Haynes Yamaha Xv V Twins Manual
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Yamaha XV535 through 1100 Owners Workshop Manual by Alan Ahlstrand and John H Haynes Member of the Guild of Motoring Writers Models covered: USA: Yamaha XV535 Virago. 535cc. 1987 through 1990 and 1993 through 1994 Yamaha XV535S Virago. 535cc. 1994 Yamaha XV700 Virago. 699cc. 1984 through 1987 Yamaha XV750 Virago. 748cc. 1981 through 1983 and 1988 through 1994 Yamaha XV920 Virago. 920cc. 1982 and 1983 Yamaha XV920R (chain drive). 920cc. 1981 and 1982 Yamaha XV1000 Virago. 981 cc. 1984 and 1985 Yamaha XV1100 Virago. 1063cc. 1986 through 1994 UK: Yamaha XV535. 535cc. 1988 through 1994 Yamaha XV535S. 535cc. 1994 Yamaha XV750SE Special. 748cc. 1981 through 1983 Yamaha XV750 Virago. 748cc. 1992 through 1994 Yamaha TR1 (chain drive). 981 cc. 1981 through 1985 Yamaha XV1000 Virago. 981 cc. 1986 through 1989 Yamaha XV1100 Virago. 1063 cc. 1989 through 1994 ABCDE FGHIJ KLMNO PQRS Haynes Publishing Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, Inc 861 Lawrence Drive Newbury Park California 91320 USA .
Acknowledgements Our thanks to Mitsui Machinery Sales (UK) Ltd for permission to reproduce certain illustrations used in this manual. We would also like to thank NGK Spark Plugs (UK) Ltd for supplying the color spark plug condition photos and the Avon Rubber Company for supplying information on tire fitting. Special thanks to Grand Prix Kawasaki/Yamaha, Santa Clara, California, for providing the facilities used for these photographs; to Mark Woodward, service manager, for arranging the facilities and fitting the mechanical work into his shops busy schedule; and to Denny Jewell, service technician, for doing the mechanical work and providing valuable technical information, © Haynes North America, Inc. 1994 With permission from J.H. Haynes & Co. Ltd. A book in the Haynes Owners Workshop Manual Series Printed in the U.S.A. All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder. ISBN1 56392103 0 Library of Congress Catalog Card Number 94-73120 British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library We take great pride in the accuracy of information given in this manual, but motorcycle manufacturers make alterations and design changes during the production run of a particular motorcycle of which they do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given. 94-360
Contents Introductory pages About this manual 0-6 Introduction to the Yamaha XV 0-6 Identification numbers 0-7 Buying parts 0-8 General specifications 0-8 Maintenance techniques, tools and working facilities 0-11 Safety first! 0-17 Motorcycle chemicals and lubricants 0-18 Troubleshooting 0-19 Chapter 1 Tune-up and routine maintenance 1-1 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 2A-1 Chapter 2 Part B Engine, clutch and transmission (XV700 through 1100 models) 2B-1 Chapter 3 Part A Fuel and exhaust systems (XV535 models) 3A-1 Chapter 3 Part B Fuel and exhaust systems (XV700 through 1100 models) 3B-1 Chapter 4 Part A Ignition system (XV535 models) 4A-1 Chapter 4 Part B Ignition system (XV700 through 1100 models) 4B-1 Chapter 5 Part A Steering, suspension and final drive (XV535 models) 5A-1 Chapter 5 Part B Steering, suspension and final drive (XV700 through 1100 models) 5B-1 Chapter 6 Part A Brakes, wheels and tires (XV535 models) 6A-1 Chapter 6 Part B Brakes, wheels and tires (XV700 through 1100 models) 6B-1 Chapter 7 Part A Frame and bodywork (XV535 models) 7A-1 Chapter 7 Part B Frame and bodywork (XV700 through 1100 models) 7B-1 Chapter 8 Part A Electrical system (XV535 models) 8A-1 Chapter 8 Part B Electrical system (XV700 through 1100 models) 8B-1 Chapter 9 Wiring diagrams 9-1 Conversion factors Index IND-1
0-4 Yamaha XV The 1994 XV535S model The 1985 XV700 Virago model
Yamaha XV 0-5 The TR1 model The 1994 XV1100 Virago model
