Haynes Yamaha Xv V Twins Manual

8B-10 
Chapter 8 Part B Electrical system (XV700-1100 models)

13.6 Remove the speedometer securing

nut and lift the speedometer out 
14.1a Remove the warning light cover

screws and lift off the cover ... 
14.1b ... and pull the bulb from

the socket

5 If youre working on a 1981 through 1983 XV750, an XV920J, or

an XV920 K or MK, disassemble the cluster as necessary for access to

speedometer,

6 If youre working on an XV920 RH, XV920 RJ or TR1. remove the

nut, washer and grommet from the back of...

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

8B-11

16.2 Hazard switch terminals (1984-on XV1000 and XV1100)

Replacement

4 Disconnect the electrical connector, if you havent already done

so. Free the wiring harness from any clips or retainers.

5 Place the key in the unlocked position and remove the mounting

bolts from the underside of the switch.

6 Attach the new switch to the bracket and tighten the bolts

securely.

7 The remainder of installation is the reverse of the removal...

8B-12

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

23.1 The starting circuit cutoff relay is located beneath the seat

(early XV750 shown); it can be identified by its wire colors

23.2 Cutoff relay test connections (1981 through 1983 models)

23.3 Cutoff relay diode test connections

(1981 through 1983 models)

23 Starting circuit cut-off relay - check and replacement

Refer to illustration 23.1

1 Lift or remove the seat (see Chapter 7) and remove the relay (see

illustration).

1981...

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

8B-13

24.3 Remove the mounting bolts (arrows) 
24.4 Pull the starter motor out of the crankcase

3 Remove the starter mounting bolts (see illustration).

4 Lift the end of the starter up a little bit and slide the starter out of

the engine case (see illustration).

5 Check the condition of the O-ring on the end of the starter and

replace it if necessary. Also check the starter pinion gear and the

driven gear inside the engine for chipped or...

8B-14

Chapter 8 Part B Electrica! system (XV700-110Q models)

25.3a Check the reduction gears for wear or damage ...

damage (see illustrations). The gears arent available separately, so

the starter will have to be replaced if theyre worn or damaged.

26 Charging system testing - general information and

precautions

1 If the performance of the charging system is suspect, the system

asa whole should be checked first, followed by testing of the individual

components (the alternator and the voltage...

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

-8B-15

28.6 Hold the thrust collar in with a flat steel ruler or similar

tool while installing the cover

28.11 Remove the rotor retaining nut and washer

Install the cover and tighten the Allen bolts evenly, in a criss-cross

pattern, to the torque listed in this Chapters Specifications.

Stator

Refer to illustration 28.8

7 Remove the alternator cover as described above.

28.12a Take off the rotor together with the intermediate gear 
28.8...

8B-16

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

28.13a The legs on the intermediate gear fit into the gaps

between the rotor springs

28.13b Make sure the mark on the gear aligns with

the hole in the rotor

13 Installation is the reverse of the removal steps, with the following

additions:

a) If the intermediate gear was removed from the back of the rotor,

position the three pairs of rotor springs with gaps between them

and press the gear into position. Make sure its alignment mark...

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

8B-17

29.3a Remove the oil level

switch cover ... 
29.3b .. .and unscrew the switch

from the crankcase 
30.3 The spring clips must fit into the

notches in the crankcase

Removal

2 Remove the starter motor (see Section 24) and the alternator

cover (see Section 28).

XV920 and 1981 through 1985 XV700 and XV750 models

Refer to illustrations 30.3 and 30.4

3 Remove the snap-ring and the spring clip (see illustration).

4 Remove the starter motor...

8B-18

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

30.7 Starter clutch details (XV1000, XV1100 and 1986 and later

XV700 and XV750 models)

1 Starter clutch 10 Drive lever shaft

2 Snap-ring 11 Oil seal

3 Shaft 12 Collar

4 Starter wheel - 13 Screw

5 Inner idler gear 14 Drive lever

6 Outer idler gear 15 return spring

7 Thrust collar 16 Pivot bolt

8 Spring 17 Gasket

9 Collar 18 Nut 
30.10a Remove the solenoid screws and nuts .,

30.10b ... then remove the cover and remove the solenoid...

Chapter 8 Part B Electrical system (XV700-1100 models) 
8B-19

30.12a Check the components for wear and damage (XV920 and

1981 through 1985 XV700 and XV750) 
30.12b Measure the tightness of the spring clips by rotating them

with a spring scale; replace them if they turn too easily

30.13a Check the components for wear and damage (XV1000,

XV1100 and 1986 and later XV700 and XV750 models) 
30.13b Check the bushing in the starter clutch for wear

or damage ...

30.13c ... also inspect the clutch splines...