User manual YAMAHA XVS1100 SERVICE MANUAL

[. . . ] EB000000 XVS1100 (L) SERVICE MANUAL ©1998 by Yamaha Motor Co. , Ltd. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co. , Ltd. is expressly prohibited. EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha motorcycles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair. [. . . ] Loosen the middle drive shaft nut with the middle drive shaft nut wrench 5 . Remove the middle drive shaft nut and bearing. 4-75 MIDDLE GEAR ENG REMOVING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1. 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 necessary to lightly tap the universal joint driven yoke. Loosen: S middle driven shaft nut 1 NOTE: While holding the universal joint driven yoke 2 with the universal joint holder 3 , loosen the middle driven shaft nut. Universal joint holder 90890-04062 EAS00438 CHECKING THE MIDDLE DRIVE SHAFT ASSEMBLY 1. Check: S middle drive gear 1 S middle driven gear 2 Galling/pitting/wear !Replace the middle drive shaft bearing housing assembly. 4-76 MIDDLE GEAR ENG 3. Replace the universal joint. EAS00441 ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1. Tighten: S middle drive shaft nut 1 110 Nm (11. 0 mSkg) NOTE: S Set the torque wrench at a right angle to the middle drive shaft nut wrench 2 . S Lock the threads on the middle drive shaft nut by staking them with a center punch. Middle drive shaft nut wrench 2 90890-04138 Middle drive shaft holder 3 90890-04055 2. Install: S spring retainers 1 NOTE: While compress the spring with the damper spring compressor 2 , and then install the spring retainers. Damper spring compressor 90890-04090 4-77 MIDDLE GEAR ENG ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY NOTE: The following points are critical when assembling the middle gears: S The collapsible collar must be replaced whenever the middle driven shaft assembly is removed from the middle driven shaft bearing housing. S When performing this procedure for the first time, be sure to have at least one extra collapsible collar on hand. Install: S bearing outer race (into the middle driven shaft bearing housing) WARNING Do not press the bearing outer race. Install: S middle driven shaft nut NOTE: Finger tighten the middle driven shaft mut. 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: S middle driven shaft assembly 1 25 Nm (2. 5 mSkg) 4-78 MIDDLE GEAR ENG 2. Install: S bearing retainer Install steps: S Attach the bearing retainer wrench 1 . Bearing retainer: 110 Nm (11. 0 mSkg) S Lock the threads on the bearing retainer by staking them with a center punch. 4. Install the universal joint holder 1 and middle gear backlash band 2 as shown. Universal joint holder 90890-04062 Middle gear backlash band 90890-01231 b. Make sure that the dial gauge plunger on the middle gear backlash band as shown. Remove the middle driven pinion gear nut and apply the LOCKTITE® on it. [. . . ] (However, it is on while the engine is running. ) Display condition code Item Condition Response When engine is stationary When engine is running Throttle position Disconnected sensor (TPS) Short-circuit Locked S Enables the motorcycle to run so that the ignition timing is fixed when the throttle is fully opened. S Displays the condition code on the enigne indicator light. Blinks in Light on Fault code: 3 Speed sensor Disconnected short-circuit Blinks in Light on Fault code: 4 Display order on the engine indicator light 1 2 3 4 Light on (seconds) . . 0. 5 seconds 0. 5 seconds Fault code 3 seconds Light on Light off 1 2 3 4 Repetition 7-48 SELF-DIAGNOSIS EAS00835 ELEC TROUBLESHOOTING The engine warning light starts to display the self-diagnosis sequence. speed sensor NOTE: S Before troubleshooting, remove the following part(-s): 1) rider seat 2) fuel tank 3) air filter case 4) left side cover S Troubleshoot with the following special tool(-s). [. . . ]