Owners Manual For 2007 Xvs1100
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Fortunately, Haynes cruises to the rescue with the introduction of its new Service and Repair Manual for all Yamaha XVS650 and 1100 models – XVS650 (‘97-’05), XVS650A Classic (‘98-’05), XVS1100 (‘99–’05) and XVS1100A Classic (‘00–’05). Hailed as “ essential reading for any biker tackling his own servicing” by Motor Cycle News, Haynes manuals have an enviable reputation. The new manual provides fully illustrated, step-by-step instructions for DIY servicing, overhaul and repairs of the engine and transmission, fuel and ignition systems, suspension and steering, the braking system and the electrical system. Each task is given a spanner rating for complexity and experience required. Checking and adjusting the valve clearances is rated as three spanners out of five.
There are full-colour sections on the history of the models, on daily preride hecks and those all-important wiring diagrams, plus tools required and Haynes Hints. For instance, when changing the brake fluid how to tell when all the old fluid has been displaced The section guiding readers Incoming search terms:. Cover the throttle bodies to prevent anything from dropping into the engine. Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3.
Remove the air cleaner box. (Refer to Service Manual, Page 5-14) 4. Remove and replace the ISC valve.
(Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation. Install the air cleaner box in reverse order of removal. (Refer to Service Manual, Page 5-14) 6. Lower the fuel tank.
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(Refer to Service Manual, Page 5-3) 7. Remove the upper seat rail plate.
Disconnect and remove the ECM. (Figure 1) @ ISC Valve Mounting Screw Torque: 2.1± ±0.6 N.m (1.5± ±0.4 lb-ft)! Carefully insert the ISC valve straight into the throttle body hole to prevent damaging the o-ring. Turn the ISC valve slightly to confirm that the o-ring has not twisted. Using the new screw provided in the replacement parts kit, make sure the screw is completely seated on the plate after the screw has been tightened to the specified torque. Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation.!
Cover the throttle bodies to prevent anything from dropping into the engine. Remove the front seat and disconnect the battery.
(Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box. (Refer to Service Manual, Page 5-14) REPLACEMENT PROCEDURE: 8.
Install the new ECM in reverse order of removal. Apply thread lock to the upper plate mounting bolts when reinstalling the upper seat rail plate.
Incoming search terms:. REMOVAL Prepare for Service Touring Models: Remove left side saddlebag, left side cover, and maxi-fuse. Refer to SADDLEBAG and MAXI-FUSE in Service Manual. Softail and Dyna Models: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury.
Remove seat according to the instructions in the Service Manual. Disconnect battery cables, negative (-) cable first. Remove fuel tank according to the instructions in the Service Manual. Sportster Models: Remove left side cover and maxi-fuse. Refer to MAXI-FUSE in Service Manual. V-Rod Models: Remove right side cover and maxi-fuse.
Refer to MAXI-FUSE in Service Manual. Remove Existing Mirrors Touring and Softail (Except FXSTD, FLSTF) Models Left side: See Figure 1. Remove acorn nut (1), star washer (2), and existing mirror (3) from clutch hand control assembly. Discard star washer and mirror but save acorn nut. Right side: See Figure 2. Remove acorn nut (1), star washer (2), and existing mirror (3) from front brake hand control assembly. Discard star washer and mirror but save acorn nut.
2 1 3 is03431 1. Star washer 3. Mirror, left Figure 1. Mirror (Except Sportster) 2 1 3 is03432 1. Star washer 3. Mirror, right Figure 2. Mirror (Touring, Softail – Except FXSTD, FLSTF) Dyna, FXSTD, FLSTF, and VRSC Models 1.
Left side: See Figure 1. Remove acorn nut (1), star washer (2), and existing mirror (3) from clutch hand control assembly. Discard star washer and mirror but save acorn nut. Right side: See Figure 3. Loosen ball stud clamp (1) to remove directional lamp assembly (2). Remove retainer (3), star washer (4), and existing mirror (5) from front brake hand control assembly.
Discard star washer and mirror but save remaining parts. 2 5 3 1 4 is03428 1. Ball stud clamp 2. Directional lamp assembly 3. Star washer 5. Mirror, right Figure 3. Mirror (Dyna, FXSTD, FLSTF, VRSC) Sportster Models Left side: See Figure 4.
