Haynes Yamaha Xv V Twins Manual
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9-10 Chapter 9 Wiring diagrams 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Alternator Rectifier/regulator Main key switch Ignition fuse Engine kill switch Starter motor Starter relay (XV700) or solenoid switch (XV1000) Battery Main fuse Headlight fuse Starter switch Signal fuse Clutch switch Sidestand switch Sidestand relay Wiring diagram - XV700 and 1000 (1984 and 1985 US models) 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Oil level indicator light Igniter unit Oil level switch Pickup coil Ignition coil Tachometer Neutral indicator light Tail fuse Front brake switch Rear brake switch Neutral switch Relay assembly Horn Horn switch Fuel warning indicator light Fuel sender 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Flasher switch Reed switch Dimmer switch High beam indicator light Headlight Instrument illumination light Tail/brake light Turn signal indicator light Flasher light Solenoid switch (XV1000) Pressure sensor (XV1000) Fuel pump controller (XV1000) Reserve switch (XV1000) Fuel pump (XV1000) Hazard switch (XVI000)
Chapter 9 Wiring diagrams 9-11 Wiring diagram (1986 and later US XV700 and XV750 models)
9-12 Chapter 9 Wiring diagrams Wiring diagram (1986 and later US XV1100 models)
Chapter 9 Wiring diagrams 9-13 Wiring diagram (1992 and later UK XV750 models) 7 Ma/n switch 2 Neutral switch 3 Alternator 4 Rectifier regulator 5 Main fuse 6 Battery 7 Solenoid relay 8 Starter motor 9 Starting circuit cutoff relay 10 Lighting switch 11 Engine kill switch 12 Start switch 13 Diode 14 Oil level switch 15 Clutch switch 16 Sidestand switch 17 Igniter unit 18 Ignition coil 19 Sparkplug 20 Pickup coil 21 Carburetor heater 22 Thermoswitch 23 Relay unit 24 Turn signal switch 25 Flasher light 26 Horn 27 Horn switch 28 Dimmer switch 29 Passing switch 30 Headlight 31 Auxiliary light 32 Front brake switch 33 Rear brake switch 34 Tail/brake light 35 Fuel sender 36 Turn signal indicator light 37 High beam indicator light 38 Instrument light 39 Fuel level indicator light 40 Oil level indicator light 41 Neutral indicator light 42 Tachometer 43 Speedometer 44 Signal fuse 45 Headlight fuse 46 Ignition fuse A Main harness B Sub-harness
9-14 Chapter 9 Wiring diagrams Wiring diagram (1986 and later XV1000 and 1100 UK models) 1 Left front turn signal 2 Right front turn signal 3 Turn signal switch 4 Clutch switch 5 Horn switch 6 Passing switch 7 Dimmer switch 8 Headlight 9 Auxiliary light 10 Fuse block 11 High beam indicator light 12 Oil level indicator light 13 Neutral indicator light 14 Turn indicator light 15 Tachometer 16 Fuel warning indicator light 17 Instrument illumination 18 Reed switch 19 Horn 20 Main switch 21 Front brake switch 22 Engine kill switch 23 Start switch 24 Lighting switch 25 Fuel reserve witch 26 Sidestand switch 27 Sidestand relay 28 Relay assembly 29 Igniter unit 30 Starter relay 31 Pressure sensor 32 Rear brake switch 33 Starter motor 34 Solenoid switch 35 Battery 36 Main fuse 37 Tail/brake light 38 Right rear turn signal 39 Left rear turn signal 40 Fuel sender 41 Diode 42 Fuel pump control unit 43 Fuel pump 44 Rectifier/regulator 45 Neutral switch 46 Oil level switch 47 Alternator 48 Body earth (ground) 49 Pickup coil 50 Sparkplug 51 Ignition coil
Conversion factors Length (distance) Inches (in) X 25.4 = Millimetres (mm) X 0.0394 = Inches (in) Feet (ft) X 0.305 = Metres (m) X 3.281 = Feet (ft) Miles X 1.609 = Kilometres (km) X 0.621 = Miles Volume (capacity) Cubic inches (cu in; in3) X 16.387 = Cubic centimetres (cc; cm3) X 0.061 = Cubic inches (cu in; in3) Imperial pints (Imp pt) X 0.568 = Litres (I) X 1.76 = Imperial pints (Imp pt) Imperial quarts (Imp qt) X 1.137 = Litres (I) X 0.88 = Imperial quarts (Imp qt) Imperial quarts (Imp qt) X 1.201 = US quarts (US qt) X 0.833 = Imperial quarts (Imp qt) US quarts (US qt) X 0.946 = Litres (I) X 1.057 = US quarts (US qt) Imperial gallons (Imp gal) X 4.546 = Litres (I) X 0.22 = Imperial gallons (Imp