Yamaha XV User manual

Contents
Introductorypages
Aboutthismanual0-6
IntroductiontotheYamahaXV0-6
Identificationnumbers0-7
Buyingparts0-8
Generalspecifications0-8
Maintenancetechniques,toolsandworkingfacilities0-11
Safetyfirst!0-17
Motorcyclechemicalsandlubricants0-18
Troubleshooting0-19
Chapter1
Tune-upandroutinemaintenance1-1
Chapter2 PartA
Engine,clutchandtransmission(XV535models)2A-1
Chapter2 PartB
Engine,clutchandtransmission(XV700through1100models)2B-1
Chapter3 PartA
Fuelandexhaustsystems(XV535models)3A-1
Chapter3 PartB
Fuelandexhaustsystems(XV700through1100models)3B-1
Chapter4 PartA
Ignitionsystem(XV535models)4A-1
Chapter4 PartB
Ignitionsystem(XV700through1100models)4B-1
Chapter5 PartA
Steering,suspensionandfinaldrive(XV535models)5A-1
Chapter5 PartB
Steering,suspensionandfinaldrive(XV700through1100models)5B-1
Chapter6 PartA
Brakes,wheelsandtires(XV535models)6A-1
Chapter6 PartB
Brakes,wheelsandtires(XV700through1100models)6B-1
Chapter7 PartA
Frameandbodywork(XV535models)7A-1
Chapter7 PartB
Frameandbodywork(XV700through1100models)7B-1
Chapter8 PartA
Electricalsystem(XV535models)8A-1
Chapter8 PartB
Electricalsystem(XV700through1100models)8B-1
Chapter9
Wiringdiagrams9-1
Conversionfactors
IndexIND-1

0-4YamahaXV
The1994XV535Smodel
The1985XV700Viragomodel

YamahaXV0-5
TheTR1model
The1994XV1100Viragomodel

0-6
Aboutthismanual
Its purpose
Thepurposeofthismanualistohelpyougetthebestvaluefrom
yourmotorcycle.Itcandosoinseveralways.Itcanhelpyoudecide
whatworkmustbedone,evenifyouchoosetohaveitdonebya
dealerservicedepartmentora repairshop;itprovidesinformationand
proceduresforroutinemaintenanceandservicing;anditoffers
diagnosticandrepairprocedurestofollowwhentroubleoccurs.
Wehopeyouusethemanualtotackletheworkyourself.For
manysimplerjobs,doingityourselfmaybequickerthanarrangingan
appointmenttogetthevehicleintoa shopandmakingthetripsto
leaveitandpickitup.Moreimportantly,a lotofmoneycanbesaved
byavoidingtheexpensetheshopmustpassontoyoutocoverits
laborandoverheadcosts.Anaddedbenefitisthesenseofsatisfaction
andaccomplishmentthatyoufeelafterdoingthejobyourself.
Using the manual
ThemanualisdividedintoChapters.EachChapterisdividedinto
numberedSections,whichareheadedinboldtypebetweenhorizontal
lines.EachSectionconsistsofconsecutivelynumberedparagraphs.
AtthebeginningofeachnumberedSectionyouwillbereferredto
anyillustrationswhichapplytotheproceduresinthatSection.The
referencenumbersusedinillustrationcaptionspinpointthepertinent
SectionandtheStepwithinthatSection.Thatis,illustration3.2means
theillustrationreferstoSection3 andStep(orparagraph)2 withinthat
Section.
Procedures,oncedescribedinthetext,arenotnormally
repeated.Whenit'snecessarytorefertoanotherChapter,the
referencewillbegivenasChapterandSectionnumber.Cross
referencesgivenwithoutuseoftheword"Chapter"applytoSections
and/orparagraphsinthesameChapter.Forexample,"seeSection8"
meansinthesameChapter.
Referencestotheleftorrightsideofthevehicleassumeyouare
sittingontheseat,facingforward.
Motorcyclemanufacturerscontinuallymakechangestospecifi-
cationsandrecommendations,andthese,whennotified,are
incorporatedintoourmanualsattheearliestopportunity.
Eventhoughwehavepreparedthismanualwithextremecare,
neitherthepublishernortheauthorcanacceptresponsibilityforany
errorsin,oromissionsfrom,theinformationgiven.
