Yamaha XS1100 / XJ650 / XJ750 / XJ900 / XJ1100 — Example photo: Levethane, CC0, Wikimedia Commons

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Yamaha · Yamaha shaft-drive air-cooled (XS750/850/1100, XJ, Virago 1976-2007)

XS1100 / XJ650 / XJ750 / XJ900 / XJ1100

Library entry covers 1978-1994

25 factory 29 guideline

Published source

Yamaha XS1100H / XS1100SH Service Manual (Yamaha Motor Co.), Maintenance and Lubrication Chart pp.1-2

Factory service manual. Covers XS1100SH (1981) service manual supplement, chart in km, mi and months.

54 items for a 1991 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, shim adjusted (incl. desmo)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Two or more carburetors
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Shaft
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

1991 Yamaha XS1100 / XJ650 / XJ750 / XJ900 / XJ1100

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

Every 1,000 mi or 6 months

1 item

Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 2,500 mi or 6 months

14 items

Change engine oil

Engine

Factory

Manual: Engine oil: change. Factory: Maintenance and lubrication chart pp.1-2: first at 600 mi and 3,000 mi
Exhaust system: check for leakage, retighten, replace gaskets if necessary

Engine

Factory

Factory: Maintenance and lubrication chart pp.1-2 (ManualsLib viewer pp.43-44, re-read from the page images; thereafter every 4,000 km (2,500 mi) or 6 months, 8,000 km (5,000 mi) or 12 months, 16,000 km (10,000 mi) or 24 months): initial 5,000 km, thereafter every 4,000 km (2,500 mi) or 6 months
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plugs: check, gap, clean. Factory: Maintenance and lubrication chart pp.1-2
Synchronize carburetors

Fuel and air

Factory

Manual: Carburetor synchronization and idle speed: adjust. Factory: Maintenance and lubrication chart pp.1-2: dealer item; exhaust system checked at the same interval
Check battery electrolyte, top up with distilled water

Ignition and electrics

Factory

Manual: Battery: check specific gravity and breather. Factory: Maintenance and lubrication chart pp.1-2
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch: adjust free play. Factory: Maintenance and lubrication chart pp.1-2: dealer item; first at 600 mi
Change pedal shaft, brake and clutch lever pivot: apply chain lube lightly

Final drive

Factory

Factory: Maintenance and lubrication chart pp.1-2 (ManualsLib viewer pp.43-44, re-read from the page images; thereafter every 4,000 km (2,500 mi) or 6 months, 8,000 km (5,000 mi) or 12 months, 16,000 km (10,000 mi) or 24 months): initial 5,000 km, thereafter every 4,000 km or 6 months
Lubricate drive shaft splines / check U-joint

Final drive

Factory

Manual: Drive shaft joint: grease (25-30 cc moly grease). Factory: Maintenance and lubrication chart pp.1-2: dealer item; first at 3,000 mi
Steering bearing: check bearing assembly for looseness

Front end

Factory

Factory: Maintenance and lubrication chart pp.1-2 (ManualsLib viewer pp.43-44, re-read from the page images; thereafter every 4,000 km (2,500 mi) or 6 months, 8,000 km (5,000 mi) or 12 months, 16,000 km (10,000 mi) or 24 months): initial 5,000 km, thereafter every 4,000 km or 6 months; repack every 16,000 km (10,000 mi)
Grease and check center / side stand and springs

Rear suspension and frame

Factory

Manual: Center and side stand pivots: apply chain lube lightly. Factory: Maintenance and lubrication chart pp.1-2 (ManualsLib viewer pp.43-44, re-read from the page images; thereafter every 4,000 km (2,500 mi) or 6 months, 8,000 km (5,000 mi) or 12 months, 16,000 km (10,000 mi) or 24 months): initial 5,000 km, thereafter every 4,000 km or 6 months
Brake pedal shaft: apply grease lightly

