Haynes Yamaha Xv V Twins Manual

8A-8 
Chapter 8 Part A Electrical system (XV535 models)

13.2 ... and from the drive unit on the left

fork leg 
13.4 Remove the speedometer mounting

nuts... 
13.5 ... and the mounting screws, then

detach the speedometer from the housing I

2 Note how its routed, then unscrew the speedometer cable from

the drive gear at the left front fork (see illustration).

Speedometer removal

Refer to illustrations 13.4 and 13.5

3 Disconnect the cable from the speedometer (see illustration

13.1).

4 Remove the...

Chapter 8 Part A Electrical system (XV535 models) 
8A-9

14.6a Pull the bulb socket out of the speedometer . 
14.6b ... and pull the bulb out of the socket

15.3a Continuity table for the ignition switch (US models) 
15.3b Continuity table for the ignition switch (UK models)

15 Ignition main (key) switch - check and replacement

Check

Refer to illustration 15.3

1 Lift the seat (single seat models) or remove the seat (dual seat

models) (see Chapter 7).

2 Follow the wiring harness from the ignition...

8A-10

Chapter 8 Part A Electrical system (XV535 models)

should not be overlooked. If breakage does occur, the entire switch

and related wiring harness will have to be replaced with a new one,

since individual parts are not usually available.

2 The switches can be checked for continuity with an ohmmeter or

a continuity test light. Always disconnect the battery negative cable,

which will prevent the possibility of a short circuit, before making the

checks.

3 Trace the wiring harness of the switch...

Chapter 8 Part A Electrical system (XV535 models)

8A-11

17.1a The handlebar switches are held

together by screws (arrows); this is the

throttle side . . . 
17.1b ... the clutch side switches are also

held together by screws (arrows) 
17.1c Separate the switch halves for

access to the individual switches

18.5a Loosen the small screw (arrow) and disconnect the wire;

remove the three mounting screws ... 
18.5b ... and take the switch out of the engine; replace the O-

ring with a new one

17...

8A-12 
Chapter 8 Part A Electrical system (XV535 models)

19.5 Sidestand switch mounting screws 
20.4 Insert a pointed tool into the hole

(arrow), compress the prong and pull out

the clutch switch 
21.1 Disconnect the horn wires (A) and

remove the bracket bolt (B)

3 With the sidestand in the down position, the meter should

indicate infinite resistance.

4 If the switch fails either of these tests, replace it.

Replacement

Refer to illustration 19.5

5 With the sidestand in the up position, unscrew...

Chapter 8 Part A Electrical system (XV535 models)

8A-13

23.2 Starting circuit cut-off relay test

1 Ohmmeter

2 Blue/white terminal

3 Blue/white terminal 
4 Red/white terminal (red/

black on 1994 models)

5 Black/yellow terminal

6 12-volt battery

cables) directly from the battery positive terminal to the disconnected

end of the cable. Warning: Make the connection at the battery first and

at the cable last; sparks are likely to occur, and if they occur near the

battery they could cause it to...

8A-14 
Chapter 8 Part A Electrical system (XV535 models)

25.2 Four-brush starter motor - exploded view

1 Through-bolt 6 Cable

2 Lockwasher 7 O-rings

3 Brush end cover 8 Starter housing

4 Brush plate 9 O-ring

5 Plastic brush housing 10 Armature 
25.5 Two-brush starter - exploded view

1 Cable 7 Washer

2 Terminal nuts and washers 8 O-ring

3 Brush end cover _, 9 Through-bolt

4 Brush plate 10 Armature

5 O-ring 11 Starter housing

6 Mounting bolt

Disassembly

Four-brush starter

Refer to...

Chapter 8 Part A Electrical system (XV535 models)

8A-15

25.9 Check the commutator for cracks

and discoloring, then measure the

diameter and compare it with the

minimum diameter listed in this

Chapters Specifications 
25.10a Continuity should exist between

the commutator bars 
25.10b There should be no continuity

between the commutator bars and the

armature shaft

25.11 There should be almost no

resistance (0 ohms) between the brushes

and the brush plate 
25.12 There should be no continuity...

8A-16 
Chapter 8 Part A Electrical system (XV535 models)

27.7 Measure stator coil resistance

between 1 and 2,1 and 3, then 2 and 3 
28.1a Remove the cover bolts (arrows)...

28.1b ... and pry gently at the pry points

(not between the gasket surfaces); there :

one at the bottom ...

28.1c ... and another at the top 
28.3 Be sure there are no metal fragments

stuck to the rotor magnets (arrow) 
28.4 Slip a new gasket over the

dowels (arrows)

Because of the special tools and expertise required, it...

Chapter 8 Part A Electrical system (XV535 models)

8A-17

28.5 Guide the wiring harness out

through the back of the cover 
28.7 Remove the screws (A) to detach the

stator; the other screws (B) secure the

ignition pick-up coil and its wiring harness 
28.10 Loosen the rotor bolt with a socket,

then unscrew the bolt and remove

the washer

28.11a Use a tool like this one to

separate the rotor from the crankshaft. 
28.11 b ... then take the rotor off and lift

the Woodruff key (arrow) out of its slot...