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STAR XVS95CE 2DX1 2014
Yamaha STAR XVS95CE 2DX1 2014 User Manual
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2014
SERVICE MANUAL
XVS95CE(C)
LIT-11616-27-30
1TP-28197-11
2
Table of Contents
Table of Contents
7
How to Use this Manual
4
Symbols
5
General Information
9
Identification
10
Vehicle Identification Number
10
Model Label
10
Features
11
Outline of the Fi System
11
Fi System
12
Instrument Functions
13
Important Information
15
Preparation for Removal and Disassembly
15
Replacement Parts
15
Gaskets, Oil Seals and O-Rings
15
Lock Washers/Plates and Cotter Pins
15
Bearings and Oil Seals
16
Circlips
16
Rubber Parts
16
Basic Service Information
17
Quick Fasteners
17
Electrical System
18
Special Tools
22
Specifications
27
General Specifications
28
Engine Specifications
29
Chassis Specifications
36
Electrical Specifications
39
Tightening Torques
41
General Tightening Torque Specifications
41
Engine Tightening Torques
42
Chassis Tightening Torques
47
Lubrication Points and Lubricant Types
52
Engine
52
Chassis
54
Lubrication System Chart and Diagrams
56
Engine Oil Lubrication Chart
56
Lubrication Diagrams
58
Cable Routing
66
Periodic Checks and Adjustments
103
General Maintenance and Lubrication Chart
106
Introduction
106
Periodic Maintenance
106
Periodic Maintenance Chart for the Emission Control System
106
Adjusting the Valve Clearance
109
Checking the Fuel Line
109
Checking the Spark Plugs
109
Checking the Crankcase Breather Hose
112
Synchronizing the Throttle Bodies
112
CHECKING the CANISTER (for California)
114
Checking the Exhaust System
114
Replacing the Air Filter Element
114
Adjusting the Clutch Lever Free Play
115
Checking the Clutch Operation
115
Checking the Brake Fluid Level
116
Checking the Brake Operation
116
Bleeding the Hydraulic Brake System
117
Checking the Front Brake Pads
117
Checking the Rear Brake Pads
117
Checking the Front Brake Hose
118
Checking the Rear Brake Hoses
118
Checking the Tires
119
Checking the Wheels
119
Checking the Wheel Bearings
120
Adjusting the Drive Belt Slack
121
Checking the Drive Belt
121
Checking the Swingarm Pivot Shaft Bearings
121
Checking and Adjusting the Steering Head
123
Checking the Chassis Fasteners
124
Checking the Sidestand
124
Lubricating the Brake Lever
124
Lubricating the Brake Pedal
124
Lubricating the Clutch Lever
124
Lubricating the Shift Pedal
124
Lubricating the Sidestand
124
Lubricating the Steering Bearings
124
ADJUSTING the REAR SHOCK ABSORBER ASSEMBLIES (for Models Not Equipped with Gas Cylinders)
125
Checking the Front Fork
125
Checking the Rear Shock Absorber Assemblies
125
Checking the Sidestand Switch
125
ADJUSTING the REAR SHOCK ABSORBER ASSEMBLIES (for Models Equipped with Gas Cylinders)
126
Checking the Engine Oil Level
126
Changing the Engine Oil
127
Adjusting the Rear Brake Light Switch
129
Checking and Lubricating the Cables
129
Checking the Brake Light Switch
129
Checking the Throttle Grip Operation
129
Chassis
133
General Chassis
136
Installing the Rider Seat
137
Installing the Tool Box
140
Front Wheel
145
Removing the Front Wheel
147
Disassembling the Front Wheel
147
Checking the Front Wheel
147
Assembling the Front Wheel
148
Adjusting the Front Wheel Static Balance
148
Installing the Front Wheel (Front Brake Disc)
149
Rear Wheel
151
Removing the Rear Wheel (Disc)
155
Disassembling the Rear Wheel
155
Checking the Rear Wheel
155