Remove locknut (1), washer (2), and existing mirror (3) from clutch hand control assembly. Discard washer and mirror but save locknut. Right side: See Figure 4. Remove locknut (1), washer (2), and existing mirror (4) from front brake hand control assembly. Discard washer and mirror but save locknut. 3 2 1 2 1 4 is03414 1.
Locknut (2) 2. Washer (2) 3. Mirror, left 4. Mirror, right Figure 4. Remove Mirrors (Sportster) INSTALLATION Install Lighted Mirrors Touring and Softail (Except FXSTD, FLSTF, FXSTS, FLSTS) Models 1. Left side: See Figure 5.
Install mirror stem (1) through clutch hand control assembly. Incoming search terms:. Removing Your Old Filter and Beauty Cover In order to install the new Remote Oil Filter Kit, you’ll need to remove the stock Yamaha “beauty cover” and the old filter and filter cover. Remove the engine parts necessary to access the stock filter as outlined in the V-Star owner’s manual. The parts should come off in this order: 1. Muffler assembly 2. Front exhaust pipe 3.
Rear brake reservoir cover bolt and brake cover (the reservoir should not be removed, it can remain in place and be moved aside as needed) 4. Right floorboard (this can be simply loosened, by loosening the two bolts underneath) With the above parts removed, you can remove the Allen bolts holding the beauty cover and filter cap from your engine.
There are five Allen bolts holding the beauty cover (so named, because most of the cover just covers the chromed side of the engine There are five bolts holding the cover. Ignore the three on the “Yamaha” cap in the middle – these just hold the Yamaha cap to the beauty cover itself. One bolt is hidd – in this picture – just be the Yamaha ca en low p.
The bottommost bolt on the beauty cover will likely leak some oil when you remove it – it holds on the inner oil filter cover. Once you remove the beauty cover, you can remove the oil filter cover, and the oil filter Keep these two “O” rings, you’ll need them for the remote kit Old oil filter. Toss it away; you’ll never need one again! Throw away the old filter, and carefully remove the orange and black “O” rings from the filter cover (see picture above). These two “O” rings will go on the new engine cap in the same order as on the old filter cover.
“O” ring for bottom bolt. When the beauty cover and filter cover are removed, be sure not to lose the tiny “O” ring that the bottom bolt goes through. Preparing the Remote Oil Filter Kit Remove the orange and black “O” rings from the stock filter cover plate, and place them on the Remote Oil Filter Kit engine cap – black on the inside, orange on the outside – just like on the stock filter cover. Incoming search terms:. This instruction sheet references Service Manual information.
A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. Kit Contents See Figure 2 and Table 1.
INSTALLATION 1. Position the vehicle on a motorcycle lift table. To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. Refer to the Service Manual and follow the instructions given to remove the Maxi® Fuse. Raise the vehicle on the lift table to allow access to the lower front portion of the frame. 2008+ 2007 7 8 11 3 3 4 4 12 5 5 1 1 9 2 2 10 6 6 9 9 11 13 is02652c 8.
Two-pin voltage regulator connector (2007 only) Voltage regulator 2. Voltage regulator attaching screws (2) Cable strap (2 for 2007, 1 for 2008 and later) 10. Lower voltage regulator cover (2007 only) Voltage regulator bracket 4. Bracket screw to engine crankcase (2) Oxygen sensor connector 12. Crank position sensor connector (2007 only) Voltage regulator caddy 6. Voltage regulator caddy cover Horn connectors (some 2008 and later models) 7. Four-pin voltage regulator connector (2007 only) Figure 1.
Original Equipment Voltage Regulator NOTE For 2007 models: The ground wire on the voltage regulator must be re-attached at the original location when re-installing the voltage regulator to ensure adequate ground. For ALL models: See Figure 1. Remove and discard the voltage regulator caddy cover (6) from the regulator bracket (3) and caddy (5).
For 2007 models: In addition, remove the lower voltage regulator cover (10). Remove and retain the hex socket head screw (4) at the top left of the bracket For 2007 models: In addition, disconnect the ground wire. Free the cable straps (9) from the regulator bracket, beneath the regulator. Remove the two hex socket head screws with washers (2) retaining the voltage regulator to the bracket. Remove and save the regulator, but discard the screws. Remove and retain the screw (4) at the top right of the regulator bracket. Remove the bracket from the engine.
