Front suspension and handlebars of motorcycle Yamaha XVS 1100 Drag Star (1998-2008)

Removing the front fork
Order Job name/Part name Quantity Remarks Removing the front fork Remove the parts in the order listed. Front wheel Refer to " Front wheel and brake discs ". 1 Brake hose holders 2 2 Brake caliper assembly 2 3 Front fender 1 4 Turn signal light...

Disassembling the front fork
Order Job name/Part name Quantity Remarks Disassembling the front fork Disassemble the parts in the order listed. (1) Cap bolt 1 Refer to " Disassembling/assembling the front fork legs ". (2) O-ring 1 (3) Spacer 1 (4) Spring seat 1 (5) Fork spring 1...

Removing the front fork legs
The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. Warning! Securely support the motorcycle so that there is no danger of it falling over. Note: Place the motorcycle on a suitable stand so...

Disassembling the front fork legs
The following procedure applies to both of the front fork legs. 1. Remove: cap bolt O-ring spacer spring seat fork spring 2. Drain fork oil 3. Remove: dust seal (1) oil seal clip (2) (with a flat-head screwdriver) Caution! Do not scratch the inner...

Checking the front fork legs
The following procedure applies to both of the front fork legs. 1. Check: inner tube (1) outer tube (2) Bends/damage/scratches → Replace. Warning! Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure: spring...

Assembling the front fork legs
The following procedure applies to both of the front fork legs. Warning! Make sure that the oil levels both front fork legs are equal. Uneven oil levels can result in poor handling and a loss of stability. Note: When assembling the front fork leg,...

Installing the front fork legs
The following procedure applies to both of the front fork legs. 1. Install: front fork leg Temporarily tighten the upper and lower bracket pinch bolts. Note: Make sure that the inner fork tube is flush with the top of the upper bracket. 2. Tighten:...

Removing the handlebar
Order Job name/Part name Quantity Remarks Removing the handlebar Remove the parts in the order listed. Stand the motorcycle on a level surface. Warning! Securely support the motorcycle so that there is no danger of it falling over. 1 Plastic locking...

Checking the handlebar
1. Stand the motorcycle on a level surface. Warning! Securely support the motorcycle so that there is no danger of it falling over. 2. Check: handlebar (1) Bends/cracks/damage → Replace. Warning! Do not attempt to straighten a bent handlebar as this...

Installing the handlebar
1. Stand the motorcycle on a level surface. Warning! Securely support the motorcycle so that there is no danger of it falling over. 2. Install: handlebar upper handlebar holders: 28 Nm (2.8 m·kg) Caution! First, tighten the bolts on the front side...

Steering head — removing
Order Job name/Part name Quantity Remarks Removing the lower bracket Remove the parts in the order listed. Stand the motorcycle on a level surface. Warning! Securely support the motorcycle so that there is no danger of it falling over. Front fork...

Removing the lower bracket
1. Stand the motorcycle on a level surface. Warning! Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: upper ring nut (1) lower ring nut (2) Note: Hold the lower ring nut with the exhaust and steering nut...

Checking the steering head
1. Wash: bearings bearing races Recommended cleaning solvent: Kerosine 2. Check bearings (1) bearing races (2) Damage/pitting → Replace. 3. Replace: bearings bearing races a. Remove the bearing reces from the steering head pipe with a long rod (1)...

Installing the steering head
1. Lubricate: upper bearing lower bearing bearing races Recommended lubricant: Lithium soap base grease 2. Install: Lower ring nut (1) rubber washer (2) upper ring nut (3) lock washer (4). Refer to " Checking and adjusting the steering head ". 3....