2005 yamaha v star 1100 classic manual

Lock plate 3. Clutch boss spring Clutch spring bolt 4. Plate seat Spring plate 5. Clutch boss Clutch spring 6. Remove the pressure plate B, Figure Remove the washer Figure 11 and the release bearing Figure 12 from pushrod No. Remove pushrod No. However, do not use a steel washer. Steel will damage the gear teeth. If a clutch holder is not available, stuff a shop cloth, copper penny, or brass washer Figure 18 between the primary drive gear and the primary driven gear on the clutch housing.

Lift the other end from the hole and remove the retaining wire from the clutch hub. Remove clutch plate No. The last item installed should be friction disc. Make sure the marked tab on each friction disc sits in the marked slots on the clutch housing as shown in Figure If necessary, remove the fric- tion discs and clutch plates. Check the inner splines Figure 30 on the clutch plates. Minor roughness can be cleaned with an oilstone or fine file. If any one plate has excessive roughness or wear, re- place all the clutch plates as a set.

They must be smooth for chatter-free operation. If there is any excessive damage, replace the compo- nents. Inspect the posts B, Figure 32 for wear or galling. If there is any excessive damage, re- place the clutch boss. Pushrod No. O-ring 3. Adjuster 4. Push screw 5. Ball assembly 6. Housing 7. Oil seal 8. Pin 9. Clutch lever Spring 1. Remove the alternator cover as described in Chapter Five.

Apply grease to the balls in the ball assembly A, Figure Lower the ball assembly A, Figure 41 onto the push screw B. Seat the balls in the detents. Invert the assembly and install it into the housing on the inboard side of the alternator cover Figure Remove the mounting bolts A, Figure 45 , and pull the clutch adjuster cover B from the alternator cover.

Disconnect the clutch cable Figure 46 from the clutch lever. Pull the clutch cable end from the port in the alternator cover. Before removing the primary drive gear, set the front cylinder to top dead center on the compression stroke, The Yamaha sheave holder part No. YU and note the position of the timing or , or an equivalent flywheel holder, marks on the cam sprocket plate and is needed to service the primary drive gear.

Remove the cylinder head and the cam chain drive assembly from the front cylinder Chapter Four. Remove the clutch as described in this chapter. Bend the ears of the lockwasher A, Figure 50 away from the primary gear nut.

Push the springs as far apart as possible. Install the cam chain drive assembly and the cylinder head as described in Chapter Four. Install the clutch as described in this chapter. Loosen the shift lever clamp bolt B, Figure 2. Remove the footrest bracket bolts Figure 3. Locknut 2. E-clip Shift rod 3. Stopper lever spring Snap ring 4.

Stopper lever Shift pedal 5. Collar XVSA models 6. Wave washer 7. Shift shaft spring XVSA models 8. Install the shift lever so the index mark A, Figure 2 on the shift shaft aligns with the slot in the shift lever.

Slide the end of the shift shaft into the crankcase boss B, Figure 6 until the assembly bottoms. The arms of the shift shaft spring C, Figure 4 must straddle the post in the crankcase. Retainer screw 6. Neutral pin 2. Shift fork shaft 7. Bearing retainer 8. Pin 20 mm 3. Shift fork shaft 9. Pin 16 mm 4. Shift fork Shift cam 5. Check the pins B, Figure 12 and shift cam ramps C for wear. Gear b. Middle drive gear Countershaft first gear Mainshaft fourth gear 3. Countershaft fourth gear Splined washer 4.

Snap ring 5. Splined washer Mainshaft second-third 6. Install fourth gear A, Figure 19 onto the mainshaft, and slide it up against first gear. Make sure the engagement dogs on the gear face away from first gear. Install a splined washer B, Figure 19 and a new snap ring C. If it is still installed, remove the middle drive gear Figure 23 from the countershaft. Remove first gear, then remove fourth gear. Remove the snap ring and the splined washer. Remove the countershaft third gear.

Install first gear Figure 30 so its flat side faces out. Install the middle drive gear Figure 23 so its splines engage those on the countershaft. Mesh both assembled transmission shafts to- gether with the middle driven gear Figure Make sure all gears mate properly.

Have these tools on hand before beginning this procedure. Bearing retainer 2. Spring retainer 3. Spring seat 4. Damper spring 5. Damper cam male 6. Damper cam female 7.