For 2008 and later models: Free the strap (9) that ties the jiffy stand wiring to the voltage regulator bracket. Unfasten the three-way jiffy stand sensor connector and the two-way crank position sensor connector 79 (12) from the T-studs on the back of the regulator bracket (3). Discard the bracket. Disconnect both plugs from the back of the voltage regulator (1). For 2007 models: Unfasten the four-way (7) and two-way (8) voltage regulator connectors from the T-studs on the back of the regulator bracket (3), and discard the bracket. Disconnect the voltage regulator (1) at both connectors.
For 2008 and later models: Unclip the two-way O 2 (oxygen) sensor electrical connector 138 (11) from the voltage regulator caddy (5). For 2007 models: Unfasten the two-way crank position sensor connector 79 (12) from the voltage regulator caddy (5).
Remove the caddy from the vehicle frame. For 2007 models: Unclamp the bottom of the caddy from the engine mount spacers. For ALL models: Unhook the top clips from around the tabs on the front of the engine casting. Remove the original equipment (O.E.) caddy from the vehicle frame, and discard it. Incoming search terms:. According to Federal law, any affected units in your new or used inventory cannot be sold or leased until they are repaired. Refer to the REPAIR VERIFICATION and REPAIR PROCEDURE sections of this Service Bulletin.
Before you begin the repair procedure, check if the repair has been performed on the unit. See the IDENTIFICATION section of this Ser- vice Bulletin for more details. If there is a punch mark – No further action is necessary. If there is no punch mark – You must pro- ceed with the REPAIR PROCEDURE sec- tion of this Service Bulletin. NOTE: Units repaired in the warehouse may not be reflected on iN at the begin- ning of the campaign.
For this reason, always check the VIN stamp prior to per- forming this repair. If you have any questions about repair verifi- cation, please contact your DSeM or TechLine at (800) 421-1900, option 9. NOTE: Refer to section 2-7 of the 2003-2008 VTX1300C/R/S/T Service Manual for specific fuel tank removal instructions. Remove the fuel tank using the procedure in the Service Manual. However, do not remove the fuel valve from the fuel tank. Drain the fuel into an approved container.
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Remove the four screws and diaphragm cover. NOTE: The diaphragm cover is under spring pressure. Do not lose the spring or screws. The countermeasure part has a paint mark near the air vent hole. Replace the diaphragm, spring, cover, and screws with new parts included in the kit.
Install the new diaphragm with the plastic retainer facing the diaphragm cover. NOTE: Make sure the air vent hole is facing downward towards the ground. Reinstall the fuel tank using the procedures in the Service Manual. Refill the fuel tank. INSTALLATION 1.
Remove existing front wheel assembly. Save axle, axle nut, brake disc, and wheel spacers for kit installation.
Refer to FRONT WHEEL in service manual. For FLSTC and FLSTN Models: Discard moon-style hub cap. Or FXSTD: Discard tapered spacer.
NOTE Install short valve stem (43157-83A) included in the installation kit. Discard all other valve stems. See Figure 2. Install valve stem assembly (L) on wheel. Refer to TIRES in service manual. Do not re-use brake disc/rotor screws.
Re-using these screws can result in torque loss and damage to brake components. (00319c) NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. The side with the machined groove on the hub face is the primary bearing side for all kits except Kits 41681-07 and 40818-08. For Kit 41681-07: Install the wheel so that the hub markings are on the left side and the machined groove is on the right side of the motorcycle. For 2006 and later FXDWG Models: When correctly installed, the tire will be 0.08-0.2 in (2-5 mm) off of center, compared to the fender.
For 2007 and later FX Softail and 2008 and later FXDWG Models: The left side of the wheel is the primary bearing side. For 2006 and earlier FX Softail and 2007 and earlier FXDWG Models: The right side of the wheel is the primary bearing side. For Kit 40818-08:. Proper installation of this kit requires the separate purchase of two floating brake discs (44343-01 for 2004 – 2007 models and 44553-06A (stock) or 41500012 (polished) for 2008 and later models) and a tire (43371-07 on 2004-2008 models and 44026-09A on 2009-later models).
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The left side of the wheel has machined DOT markings to identify it as the primary bearing side. For 2008 and later Touring: Install bearing shim (43903- 08) under the primary bearing. Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. Refer to FRONT WHEEL in service manual. For FLSTC and FLSTN Models: Install wheel kit and right hand wheel spacer provided in installation kit. Refer to FRONT WHEEL in service manual.
