Figure 29). While there are many types and styles of micrometers, most of the proce- dures in this manual call for an outside ...

[Page 16] Yamaha 1100

1. Read the upper half of the sleeve line and count the number of lines visible. Each upper line equals 1 mm. 2. See if the half-millimeter line is visible on the lower sleeve line. If so, add 0.50 to the reading in Step 1. 3. Read the thimble mark t...

[Page 17] Yamaha 1100

Care Micrometers are precision instruments. They must be used and maintained with great care. Note the following: 1. Store micrometers in protective cases or separate padded drawers in a toolbox. 2. When in storage, make sure the spindle and anvil fa...

[Page 18] Yamaha 1100

mounting bases: magnetic, clamp, or screw-in stud. When purchasing a dial indicator, select the mag - netic stand type (B, Figure 36) with a continuous dial. Cylinder Bore Gauge A cylinder bore gauge is similar to a dial indica - tor. The gauge set s...

[Page 19] Yamaha 1100

electrical basics is necessary to perform simple diagnostic tests. Voltage Voltage is the electrical potential or pressure in an electrical circuit and is expressed in volts. The more pressure (voltage) in a circuit, the more work can be performed. D...

[Page 20] Yamaha 1100

starting the procedure. Perform each procedure in sequence. 10. Recommendations are occasionally made to re - fer service to a dealership or specialist. In these cases, the work can be performed more economi- cally by the specialist than by the home ...

[Page 21] Yamaha 1100

Repairing Damaged Threads Occasionally, threads are stripped through care - lessness or impact damage. Often the threads can be repaired by running a tap (for internal threads on nuts) or die (for external threads on bolts) through the threads (Figur...

[Page 22] Yamaha 1100

sulting from friction. Because bearings are preci - sion parts, they must be properly lubricated and maintained. If a bearing is damaged, replace it im - mediately. When installing a new bearing, take care to prevent damaging it. Bearing replacement ...

[Page 23] Yamaha 1100

When installing a bearing onto a shaft, apply pres - sure to the inner bearing race (Figure 48). 2. When installing a bearing as described in Step 1, some type of driver is required. Never strike the bearing directly with a hammer or the bearing will...

[Page 24] Yamaha 1100

2. Follow this step when installing a bearing in a housing. Bearings are generally installed in a hous - ing with a slight interference fit. Driving the bearing into the housing using normal methods may damage the housing or cause bearing damage. Ins...

[Page 25] Yamaha 1100

Seal Replacement Seals (Figure 51) are used to contain oil, water, grease or combustion gasses in a housing or shaft. Improper removal of a seal can damage the housing or shaft. Improper installation of the seal can dam - age the seal. Note the follo...

[Page 26] Yamaha 1100

riding time since the last service. Fill the engine with the recommended type of oil. 3. Drain all fuel from the fuel tank, run the engine until all the fuel is consumed from the lines and car - buretor. 4. Remove the spark plugs and pour a teaspoon ...

[Page 27] Yamaha 1100

Table 1 XVS1100 SERIAL NUMBERS (continued) Year/model Starting VIN number Starting primary ID number Model code 2003 XVS1100R (USA) JYAVP11E*3A034321 VP11E-0034321 5PBD XVS1100R C (Ca) JYAVP11Y*3A004090 VP11Y-0004090 5PBE XVS1100R (Cdn) – – – X...

[Page 28] Yamaha 1100

Table 3 MODEL NAMES AND NUMBERS Model Name Model number USA, California and Canada models V-Star 1100 (1999 model) XVS1100 V-Star 1100 Custom (2000-on) XVS1100 V-Star 1100 Classic XVS1100A V-Star 1100 Silverado XVS1100A V-Star 1100 Classic Cast Wheel...

[Page 29] Yamaha 1100

Table 6 DECIMAL AND METRIC EQUIVALENTS Decimal Metric Decimal Metric Fractions in. mm Fractions in. mm 1/64 0.015625 0.39688 33/64 0.515625 13.09687 1/32 0.03125 0.79375 17/32 0.53125 13.49375 3/64 0.046875 1.19062 35/64 0.546875 13.89062 1/16 0.0625...