Middle drive shaft nut 8. Bearing 9. Middle drive shaft shims Middle drive shaft Apply engine oil to the teeth of the middle drive shaft and install the middle drive shaft assembly into the crankcase.

Turn the bearing retainer A, Figure 40 until it is in place. Inspect the internal splines on the male and fe- male sides of the damper cam. The Yamaha universal joint holder part No. Inspect the damper spring for wear, cracks or YM or , or its equivalent, is damage. Bearing Speed sensor bracket 2. Middle driven shaft Bolt 3. Rotor 4. Collapsible collar Drive yoke 5. Collar Washer 6. O-ring Middle driven shaft nut 7. Remove the driven yoke C, Figure 46 from the drive yoke B.

Hold the drive yoke with the universal joint holder A, Figure 48 and loosen the middle driven shaft nut B. Install the universal joint holder A, Figure 48 onto the drive yoke and install the middle gear backlash band Figure 49 onto the middle drive shaft assembly.

Install the bearing housing bolts A, Figure 45 They may also be damaged. Dur- NOTE ing inspection, compare measurements to the speci- During removal, label each hose and fications in the tables at the end of this chapter. Fuel tank 6. Seat bracket bolt 2.

Fuel hose 7. Passenger seat 3. Fuel tank bolt 8. Nut 4. Meter connector 5. Seat bracket 8. Raise the fuel tank bracket and support the tank. Pull the meter connector B, Figure 5 from be- neath the ignitor panel and disconnect the pin meter connector A, Figure 6 from its harness Pull the tank bracket rearward until the tank is free of the damper A, Figure 7 on each side of the frame.

Remove the fuel tank. Installation is the reverse of removal. O-ring 2. Fuel valve body 3. Clamp 4. Fuel hose 5. Valve packing 6. Valve seal 7. Lever 8. Wave washer 9. Plate Pan head screw Screw 3. Drain the fuel from the tank into a clean, sealable b. Cover bolt Surge tank base Air filter housing 2. Air filter cover Air filter housing bracket lower 3.

Air filter Air filter housing duct Cylinder head 4. Remove the cover bolts A, Figure 10 and pull the air filter cover B from the housing. Lift the air filter A, Figure 11 from the posts in the air filter housing. Loosen the clamp B, Figure 11 that secures the surge tank duct to the back of the air filter housing. Remove the plug A, Figure 15 from the drain hose on the air filter housing. Clean out accumu- lated moisture or dirt. If necessary, blow the hose clear with compressed air.

Inspect all components of the air filter housing assembly. If removed, install the cylinder head breather hose Figure 20 onto the surge tank fitting so the dots on the hose face forward. Make sure the clamp A, Figure 19 on each car- buretor duct is loose and the carburetor breather hose B faces up.

At full throttle, the carburetor venturi is fully open and the needle is lifted far enough to permit the main jet to flow at full capacity. The choke circuit is a bystarter system. If necessary, turn the pull cable adjuster C, Figure 26 to create addi- tional slack. Loosen the cable clamp screw A, Figure 27 and disconnect the choke cable end B from the choke linkage.

Route the throttle cables and choke cable along their original paths. These cables must not be twisted, kinked or pinched. Secure the cables in the holder B, Figure 7.

Connect each hose to the fitting noted during removal and route the hose along its original path. Remove the cotter pin A, Figure 35 and washer. Remove the throttle arm B, Figure 35 from the throttle shaft on the front carburetor. Remove the mounting screw A, Figure 36 and lift the choke linkage B from the starter plunger on the rear carburetor. Throttle position 1.

Screw 2. Choke cable bracket sensor TPS Carburetor heater 3. Top cover 4. Spring Ground terminal 5. Needle retainer Pilot jet 6. Jet needle Spacer 7. If the carburetors were not separated, disconnect the carburetor heater wires by performing Steps in Separation in this section.

Remove the top cover as follows: a. Remove the top cover screws A, Figure When servicing the rear carburetor, remove the choke cable bracket B, Figure 41 from the top cover. Remove the carburetor heater A, Figure 48 and its washer from the bottom of the carburetor body.

