Yamaha V star 1100 User Manual

WARNINGS, CAUTIONS
AND NOTES
The terms WARNING, CAUTION and NOTE
have specific meanings in this manual.
A WARNING emphasizes areas where injury or
even death could result from negligence. Mechani
-
cal damage may also occur. WARNINGS should be
taken seriously.
A CAUTION emphasizes areas where equipment
damage could result. Disregarding a CAUTION
could cause permanent mechanical damage, though
injury is unlikely.
A NOTE provides additional information to
make a step or procedure easier or clearer. Disre
-
garding a NOTE could cause inconvenience but
would not cause equipment damage or personal
injury.
SAFETY
Professional mechanics can work for years and
never sustain a serious injury or mishap. Follow
these guidelines and practice common sense to
safely service the motorcycle.
1. Do not operate the vehicle in an enclosed area.
The exhaust gasses contain carbon monoxide, a poi-
sonous gas that is odorless, colorless, and tasteless.
Carbon monoxide levels build quickly in a small
enclosed area, and it can cause unconsciousness and
death in a short time. Make sure the work area is
properly ventilated or operate the vehicle outside.
2. Never use gasoline or any extremely flammable
liquid to clean parts. Refer to Cleaning Parts and
Handling Gasoline Safely in this section.
3. Never smoke or use a torch in the vicinity of
flammable liquids, such as gasoline or cleaning sol
-
vent.
4. When welding or brazing on the motorcycle, re
-
move the fuel tank, carburetor and shocks to a safe
distance at least 50 ft. (15 m) away.
5. Use the correct type and size tool to avoid dam
-
aging fasteners.
6. Keep tools clean and in good condition. Replace
or repair worn or damaged equipment.
7. When loosening a tight fastener, be guided by
what would happen if the tool slips.
8. When replacing fasteners, make sure the new
fasteners are of the same size and strength as the
original ones.
9. Keep the work area clean and organized.
10. Wear eye protection any time the safety of your
eyes is in question. This includes procedures in
-
volving drilling, grinding, hammering, compressed
air and chemicals.
11. Wear the correct clothing for the job. Tie up or
cover long hair so it cannot be caught in moving
equipment.
12. Do not carry sharp tools in clothing pockets.
13. Always have an approved fire extinguisher
available. Make sure it is rated for gasoline (Class
B) and electrical (Class C) fires.
14. Do not use compressed air to clean clothes, the
motorcycle or the work area. Debris may be blown
into your eyes or skin. Never direct compressed air
at yourself or someone else. Do not allow children
to use or play with any compressed air equipment.
15. When using compressed air to dry rotating
parts, hold the part so it can not rotate. Do not allow
the force of the air to spin the part. The air jet is ca-
pable of rotating parts at extreme speed. The part
may be damaged or disintegrate, causing serious
injury.
16. Do not inhale the dust created by brake pad and
clutch wear. In most cases, these particles contain
asbestos. In addition, some types of insulating ma-
terials and gaskets may contain asbestos. Inhaling
asbestos particles is hazardous to health.
17. Never work on the vehicle while someone is
working under it.
18. When placing the vehicle on a stand, make sure
it is secure before walking away.
Handling Gasoline Safely
Gasoline is a volatile, flammable liquid and is one
of the most dangerous items in the shop.
Because gasoline is used so often, many people
forget that it is hazardous. Only use gasoline as fuel
for gasoline internal combustion engines. When
working on a vehicle, remember that gasoline is al
-
ways present in the fuel tank, fuel lines and carbure
-
tors. To avoid a disastrous accident when working
around the fuel system, observe the following
precautions:
1. Never use gasoline to clean parts. See Cleaning
Parts in this section.
2. When working on the fuel system, work outside
or in a well-ventilated area.
2 CHAPTER ONE

Yamaha V star 1100 Specifications

General

Displacement	1063cc
Bore x Stroke	95.0mm x 75.0mm
Compression Ratio	8.3:1
Ignition	TCI
Transmission	5-speed
Final Drive	Shaft
Front Suspension	Telescopic fork
Front Brakes	Dual disc
Front Tire	130/90-16
Rear Tire	170/80-15
Engine Type	Air-cooled, SOHC, V-twin
Fuel Capacity	4.5 gallons
Rear Brakes	Single disc

Summary

WARNINGS, CAUTIONS AND NOTES

WARNING

Emphasizes areas where injury or death could result from negligence. Mechanical damage may occur.

SAFETY GUIDELINES

Ventilation and Environment

Do not operate in enclosed areas; ensure proper ventilation. Avoid flammable liquids.