[Page 30] Yamaha 1100

Table 8 CONVERSION FORMULAS Multiply: By: To get the equivalent of: Length Inches 25.4 Millimeter Inches 2.54 Centimeter Miles 1.609 Kilometer Feet 0.3048 Meter Millimeter 0.03937 Inches Centimeter 0.3937 Inches Kilometer 0.6214 Mile Meter 0.0006214 ...

[Page 31] Yamaha 1100

Table 9 TECHNICAL ABBREVIATIONS (continued) AIS Air induction system ATDC After top dead center API American Petroleum Institute Aus Australia model BBDC Before bottom dead center BDC Bottom dead center BTDC Before top dead center C Celsius (centigra...

[Page 32] Yamaha 1100

Table 10 METRIC TAP AND DRILL SIZE (continued) Metric Drill Decimal size equivalent fraction Nearest fraction 5 × 0.90 No. 20 0.161 5/32 6 × 1.00 No. 9 0.196 13/64 7 × 1.00 16/64 0.234 15/64 8 × 1.00 J 0.277 9/32 8 × 1.25 17/64 0.265 17/64 9 × ...

[Page 33] Yamaha 1100

CHAPTER TWO TROUBLESHOOTING Begin any troubleshooting procedure by defining the symptoms as precisely as possible. Gather as much information as possible to aid diagnosis. Never assume anything and do not overlook the ob- vious. Make sure there is fu...

[Page 34] Yamaha 1100

TROUBLESHOOTING 35 2 FOUR-STROKE ENGINE OPERATING PRINCIPLES Intake valve opens as piston begins downward, drawing air/fuel mixture into the cylinder through the valve. COMPRESSION INTAKE Intake valve closes and piston rises in cylinder, compressing ...

[Page 35] Yamaha 1100

c. The engine can start when the sidestand is up and the transmission is in neutral. d. If the sidestand is up, the engine will also start if the transmission is in gear and the clutch le - ver is pulled in. 2. Before starting the engine, shift the t...

[Page 36] Yamaha 1100

If you smell gasoline after attempting to start the engine, the engine is probably flooded. To start a flooded engine: 1. Move the choke lever (Figure 3) to the fully off position. 2. Turn the engine stop switch to the run position (A, Figure 2). 3. ...

[Page 37] Yamaha 1100

WARNING Make sure the spark plug is away from the spark plug hole in the cylin der so the spark cannot ignite the mix ture in that cylinder. If the engine is flooded, do not perform this test. The firing of the spark plug can ignite fuel ejected from...

[Page 38] Yamaha 1100

5. If the spark is good, check the following: a. Try starting the engine by following normal starting procedures. If the engine does not start, go to Step 6. b. If the engine starts but then stops, check for an inoperative choke, incorrect carburetor...

[Page 39] Yamaha 1100

a. Incorrect ignition timing due to a malfunc - tioning ignition component. b. Improperly adjusted valves or worn valve seats. c. Low engine compression. d. Clogged carburetor jet(s). e. Fouled spark plugs. f. Incorrect spark plug heat range. g. Oil ...

[Page 40] Yamaha 1100

2. Carburetor adjustment incorrect; mixture too rich. 3. Choke not operating correctly. 4. Contaminants in the fuel. 5. Clogged fuel line. 6. Spark plugs fouled. 7. Ignition coil defective. 8. Ignitor unit or pickup coil defective 9. Loose or defecti...

[Page 41] Yamaha 1100

ENGINE LUBRICATION An improperly operating engine lubrication sys - tem will quickly lead to engine seizure. Check the engine oil level before each ride, and top off the oil as described in Chapter Three. Oil pump service is described in Chapter Five...

[Page 42] Yamaha 1100

ENGINE LEAKDOWN TEST Perform an engine leakdown test to pinpoint en - gine problems caused by compression leaks. While a compression test (Chapter Three) can identify a weak cylinder, a leakdown test can determine where the leak occurs. A cylinder le...

