Haynes Yamaha Xv V Twins Manual

8A-18 
Chapter 8 Part A Electrical system (XV535 models)

29.3a Compress the pin and spring (A)

and remove the roller (B)... 
29.3b ... then remove the pin and spring

from their bore 
29.6 Press the pin and spring into their

bore with a pointed tool and install

the roller

30.2 Free the wiring harness and hose, remove the screws and

remove the fuel tap (1) from the tank

2 Place the large starter driven gear in the starter clutch and try to

turn it. It should turn freely in one direction and not...

8B-1

Chapter 8 Part B

Electrical system (XV700-1100 models)

Contents

Section

Alternator cover, stator, rotor and regulator/rectifier - removal

and installation 28

Battery - charging 4

Battery - inspection and maintenance 3

Brake light switches - check and replacement 12

Charging system - output test 27

Charging system testing - general information and precautions... 26

Clutch switch - check and replacement 20

Electrical troubleshooting 2

Fuses - check and replacement 5

General information...

8B-2 
Chapter 8 Part B Electrical system (XV700-1100 models)

1984 and 1985 models

Main 20 amps

Headlight 15 amps

Turn signals 15 amps

Ignition : 10 amps

Tail/brake lights 10 amps

1986 and later models

Main 30 amps

Headlight 15 amps

Turn signals 15 amps

Ignition 10 amps

Tail/brake lights 10 amps

Charging system

Statorcoil resistance 0.5 ohms+/ 10 percent at 20-degrees C (68-degrees F)

Charging system output 14.3 to 15.3 volts at 2,000 rpm

Starter

Starter commutator diameter

Standard.......

Chapter 8 Part B Electrical system (XV700-1100 models)

8B-3

5.1 The main fuse is located beneath the seat; separate the

halves of the fuse holder to expose the fuse 
5.2 The accessory fuse block on 1981 through 1983 models is

behind a cover on the front of the lower triple clamp

1 General information

The machines covered by this manual are equipped with a 12-volt

electrical system.

The charging system models uses a rotor with permanent

magnets that rotates around a stator coil of copper wire....

8B-4 
Chapter 8 Part B Electrical system (XV700-1100 models)

7.1a Remove the headlight cover screws .

carefully for evidence of a short circuit. Look for bare wires and

chafed, melted or burned insulation. If a fuse is replaced before the

cause is located, the new fuse will blow immediately.

9 Never, under any circumstances, use a higher rated fuse or bridge

the fuse block terminals, as damage to the electrical system could result.

10 Occasionally a fuse will blow or cause an open circuit for no...

Chapter 8 Part B Electrical system (XV700-1100 models)

8B-5

7.1c Tilt the headlight cover forward,

remove the rubber dust cover

and unplug the connector 
7.2a If the headlight bulb is secured by a

retainer ring, turn it counterclockwise

(anti-clockwise) arid remove it... 
7.2b ... then lift out the bulb (but make

sure it has cooled first)

7.5 UK models have a parking light bulb

in the headlight reflector 
8.3 Horizontal adjustment is controlled

by a screw 
8.5a To make vertical adjustments on...

8B-6 
Chapter 8 Part B Electrical system (XV700-1100 models)

11.3 The turn signal relay on 1981 through

1983 models is a separate unit 
12.7 Disconnect the electrical connector

and the spring, then either remove the

nut from the bracket or unscrew

the switch from the nut 
13.1 Unscrew the cable nut from the base

of the speedometer

13.2a On models so equipped, remove

the speedometer cable retainer bolt 
13.2b Detach the speedometer cable

from the guide (remove the

guide if necessary) 
13.2c On...

Chapter 8 Part B Electrical system (XV700-1100 models) 
8B-7

13.4a Instrument cluster (XV750, XV920 K

and MK) - exploded view

1 Speedometer

2 Wiring harness

3 Bulb

4 Tachometer

5 Wiring harness

6 Bulb

7 Instrument top cover

8 Speedometer lower cover

9 Tachometer lower cover

10 Bracket

11 Grommet

12 Rubber damper

13 Washer

14 Nut

15 Screw

16 Mounting bracket

17 Screw

18 Lockwasher

19 Washer

20 Screw

21 Lockwasher

22 Washer

23 Nut

24 Lockwasher

25 Washer

26 Speedometer cable...

8B-8 
Chapter 8 Part B Electrical system (XV700-1100 models)

13.4b Instrument cluster (XV920J)

exploded view

1 Top cover

2 Display panel

3 LCD unit

4 LCD unit

5 LCD unit

6 Circuit board

7 Screw

8 Lockwasher

9 Washer

10 Odometer

11 Sender unit

12 Pilot box

13 Washer

14 Lockwasher

15 Screw

16 Sender unit

17 Wiring harness

18 Bulb

19 Lower cover

20 Screw

21 Lockwasher

22 Washer

23 Rubber seal

24 Mounting bracket

25 Nut

26 Washer

27 Grommet

28 Grommet

29 Collar

30 Washer

31...

Chapter 8 Part B Electrical system (XV700-1100 models) 
8B-9

13.4c Instrument cluster (XV920 RH, XV920 RJ and TR1)

1 Speedometer

2 Distance sensor

3 Wiring harness

4 Bulb

5 Tachometer

6 Wiring harness

7 Bulb

8 Warning light cover 
9 Lower cover

10 Wiring

11 Bulb

12 Mounting bracket

13 Speedometer housing

14 Tachometer housing

15 Bolt

16 Washer 
17 Lockwasher

18 Nut

19 Washer

20 Nut

21 Grommet

22 Sealing ring

23 Screw

24 Lockwasher 
25 Washer

26 Screw

27 Rubber damper

28 Collar...