NOTE
ANoteprovidesinformationnecessarytoproperlycompletea procedureorinformationwhichwillmaketheprocedureeasier
tounderstand.
CAUTION
ACautionprovidesa specialprocedureorspecialstepswhichmustbetakenwhilecompletingtheprocedurewherethe
Cautionisfound.Notheedinga Cautioncanresultindamagetotheassemblybeingworkedon.
WARNING
AWarningprovidesa specialprocedureorspecialstepswhichmustbetakenwhilecompletingtheprocedurewherethe
Warningisfound.Notheedinga Warningcanresultinpersonalinjury.
IntroductiontotheYamahaXV
TheYamahaXV(Virago)seriesarehighlysuccessfulandpopular
cruiser-stylemotorcycles.
Theengineon allmodelsis an air-cooled,V-twinwithoverhead
camshafts..
FuelisdeliveredtothecylindersbytwoHitachiorMikuni
carburetors;XV535,XV1000andXV1100modelsuseanelectricfuel
pump.
Thefrontsuspensionusesa pairofconventionalforks,adjustable
byvaryingtheforkairpressureonsomemodels.Forkdampingis
adjustableonXV920J models.
Therearsuspensionon1981through1983modelsusesa single
shockabsorberandcoilspring.Latermodelsusetwinrearshock
absorberswithconcentriccoilsprings.Springpreloadisadjustableon
allXV700through1100models;shockabsorberdampingisadjustable
on1984andlaterXV700through1100models.
Thefrontbrakeusesa singleordualdisc;a drumbrakeisusedat
therear.
Shaftfinaldriveisusedonmostofthebikescoveredinthis
manual.Somemodelsuseanunusualchaindrivesystem,withthe
chaincompletelyenclosedin housingsandrunningin a bathof grease.

0-7
Identificationnumbers
Theframeserialnumberisstampedintotherightsideofthe
frameandprintedon a labelaffixedto theframe.Theenginenumberis
stampedintotherightuppersideofthecrankcase.Bothofthese
numbersshouldberecordedandkeptina safeplacesotheycanbe
furnishedtolawenforcementofficialsintheeventofa theft.
Theframeserialnumber,engineserialnumberandcarburetor
identificationnumbershouldalsobekeptina handyplace(suchas
withyourdriver'slicense)sotheyarealwaysavailablewhen
purchasingororderingpartsforyourmachine.
Themodelscoveredbythismanualareasfollows:
XV535,1987through1990US
XV535,1993and1994US
XV535,1988through1994UK
XV700,1984through1987US
XV750,1981through1983and1988through1994US
XV750,1981through1983UK,1992through1994UK
XV920,1981through1983US
XV1000shaftdrive,1984and1985US,
1986through1989UK
XV1000chaindrive(TR1),1981through1985UK
XV1100,1986through1994US,1989through1994UK
Identifying engines and model years
Theproceduresinthismanualidentifythebikesbymodelyear.
Todeterminewhichmodelyeara givenmachineis,lookforthe
followingidentificationcodesintheengineandframenumbers:
Theframenumberisstampedintherightsideoftheframeandis
alsodisplayedona decal
Theenginenumberisstampedintherightsideofthecrankcase
YearCode
XV535models
1987and1988US2GV
1989and1990US3JC1/3JC2
1993US3JC7/3JC8
1994US
XV5353JCA,3JCB
XV535S3JCB,3JCD
1988UK3BT1
1989UK.3BT2/3BT5
1990UK3BTC/3BT8
1991UK3BTE/3BTF
1992UK3BTK/3BTM
1993UK3BTR/3BTT
1994UK
XV5354KU2/3BTW
XV535S4KU4(flathandlebar)
XV535S3BTV/3BTY(uprighthandlebar)
XV700models
198442W/42X
198556E/56F
1986and19871RM/1RV/1RR/1TU
XV750models
1981through1983US
XV750H,J,K 4X7
XV750MK20X
1988US..3AL/3CM
1989US3JL1/3JL2
1990US3JL4/3JL5
1991US3JL7/3JL8
1992US3JUV3JLB
1993US3JLD/3JLE
1994US3JLG/3JLH
1981through1983UK5G5
1992and1993UK4FY1
1994UK4FY4
XV920models
1981and1982chaindrive5H1
1982shaftdrive10L
1983shaftdrive
XV920K 24M
XV920MK27Y
XV1000models
1984US42G/42H
1985US56V/56W
1981UK5A8
1982through1985UK19T
1986and1987UK2AE
1988and1989UK3DR1
XV1100models
1986and1987US1TE/1TA
1988US3CF/3CG
1989US3JK1/3JK2
1990US3JK4/3JK5
1991US3JK7/3JK8
1992US3JKB/3JKC
1993US3JKA/3JKE
1994US3JKG/3JKH
1989and1990UK3LP1
1991UK. 3LP2
1992and1993UK3LP4
1994UK3LP8

0-8
Buyingparts
Onceyouhavefoundall theidentificationnumbers,recordthem
forreferencewhenbuyingparts.Sincethemanufacturerschange
specifications,partsandvendors(companies thatmanufacturevarious
componentsonthemachine),providingtheIDnumbersistheonlyway
tobereasonablysurethatyouarebuyingthecorrectparts.