[Page 43] Yamaha 1100

Clutch Slips If the engine speed increases without an increase in motorcycle speed, the clutch is probably slipping. Some main causes of clutch slipping are: 1. Incorrect clutch cable adjustment. 2. Weak clutch springs. 3. Worn clutch or friction pla...

[Page 44] Yamaha 1100

5. Bent or damaged shift fork. 6. Worn gear dogs or slots. 7. Damaged shift drum grooves. Jumps Out of Gear 1. Loose or damaged shift drum stopper arm. 2. Bent or damaged shift fork(s). 3. Bent shift fork shaft(s). 4. Damaged shift drum grooves. 5. W...

[Page 45] Yamaha 1100

7. Incorrect air/fuel mixture. 8. Plugged carburetor jets. 9. Partially plugged fuel tank breather hose. 10. Faulty fuel pump. 11. Faulty starting circuit cutoff relay. Incorrect Fast Idle Speed A fast idle speed can be due to one of the follow - ing...

[Page 46] Yamaha 1100

shooting procedures listed below. Refer to the wir - ing diagram at the end of this book. Perform the troubleshooting test procedures in the listed sequence. Each test presumes the compo - nents tested in the earlier steps are working prop - erly. Th...

[Page 47] Yamaha 1100

6. Check all electrical wires where they join with the individual metal terminals in both the male and female connectors. NOTE Dielectric grease is special grease that can be used on electrical compo nents such as connectors and battery connections. ...

[Page 48] Yamaha 1100

3. Select two points within the circuit where there should be continuity. 4. Attach one lead of the self-powered test light to each point. 5. If there is continuity, the self-powered test light bulb will turn on. 6. If there is no continuity, the sel...

[Page 49] Yamaha 1100

nection to ground is good so the problem is between the lamp and the power source. To isolate the problem, connect the jumper be - tween the battery and the lamp (B, Figure 13). If it comes on, the problem is between these two points. Next, connect t...

[Page 50] Yamaha 1100

4. The voltmeter should indicate 0 volts. If there is a drop of 1 volt or more, there is a problem within the circuit. A voltage drop reading of 12 volts indi - cates an open in the circuit. Continuity Test A continuity test is used to determine the ...

[Page 51] Yamaha 1100

is good, the cause must be in the wiring used only by the suspect circuit. If all related circuits are faulty at the same time, the probable cause is a poor ground connection or a blown fuse(s). As with all troubleshooting, analyze typical symptoms i...

[Page 52] Yamaha 1100

4. Test the starting circuit cutoff relay (SCCR) by performing the continuity test described in Chapter Nine. 5. Test the starting system diode by performing the SCCR diode test described in Chapter Nine. 6. Test the continuity of the starter relay (...

[Page 53] Yamaha 1100

A turn signal light and/or turn signal indicator fails to flash 1. Check the continuity of the affected turn signal bulb and socket. 2. Check the continuity of the bulb and socket for the turn signal indicator light. 3. Check the continuity of the tu...

[Page 54] Yamaha 1100

Soft Suspension (Front Fork) 1. Insufficient tire pressure. 2. Insufficient fork oil level or fluid capacity. 3. Incorrect oil viscosity. 4. Weak or damaged fork springs. Soft Suspension (Rear Shock Absorbers) 1. Insufficient rear tire pressure. 2. W...

[Page 55] Yamaha 1100

CHAPTER THREE LUBRICATION, MAINTENANCE AND TUNE-UP This chapter describes lubrication, maintenance and tune-up procedures. Minor problems found during periodic inspec- tions are generally simple and inexpensive to cor- rect. However, they could lead ...

[Page 56] Yamaha 1100

For convenience, most of the procedures listed in Table 1 are described in this chapter. Procedures that require more than minor disassembly or adjust- ment are covered in the appropriate chapter in the manual. Refer to the Table of Contents or Index...

[Page 57] Yamaha 1100

5. Wipe the interior of the air filter housing with a shop rag dampened with cleaning solvent. Remove any debris that may have passed through a broken element. 6. Inspect the air filter element for tears or other damage that would allow unfiltered ai...

