Motorcycle engine repair Yamaha XVS 1100 Drag Star (1998-2008)

Mufflers, brake pedal and side cover
Order Job name/Part name Quantity Remarks Removing the muffler, brake pedal and side cover Remove the parts in the order listed. Stand the motorcycle on a level surface. Warning! Securely support the motorcycle so there is no danger of it falling...

Leads, shift pedal and clutch cable
Order Job name/Part name Quantity Remarks Removing the leads, shift pedal and clutch cable Remove the parts in the order listed. 1 Tool box cover 1 2 Left side cover 1 3 AC magneto lead/pickup lead/side stand switch lead/speed sensor lead 1/1/1...

Engine mounting bolts
Order Job name/Part name Quantity Remarks Engine mounting bolt removal Remove the parts in the order below. Place a suitable stand under the frame and engine. Left crankcase cover Refer to " Generator and starter clutch " Tool box Refer to " Rear...

Installing the engine
1. Tighten the bolts in the following order. Bolt (1): 48 Nm (4.8 m·kg) Bolt (2): 48 Nm (4.8 m·kg) Bolt (3): 48 Nm (4.8 m·kg) Bolt (4): 48 Nm (4.8 m·kg) Bolt (5): 48 Nm (4.8 m·kg) 2. Install: shift arm (1) Note: Align the punch mark (a) in the shift...

Rear cylinder head
Order Job name/Part name Quantity Remarks Cylinder head removal Remove the parts in the order listed. Engine assembly Refer to " Engine removal ". Left crankcase cover Refer to " Generator and starter clutch ". 1 Tappet cover (exhaust)/O-ring 1/1 2...

Front cylinder head
Order Job name/Part name Quantity Remarks Cylinder head removal Remove the parts in the order listed. Engine assembly Refer to " Engine removal ". Oil delivery pipes Refer to " Rear cylinder head ". Right crankcase cover Refer to " Clutch ". 1...

Removing the cylinder heads
Rear cylinder head 1. Remove: camshaft sprocket cover tappet covers 2. Align: "T" mark (a) (with the stationary pointer (b) a. Temporarily install the left crankcase cover without the pickup coil and stator coil. b. Turn the crankshaft clockwise. c....

Checking the cylinder heads
The following procedure applies to all of the cylinder heads. 1. Eliminate: combustion chamber carbon deposits (with a rounded scraper) Note: Do not use a sharp instrument to avoid damaging or scratching: spark plug threads valve seats 2. Check:...

Checking the timing chain tensioner
1. Check: timing chain tensioner Cracks/damage/rough movement → Replace. a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. Note: While pressing the timing chain tensioner rod, wind it clockwise with a...

Installing the cylinder heads
Rear cylinder head 1. Install: dowel pins gasket Note: The "5EL" mark on the gasket must face up side of the cylinder. 2. Install: nuts (cylinder head) (M12: 1-4) 50 Nm (5.0 m·kg) cap nut (cylinder head) (M10: 5) 35 Nm (3.5 m·kg) bolts (cylinder...

Rocker arms and camshaft
Order Job name/Part name Quantity Remarks Removing the rocker arm and camshaft Remove the parts in the order listed. Cylinder heads Refer to " Cylinder head ". 1 Stopper plate 1 2 Camshaft bushing 1 Refer to " Removing/installing the rocker arm and...

Removing the rocker arms and camshaft
1. Remove: rocker arm shafts (intake and exhaust) (1) rocker arms (2) Note: Use a slide hammer (3) and weight (4) to remove the rocker arm shafts. Slide hammer bolt (M8): 90890-01085 Weight: 90890-01084 2. Remove: camshaft bushing (1) camshaft (2)...

Checking the camshafts
1. Check: camshaft bushings Damage/wear → Replace. 2. Check: camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 3. Measure: camshaft lobe dimensions (a) and (b) Out of specification → Replace the camshaft. Camshaft lobe...

Checking the rocker arms and rocker arm shafts
The following procedure applies to all of the rocker arms and rocker arm shafts. 1. Check: rocker arm. Damage/wear → Replace. rocker arm lobe (1) valve adjuster (2). Excessive wear → Replace. 2. Check: rocker arm shaft Blue discoloration/excessive...

Installing the camshaft and rocker arms
1. Lubricate: camshaft Recommended lubricant: Camshaft/Bushing: Molybdenum disulfide oil 2. Install: camshaft (1) camshaft bushing (2) Note: The dowel pin (a) on the end of the camshaft must align with the timing mark (b) on the cylinder head. Make...

Valves and valve springs
Order Job name/Part name Quantity Remarks Removing the valves and valve springs. Remove the parts in the order listed. Cylinder heads Refer to " Cylinder heads ". Rocker arms and camshafts Refer to " Rocker arms and camshaft ". 1 Valve cotters 4...

Removing the valves
The following procedure applies to all of the valves and related components. Note: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure that the valves properly seal. 1. Check: valve sealing...

Checking the valves and valve guides
The following procedure applies to all of the valve and valve guides. 1. Measure: valve-stem-to-valve-guide clearance Valve-stem-to-valve-guide clearance = Valve guide inside diameter (a) - Valve stem diameter (b) Out of specification Replace the...

Checking the valve seats
The following procedure applies to all of the valves and valve seats. 1. Eliminate: carbon deposits (from the valve face and valve seat) 2. Check: valve seat Pitting/wear → Replace the cylinder head. 3. Measure: valve seat width (a) Out of...