Wheneverpossible,takethewornparttothedealersodirect
comparisonwiththenewcomponentcanbemade.Alongthetrailfrom
themanufacturertothepartsshelf,therearenumerousplacesthatthe
partcanendupwiththewrongnumberorbelistedincorrectly.
Thetwoplacestopurchasenewpartsforyourmotorcycle- the
accessorystoreandthefranchiseddealer- differinthetypeofparts
theycarry.Whiledealerscanobtainvirtuallyeverypartforyour
motorcycle,theaccessorydealerisusuallylimitedtonormalhighwear
itemssuchasshockabsorbers,tune-upparts,variousenginegaskets,
cables,chains,brakeparts,etc.Rarelywillanaccessoryoutlethave
majorsuspensioncomponents,cylinders,transmissiongears,or
cases.
Usedpartscanbeobtainedforroughlyhalfthepriceofnewones,
butyoucan'talwaysbesureofwhatyou'regetting.Onceagain,take
yourwornparttothewreckingyard(breaker)fordirectcomparison.
Whetherbuyingnew,usedor rebuiltparts,thebestcourseis to
dealdirectlywithsomeonewhospecializesinpartsforyourparticular
make.
Generalspecifications
XV535models
1987and1988USmodels
Wheelbase1511mm(59.5inches)
Overalllength2210mm(87.0inches)
Overallwidth815mm(32.1inches)
Overallheight1100mm(43.3inches)
Seatheight700 mm(27.6inches)
Groundclearance(minimum)145mm(5.7inches)
Weight(withoilandfullfueltank)
USexceptCalifornia185kg(408lbs)
California186kg(410lbs)
1989-onUSmodels
Wheelbase1520mm(59.8inches)
Overalllength2225mm(87.6inches)
Overallwidth810 mm(31.9inches)
Overallheight1110mm(43.7inches)
Seatheight720mm(28.3inches)
Groundclearance(minimum)160mm(6.3inches)
Weight(withoilandfullfueltank)
USexceptCalifornia195kg(430lbs)
California196kg(432lbs)
1988UKmodels
Wheelbase. 1520mm(59.8inches)
Overalllength2225mm(87.6inches)
Overallwidth810mm(31.9inches)
Overallheight1100mm(43.3inches)
Seatheight700 mm(27.6inches)
Groundclearance(minimum)160mm(6.3inches)
Weight(withoilandfullfueltank)188kg(415lbs)

Generalspecifications0-9
1989-onUKmodels
Wheelbase1520mm(59.8inches)
Overalllength2285mm(90.0inches)
Overallwidth
Flathandlebar725mm(88.6inches)
Uprighthandlebar810mm(31.9inches)
Overallheight
Flathandlebar1070mm(42.1inches)
Uprighthandlebar1110mm(43.7inches)
Seatheight720mm(28.3inches)
Groundclearance(minimum)160mm(6.3inches)
Weight(withoilandfullfueltank)195kg(430lbs)
XV700andUSXV1000models
Wheelbase1525mm(60.0inches)
Overalllength2235mm(88.0inches)
Overallwidth840 mm(33.1inches)
Overallheight1170mm(46.1inches)
Seatheight715mm(28.1inches)
Groundclearance(minimum)145mm(5.7inches)
Weight(withoil andfullfueltank)
1984and1985XV700models225kg(496lbs)
1986and1987XV700models229kg(505lbs)
XV1000models236kg(520lbs)
XV750models(1981through1983)
Wheelbase1520mm(59.8inches)
Overalllength2230mm(87.8inches)
Overallwidth
USmodels805mm(31,7inches)
UKmodels840mm(33.1inches)
Overallheight
USmodels1160mm(45.7inches)
UKmodels1210mm(47.6inches)