0-6 About this manual Its purpose The purpose of this manual is to help you get the best value from your motorcycle. It can do so in several ways. It can help you decide what work must be done, even if you choose to have it done by a dealer service department or a repair shop; it provides information and procedures for routine maintenance and servicing; and it offers diagnostic and repair procedures to follow when trouble occurs. We hope you use the manual to tackle the work yourself. For many simpler jobs, doing it yourself may be quicker than arranging an appointment to get the vehicle into a shop and making the trips to leave it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop must pass on to you to cover its labor and overhead costs. An added benefit is the sense of satisfaction and accomplishment that you feel after doing the job yourself. Using the manual The manual is divided into Chapters. Each Chapter is divided into numbered Sections, which are headed in bold type between horizontal lines. Each Section consists of consecutively numbered paragraphs. At the beginning of each numbered Section you will be referred to any illustrations which apply to the procedures in that Section. The reference numbers used in illustration captions pinpoint the pertinent Section and the Step within that Section. That is, illustration 3.2 means the illustration refers to Section 3 and Step (or paragraph) 2 within that Section. Procedures, once described in the text, are not normally repeated. When its necessary to refer to another Chapter, the reference will be given as Chapter and Section number. Cross references given without use of the word Chapter apply to Sections and/or paragraphs in the same Chapter. For example, see Section 8 means in the same Chapter. References to the left or right side of the vehicle assume you are sitting on the seat, facing forward. Motorcycle manufacturers continually make changes to specifi- cations and recommendations, and these, when notified, are incorporated into our manuals at the earliest opportunity. Even though we have prepared this manual with extreme care, neither the publisher nor the author can accept responsibility for any errors in, or omissions from, the information given. NOTE A Note provides information necessary to properly complete a procedure or information which will make the procedure easier to understand. CAUTION A Caution provides a special procedure or special steps which must be taken while completing the procedure where the Caution is found. Not heeding a Caution can result in damage to the assembly being worked on. WARNING A Warning provides a special procedure or special steps which must be taken while completing the procedure where the Warning is found. Not heeding a Warning can result in personal injury. Introduction to the Yamaha XV The Yamaha XV (Virago) series are highly successful and popular cruiser-style motorcycles. The engine on all models is an air-cooled, V-twin with overhead camshafts. . Fuel is delivered to the cylinders by two Hitachi or Mikuni carburetors; XV535, XV1000 and XV1100 models use an electric fuel pump. The front suspension uses a pair of conventional forks, adjustable by varying the fork air pressure on some models. Fork damping is adjustable on XV920 J models. The rear suspension on 1981 through 1983 models uses a single shock absorber and coil spring. Later models use twin rear shock absorbers with concentric coil springs. Spring preload is adjustable on all XV700 through 1100 models; shock absorber damping is adjustable on 1984 and later XV700 through 1100 models. The front brake uses a single or dual disc; a drum brake is used at the rear. Shaft final drive is used on most of the bikes covered in this manual. Some models use an unusual chain drive system, with the chain completely enclosed in housings and running in a bath of grease.