Checking the Rear Brake Caliper Bracket
155
Checking the Rear Wheel Drive Hub
155
Checking and Replacing the Rear Wheel Pulley
155
Assembling the Rear Wheel
156
Adjusting the Rear Wheel Static Balance
156
Installing the Rear Wheel (Rear Brake Disc)
156
Front Brake
158
Introduction
163
Checking the Front Brake Disc
163
Replacing the Front Brake Pads
164
Removing the Front Brake Caliper
165
Disassembling the Front Brake Caliper
165
Checking the Front Brake Calipers
165
Assembling the Front Brake Caliper
166
Installing the Front Brake Caliper
166
Removing the Front Brake Master Cylinder
167
Checking the Front Brake Master Cylinder
167
Assembling the Front Brake Master Cylinder
168
Installing the Front Brake Master Cylinder
168
Rear Brake
170
Introduction
176
Checking the Rear Brake Disc
176
Replacing the Rear Brake Pads
176
Removing the Rear Brake Caliper
177
Disassembling the Rear Brake Caliper
177
Checking the Rear Brake Caliper
178
Assembling the Rear Brake Caliper
178
Installing the Rear Brake Caliper
178
Removing the Rear Brake Master Cylinder
179
Checking the Rear Brake Master Cylinder
180
Assembling the Rear Brake Master Cylinder
180
Installing the Rear Brake Master Cylinder
180
Handlebar
182
Removing the Handlebar
184
Checking the Handlebar
184
Installing the Handlebar
184
Front Fork
187
Removing the Front Fork Legs
191
Disassembling the Front Fork Legs
191
Checking the Front Fork Legs
192
Assembling the Front Fork Legs
192
Installing the Front Fork Legs
195
Steering Head
196
Removing the Lower Bracket
198
Checking the Steering Head
198
Installing the Steering Head
198
Swingarm and Rear Shock Absorber Assemblies
200
Removing the Swingarm and Rear Shock Absorber Assemblies
202
Checking the Swingarm
202
HANDLING the REAR SHOCK ABSORBER and GAS CYLINDER (for Models Equipped with Gas Cylinders)
202
DISPOSING of a REAR SHOCK ABSORBER (for Models Equipped with Gas Cylinders)
203
Checking the Rear Shock Absorber Assemblies
203
Installing the Swingarm and Rear Shock Absorber Assemblies
203
Belt Drive
205
Removing the Drive Belt and Drive Pulley
206
Checking the Drive Belt
206
Installing the Drive Belt and Drive Pulley
206
Engine
209
Engine Inspection
212
Measuring the Compression Pressure
212
Engine Removal
214
Installing the Exhaust Pipe
216
Installing the Muffler
217
Installing the Shift Arm
220
Adjusting the Shift Pedal
220
Installing the Horn
222
Removing the Engine
225
Installing the Engine
225
Camshafts
227
Removing the Camshafts and Rocker Arms
230
Checking the Camshafts
231
Checking the Camshaft Sprockets
232
Checking the Rocker Arms and Rocker Arm Shafts
232
Checking the Timing Chain Tensioners
233
Installing the Rocker Arms and Camshafts
233
Installing the Cylinder Head Covers
236
Cylinder Heads
237
Removing the Cylinder Heads
238
Checking the Cylinder Heads
238
Installing the Cylinder Heads
238
Valves and Valve Springs
241
Removing the Valves
241
Checking the Valves and Valve Guides
241
Checking the Valve Seats
243
Checking the Valve Springs
244
Installing the Valves
245
Cylinders and Pistons
248
Removing the Pistons
248
Checking the Cylinders and Pistons
248
Checking the Piston Rings
249
Checking the Piston Pins
250
Installing the Pistons and Cylinders
251
Generator and Starter Clutch
253
Removing the Generator
256
Removing the Starter Clutch
256
Checking the Starter Clutch
256
Installing the Starter Clutch
257
Installing the Generator
257
Installing the Generator Cover
258
Clutch
259