Checking the valve springs
The following procedure applies to all of the valve springs. 1. Measure: valve spring free length (a) Out of specification → Replace the valve spring. Valve spring free length (intake and exhaust): 44.6 mm Limit: 43.5 mm 2. Measure: compressed...

Installing the valves
The following procedure applies to all of the valves and related components. 1. Deburr: valve stem end (with an oil stone) 2. Lubricate: valve stem oil seal: New (with the recommended lubricant) Recommended lubricant: Molybdenum disulfide oil 3....

Cylinders and pistons
Order Job name/Part name Quantity Remarks Removing the cylinders and pistons Remove the parts in the order listed. Cylinder heads Refer to " Cylinder heads ". 1 Timing chain guide 1 The "5EL" mark should face towards the cylinder head. 2 Cylinder 1...

Removing the pistons
The following procedure applies to all of the pistons. 1. Remove: piston pin clip (1) piston pin (2) piston (3) Caution! Do not use a hammer to drive the piston pin out. Note: Before removing the piston pin clip, cover the crankcase opening with a...

Checking the cylinders and pistons
The following procedure applies to all of the cylinders and pistons. 1. Check: piston wall cylinder wall Vertical scratches → Rebore or replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: piston-to-cylinder clearance...

Checking the piston rings
1. Measure: piston ring side clearance Out of specification → Replace the piston and piston rings as a set. Note: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston...

Checking the piston pins
The following procedure applies to all of the piston pins. 1. Check: piston pin Blue discoloration/grooves → Replace, then inspect the lubrication system. 2. Measure: piston pin outside diameter (a) Out of specification → Replace the piston pin....

Installing the pistons and cylinders
The following procedure applies to all of the pistons and cylinders. 1. Install: oil ring expander lower oil ring rail upper oil ring rail 2nd ring top ring Note: Be sure to install the piston rings so that the manufacuturer's marks or numbers face...

Removing the timing gears
Order Job name/Part name Quantity Remarks Removing the timing gears Remove the parts in the order listed. Cylinder heads Refer to " Cylinder head ". Cylinders Refer to " Cylinders and pistons ". Clutch assembly Refer to " Clutch ". 1 Primary drive...

Removing the timing drive gear
Front cylinder 1. Straighten the lock washer tab. 2. Remove: primary drive gear nut (1) Note: While holding the generator rotor with the sheave holder, loosen the primary drive gear nut. 3. Remove: timing drive gear (2) dowel pins springs Note: When...

Checking the timing chains, camshaft sprockets, and timing chain guides
The following procedure applies to all of the timing chains, camshaft sprockets, and timing chain guides. 1. Check: timing chain (1) Damage/sitffness → Replace the timing chain and its respective camshaft sprockets as a set. 2. Check: camshaft...

Checking the primary drive
1. Check: primary drive gear primary driven gear Damage/wear → Replace the primary drive and primary driven gears as a set. Excessive noise during operation → Replace the primary drive and primary driven gears as a set. 2. Check:...

Installing the timing drive gears
1. Install: timing chain (onto the timing chain drive gear sprocket) Note: To prevent the timing chain from falling into the crankcase, fasten it with a wire. 2. Install: timing chain drive gear sprocket timing chain drive gear shaft Note: Make sure...

Removing the crankshaft assembly
Order Job name/Part name Quantity Remarks Removing the crankshaft assembly Remove the parts in the order listed. Engine assembly Refer to " Engine removal ". Cylinder head Refer to " Cylinder heads ". Cylinder and piston Refer to " Cylinders and...

Removing the crankshaft and connecting rod
Order Job name/Part name Quantity Remarks Removing the crankshaft and connecting rod Remove the parts in the order listed. 1 Crankshaft assembly 1 Refer to " Removing/installing the crankshaft ". 2 Oil pump drive sprocket 1 3 Bearing 1 4 Nuts...

Disassembling the crankcase
1. Remove: crankcase bolts Note: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Loosen the bolts in decreasing numerical order (refer to the numbers in the...

Removing the crankshaft
1. Remove: crankshaft assembly (1) Note: Remove the crankshaft assembly with the crankcase separating tool (2). Make sure that the crankcase separating tool is centered over the crankshaft assembly. Crankcase separating tool: 90890-01135

Removing the connecting rods
1. Remove: connecting rods (1) big end bearings Note: Identify the position of each big end bearing so that it can be reinstalled in its original place.

Checking the crankshaft and connecting rods
1. Measure: crankshaft runout Out of specification → Replace the crankshaft. Crankshaft runout: Less than 0.02 mm 2. Check: crankshaft journal surfaces crankshaft pin surfaces bearing surfaces Scratches/wear → Replace the crankshaft. 3. Measure:...

Checking the bearings and oil seals
1. Check: bearings Clean and lubricate the bearings, then rotate the inner race with your finger Rough movement → Replace. 2. Check: oil seals Damage/wear → Replace.

Installing the crankshaft
3. Install: connecting rod bearings (1) Note: Align the projection (a) of the bearings with the notches (b) in the connecting rod cap. Install each bearing in its original place. 4. Install: connecting rods (1) Note: The stamped "Y" mark (a) on the...

Assembling the crankcase
1. Apply: engine oil (onto the main journal bearings) sealant (onto the crankcase mating surfaces) Yamaha Bond No. 1215: 90890-85505 2. Tighten: crankcase bolts (follow the proper tightening sequence) Note: The numbers embossed on the crankcase...