Seatheight....notspecified
Groundclearance(minimum)145mm(5.7inches)
Weight(dry)
USmodels225kg(496lbs)
UKmodels. 211kg(465lbs)
XV750models(1988-onUS)
Wtieelbase1525mm(60.0inches)
Overalllength2285mm(90.0inches)
Overallwidth840mm(33.1inches)
Overallheight1190mm(46.9inches)
Seatheight715mm(28.1inches)
Groundclearance(minimum)145mm(5.7inches)
WeightNotspecified
XV750models(1992-onUK)
Wheelbase1525mm(60.0inches)
Overalllength2285mm(90.0inches)
Overallwidth840 mm(33.1inches)
Overallheight..1190mm(46.9inches)
Seatheight715mm(28.1inches)
Groundclearance(minimum)145mm(5.7inches)
Weight
1992and1993models235kg(518lbs)
1994models236kg(520lbs)
XV920J models
Wheelbase1520mm(59.8inches)
Overalllength2220mm(87.4inches)
Overallwidth. 840mm(33.1inches)
Overallheight1205mm(47.4inches)
SeatheightNotspecified
Groundclearance(minimum). 145mm(5.7inches)
Weight225kg(496lbs)

0-10Generalspecifications
XV920K andMKmodels
Wheelbase1520mm(59.8inches)
Overalllength2230mm(87.8inches)
Overallwidth805mm(31.7inches)
Overallheight1160mm(45.7inches)
SeatheightNotspecified
Groundclearance(minimum)145mm(5.7inches)
Weight235kg(518lbs)
XV920RHandRJmodels
Wheelbase1540mm(60.6inches)
Overalllength2260mm(89.0inches)
Overallwidth930 mm(36.6inches)
Overallheight1170mm(46.1inches)
SeatheightNotspecified
Groundclearance(minimum)140mm(5.5inches)
Weight224 kg(493lbs)
XV1000models(1981through1985UKTR1)
Wheelbase1540mm(60.6inches)
Overalllength2265mm(89.2inches)
Overallwidth730mm(28.7inches)
Overallheight1170mm(46.1inches)
SeatheightNotspecified
Groundclearance(minimum)140mm(5.5inches)
Weight220 kg(485lbs)
XV1100models(1986-on)
Wheelbase1525mm(60.0inches)
Overalllength
USmodels2235mm(88.0inches)•
UKmodels2285mm(90.0inches)
Overallwidth840 mm(33.1inches)
Overallheight
1986and19871170mm(46.1inches)
1988-on1190mm(46.9inches)
Seatheight715mm(28.1inches)
Groundclearance(minimum)145mm(5.7inches)
Weight(withoil andfullfueltank)
USmodels239kg(527lbs)
UKmodels240kg(529lbs)

0-11
Maintenancetechniques,
toolsandworkingfacilities
Basic maintenance techniques
Therearea numberoftechniquesinvolvedinmaintenanceand
repairthatwillbereferredtothroughoutthismanual.Applicationof
thesetechniqueswillenabletheamateurmechanictobemore
efficient,betterorganizedandcapableofperformingthevarioustasks
properly,whichwillensurethattherepairjobisthoroughand
complete.
Fasteningsystems
Fasteners,basically,arenuts,boltsandscrewsusedtoholdtwo
ormorepartstogether.Therearea fewthingstokeepinmindwhen
workingwithfasteners.Almostall ofthemusea lockingdeviceof
sometype(eithera lockwasher,locknut,lockingtaborthread
adhesive).Allthreadedfastenersshouldbeclean,straight,have
undamagedthreadsandundamagedcornersonthehexheadwhere
thewrenchfits.Developthehabitofreplacingalldamagednutsand
boltswithnewones.
