Elements of transmission motorcycle Yamaha XVS 1100 Drag Star (1998-2008)

Clutch — right crankcase cover
Order Job name/Part name Quantity Remarks Removing the right clutch 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 over. Engine oil...

Clutch assembly
Order Job name/Part name Quantity Remarks Removing the clutch Remove the parts in the order listed. 1 Clutch spring bolts 6 Refer to " Installing the clutch ". 2 Clutch spring plate 1 3 Clutch spring 1 4 Clutch spring seat 1 5 Clutch pressure plate...

Removing the clutch
1. Straighten the lock washer tab. 2. Loosen: clutch boss nut (1) Note: While holding the clutch boss (2) with the clutch holding tool (3), loosen the clutch boss nut. Clutch holding tool: 90890-04086 3. Remove: clutch boss nut (1) lock washer (2)...

Checking the friction plates
The following procedure applies to all of the friction plates. 1. Check: friction plate Damage/wear → Replace the friction plates as a set. 2. Measure: friction plate thickness Out of specification → Replace the friction plates as a set. Note:...

Checking the clutch boss
1. Check: clutch boss splines Damage/pitting/wear → Replace the clutch boss. Note: Pitting on the clutch boss splines will cause erratic clutch operation.

Checking the clutch push rods
1. Check: short clutch push rod (1) long clutch push rod (2) Cracks/damage/wear → Replace the defective part(-s). 2. Measure: long clutch push rod bending limit Out of specification → Replace the long clutch push rod. Long clutch push rod bending...

Checking the clutch plates
The following procedure applies to all of the clutch plates. 1. Check: clutch plate Damage → Replace the clutch plates as a set. 2. Measure: clutch plate warpage (with a surface plate and thickness gauge (1)) Out of specification → Replace the...

Checking the clutch spring and clutch spring seat plate
1. Check: clutch spring plate Damage → Replace. 2. Check: clutch spring plate seat Damage → Replace. 3. Measure: clutch spring free height Out of specification → Replace the clutch spring Clutch spring free height: 7.2 mm Limit: 6.5 mm

Checking the clutch housing
1. Check: clutch housing dogs Damage/pitting/wear → Deburr the clutch housing dogs or replace the clutch housing. Note: Pitting on the clutch housing dogs will cause erratic clutch operation.

Installing the clutch
1. Install: clutch housing (1) Note: If the wire circlip (2) has been removed, carefully install a new one as shown. 2. Tighten: lock washer (New) clutch boss nut 1: 70 Nm (7.0 m·kg) Note: While holding the clutch boss with the clutch holding tool...

Removing the shift shaft and stopper lever
Order Job name/Part name Quantity Remarks Removing the shift shaft and stopper lever. Remove the parts in the order listed. Engine oil Refer to " Engine oil replacement ". Left crankcase cover Refer to " Generator and starter clutch ". Rotor...

Checking the shift shaft
1. Check: shift shaft (1) shift lever (2). Bends/damage/wear → Replace. shift lever spring (3). Damage/wear Replace. Checking the stopper lever 1. Check: stopper lever Bends/damage → Replace. Roller turns roughly → Replace the stopper lever.

Installing the shift shaft
1. Install: stopper lever (1) stopper lever spring (2) shift shaft lever (3) Note: Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss. Mesh the stopper lever with the shift drum segment assembly.

Transmission removal
Order Job name/Part name Quantity Remarks Transmission removal Remove the parts in the order listed. Crankcase separation Refer to " Crankshaft ". 1 Guide bar 1 Refer to " Installing the transmission ". 2 Shift fork 1 "R" 1 3 Shift fork 2 "C" 1 4...

Checking the shift forks
The following procedure applies to all of the shift forks and related components. 1. Check: shift fork cam follower (1) shift fork pawl (2) Bends/damage/scoring/wear → Replace the shift fork. 2. Check: shift fork guide bar Roll the shift fork guide...

Checking the shift drum assembly
1. Check: shift drum grooves. Damage/scratches/wear → Replace the shift drum. shift drum segment (1). Damage/wear → Replace. shift drum bearing (2). Damage/pitting → Replace.

Checking the transmission
1. Measure: main axle runout (with a centering device and dial gauge) Out of specification → Replace the main axle. Main axle runout limit: 0.08 mm 2. Measure: drive axle runout (with a centering device and dial gauge) Out of specification → Replace...

Installing the transmission
1. Install: shift drum assembly Note: Turn the shift drum assembly to the neutral position. 2. Install: main axle assembly (1) drive axle assembly (2) shift fork "L" (3) shift fork "C" (4) shift fork "R" (5) shift fork guide bars (6) Note: The...

Removing the middle drive pinion gear
Order Job name/Part name Quantity Remarks Removing the middle drive pinion gear Remove the parts in the order listed. Sepalate the crankcase Refer to " Crankshaft and connecting rod ." 1 Bearing retainer 1 Refer to " Removing the middle drive shaft...

Removing the middle driven pinion gear
Order Job name/Part name Quantity Remarks Removing the middle driven pinion gear. Remove the parts in the order listed. 1 Bolts 3 Refer to " Removing the middle driven shaft assembly / Installing the universal joint ". 2 Circlips 2 3 Bearings 2 4...