gal) Imperial gallons (Imp gal) X 1.201 = US gallons (US gal) X 0.833 = Imperial gallons (Imp gal) US gallons (US gal) X 3.785 = Litres (I) X 0.264 = US gallons (US gal) Mass (weight) Ounces (oz) X 28.35 = Grams (g) X 0.035 Ounces (oz) Pounds (Ib) X 0.454 = Kilograms (kg) X 2.205 = Pounds (Ib) Force Ounces-force (ozf; oz) X 0.278 = Newtons (N) X 3.6 = Ounces-force (orf; oz) Pounds-force (Ibf; Ib) X 4.448 = Newtons (N) X 0.225 = Pounds-force (Ibf; Ib) Newtons (N) X 0.1 = Kilograms-force (kgf; kg) X 9.81 = Newtons (N) Pressure Pounds-force per square inch X 0.070 = Kilograms-force per square X 14.223 = Pounds-force per square inch (psi; Ibf/in2; Ib/in2) centimetre (kgf/cm2; kg/cm2) (psi; Ibf/in2; Ib/in2) Pounds-force per square inch X 0.068 = Atmospheres (atm) X 14.696 = Pounds-force per square inch (psi; Ibf/in2; Ib/in2) (psi; Ibf/in2; Ib/in2) Pounds-force per square inch X 0.069 = Bars X 14.5 = Pounds-force per square inch (psi; Ibf/in2; Ib/in2) (psi; Ibf/in2; Ib/in2) Pounds-force per square inch X 6.895 = Kilopascals (kPa) X 0.145 = Pounds-force per square inch (psi; Ibf/in2; Ib/in2) (psi; Ibf/in2; Ib/in2) Kilopascals (kPa) X 0.01 = Kilograms-force per square X 98.1 = Kilopascals (kPa) centimetre (kgf/cm2; kg/cm2) Torque (moment of force) Pounds-force inches X 1.152 = Kilograms-force centimetre X 0.868 = Pounds-force inches (Ibf in; Ib in) (kgf cm; kg cm) (Ibf in; Ib in) Pounds-force inches X 0.113 = Newton metres (Nm) X 8.85 = Pounds-force inches (Ibf in; Ib in) (Ibf in; Ib in) Pounds-force inches X 0,083 = Pounds-force feet (Ibf ft; Ib ft) X 12 = Pounds-force inches (Ibf in; Ib in) (Ibf in; Ib in) Pounds-force feet (Ibf ft; Ib ft) X 0.138 = Kilograms-force metres X 7.233 = Pounds-force feet (Ibf ft; Ib ft) (kgf m; kg m) Pounds-force feet (Ibf ft; Ib ft) X 1.356 = Newton metres (Nm) X 0.738 = Pounds-force feet (Ibf ft; Ib ft) Newton metres (Nm) X 0.102 = Kilograms-force metres X 9.804 = Newton metres (Nm) (kgf m; kg m) Power Horsepower (hp) X 745.7 = Watts (W) X 0.0013 = Horsepower (hp) Velocity (speed) Miles per hour (miles/hr; mph) X 1.609 = Kilometres per hour (km/hr; kph) X 0.621 = Miles per hour (miles/hr; mph) Fuel consumption* Miles per gallon, Imperial (mpg) X 0.354 = Kilometres per litre (km/I) X 2.825 = Miles per gallon, Imperial (mpg) Miles per gallon, US (mpg) X 0.425 = Kilometres per litre (km/I) X 2.352 = Miles per gallon, US (mpg) Temperature Degrees Fahrenheit = (°C x 1.8) + 32 Degrees Celsius (Degrees Centigrade; °C) = (°F - 32) x 0.56 *lt is common practice to convert from miles per gallon (mpg) to litres/100 kilometres (1/100km), where mpg (Imperial) x 1/100 km = 282 and mpg (US) x 1/100 km = 235
IND-1 Index A About this manual, 0-5 Acknowledgements, 0-2 Air filter, element, servicing, 1-16 Alternator, removal and installation XV535 models, 8A-16 XV700 through 1100 models. 8B-14 B Battery charging, 8A-4 inspection and maintenance. 1 -8 Bearings connecting rod. general note. XV700 through 1100 models, 2B-41 connecting rod, inspection and selection XV535 models. 2A-48 XV700 through 1100 models, 2B-42 main, inspection and selection XV535 models. 2A-46 XV700 through 1100 models, 2B-40 main and connection rod, general note XV535 models, 2A-46 XV700 through 1100 models, 2B-41 wheel, inspection and replacement, see Wheel bearings Bodywork XV535 models, 7A-1 through 7A-6 XV700 through 1100 models, 7B-1 through 7B-4 Brake caliper, removal, overhaul and installation XV535 models, 6A-4 XV700 through 1100 models, 6B-7 disc, removal, inspection and installation XV535 models, 6A-5 XV700 through 1100 models, 6B-9 fluid level, check, 1-8 front master cylinder, removal, inspection and installation XV535 models, 6A-6 XV700 through 1100 models, 6B-9 front pads, replacement XV535 models, 6A-2 XV700 through 1100 models, 6B-3 general information XV535 models, 6A-1 XV700 through 1100 models, 6B-1 hoses and lines, inspection and replacement XV535 models. 