Maintenance specifications of engine (Yamaha XVS 1100 Drag Star)

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 diameter	24.96-24.98 mm	•••
Shaft-to-cap clearance	0.020-0.061 mm	•••
Cam dimensions
Intake
"A"	39.112-39.212 mm	39.012 mm
"B"	#1: 32.093-32.193 mm	#1: 31.993 mm
	#2: 32.127-32.227 mm	#2: 32.027 mm
"C"	7.162 mm	7.012 mm
Exhaust
"A"	39.145-39.245 mm	39.045 mm
"B"	32.200-32.300 mm	32.100 mm
"C"	7.195 mm	7.045 mm
Camshaft runout limit	•••	0.03 mm
Timing chain:
Timing chain type/No. of links	SILENT CHAIN/98L	•••
Timing chain adjustment method	Automatic	•••
Rocker arm/rocker arm shaft:
Bearing inside diameter	14.000 mm-14.018 mm	14.036 mm
Shaft outside diameter	13.985 mm-13.991 mm	13.95 mm
Arm-to-shaft clearance	0.009 mm-0.033 mm	0.086 mm
Valve, valve seat, valve guide:
Valve clearance (cold)
IN	0.07-0.12 mm	•••
EX	0.12-0.17 mm	•••
Valve dimensions:
"A" head diameter
IN	47.0~47.2 mm	•••
EX	39.0~39.2 mm	•••
"B" face width
IN	2.1 mm	•••
EX	2.1 mm	•••
"C" seat width
IN	1.2~1.4 mm	1.8 mm
EX	1.2~1.4 mm	1.8 mm
"D" margin thickness
IN	1.1~1.5 mm	0.8 mm
EX	1.1~1.5 mm	0.8 mm
Stem outside diameter
IN	7.975~7.990 mm	•••
EX	7.960~7.975 mm	•••
Guide inside diameter
IN	8.000~8.012 mm	•••
EX	8.000~8.012 mm	•••
Stem-to-guide clearance
IN	0.010~0.037 mm	0.08 mm
EX	0.025~0.052 mm	0.10 mm
Stem runout limit	•••	0.03 mm
Valve seat width
IN	1.2-1.4 mm	2.0 mm
EX	1.2-1.4 mm	2.0 mm
Valve spring:
Free length
IN	44.6 mm	43.5 mm
EX	44.6 mm	43.5 mm
Set length (valve closed)
IN	40 mm	•••
EX	40 mm	•••
Compressed pressure
IN	160.7 N (16.4 kg)	•••
(installed) EX	160.7 N (16.4 kg)	•••
Tilt limit*
IN	•••	2.5°/1.9mm
EX	•••	2.5°/1.9mm
Direction of winding (top view)
IN	Clockwise	•••
EX	Clockwise	•••
Piston:
Piston to cylinder clearance	0.025-0.050 mm	0.15 mm
Piston size "D"	94.960-94.975 mm	•••
Measuring point "H"	5 mm	•••
Piston off-set	0 mm	•••
Piston pin bore inside diameter	22.004-22.015 mm	•••
Piston pin outside diameter	21.991-22.000 mm	•••
Piston rings:
Top ring:
Type	Plain	•••
Dimensions (B x T)	1.5 x 3.8 mm	•••
End gap (installed)	0.3-0.5 mm	0.8 mm
Side clearance (installed)	0.04-0.08 mm	0.1 mm
2nd ring:
Type	Taper	•••
Dimensions (B x T)	1.2 x 3.8 mm	•••
End gap (installed)	0.30-0.45 mm	0.8 mm
Side clearance	0.03-0.07 mm	0.1 mm
Oil ring:
Dimensions (B x T)	2.5 x 3.4 mm	•••
End gap (installed)	0.2-0.7 mm	•••
Connecting rod:
Oil clearance	0.044-0.073 mm	•••
Color code (corresponding size)	(1) Blue (2) Black (3) Brown (4) Green (5) Yellow	•••
Crankshaft:
Crank width "A"	101.95-102.00 mm	•••
Runout limit "C"	•••	0.02 mm
Big end side clearance "D"	0.320-0.474 mm	•••
Clutch:
Friction plate thickness	2.9-3.1 mm	2.8 mm
Quantity	8	•••
Clutch plate thickness	2.5-2.7 mm	0.1 mm
Quantity	1	•••
Clutch plate thickness	1.9-2.1 mm	0.1 mm
Quantity	7
Clutch spring free length	7.2 mm	6.5 mm
Quantity	1	•••
Clutch housing thrust clearance	0.05-0.40 mm	•••
Clutch housing radial clearance	0.010-0.044 mm	•••
Clutch release method	Inner push, screw push	•••
Push rod bending limit	•••	0.5 mm
Transmission:
Main axle deflection limit	•••	0.08 mm
Drive axle deflection limit	•••	0.08 mm
Shifter:
Shifter type	Guide bar	•••
Carburetor:
I. D. mark	5EL1 00	•••
Main jet (M.J)	#1: #110, #2: #112.5	•••
Main air jet (M.A.J)	#55	•••
Jet needle (J.N)	#1: 5DL39-53-3/5, #2: 5DL40-53-3/5	•••
Needle jet (N.J)	P-0M	•••
Pilot air jet
(P.A.J.1)	#63.8	••••
(P.A.J.2)	#145	••••
Pilot outlet (P.O)	1.0	•••
Pilot jet (P.J)	#17.5	•••
Bypass 1 (B.P.1)	0.8	•••
Bypass 2 (B.P.2)	0.8	•••
Bypass 3 (B.P.3)	0.8	•••
Pilot screw (P.S)	3	•••
Valve seat size (V.S)	1.2	•••
Starter jet (G.S.1)	#42.5	•••
Starter jet (G.S.2)	0.8	•••
Throttle valve size (Th.V)	#125	•••
Fuel level (F.L)	4~5 mm	•••
Engine idle speed	950-1,050 r/min	•••
Intake vacuum	34.7-37.3 kPa (260-280 mmHg)	•••
Engine oil temperature	75-85°C	•••
Fuel pump:
Type	Electrical type	•••
Model/manufacturer	UC-Z6M/MITSUBISHI	•••
Consumption amperage (max)	0.8 A	•••
Output pressure	12 kPa (0.12 kg/cm²)	•••
Lubrication system:
Oil filter type	Paper type	•••
Oil pump type	Trochoid type	•••
Tip clearance "A" or "B"	0.03-0.09 mm	0.15 mm
Side clearance	0.03-0.08 mm	0.15 mm
Relief valve operating pressure	450-550 kPa (4.5-5.5 kg/cm²)	•••
Shaft drive:
Middle gear backlash	0.1-0.2 mm	•••
Final gear backlash	0.1-0.2 mm	•••

Lubrication chart

Cylinder head tightening sequence

Crankcase tightening sequence

Left crankcase

Right crankcase

Tightening torques