[Page 58] Yamaha 1100

2. Remove the spark plugs as described in this chapter. 3. Insert each spark plug into its spark plug cap, and ground the spark plug against the cylinder head (Figure 7). 4. Turn the compression gauge into one cylinder following the manufacturer’s ...

[Page 59] Yamaha 1100

8. Shut off the engine, and disconnect the timing light and portable tachometer. Install the timing in - spection cover (A, Figure 9). Valve Clearance Valve clearance measurement and adjustment must be performed with the engine at room temper- ature ...

[Page 60] Yamaha 1100

NOTE A cylinder at TDC on the compression stroke has free play in both rocker arms, which indicates that both valves are closed. 9. Make sure the cylinder is at TDC by pressing each rocker arm. The intake and exhaust rocker arms should have free play...

[Page 61] Yamaha 1100

13. Perform Steps 10 and 11 to check and adjust each valve in the front cylinder. 14. When the clearance of each valve is within specification, reinstall the removed parts by revers- ing the removal procedure. Note the following: a. Before installing...

[Page 62] Yamaha 1100

CAUTION Do not clean the spark plugs with a sand blasting device. This type of cleaning may leave abrasive material on the plug, which can enter the cylin der and cause damage. 6. Inspect the spark plug carefully. Look for a plug with broken center p...

[Page 63] Yamaha 1100

the spark plug post. If the cap does not completely contact the plug, the en gine may falter and cut out at high en gine speeds. 6. Install each plug cap onto the correct spark plug. Press the cap onto the spark plug and rotate the as - sembly slight...

[Page 64] Yamaha 1100

Carbon fouled Soft, dry, sooty deposits covering the entire firing end of the plug are evidence of incomplete combus - tion. Even though the firing end of the plug is dry, the deposits decrease the plug’s insulation. The car - bon forms an electric...

[Page 65] Yamaha 1100

blistered porcelain insulator surface. This condition is commonly caused by a spark plug with a heat range that is too hot. If the spark plug heat range is correct, consider the following causes: 1. Lean air/fuel mixture. 2. Improperly operating igni...

[Page 66] Yamaha 1100

oils are designed specifically for au tomotive applications. The additives added to these oils may cause engine and/or clutch damage in motorcycle applications. NOTE Never dispose of engine oil in the trash, on the ground or down a storm drain. Many ...

[Page 67] Yamaha 1100

in the hole with the small O-ring. See A, Fig - ure 30 and B, Figure 28. Torque the oil filter outer cover bolts to 10 N•m (89 in.-lb.). 9. Remove the oil filler cap (D, Figure 9) and in - sert a funnel into the oil filler hole. Fill the crank - ca...

[Page 68] Yamaha 1100

4. Attach a portable tachometer to the No. 2 cylin - der (front cylinder) spark plug lead following the manufacturer’s instructions. 5. Remove the plug (Figure 33) from the vacuum fitting on each cylinder’s intake manifold. On mod - els with an A...

[Page 69] Yamaha 1100

6. Rev the engine a couple of times to see if it set - tles down to the set speed. Readjust as necessary. 7. Shut off the engine and disconnect the portable tachometer. Throttle Cable Adjustment Always check the throttle cables before making any carb...

[Page 70] Yamaha 1100

routed incorrectly or there is insufficient cable free play. Make the necessary corrections. CONTROL CABLES Lubricate and adjust the control cables at the in - tervals specified in Table 1. When lubricating a ca - ble, also inspect it for fraying and...

[Page 71] Yamaha 1100

4. Attach a cable lubricator to the cable following the manufacturer’s instructions. 5. Insert the nozzle of the lubricant can into the lu - bricator (Figure 40), press the button on the can and hold it down until the lubricant begins to flow out o...

[Page 72] Yamaha 1100

1. Securely support the motorcycle on a level sur- face. 2. Operate the sidestand, and check its movement and spring tension. Replace the spring if it is weak or damaged. 3. Lubricate the sidestand pivot surfaces with lith - ium soap grease. 4. Check...