For FXSTD Models: Install wheel kit, stock wheel spacer and right side wheel spacer provided in installation kit in place of the tapered spacer discarded in Step 1. Refer to FRONT WHEEL in service manual. For FXSTS Models: Install wheel kit, stock wheel spacers and spacer provided in installation kit between the left side wheel spacer and the left fork.
For all other models: Install previously removed wheel spacers. Refer to FRONT WHEEL in service manual. Install front wheel (1), stock axle and stock axle nut. Refer to FRONT WHEEL in service manual. MAINTENANCE AND CLEANING Chrome parts must be maintained regularly to verify that they keep their original shine and luster.
Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant. Remove existing front wheel assembly. Save axle, axle nut, brake disc, and wheel spacers for kit installation. Refer to FRONT WHEEL in service manual. For FLSTC and FLSTN Models: Discard moon-style hub cap.J04065 1 of 8 For FXSTD Models: Discard the tapered r ight side wheel spacer.
Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake components. (00319c) NOTE. For Kits 43573-08, 43575-08, 43703-08, 43978-07, 43771- 07, 43609-07, 44323-07, 44282-07, 44322-07, 43975-07, 43602-07 and 43773-07 install short valve stem (43157- 83A) included in the installation kit. For Kits 40943-09, 40966-09 and 40996-09 install long valve stem (43206-01) included in the installation kit. See Figure 2. Install valve stem assembly (L, M or N) on wheel.
Refer to TIRES in service manual. Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. Refer to FRONT WHEEL in Service Manual.
NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. For Kits 43573-08, 43575-08, 43703-08, 43978-07, 43771-07, 43609-07, 40943-09, 40966-09 and 40996-09:. The left side of the wheel has a machined groove (item 5, Figure 2) in the hub face and/or DOT markings to identify it as the brake disc and primary bearing side. Install the wheel so that the valve stem is on the right side of the motorcycle. For Kits 44323-07, 44322-07 and 44282-07:.
Install the wheel so that the hub markings are on the left side of the motorcycle. The left side of the wheel has a machined groove (item 5, Figure 2) in the hub face and hub markings to identify it as the primary bearing side.
These kits include one or two hub plates (43985-00) to install between the brake disc and the wheel and a chrome hub cap (43986-00) to install on the wheel opposite the brake disc side. Hub covers must be installed to prevent water intrusion, which could cause an imbalance condition.
Dual brake disc models: Install one stainless steel hub plate (3) between each brake disc and wheel hub. Discard chrome hub cap (2). Install brake discs according to service manual procedures. Single brake disc models: Install one stainless steel hub plate (3) between the brake disc and wheel hub. Install the brake disc according to service manual procedures.
Install the chrome hub cap (2) on the side opposite the brake disc. Discard extra stainless steel hub plate (3). The gross axle weight ratings is unaffected by the installation of this wheel on a vehicle equipped with a 21-inch wheel. For Kits 43975-07, 43773-07, and 43602-07:. The wheel has a machined groove (item 5, Figure 2) in the hub face to identify the right side.
For 2007 and later FX Softail Models and 2008 and later FXDWG: The left side of the wheel is the primary bearing side. Yamaha ct 175 repair manual. For all other models the right side of the wheel is the primary bearing side. For Kit 43602-07: An arrow is engraved into the right side hub to indicate the direction of rotation. For Kits 43975-07 and 43773-07: An arrow is cast between the spokes on the right side to indicate the direction of rotation.
These kits include one or two hub plates (43985-00) to install between the brake disc and the wheel and a chrome hub cap (43986-00) to install on the wheel opposite the brake-disc side. Hub covers must be installed to prevent water intrusion, which could cause an imbalance condition. Dual brake disc models: Install one stainless steel hub plate (3) between each brake disc and wheel hub. Discard chrome hub cap (2). Install brake discs according to service manual procedures. Single brake disc models: Install one stainless steel hub plate (3) between the brake disc and wheel hub. Install the brake disc according to service manual procedures.
Install the chrome hub cap (2) on the side opposite the brake disc. Discard extra stainless steel hub plate (3). Install wheel assembly parts from the appropriate Service Parts table for this fitment and stock brake disc. Discard parts from the installation kit that are not required. Refer to FRONT WHEEL in Service Manual. For FLSTC and FLSTN Models: Install wheel kit and right side wheel spacer provided in installation kit. For FXSTD Models: Install wheel kit, stock left wheel spacer and right side wheel spacer from installation kit in place of the tapered right side wheel spacer discarded in Step 1.