Rustednutsandboltsshouldbetreatedwitha penetratingoil to
easeremovalandpreventbreakage.Somemechanicsuseturpentine
ina spouttypeoil can,whichworksquitewell.Afterapplyingtherust
penetrant,letit"work"fora fewminutesbeforetryingtoloosenthenut
orbolt.Badlyrustedfastenersmayhavetobechiseledofforremoved
witha specialnutbreaker,availableattoolstores.
Ifa boltorstudbreaksoffinanassembly,itcanbedrilledoutand
removedwitha specialtoolcalledanE-Zout(orscrewextractor).
Mostdealerservicedepartmentsandmotorcyclerepairshopscan
performthistask,aswellasothers(suchastherepairofthreaded
holesthathavebeenstrippedout).
Flatwashersandlockwashers,whenremovedfromanassembly,
shouldalwaysbereplacedexactlyasremoved.Replaceanydamaged
washerswithnewones.Alwaysusea flatwasherbetweena lock
washerandanysoftmetalsurface(suchasaluminum),thinsheet
metalorplastic.Speciallocknutscanonlybeusedonceortwice
beforetheylosetheirlockingabilityandmustbereplaced.
Tighteningsequencesandprocedures
Whenthreadedfastenersaretightened,theyareoftentightened
toa specifictorquevalue(torqueisbasicallya twistingforce).Over-
tighteningthefastenercanweakenitandcauseittobreak,while
under-tighteningcancauseittoeventuallycomeloose.Eachbolt,
dependingonthematerialit'smadeof,thediameterofitsshankand
thematerialitisthreadedinto,hasa specifictorquevalue,whichis
notedintheSpecifications.Besuretofollowthetorquerecommen-
dationsclosely.
Fastenerslaidoutina pattern(i.e.cylinderheadbolts,engine
casebolts,etc.)mustbeloosenedortightenedina sequencetoavoid
warpingthecomponent.Initially,thebolts/nutsshouldgoonfinger
tightonly.Next,theyshouldbetightenedonefullturneach,ina criss-
crossordiagonalpattern.Aftereachonehasbeentightenedonefull
turn,returntothefirstonetightenedandtightenthemallonehalfturn,
followingthesamepattern.Finally,tighteneachofthemonequarter
turnata timeuntileachfastenerhasbeentightenedtotheproper
torque.Toloosenandremovethefastenerstheprocedurewouldbe
reversed.
Disassemblysequence
Componentdisassemblyshouldbedonewithcareandpurpose
tohelpensurethatthepartsgobacktogetherproperlyduring
reassembly.Alwayskeeptrackofthesequenceinwhichpartsare
removed.Takenoteofspecialcharacteristicsormarksonpartsthat
canbeinstalledmorethanoneway(suchasa groovedthrustwasher
ona shaft).It'sa goodideatolaythedisassembledpartsoutona
cleansurfaceintheorderthattheywereremoved.Itmayalsobe
helpfultomakesketchesortakeinstantphotosofcomponentsbefore
removal.
Whenremovingfastenersfroma component,keeptrackoftheir
locations.Sometimesthreadinga boltbackina part,orputtingthe
washersandnutbackona stud,canpreventmixupslater.Ifnutsand
boltscan'tbereturnedtotheiroriginallocations,theyshouldbekeptin
acompartmentedboxora seriesofsmallboxes.A cupcakeormuffin
tinisidealforthispurpose,sinceeachcavitycanholdtheboltsand
nutsfroma particulararea(i.e.enginecasebolts,valvecoverbolts,
enginemountbolts,etc.).A panofthistypeisespeciallyhelpfulwhen
workingonassemblieswithverysmallparts(suchasthecarburetors
andthevalvetrain).Thecavitiescanbemarkedwithpaintortapeto
identifythecontents.
Wheneverwiringlooms,harnessesorconnectorsareseparated,
it'sa goodideatoidentifythetwohalveswithnumberedpiecesof
maskingtapesotheycanbeeasilyreconnected.
Gasketsealingsurfaces
Throughoutanymotorcycle,gasketsareusedto sealthemating
surfacesbetweencomponentsandkeeplubricants,fluids,vacuumor
pressurecontainedinanassembly.