When servicing the rear carburetor, also re- move the heater ground terminal B, Figure Remove the mounting screws A, Figure 49 and lift the float bowl B from the carburetor body. Remove the screw A, Figure 53 and pull the valve seat B from the carburetor body.

Remove the pilot jet Figure Remove the starter jet Figure 55 and spacer. Remove the main jet Figure Install the float pin B, Figure 51 and secure it with the screw A.

Install a new float bowl O-ring Figure 50 and set the float bowl onto the bottom of the carburetor B, Figure If removed, install the starter plunger B, Fig- ure Assemble the coasting enricher, if it was disas- sembled, as follows: a. Install the coasting enricher diaphragm B, Figure 40 onto the carburetor Figure Install the spring A, Figure 40 into the cen- ter of the diaphragm.

Inspect the vacuum piston B, Figure 61 for scoring and wear. Replace it if necessary. Inspect the diaphragm on the vacuum piston for tears, cracks or other damage. Page Fuel Level If a pilot screw must Drill stop be removed, perform the procedure as described, then have a Yamaha deal Plug ership perfom the final adjustment. Page Fuel level inspection re- quires a special fuel level gauge Yamaha part No.

Reinstall the carburetor assembly and re- YMA or Perform the test in the listed sequence. Connect the positive lead of an ohmmeter to the yellow terminal Figure 77 on the sensor side of the connector and connect the negative lead to the black terminal. With the throttle fully closed, rotate the sensor body B, Figure 78 until the resistance is within the fully closed range specified in Table 2. Disconnect the four-pin harness connector from the carburetor heater relay and remove the relay.

Thermo Switch Test 1. Disconnect the two-pin thermo switch connector B, Figure 75 from its harness mate. Replace the thermo switch if the test results are not within the above specifications. Carburetor Heater Test 1. Disconnect the electrical lead from the carbure- tor heater and remove the heater from the carbure- tor. Tie a piece of heavy string or cord to the ends of the throttle cable at the carburetor.

Starting at the choke lever, carefully pull the cable from the motorcycle, following the path of the original cable.

Lubricate the new cable as described in Chap- ter Three. Untie the string from the old cable and tie it to the carburetor end of the new cable. Position the filter so its arrow points toward the fuel pump.

Check the hose clamps for damage; replace them if necessary. After installation is complete, thoroughly check for leaks. Disconnect the electrical lead from the negative battery terminal. Remove the fuel tank and surge tank as de- scribed in this chapter.

Remove the frame neck cover Chapter Four- teen. Remove the starting circuit cutoff relay C, Fig- ure 75 from the mounting tang and disconnect the connector from the relay. Vacuum hose to rear cylinder intake manifold 2. Orifice 3. AIS air filter 4. Air filter housing 5. Air cut valve 6. Reed valve 7. Housing 8. Bracket 9. AIS output hose AIS pipe to rear cylinder Remove the toolbox cover and the side cover from the left side as described in Chapter Fourteen. Release the hose clamp Figure 96 and discon- nect the AIS pipe from its fitting on each cylinder head.

Replace any component that is worn, damaged or out of specification. Fitting 2. Solenoid valve 3. Rollover valve 4. Clamp 5. Label each hose before removal so they can be easily identified during assembly. Remove the toolbox cover and the side cover from the left side of the motorcycle.

Hanger bolt 9. Exhaust manifold 2. Muffler assembly Nut 3. Muffler gasket Front exhaust pipe 4. Clamp screw Exhaust cover 5. Rear exhaust pipe Nut 6. Bolt Loosen the muffler clamp screw A, Figure on each muffler. Remove the muffler hanger bolts B, Figure Pull the muffler assembly rearward. Separate each muffler from its respective exhaust pipe and remove the muffler assembly. After installation is complete, start the engine and make sure there are no exhaust leaks.

Correct any leak prior to riding the bike. Charging system. Ignition system. The ammeter should read less than 0. If the amperage is greater, there is a current draw on the system that will discharge the battery. Charging Voltage Test 1. Connect an engine tachometer to the spark plug lead on the No. Apply a medium-strength threadlocking compound to the threads of the stator mount- ing screws C, Figure 7 and the pickup coil mounting screws B. Alternator cover bolt vides longer component life and delivers a strong, tion coil and the magnetic field within the coil col- reliable spark throughout the entire range of engine lapses.