6A-10 XV700 through 1,100 models, 6B-13 light switches, check and replacement XV535 models, 8A-7 XV700 through 1100 models, 8B-6 master cylinder, removal, overhaul and installation XV535 models, 6A-6 XV700 through 1100 models, 6B-9 pedal position, check and adjustment, 1-10 rear shoes, replacement XV535 models, 6A-7 XV700 through 1100 models, 6B-10 system, check, 1-10 system bleeding (all models), 6A-10 Brakes XV535 models, 6A-1 through 6A-18 XV700 through 1100 models, 6B-1 through 6B-20 Breaking-in the engine XV535 models, 2A-59 XV700 through 1100 models, 2B-49 Bulbs headlight, replacement XV535 models, 2A-59 XV700 through 1100 models, 2B-49 instrument and warning light, replacement XV535 models, 8A-8 XV700 through 1100 models, 8B-10 taillight and turn signal, replacement XV535 models, 8A-6 XV700 through 1100 models, 8B-6 Buying parts, 0-7 c Cable choke, removal and installation, 3B-14
Index IND-2 clutch, see Clutch cable throttle, adjustment, 1-11 throttle, removal and installation XV535 models, 3A-16 XV700 through 1100 models, 3B-13 Caliper (brake), removal, overhaul and installation, see Brake caliper Camshaft chain, removal, inspection and installation XV535 models, 2A-37 XV700 through 1100 models, 2B-22 chain tensioner, removal and installation XV535 models, 2A-7 XV700 through 1100 models, 2B-13 removal, inspection and installation XV535 models, 2A-9 XV700 through 1100 models, 2B-14 Carburetor synchronization, check and adjustment, 1-23 Carburetors disassembly, cleaning and inspection XV535 models, 3A-7 XV700 through 1100 models, 3B-6 fuel level adjustment XV535 models, 3A-15 XV700 through 1100 models, 3B-13 removal and installation XV535 models, 3A-5 XV700 through 1100 models, 3B-6 overhaul, general information XV535 models, 3A-5 XV700 through 1100 models, 3B-5 . Centerstand, maintenance (XV700 -1100 models, 7B-2 Chain camshaft, removal, inspection and installation, see Camshaft drive check, adjustment and lubrication, 1-13 removal, cleaning and installation, 5B-20 guides, camshaft, see Camshaft chain Charging system output test XV535 models, 8A-16 XV700 through 1100 models, 8B-14 testing, general information and precautions XV535 models, 8A-15 XV700 through 1100 models, 8B-14 Chemicals and lubricants, 0-15 Choke cable, removal and installation, see Cable Clutch cable, adjustment, 1-12 cable, replacement XV535 models, 2A-29 XV700 through 1100 models, 2B-27 components, removal, inspection and installation XV535 models, 2A-29 XV700 through 1100 models, 2B-29 Coil, ignition, check, removal and installation XV535 models, 4A-2 XV700 through 1100 models, 4B-2 Compression check, 1-17 Connecting rods and bearings, see Bearings Crankcase components, inspection and servicing XV535 models, 2A-46 XV700 through 1100 models, 2B-37 disassembly and reassembly XV535 models, 2A-44 XV700 through 1100 models, 2B-35 Crankshaft, removal, inspection and installation XV535 models, 2A-46 XV700 through 1100 models, 2B-39 Cush drive (chain drive models), 6B-18 Cylinders, removal, inspection and installation XV535 models, 2A-23 XV700 through 1100 models, 2B-20 Cylinder head disassembly, inspection and reassembly XV535 models, 2A-18 XV700 through 1100 models, 2B-20 removal and installation XV535 models, 2A-18 XV700 through 1100 models, 2B-20 D Diagnosis, 0-16 through 23 Disc brake, see Brake Drive chain, see Chain Driveshaft and final drive, removal, inspection and installation XV535 models, 5A-13 XV700 through 1100 models, 5B-18 E Electrical system alternator, removal and installation, see Alternator battery, see Battery charging system, output test, see Charging system charging system testing, general information and precautions, see Charging system fuses, check and replacement, see Fuses general information XV535 models, 8A-3 XV700 through 1100 models, 8B-3 handlebar switches, see Switch ignition main (key) switch, check and replacement, see Switch lighting system, check, see Lighting system starter motor, see Starter starter relay, check and replacement, see Starter wiring diagrams, 9-1 Engine break-in procedure, see Breaking-in the engine cam chain tensioner, removal and installation, see