0-7 Identification numbers The frame serial number is stamped into the right side of the frame and printed on a label affixed to the frame. The engine number is stamped into the right upper side of the crankcase. Both of these numbers should be recorded and kept in a safe place so they can be furnished to law enforcement officials in the event of a theft. The frame serial number, engine serial number and carburetor identification number should also be kept in a handy place (such as with your drivers license) so they are always available when purchasing or ordering parts for your machine. The models covered by this manual are as follows: XV535, 1987 through 1990 US XV535, 1993 and 1994 US XV535, 1988 through 1994 UK XV700,1984 through 1987 US XV750, 1981 through 1983 and 1988 through 1994 US XV750, 1981 through 1983 UK, 1992 through 1994 UK XV920, 1981 through 1983 US XV1000 shaft drive, 1984 and 1985 US, 1986 through 1989 UK XV1000 chain drive (TR1), 1981 through 1985 UK XV1100, 1986 through 1994 US, 1989 through 1994 UK Identifying engines and model years The procedures in this manual identify the bikes by model year. To determine which model year a given machine is, look for the following identification codes in the engine and frame numbers: The frame number is stamped in the right side of the frame and is also displayed on a decal The engine number is stamped in the right side of the crankcase Year Code XV535 models 1987and 1988 US 2GV 1989 and 1990 US 3JC1/3JC2 1993 US 3JC7/3JC8 1994 US XV535 3JCA, 3JCB XV535S 3JCB, 3JCD 1988 UK 3BT1 1989 UK. 3BT2/3BT5 1990 UK 3BTC/3BT8 1991 UK 3BTE/3BTF 1992 UK 3BTK/3BTM 1993 UK 3BTR/3BTT 1994 UK XV535 4KU2/3BTW XV535S 4KU4 (flat handlebar) XV535S 3BTV/3BTY (upright handlebar) XV700 models 1984 42W/42X 1985 56E/56F 1986 and 1987 1RM/1RV/1RR/1TU XV750 models 1981 through 1983 US XV750 H, J, K 4X7 XV750 MK 20X 1988 US.. 3AL/3CM 1989 US 3JL1/3JL2 1990 US 3JL4/3JL5 1991 US 3JL7/3JL8 1992 US 3JUV3JLB 1993 US 3JLD/3JLE 1994 US 3JLG/3JLH 1981 through 1983 UK 5G5 1992 and 1993 UK 4FY1 1994 UK 4FY4 XV920 models 1981 and 1982 chain drive 5H1 1982 shaft drive 10L 1983 shaft drive XV920 K 24M XV920 MK 27Y XV1000 models 1984 US 42G/42H 1985 US 56V/56W 1981 UK 5A8 1982 through 1985 UK 19T 1986 and 1987 UK 2AE 1988 and 1989 UK 3DR1 XV1100 models 1986 and 1987 US 1TE/1TA 1988 US 3CF/3CG 1989 US 3JK1/3JK2 1990 US 3JK4/3JK5 1991 US 3JK7/3JK8 1992 US 3JKB/3JKC 1993 US 3JKA/3JKE 1994 US 3JKG/3JKH 1989 and 1990 UK 3LP1 1991 UK . 3LP2 1992 and 1993 UK 3LP4 1994 UK 3LP8
0-8 Buying parts Once you have found all the identification numbers, record them for reference when buying parts. Since the manufacturers change specifications, parts and vendors (companies that manufacture various components on the machine), providing the ID numbers is the only way to be reasonably sure that you are buying the correct parts. Whenever possible, take the worn part to the dealer so direct comparison with the new component can be made. Along the trail from the manufacturer to the parts shelf, there are numerous places that the part can end up with the wrong number or be listed incorrectly. The two places to purchase new parts for your motorcycle - the accessory store and the franchised dealer - differ in the type of parts they carry. While dealers can obtain virtually every part for your motorcycle, the accessory dealer is usually limited to normal high wear items such as shock absorbers, tune-up parts, various engine gaskets, cables, chains, brake parts, etc. Rarely will an