Never connect the battery backwards. If the bat- tery polarity is incorrect, the voltage regulator, al- ternator and ignitor unit will be damaged. Do not disconnect the battery while the engine is running. Keep all connections between the various units clean and tight. Remove the fuel tank, air filter housing and surge tank as described in Chapter Eight, and the re- move the frame neck cover Chapter Fifteen.

Disconnect the electrical lead from the negative battery terminal A, Figure 1. Page Before purchasing a new ignitor unit, have the system checked by a Yamaha dealership or another qualified shop. Most motorcycle dealerships will not accept returns on electrical components. Apply a dielectric compound to the electrical connectors prior to reconnecting them. Make sure the electrical connections are free of corrosion and are completely coupled to each other.

Tighten the screws securely. Install all removed items. Case bolt Armature 2. Rear end cap Brush holder 12 Armature housing negative brush set Positive brush set 14 Gear plate 5. Planetary gear 6. Remove the front end cap D, Figure 17 from the housing and remove the locating key Figure It could come out with the end cap or it could remain in the housing.

Lift each planetary gear Figure 21 from its post in the front end cap. Remove the shims A, Figure 28 from the commutator end of the armature shaft. Record the number of shims and their locations. Store the shims in a marked plastic bag.

Pull the armature Figure 29 from the arma- ture housing. The number and or- der of the washers and shims varies. Remove the brush holder assembly Figure 32 from the armature housing. Remove the insulator A, Figure 33 from the brush holder assembly. Make sure an insulated portion of each posi- tive brush wire Figure 35 touches the brush holder. If bare wire from the positive brush touches the brush holder, disassemble the brush holder assembly and reassemble it properly.

Page 1. Pull the spring away from each brush and pull undercut is less than specification Table 1 , have the brush out of its holder. Measure the length of the commutator serviced by a Yamaha dealership or each brush with a vernier caliper. If the length of electrical repair shop.

Inspect the commutator copper bars for discolor- ation. If a pair of bars is discolored, armature coils are grounded. Replace the starter. Measure the diameter of the commutator with a vernier caliper. Replace the starter if the commuta- tor diameter is less than the service limit specified in Undercut Table 1. Lift the starting circuit cutoff relay Figure 47 from its tang and disconnect the pin connector from the relay. Make sure the electrical terminals are clean and pack the con- nector with dielectric grease.

Replace the starting circuit cutoff relay if the ig- nition system diode fails either portion the test. Connect the ohmmeter positive test lead to the red C, Figure 52 terminal in the relay; connect the negative test lead to the black terminal D. The re- lay should have continuity. On XVS models, remove the two headlight housing bolts and remove the hous- ing from the headlight bracket.

On on XVS models, remove the headlight housing bolts and remove the housing from the headlight bracket. Headlight rim 9. Bulb plate 2. Bulb clip Socket cover 3. Retaining ring Screw 4. Lens Headlight housing 5. Save my name, email, and website in this browser for the next time I comment. Skip to content. What is a Yamaha V Star repair manual? Example Image Yamaha V Star Service Manual Table of Contents A Yamaha V Star motorcycle repair manual is defined as a book of instructions or handbook for learning how fix or mend a motorcycle that is suffering from mechanical damage or a fault.

Why is a Yamaha V Star repair manual necessary? Should you fix your motorbike yourself? Click on links below to gain instant access. With some manuals you are required to download the main manual and up to two supplement manuals.

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V Star Classic Supplement 1. If the fork oil becomes contaminated with dirt and water, change it immediately. Changing the fork oil requires disassembling and assembling the fork leg. Add to Cart. Item Description. The 'Ask a Question' function requires JavaScript.

I'm a DIY guy and this manual is a fantastic aid when doing any work on my bike. Highly detailed descriptions accompanied by many photograph depictions to guide you in either routine maintenance or full teardown.

There are specification sections that provide all necessary technical data. My hat is off to The Motor Bookstore for the ease of ordering and prompt delivery of the product. The product arrived in perfect condition and exceeds all expectations.

Was this rating helpful to you? Keith Sirico verified customer July 6, Wasnt sure what to expect as far as detailed information, but I this Manuel provides more than enough detailed info on what ever you may be looking to fix or trouble shoot. Highly recommend buying. John k verified customer April 30, Manual came in plastic wrap in excellent condition.

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