Camshaft camshaft chain, removal, inspection and installation, see Camshaft camshafts, removal, inspection and installation, see Camshaft connecting rods, bearing inspection and selection, see Bearing connecting rods and bearings, removal and installation, see Bearing crankcase, disassembly and reassembly, see Crankcase crankcase components, inspection and servicing, see Crankcase crankshaft and main bearings, removal, inspection and installation, see Crankshaft cylinder block, removal, inspection and installation, see Block cylinder head, disassembly, inspection and reassembly, see Cylinder head cylinder head, removal and installation, see Cylinder head disassembly and reassembly, general information, see Cylinder head identification number, 0-6 ignition system, see Ignition Initial start-up after overhaul XV535 models, 2A-29 XV700 through 1100 models, 2B-49 main and connecting rod bearings, general note, see Bearing main bearing selection, see Bearing oil change, see Oil level check, see Oil IND
IND-3 Index oil pressure relief valves, removal, check and installation, see Oil oil pump, pressure check, removal, inspection and installation, see Oil Piston rings, installation, see Piston Pistons, removal, inspection and installation, see Piston removal and installation XV535 models, 2A-5 XV700 through 1100 models, 2B-11 Engine fuel and exhaust systems XV535 models, 3A-1 XV700 through 1100 models, 3B-1 Exhaust system check, 1-24 removal and installation XV535 models, 3A-16 XV700 through 1100 models^ 3B-14 External shift mechanism, removal, inspection and installation, see Shift mechanism F Fasteners, check, 1-25 Fault-finding, 0-16 through 23 Fender (mudguard) front, removal and installation XV535 models, 7A-6 XV700 through 1100 models, 7B-3 rear, removal and installation XV535 models, 7A-6 XV700 through 1100 models, 7B-3 Filter air, servicing, 1-16 fuel, cleaning, 1-25 fuel, replacement, 1-25 oil, change, 1-14 Final drive chain, removal, cleaning and installation, see Chain driveshaft, see Driveshaft and final drive rear wheel coupling/rubber damper (chain drive models), see Cush drive sprockets, check and replacement, 5B-20 Fluid, level checks, 1-7 Footpegs and pads, removal and installation, see Frame and bodywork Forks disassembly, inspection and reassembly XV535 models, 5A-4 XV700 through 1100 models, 5B-12 oil change XV535 models, 5A-2 XV700 through 1100 models, 5B-9 removal and installation, XV535 models, 5A-3 XV700 through 1100 models, 5B-10 Frame identification number, 0-6 inspection and repair, see Frame and bodywork Frame and bodywork backrest and shock absorber cover (XV535 models), removal and installation, 7A-5 footpegs and pads, removal and installation XV535 models, 7A-2 XV700 through 1100 models, 7B-1 frame, inspection and repair, 7A-1 frame cover (XV535 models), removal and installation, 7A-3 front fender/mudguard, removal and installation, see Fender (mudguard) general information XV535 models, 7A-1 XV700 through 1100 models, 7B-1 rear fender/mudguard, removal and installation, see Fender (mudguard) seat, removal and installation, see Seat side covers, removal and installation, see Side covers sidestand, maintenance, see Sidestand sidestand, removal and installation, see Sidestand top cover (XV535 models), removal and installation, 8-2 Front wheel, removal and installation, see Wheel Fuel filter cleaning, see Filter filter replacement, see Filter system check, 1 -25 Fuel system (XV535 models), 3A-1 through 3A-20 Fuel system (XV700 through 1100 models), 3B-1 through 3B-20 Fuel tank cleaning and repair XV535 models, 3A-4 XV700 through 1100 models, 3B-5 removal and installation XV535 models, 3A-3 XV700 through 1100 models, 3B-5 Fuses, check and replacement XV535 models, 8A-4 XV700 through 1100 models, 8B-3 G Gauges, replacement, see Speedometer and cable General information brakes XV535 models, 6A-1 XV700 through 1100 models, 6B-1 electrical system XV535 models, 8A-1 XV700 through 1100 models, 8B-1 engine - XV535 models, 2A-1 XV700 through 1100 models, 2B-1 frame and bodywork XV535 models, 7A-1 XV700 through 1100 models, 7B-1 fuel and exhaust systems XV535 models, 3A-1 XV700 through 1100 models, 3B-1 ignition system XV535 models, 4A-1 XV700 through 1100 models, 4B-1 steering, suspension and final drive XV535 models, 6A-1 • XV700 through 1100 models, 6B-1 H Handlebar switches, see Switch Handlebars, removal and installation XV535 models, 5A-2 XV700 through 1100 models, 5B-3 Head, cylinder, removal and installation, see Cylinder head Headlight aim, check and adjustment XV535 models, 8A-5 XV700 through 1100 models, 8B-4