Personal Protection

Wear eye protection, correct clothing, tie up long hair. Do not carry sharp tools in pockets.

Brake Pad Dust

Do not inhale brake pad dust; it may contain asbestos, hazardous to health.

HANDLING GASOLINE SAFELY

Gasoline Hazards

Gasoline is volatile, flammable, and hazardous. Vapor is heavier than air and easily ignited.

General Precautions

Work in well-ventilated areas, wear safety glasses, avoid sparks and flames.

Fuel Handling

Do not add fuel near open flames or smokers. Allow engine to cool before working on fuel system.

Fire Safety

Do not pour water on gasoline fires. Use Class B, BC, or ABC extinguisher.

Refueling Precautions

Turn off engine before refueling. Do not overfill tank. Leave air space for expansion.

FASTENERS AND TORQUE

CAUTION: Threading

Torque Specifications

Use a torque wrench for correct tightness. Specifications vary by component.

TOOLS AND MEASURING INSTRUMENTS

Torque Wrenches and Adapters

Precision tools for accurate tightening. Adapters change effective lever length.

Precision Measuring Tools

Feeler gauges, calipers, micrometers, etc. Ensure proper care and use for accurate results.

ENGINE LUBRICATION AND FLUIDS

Engine Oils

Brake Fluid

Hydraulic fluid for brakes. Use only DOT 4; do not intermix types.

Engine Oil Level Check

Check oil level through sight glass in alternator cover. Ensure correct level.

Engine Oil and Filter Change

Follow recommended intervals. Use SE, SF, or SG API classification oil.

ENGINE TOP END COMPONENTS

VALVES AND VALVE COMPONENTS

Valve Seat Inspection and Reconditioning

Inspect valve seats for wear or damage. Recondition or replace as needed.

ENGINE LOWER END COMPONENTS

CRANKCASE ASSEMBLY

CRANKSHAFT AND CONNECTING RODS

Procedures for removal, installation, inspection, and clearance checks.

CONNECTING RODS

CLUTCH AND PRIMARY DRIVE GEAR

CLUTCH

Service procedures for clutch plates, discs, springs, and related components.

TRANSMISSION, SHIFT MECHANISM AND MIDDLE GEAR

TRANSMISSION

CHECKING MIDDLE GEAR BACKLASH

Procedure for measuring and adjusting middle gear backlash.

CHAPTER EIGHT

AIR/FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS

CARBURETOR

Operation, removal, installation, cleaning, inspection, and assembly.

FUEL LEVEL

FUEL PUMP

Removal, installation, operational test, resistance test, and relay test.

CHAPTER NINE

ELECTRICAL SYSTEM

Service procedures for electrical sub-systems and components.

CHARGING SYSTEM

Components, troubleshooting, current draw test, and charging voltage test.

IGNITION SYSTEM

Components, troubleshooting, spark plug cap and ignition coil resistance tests.

STARTING SYSTEM

Components, troubleshooting, starter operational test, disassembly, assembly, and inspection.

STARTING CIRCUIT CUTOFF RELAY

CHAPTER TEN

WHEEL AND TIRES

Repair and maintenance procedures for wheels, tires, and related components.

WHEEL INSPECTION

Inspection of seals, bearings, runout, and brake disc condition.

FRONT WHEEL

REAR WHEEL

WHEEL BALANCE

Procedure for balancing wheels, including static and dynamic methods.

CHAPTER ELEVEN

FRONT SUSPENSION AND STEERING

Service procedures for handlebars, front forks, and steering components.

FRONT FORK

Procedures for fork leg removal, disassembly, installation, and inspection.

STEERING HEAD

Removal, installation, and inspection of the steering head components.

STEERING HEAD BEARING RACES

CHAPTER TWELVE

REAR SUSPENSION AND FINAL DRIVE

Service procedures for rear shock absorber, swing arm, drive shaft, and final drive.

SHOCK ABSORBER

SWING ARM

FINAL DRIVE ASSEMBLY

Removal, installation, inspection, gear lash measurement, and shim selection.

Gearcase Bearing Replacement

CHAPTER THIRTEEN

BRAKES

Service procedures for front and rear brake systems.

BRAKE SERVICE

PREVENTING BRAKE FLUID DAMAGE

Precautions to prevent damage from brake fluid spills.

BRAKE BLEEDING

Procedures for bleeding air from the brake system (manual and vacuum).

BRAKE PADS

Inspection and replacement procedures for front and rear brake pads.

FRONT CALIPER

FRONT MASTER CYLINDER

REAR BRAKE MASTER CYLINDER

BRAKE DISC

BRAKE HOSE REPLACEMENT

CHAPTER FOURTEEN