Brakes

Factory

Factory: Maintenance and lubrication chart pp.1-2 (ManualsLib viewer pp.43-44, re-read from the page images; thereafter every 4,000 km (2,500 mi) or 6 months, 8,000 km (5,000 mi) or 12 months, 16,000 km (10,000 mi) or 24 months): initial 5,000 km, thereafter every 4,000 km or 6 months; lithium soap base grease
Check brake pads and discs

Brakes

Factory

Manual: Brake system: adjust free play, replace pads as needed. Factory: Maintenance and lubrication chart pp.1-2: dealer item; first at 600 mi
Check wheel bearings for play

Wheels and tires

Factory

Manual: Wheel bearings: check. Factory: Maintenance and lubrication chart pp.1-2: dealer item
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Control and meter cables: lubricate. Factory: Maintenance and lubrication chart pp.1-2: dealer item; pedal shafts, lever pivots and stand pivots every 2,500 mi

Every 3,000 mi or 12 months

4 items

Check throttle cable(s) free play and return

Fuel and air

Guideline
Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline

Every 5,000 mi or 12 months

7 items

Check and adjust valve clearances

Engine

Factory

Manual: Valve clearance: check and adjust (engine cold). Factory: Maintenance and lubrication chart pp.1-2: dealer item; first at 3,000 mi; cam chain tension adjusted at the same interval, first at 600 mi
Check engine breather and oil return

Engine

Factory

Manual: Crankcase ventilation hose: check. Factory: Maintenance and lubrication chart pp.1-2: dealer item
Replace oil filter

Engine

Factory

Manual: Oil filter: replace. Factory: Maintenance and lubrication chart pp.1-2: first at 600 mi and 3,000 mi
Clean / inspect air filter

Fuel and air

Factory

Manual: Air filter (dry): clean with compressed air. Factory: Maintenance and lubrication chart pp.1-2: first at 3,000 mi
Replace fuel lines

Fuel and air

Factory

Manual: Fuel hose and vacuum pipe: check. Factory: Maintenance and lubrication chart pp.1-2: dealer item
Cam chain: adjust chain tension

Final drive

Factory

Factory: Maintenance and lubrication chart pp.1-2 (ManualsLib viewer pp.43-44, re-read from the page images; thereafter every 4,000 km (2,500 mi) or 6 months, 8,000 km (5,000 mi) or 12 months, 16,000 km (10,000 mi) or 24 months): initial 1,000 and 5,000 km, thereafter every 8,000 km (5,000 mi) or 12 months
Change final drive (rear drive) oil

Final drive

Factory

Manual: Middle and final gear oil: replace. Factory: Maintenance and lubrication chart pp.1-2: first at 600 mi; SAE 80 API GL-4 hypoid gear oil

Every 6,000 mi or 12 months

6 items

Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check final drive for leaks and bearing play

Final drive

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 7,500 mi or 18 months

1 item

Replace spark plugs

Engine

Factory

Manual: Spark plugs: replace. Factory: Maintenance and lubrication chart pp.1-2: first at 8,000 mi (13,000 km)

Every 8,000 mi or 2 years

1 item

Check valve clearances (shim adjusted)

Engine

Guideline

Every 10,000 mi or 2 years

4 items

Compression test (or leak-down)

Engine

Guideline
Change fork oil

Front end

Factory

Manual: Front fork oil: drain and refill. Factory: Maintenance and lubrication chart pp.1-2: dealer item
Check steering head bearing adjustment

Front end

Factory

Manual: Steering bearing: repack. Factory: Maintenance and lubrication chart pp.1-2: dealer item; check every 2,500 mi
Grease swingarm pivot

Rear suspension and frame

Factory

Manual: Rear arm pivot bearings: repack. Factory: Maintenance and lubrication chart pp.1-2: dealer item

Every 12,000 mi or 2 years

1 item

Replace air filter element

Fuel and air

Guideline

Every 20,000 mi or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

1 item

Check speedometer / odometer against a known distance

Controls and cables

Guideline

Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

3 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Guideline

Every 4 years

2 items

Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.