[Page 73] Yamaha 1100

Removal/Installation 1. Securely support the motorcycle on a level sur - face. 2. Remove the battery cover as described in Chap - ter Fourteen. 3. Disconnect the negative cable (A, Figure 46) from the battery. 4. Pull back the boot and disconnect the...

[Page 74] Yamaha 1100

Charging A digital voltmeter and a charger with an adjust- able amperage output are required when charging a maintenance free battery. If this equipment is not available, have the battery charged by a shop with the proper equipment. Excessive voltage...

[Page 75] Yamaha 1100

10. Install the battery into the motorcycle as de - scribed in this chapter. New Battery Initialization Always replace a maintenance free battery with another maintenance free battery. Also make sure the battery is charged completely before installin...

[Page 76] Yamaha 1100

runout (side-to-side movement) or radial runout (up-and-down movement) exceeds the specifica - tion in Table 5, remeasure both axial and radial run - out (Figure 49) as described in Chapter Ten. FRONT SUSPENSION Fork Oil Change Yamaha does not provid...

[Page 77] Yamaha 1100

2. The front fork makes a clicking or clunking noise when the front brake is applied. 3. The steering feels tight or slow. 4. The motorcycle does not want to steer straight on level road surfaces. Inspection 1. Securely support the motorcycle so that...

[Page 78] Yamaha 1100

ter Twelve for correct tightening pro cedures and torque specifications. Shock Absorber Spring Preload Adjustment CAUTION Never turn the cam ring beyond the maximum or minimum position. The spring preload can be adjusted to seven dif - ferent positio...

[Page 79] Yamaha 1100

BRAKES Brake Hoses and Seals Replace the brake hoses and piston seals every two years. Check the brake hoses between the master cylin - der and each brake caliper. If there is any leak, tighten the connections and bleed the brakes as de - scribed in ...

[Page 80] Yamaha 1100

5. Add brake fluid from a sealed brake fluid con - tainer. 6. Reinstall the diaphragm, diaphragm plate and the top cover. Brake Pad Inspection Inspect the brake pads for excessive or uneven wear, scoring and oil or grease on the friction sur - face. ...

[Page 81] Yamaha 1100

clockwise to raise the brake pedal and coun - terclockwise to lower it. b. Tighten the locknut to 16 N•m (12 ft.-lb.). c. Check the end of the brake pushrod. It must be visible through the hole (C, Figure 64)in the clevis. 4. After adjusting the br...

[Page 82] Yamaha 1100

Table 1 MAINTENANCE SCHEDULE* (continued) 4000 miles (7000 km) or 7 months Check the valve clearance; adjust as necessary Check the condition of the spark plugs; clean and adjust the gap as necessary Check the crankcase ventilation hose for cracks or...

[Page 83] Yamaha 1100

Table 2 TIRE SPECIFICATIONS XVS1100 models Front tire size 110/90-18 61S Manufacturer Bridgestone Exedra L309, Dunlop K555F Rear tire size 170/80-15M/C 77S Manufacturer USA, California and Canada models Bridgestone Exedra G546G, Dunlop K555 Europe an...

[Page 84] Yamaha 1100

Table 4 RECOMMENDED LUBRICANTS AND FLUIDS (continued) Engine oil API classification SE, SF or SG Viscosity 5° C (40° F) or above SAE 20W40 15° C (60° F) or below SAE 10W30 Capacity Oil change only 3.0 L (3.2 U.S. qt. [2.6 Imp. qt.]) Oil and filte...

[Page 85] Yamaha 1100

Table 6 MAINTENANCE AND TUNE UP TORQUE SPECIFICATIONS Item N•m in.-lb. ft.-lb. Air filter cover bolts 10 89 – Brake pedal height adjuster locknut 16 – 12 Cam sprocket cover bolts 10 89 – Clutch adjuster locknut 12 106 – Final gearcase drain...

[Page 86] Yamaha 1100

CHAPTER FOUR ENGINE TOP END This chapter provides complete service and over - haul procedures for the engine top end components. This includes the camshafts, valves, cylinder heads, pistons, piston rings and the cylinder blocks. Refer to Chapter Thre...