Removing the Primary Drive Gear
264
Removing the Clutch
264
Checking the Friction Plates
264
Checking the Clutch Plates
265
Checking the Clutch Spring Plate
265
Checking the Clutch Housing
265
Checking the Clutch Boss
266
Checking the Pressure Plate
266
Checking the Primary Drive Gear
266
Checking the Primary Driven Gear
266
Checking the Pull Lever Shaft and Pull Rod
266
Checking the Oil Pump Drive Sprocket and Oil Pump Drive Chain
266
Installing the Clutch
266
Installing the Primary Drive Gear
269
Shift Shaft
271
Checking the Shift Shaft
271
Checking the Stopper Lever
271
Installing the Shift Shaft
271
Electric Starter
272
Checking the Starter Motor
274
Assembling the Starter Motor
275
Crankcase
276
Disassembling the Crankcase
280
Checking the Crankcase
280
Checking the Bearings and Oil Seal
280
Checking the Oil Delivery Pipes
280
Checking the Timing Chains
280
Checking the Oil Pump Driven Sprocket
280
Installing the Bearing Retainers
280
Assembling the Crankcase
281
Oil Pump
284
Checking the Oil Pump
284
Checking the Relief Valve
284
Checking the Oil Strainer
284
Assembling the Oil Pump
284
Installing the Oil Pump Assembly
285
Crankshaft
286
Removing the Connecting Rods
287
Checking the Crankshaft and Connecting Rods
287
Installing the Connecting Rods
289
Installing the Crankshaft Assembly
290
Transmission
294
Checking the Shift Forks
294
Checking the Shift Drum Assembly
294
Checking the Transmission
294
Assembling the Main Axle and Drive Axle
295
Installing the Shift Forks and Shift Drum Assembly
295
Fuel System
297
Fuel Tank
299
Checking the Fuel Pump Body
301
Checking the Rollover Valve
301
Removing the Fuel Pump
301
Removing the Fuel Tank
301
Installing the Fuel Pump
302
Installing the Fuel Sender
303
Throttle Bodies
306
Checking the Injectors
307
Installing the Injectors
307
Checking the Throttle Bodies
307
Checking the Intake Manifold Joints
307
Checking the Pressure Regulator Operation
307
Adjusting the Throttle Position Sensor
308
Removing the Intake Manifold Assembly
309
Installing the Intake Manifold Assembly
309
Electrical System
311
Ignition System
314
Circuit Diagram
314
Engine Stopping Due to Sidestand Operation
316
Troubleshooting
317
Electric Starting System
320
Circuit Diagram
320
Starting Circuit Cut-Off System Operation
322
Troubleshooting
323
Charging System
326
Circuit Diagram
326
Troubleshooting
328
Lighting System
330
Circuit Diagram
330
Troubleshooting
332
Signaling System
334
Circuit Diagram
334
Troubleshooting
336
Fuel Injection System
340
Circuit Diagram
340
Ecu Self-Diagnostic Function
342
Troubleshooting Method
343
Yamaha Diagnostic Tool
344
Troubleshooting Details
345
Electrical Components
384
Checking the Switches
388
Troubleshooting
407
Default Chapter
407
General Information
407
Troubleshooting
408
General Information
408
Starting Failures
408
Incorrect Engine Idling Speed
408
Poor Medium-And-High-Speed Performance
409
Faulty Gear Shifting
409
Shift Pedal Does Not Move
409
Jumps out of Gear
409
Faulty Clutch
409
Overheating
409
Poor Braking Performance
410
Faulty Front Fork Legs
410
Unstable Handling
410
Faulty Lighting or Signaling System
410
Self-Diagnostic Function and Diagnostic Code Table
413
Wiring Diagram
418
4
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Yamaha STAR XVS95CE 2DX1 2014 Specifications
General
Brand
Yamaha
Model
STAR XVS95CE 2DX1 2014
Category
Motorcycle
Language
English
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