Refer to FRONT WHEEL in service manual. For FXSTS Models: Install the left side wheel spacer provided in the kit between the stock left wheel spacer and the left fork. All other models: Install wheel spacers previously removed.
Install front wheel (1), stock axle and stock axle nut. Refer to FRONT WHEEL in service manual Incoming search terms:.
REMOVAL Prepare for Service 1. Position motorcycle on a suitable lift.
NOTE If vehicle is equipped with Harley-Davidson Smart Security System, see owner’s manual for instructions to disarm the system. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. Disconnect battery cables, negative (-) battery cable first. Remove seat according to the instructions in the service manual. Refer to service manual to remove left saddlebag and side cover. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury.
Remove fuel tank according to the instructions in the service manual. Remove Engine Components 1. Remove existing air cleaner assembly. Discard backplate but save remaining parts. Refer to AIR CLEANER REMOVAL in service manual.
Remove existing exhaust system. Refer to EXHAUST SYSTEM REMOVAL in service manual. Remove engine from chassis following the instructions in the service manual. Disassemble engine top end and bottom end. Refer to appropriate ENGINE sections in service manual.
Remove existing clutch diaphragm spring. Refer to CLUTCH REMOVAL in service manual. The procedures in this instruction sheet should be performed by one experienced in precision measuring techniques. Failure to meet tolerances called for in this instruction sheet can result in engine damage. (00511b) -J04793 1 2 is03517 1. O-ring counterbore 2.
Spigot bore Figure 1. Spigot Bore and O-Ring Counterbore Dimensions Table 1.
Spigot Bore and O-Ring Counterbore Dimensions Depth Bore Description 1.625 +/- 0.010 in. (41.3 +/- 0.25 mm) 4.205 +/- 0.010 in. (107 +/- 0.25 mm) Spigot Bore 0.085 +/- 0.003 in.
(2.16 +/- 0.08 mm) 4.415 +/- 0.002 in. (112 +/- 0.05 mm) O-Ring Counter- bore is03456 Figure 2. Cylinder Wall MACHINE CRANKCASE Crankcase Boring Preparation NOTE During final assembly of the engine, Harley-Davidson recommends replacing the OE cylinder studs with Screamin’ Eagle High Tensile Studs (16505-01). Remove cylinder studs from the engine crankcase. Mask off all bearings and oil holes to prevent debris and contaminants from entering those areas.
Inspect and clean engine case mating surfaces. See Figure 6. Reassemble engine case with OE screws, except the top center screw between the cylinders, and tighten to specifications listed in service manual.
NOTE To prevent damage to crankcase boring tool, it is important to replace the top center screw with a modified top center screw (1093). This screw is included in the Crankcase Boring Tool Kit (94419-06) and can be purchased separately from a Harley- Davidson dealer.
Install modified top center screw (1093) between the cylinders and tighten to 50-90 in-lbs (5.6-10.2 Nm). See Figure 1 and Table 1. Machine crankcase cylinder spigot bore and O-ring counterbore to the dimensions shown. Modify Crankcase Incoming search terms:.
The Yamaha V-Star manual by Clymer is the best reference book for repair and service information for your Yamaha V-Star. Every Clymer motorcycle service manual is written for the do-it-yourselfer as well as the experienced mechanic, Clymer motorcycle repair manuals are the cheapest way to keep your motorcycle running properly. Every Clymer motorcycle service manual contains hundreds of original photographs and illustrations obtained from the complete disassembly and assembly of the motorcycle covered. This, in addition to extensive research, is how Clymer repair manuals achieve an unmatched level of detail, accuracy and clarity to guide the reader through each service, troubleshooting and repair procedure.
CHAPTER NINE: ELECTRICAL SYSTEM Charging system Stator Voltage regulator/rectifier Ignition system Spark plug cap Ignition coil Pickup coil Diode Ignitor unit Starting system Starter Starting circuit cutoff relay Starter relay Lighting system Headlight Meter assembly Taillight/brake light Signal system Horn Turn signals Neutral indicator light Oil level indicator light Speed sensor Switches Self-diagnostic system Fuses Wiring connectors Replacement bulbs Specifications.