Yamaha Virago XV535-1100 1981-1994 Service Manual

Size:
52.13 Mb
Download

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). 981cc. 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 shop's 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-upand 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 it's 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 specifications 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-stylemotorcycles.

The engine on all models is an air-cooled,V-twinwith 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.

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 driver's 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

0-7

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 U S . .

 

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-upparts, 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 can't always be sure of what you're 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-onUS 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-onUK 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-onUS)

 

 

 

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-onUK)

 

 

 

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)