Introduction to repair manual motorcycle Yamaha XVS 1100 Drag Star (1998-2008)

Safety comes first
A motorcycle is a wonderful vehicle that can give you an incomparable feeling of power and freedom. However, it also imposes certain restrictions that you must obey, since even the best motorcycles are subject to the laws of physics. Regular care...

Illustrated symbols
Illustrated symbols (1) to (9) are printed on the top right of each page and indicate the subject of each chapter. (1) General information (2) Specifications (3) Periodic inspections and adjustments (4) Engine (5) Cooling system (6) Carburetion (7)...

Motorcycle identification
Vehicle identification number The vehicle identification number (1) is stamped into the right side of the steering head. Model label The model label (1) is affixed to the frame. This information will be needed to order spare parts.

Preparation for removal procedures
1. Remove all dirt, mud, dust and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. Refer to the " SPECIAL TOOLS " section. 3. When disassembling the machine, always keep mated parts together. This includes...

Replacement parts
1. Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality. Gaskets, oil seals and O-rings 1. Replace all...

Checking of connections
Check the connectors for stains, rust, moisture, etc. 1. Disconnect: Connector 2. Check: Connector Moisture → Dry each terminal with an air blower. Stains/rust → Connect and disconnect the terminals several times. 3. Check: Connector leads Looseness...

Special tools for motorcycle repair
The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may...

General specifications of motorcycle
Item Standard Model code: XVS1100: 5EL1 (For Europe) 5EL2 (For D, A, FIN) 5EL3 (For Australia) Dimensions: Overall length 2,405 mm Overall width 895 mm Overall height 1,095 mm Seat height 690 mm Wheelbase 1,640 mm Minimum ground clearance 145 mm...

Maintenance specifications of engine
Item Standard Limit Cylinder head: Warp limit* ••• 0.03 mm Cylinder: Bore size 95.00-95.01 mm 95.1 mm Measuring point* 40 mm ••• Camshaft: Drive method Chain drive (left & right) ••• Cam cap inside diameter 25.000-25.021 mm ••• Camshaft outside...

Maintenance specifications of chassis
Item Standard Limit Steering system: Steering bearing type Angular bearing ••• Front suspension: Front fork travel 140 mm ••• Fork spring free length 356.9 mm 350 mm Fitting length 319.4 mm ••• Collar length 183 mm ••• Spring rate - (K1) 8.8 N/mm...

Maintenance specifications of electrical
Item Standard Limit Voltage: 12 V ••• Ignition system: Ignition timing (B.T.D.C.) 10° at 1,000 r/min ••• Advancer type Digital type ••• T.C.I.: Pickup coil resistance/color 189-231 Ω at 20°C/Gray - Black ••• T.C.I. unit model/manufacturer...

General torque specifications
This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a...

Unit conversion table
All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. METRIC MULTIPLIER IMP ** mm x 0.03937 = ** in 2 mm x 0.03937 = 0.08 in Conversion table METRIC TO IMP Known...

Lubrication diagrams
1. Rocker arm shaft (intake); 2. Rocker arm shaft (exhaust); 3. Oil filter; 4. Oil pump; 5. Drive axle; 6. Middle drive shaft 1. Oil pump; 2. Releaf valve; 3. Oil filter; 4. Middle drive shaft 1. Camshaft; 2. Crankshaft; 3. Main axle; 4. Middle...