accessory outlet have major suspension components, cylinders, transmission gears, or cases. Used parts can be obtained for roughly half the price of new ones, but you cant always be sure of what youre getting. Once again, take your worn part to the wrecking yard (breaker) for direct comparison. Whether buying new, used or rebuilt parts, the best course is to deal directly with someone who specializes in parts for your particular make. General specifications XV535 models 1987 and 1988 US models Wheelbase 1511 mm (59.5 inches) Overall length 2210 mm (87.0 inches) Overall width 815 mm (32.1 inches) Overall height 1100 mm (43.3 inches) Seat height 700 mm (27.6 inches) Ground clearance (minimum) 145 mm (5.7 inches) Weight (with oil and full fuel tank) US except California 185 kg (408 lbs) California 186 kg (410 lbs) 1989-on US models Wheelbase 1520 mm (59.8 inches) Overall length 2225 mm (87.6 inches) Overall width 810 mm (31.9 inches) Overall height 1110 mm (43.7 inches) Seat height 720 mm (28.3 inches) Ground clearance (minimum) 160 mm (6.3 inches) Weight (with oil and full fuel tank) US except California 195 kg (430 lbs) California 196 kg (432 lbs) 1988 UK models Wheelbase . 1520 mm (59.8 inches) Overall length 2225 mm (87.6 inches) Overall width 810 mm (31.9 inches) Overall height 1100 mm (43.3 inches) Seat height 700 mm (27.6 inches) Ground clearance (minimum) 160 mm (6.3 inches) Weight (with oil and full fuel tank) 188 kg (415 lbs)
General specifications 0-9 1989-on UK models Wheelbase 1520 mm (59.8 inches) Overall length 2285 mm (90.0 inches) Overall width Flat handlebar 725 mm (88.6 inches) Upright handlebar 810 mm (31.9 inches) Overall height Flat handlebar 1070 mm (42.1 inches) Upright handlebar 1110 mm (43.7 inches) Seat height 720 mm (28.3 inches) Ground clearance (minimum) 160 mm (6.3 inches) Weight (with oil and full fuel tank) 195 kg (430 lbs) XV700 and US XV1000 models Wheelbase 1525 mm (60.0 inches) Overall length 2235 mm (88.0 inches) Overall width 840 mm (33.1 inches) Overall height 1170 mm (46.1 inches) Seat height 715 mm (28.1 inches) Ground clearance (minimum) 145 mm (5.7 inches) Weight (with oil and full fuel tank) 1984 and 1985 XV700 models 225 kg (496 lbs) 1986 and 1987 XV700 models 229 kg (505 lbs) XV1000 models 236 kg (520 lbs) XV750 models (1981 through 1983) Wheelbase 1520 mm (59.8 inches) Overall length 2230 mm (87.8 inches) Overall width US models 805 mm (31,7 inches) UK models 840 mm (33.1 inches) Overall height US models 1160 mm (45.7 inches) UK models 1210 mm (47.6 inches) Seat height.... not specified Ground clearance (minimum) 145 mm (5.7 inches) Weight (dry) US models 225 kg (496 lbs) UK models . 211 kg (465 lbs) XV750 models (1988-on US) Wtieelbase 1525 mm (60.0 inches) Overall length 2285 mm (90.0 inches) Overall width 840 mm (33.1 inches) Overall height 1190 mm (46.9 inches) Seat height 715 mm (28.1 inches) Ground clearance (minimum) 145 mm (5.7 inches) Weight Not specified XV750 models (1992-on UK) Wheelbase 1525 mm (60.0 inches) Overall length 2285 mm (90.0 inches) Overall width 840 mm (33.1 inches) Overall height.. 1190 mm (46.9 inches) Seat height 715 mm (28.1 inches) Ground clearance (minimum) 145 mm (5.7 inches) Weight 1992 and 1993 models 235 kg (518 lbs) 1994 models 236 kg (520 lbs) XV920 J models Wheelbase 1520 mm (59.8 inches) Overall length 2220 mm (87.4 inches) Overall width . 840 mm (33.1 inches) Overall height 1205 mm (47.4 inches) Seat height Not specified Ground clearance (minimum) . 145 mm (5.7 inches) Weight 225 kg (496 lbs)