Manytimesthesegasketsarecoatedwitha liquidorpastetype
gasketsealingcompoundbeforeassembly.Age,heatandpressure
cansometimescausethetwopartstosticktogethersotightlythat
theyareverydifficulttoseparate.Inmostcases,thepartcanbe
loosenedbystrikingitwitha soft-facedhammernearthemating
surfaces.A regularhammercanbeusedifa blockofwoodisplaced
betweenthehammerandthepart.Donothammeroncastpartsor
partsthatcouldbeeasilydamaged.Withanyparticularlystubborn
part,alwaysrechecktomakesurethateveryfastenerhasbeen
removed.
Avoidusinga screwdriverorbartopryapartcomponents,asthey
caneasilymarthegasketSealingsurfacesoftheparts(whichmust
remainsmooth).Ifpryingisabsolutelynecessary,usea pieceofwood,
butkeepinmindthatextraclean-upwillbenecessaryifthewood
splinters.
Afterthepartsareseparated,theoldgasketmustbecarefully
scrapedoffandthegasketsurfacescleaned.Stubborngasketmaterial
canbesoakedwitha gasketremover(availableinaerosolcans)to
softenitsoitcanbeeasilyscrapedoff.A scrapercanbefashioned
froma pieceofcoppertubingbyflatteningandsharpeningoneend.
Copperisrecommendedbecauseitisusuallysofterthanthesurfaces
tobescraped,whichreducesthechanceofgougingthepart.Some
gasketscanberemovedwitha wirebrush,butregardlessofthe
methodused,thematingsurfacesmustbeleftcleanandsmooth.Iffor
somereasonthegasketsurfaceisgouged,thena gasketsealerthick
enoughtofillscratcheswillhavetobeusedduringreassemblyofthe
components.Formostapplications,a non-drying(orsemi-drying)
gasketsealerisbest.
Hoseremovaltips
Hoseremovalprecautionscloselyparallelgasketremoval
precautions.Avoidscratchingorgougingthesurfacethatthehose
matesagainstortheconnectionmayleak.Becauseofvarious
chemicalreactions,therubberinhosescanbonditselftothemetal
spigotthatthehosefitsover.Toremovea hose,firstloosenthehose
clampsthatsecureittothespigot.Then,withslipjointpliers,grabthe
hoseattheclampandrotateitaroundthespigot.Workitbackand
forthuntilitiscompletelyfree,thenpullitoff(siliconeorother
lubricantswilleaseremovaliftheycanbeappliedbetweenthehose
andtheoutsideofthespigot).Applythesamelubricanttotheinsideof
thehoseandtheoutsideofthespigottosimplifyinstallation.

0-12Maintenancetechniques,toolsandworkingfacilities
SparkpluggapadjustingtoolFeelergaugeset
Controlcable pressureluberHandimpactscrewdriverandbits
Torquewrenches(left- clicktype;right- beamtype)
Ifa hoseclampisbrokenordamaged,donotreuseit.Also,do
notreusehosesthatarecracked,splitortorn.
Tools
Aselectionofgoodtoolsisa basicrequirementforanyonewho
planstomaintainandrepaira motorcycle.Fortheownerwhohasfew
tools,ifany,theinitialinvestmentmightseemhigh,butwhen
comparedtothespiralingcostsofroutinemaintenanceandrepair,itis
awiseone.
Tohelptheownerdecidewhichtoolsareneededtoperformthe
tasksdetailedinthismanual,thefollowingtoollistsareoffered:
Maintenanceandminorrepair,RepairandoverhaulandSpecial.The
newcomertopracticalmechanicsshouldstartoffwiththe
Maintenanceandminorrepairtoolkit,whichisadequateforthe
simplerjobs.Then,asconfidenceandexperiencegrow,theownercan
tacklemoredifficulttasks,buyingadditionaltoolsastheyareneeded.
EventuallythebasickitwillbebuiltintotheRepairandoverhaultool
set.Overa periodoftime,theexperienceddo-it-yourselferwill
assemblea toolsetcompleteenoughformostrepairandoverhaul
proceduresandwilladdtoolsfromtheSpecialcategorywhenitisfelt
thattheexpenseisjustifiedbythefrequencyofuse.