Index IND-4 bulb, replacement XV535 models, 8A-5 XV700 through 1100 models, 8B-4 Horn, check and replacement XV535 models, 8A-12 XV700 through 1100 models, 8B-11 Hoses, brake, inspection and replacement, see Brake I Identification numbers, 0-16 Idle fuel/air mixture adjustment, general information XV535 models, 3A-5 XV700 through 1100 models, 3B-5 Idle speed, check and adjustment, 1-22 Igniter, removal, check and installation XV535 models, 4A-4 XV700 through 1100 models, 4B-3 Ignition coils, check, removal and installation XV535 models, 4A-2 XV700 through 1100 models, 4B-2 main (key) switch, check and replacement, see Switch pick-up coils, check, removal and installation XV535 models, 4A-3 • XV700 through 1100 models, 4B-3 system check XV535 models, 4A-2 XV700 through 1100 models, 4B-2 general information XV535 models, 4A-1 XV700 through 1100 models, 4B-1 Ignition system XV535 models, 4A-1 through 4A-4 XV700 through 1100 models, 4B-1 through 4B-4 Instrument and warning light bulbs, replacement, see Bulbs Introduction to the Yamaha XV, 0-5 L Lash, valve, check and adjustment, 1-21 Lighting system, check XV535 models, 8A-5 XV700 through 1100 models, 8B-4 Lubricants, 0-15 Lubrication, general, 1-20 M Main and connecting rod bearings, general note, see Bearing Main bearings, removal, inspection, selection and installation, see Bearing Maintenance, introduction, 1-7 Maintenance schedule, 1-6 Maintenance techniques, 0-8 Major engine repair, general note XV535 models, 2A-4 XV700 through 1100 models, 2B-11 Master cylinder, removal, overhaul and installation, see Brake Meters, replacement, see Speedometer and cable Motor, starter, see Starter Muffler (silencer), see Exhaust system N Neutral switch, check and replacement, see Switch o Oil change, 1-14 filter, change, 1-14 fork, replacement, see Forks level switch, check and replacement, XV700 through 1100 models, 8B-16 pressure relief valve, removal, inspection and installation XV535 models, 2A-38 XV700 through 1100 models, 2B-38 pump, removal, inspection and installation XV535 models, 2A-38 XV700 through 1100 models, 2B-25 Owner maintenance, 1-1 through 1-28 P Pads (brake), see Brake Pickup-coils, check and replacement, see Ignition Piston rings, installation XV535 models, 2A-27 • XV700 through 1100 models, 2B-22 Pistons, removal, inspection and installation, XV535 models, 2A-25 XV700 through 1100 models, 2B-22 Pump, oil, removal and installation, see Oil R Rear shock absorber, removal, inspection and installation, see Shock absorber Rear suspension unit, removal and installation (1981 through 1983 models), 5B-15 Rear wheel, removal and installation, see Wheels Rear wheel coupling/rubber damper (chain drive models), check and replacement, see Cush drive Relay, starter, check and replacement, see Starter Repairs possible with the engine in the frame XV535 models, 2A-4 XV700 through 1100 models, 2B-10 Repairs requiring engine removal XV535 models, 2A-4 XV700 through 1100 models, 2B-10 Rotor (brake), inspection, removal and installation, see Brake disc Routine maintenance, 1-1 through 1-28 s Safe motorcycle repair practices, 0-14 Shift cam and forks, removal, inspection and installation XV535 models, 2A-57 XV700 through 1100 models, 2B-44 Shift mechanism, external, removal, inspection and installation XV535 models, 2A-41 XV700 through 1100 models, 2B-33 Shock absorber, rear, removal and installation XV535 models, 5A-10 XV700 through 1100 models, 5B-17 IND