Removing the middle drive shaft assembly
1. Remove: bearing retainer middle drive shaft assembly a. Straighten the thread on the bearing retainer. b. Attach the bearing retainer wrench (1). Bearing retainer wrench: 90890-04137 c. Remove the bearing retainer and middle drive shaft assembly.

Disassembling the middle drive shaft assembly
1. Remove: spring retainers (1) Note: While compressing the spring with a damper spring compressor (2), remove the spring retainers. Damper spring compressor: 90890-04090 2. Straighten the thread on the middle drive shaft nut. 3. Remove: middle...

Removing the middle driven shaft assembly
1. Remove: universal joint a. Remove the circlips (1). b. Place the universal joint in a press. c. With a pipe of the proper diameter positioned beneath the universal joint driven yoke as shown, press the bearing into the pipe. Note: It may be...

Checking the middle drive shaft assembly
1. Check: damper cam surface Scratches/wear → Replace the damper cam. 2. Check: spring Cracks/damage → Replace.

Checking the middle driven shaft assembly
1. Check: middle drive gear (1) middle driven gear (2) Galling/pitting/wear → Replace the middle driven shaft assembly. 2. Check: bearings Damage/pitting → Replace the middle drive shaft bearing housing assembly. 3. Check: O-ring oil seal Damage →...

Assembling the middle drive shaft assembly
1. Tighten: middle drive shaft nut (1): 110 Nm (11.0 m·kg) Note: Set the torque wrench at a right angle to the middle drive shaft nut wrench (2). Lock the threads on the middle drive shaft nut by staking them with a center punch. Middle drive shaft...

Assembling the middle driven shaft assembly
Note: The following points are critical when assembling the middle gears: The collapsible collar must be replaced whenever the middle driven shaft assembly is removed from the middle driven shaft bearing housing. When performing this procedure for...

Installing the middle gear assembly and adjusting the backlash
Note: When installing the middle gear assembly, be sure to replace the following parts: collapsible collar 1. Install: middle driven shaft assembly (1): 25 Nm (2.5 m·kg) 2. Install: shim middle drive shaft assembly 3. Install: bearing retainer...

Installing the universal joint
4. Install: universal joint driven yoke/cross joint (1) (into the universal joint drive yoke) Caution! Do not hammer the universal joint drive yoke or the collapsible collar may be distorted. This will result in a change in the standard spinning...

Aligning the middle gear
Note: Aligning the middle gear is necessary when any of the following parts are replaced: Crankcase Middle drive shaft 1. Select: middle drive gear shim(-s) (1) Note: Select the middle drive gear shim(-s) (1) by calculating the middle drive gear...

Shaft drive — troubleshooting
The following conditions may indicate damaged shaft drive components: A Symptoms B Possible causes 1. A pronounced hesitation or jerky movement during acceleration, deceleration, or sustained speeds. (not to be confused with engine surging or...

Checking the final drive oil for contamination and inspecting the shaft drive for leaks
1. Drain: final drive oil (from the final drive housing). Refer to " Changing the final drive oil ". 2. Check: final drive oil Large amount of metal particles → Check for bearing seizure. Note: A small amount of metal particles in the final drive...

Measuring the ring gear backlash
1. Secure the final drive assembly in a vise. 2. Remove: final drive oil drain bolt 3. Drain: final drive oil (from the final drive assembly) 4. Measure: ring gear backlash Out of specification → Adjust. Ring gear backlash: 0.1-0.2 mm a. Install a...

Adjusting the ring gear backlash
1. Remove: ring gear bearing housing nuts ring gear bearing housing bolts Note: Working in a crisscross pattern, loosen each nut 1/4 of a turn. After all of the nuts are fully loosened, remove them and the bolts. 2. Remove: ring gear bearing housing...

Final drive assembly and drive shaft
Order Job name/Part name Quantity Remarks Removing the final drive assembly and drive shaft. 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...

Disassembling the final gear
Order Job name/Part name Quantity Remarks Disassembling the final gear. Disassemble the parts in the order listed. 1 Bolts (bearing housing) 2 Note: Working in a crisscross pattern, loosen each bolt and nut 1/4 of a turn. After all the bolts and...

Disassembling the final drive assembly
1. Remove: ring gear bearing housing nuts ring gear bearing housing bolts Note: Working in a crisscross pattern, loosen each bolts and nuts 1 /4 of a turn. After all of the bolts and nuts are fully loosened, and remove them. 2. Remove: self-locking...

Removing and installing the ring gear bearings
1. Remove: collar (1) oil seal (2) bearing (3) (with an appropriate press tool (4) and an appropriate support for the final drive housing) 2. Check: bearing Damage → Replace. 3. Remove: bearing (1) a. Heat the final gear case to approximately 150°C...

Aligning the final drive pinion gear and ring gear
Note: Aligning the final drive pinion gear and ring gear is necessary when any of the following parts are replaced: Final drive housing Any bearing 1. Select: final drive pinion gear shim(-s) (1) ring gear shim(-s) (2) a. Position the final drive...

Checking the drive shaft
1. Check: drive shaft splines Damage/wear → Replace the drive shaft.

Installing the drive shaft
1. Lubricate: drive shaft splines Recommended lubricant: Molybdenum disulfide grease 2. Apply: sealant (onto both final drive housing mating surfaces) Yamaha bond No. 1215: 90890-85505 3. Install: drive shaft (to the final drive pinion gear) 4....