[Page 87] Yamaha 1100

during removal so it can be easily identified and in - stalled on the correct cylinder during assembly. Removal/Installation 1. Securely support the motorcycle on level ground. 2. Remove the fuel tank, air filter housing, and surge tank and carbureto...

[Page 88] Yamaha 1100

ENGINE TOP END 89 4 1. Cylinder head nut 2. Cylinder head cover bracket 3. Cylinder head cap nut 4. Washer 5. Cylinder bolt 6. Valve cover bolt 7. Intake valve cover 8. O-ring 9. Intake manifold 10. Intake manifold bolt 11. Dowel 3 12. Gasket 13. Rea...

[Page 89] Yamaha 1100

90 CHAPTER FOUR 13. Front cylinder head 14. Cam sprocket 15. Cam sprocket plate 16. Washer 17. Cam sprocket bolt 18. Breather plate 19. O-ring 20. Cam sprocket cover 21. Cam sprocket cover bolt 22. Gasket 23. Dowel 4 1. Cylinder head cap nut 2. Washe...

[Page 90] Yamaha 1100

mark. Take a photograph or make a drawing so you can correctly time the camshaft during assembly. 8A. When servicing the rear cylinder, set it to top dead center on the compression stroke as follows: a. Use the flywheel nut to turn the crankshaft clo...

[Page 91] Yamaha 1100

9) on the flywheel aligns with the alternator cover cutout (B). b. Rotate the crankshaft another 290° clockwise until the I-mark on the flywheel (A, Figure 11) aligns with the cutout in the alternator cover (B). c. Make sure the timing mark on the f...

[Page 92] Yamaha 1100

sprocket on the cam chain drive as sembly. If the chain is not held taut, the chain may become kinked, and cause damage to the crankcase, the cam chain, or cam chain drive assembly. 15. Tie a safety wire around the cam chain and se - cure the wire to...

[Page 93] Yamaha 1100

24. If necessary, remove the intake manifold and its O-ring from the cylinder head. NOTE An exhaust manifold is not used on the front cylinder. 25. If necessary, remove the two manifold nuts (A, Figure 19) and remove the exhaust manifold (B) from the...

[Page 94] Yamaha 1100

could be damaged if it is not tightened properly. 11. Following the tightening sequence shown in Figure 15, torque the fasteners in 1/2 turn incre - ments and in two stages to the specifications. Torque the fasteners to 1/2 the given torque, then tor...

[Page 95] Yamaha 1100

cam chain tensioner hole and tension the chain. The timing mark on the cam sprocket (B, Figure 14) should align with the pointer on the cylinder head (C) as noted during removal. 19. If the timing marks do not align, remove the sprocket. Use a screwd...

[Page 96] Yamaha 1100

25. Install the valve covers (Figure 5) onto the cyl - inder head. Lubricate the new O-ring with lithium soap grease, and torque the valve cover bolts to 10 N•m (89 in.-lb.). 26. If the intake manifold was removed, install it. Lubricate a new O-rin...

[Page 97] Yamaha 1100

use a spark plug thread tap (Figure 30) to clean the threads. If the damage is severe, restore the threads by installing a steel thread insert. Thread insert kits can be purchased at automotive supply stores or they can be installed at a Yamaha deale...

[Page 98] Yamaha 1100

sprocket on the cam chain drive as sembly. 14. Check the sliding surfaces (B, Figure 20)of the front cam chain guide and the rear chain guide (the bolted guide) for wear or damage. Replace the chain guide(s) as necessary. 15. If the exhaust manifold ...

[Page 99] Yamaha 1100

bushing is severely worn, inspect the bushing bore in the cylinder head. The surface should be smooth with no visible marks. Replace the cylinder head if this surface is worn. 3. Visually inspect the camshaft bearing journals (A, Figure 38) for wear ...

[Page 100] Yamaha 1100

Measure the cam lobe height (Figure 41) and width (Figure 42) with a micrometer. Replace the cam - shaft if a lobe is worn beyond the service limits specified in Table 2. 6. Measure the camshaft runout with a dial indica - tor and V-blocks. Replace t...