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 at all in the other. If

it turns both ways or neither way, remove the idler gear and

disassemble the starter clutch for inspection.

3 Compress the pin against its internal spring with a pointed tool

and take out the roller (see illustration). Remove the pin and spring

(see illustration).

4 Remove the remaining two pins, rollers and springs in the same

way.

5 Check all parts for wear and damage and replace parts with these

conditions. If the starter clutch needs to be replaced, unstake the ends

of its three bolts inside the alternator rotor and unscrew them to

separate the starter clutch body from the rotor. Position the new

starter clutch on the rotor and apply non-permanent thread locking

agent to the threads of the bolts. Install the bolts, tighten them to the

torque listed in this Chapters Specifications and stake their ends on

the inside of the rotor.

6 Position the spring inside one of the pins. Place the spring and pin

in their bore, compress the pin against the spring with a pointed tool

(see illustration) and install the roller.

7 Install the remaining springs, pins and rollers in the same way.

8 The remainder of installation is the reverse of the removal steps.

When installing the starter driven gear, dont forget to install the thrust

washer first (see illustration 28.11c).

30 Fuel tap solenoid (1989 and later models) - removal,

testing and installation

Refer to illustration 30.2

1 Remove the main fuel tank (see Chapter 3). Pour the fuel into an

approved container. 
2 Free the wiring harness and hose from their clips, remove the

screws and detach the fuel tap from the tank (see illustration).

3 Disconnect the hose from the fuel nozzle and connect a length of

clean rubber hose in its place.

4 Turn the fuel tap lever to On and try to blow air into the hose. It

should go through. If it doesnt, replace the fuel tap.

5 Connect a 12lvolt battery (the motorcycles battery will work) to

the solenoid wire terminals (positive to black/yellow; negative to black.

Try to blow air into the hose again. It shouldnt be possible with the

battery connected to the solenoid. If air willgo through, replace the

solenoid.

31 Carburetor heater (1994 UK models) - testing

1 Follow the wiring harness from the heater unit at the carburetor

assembly to the thermoswitch (it can be identified by its wire color).

Remove the thermoswitch from the wiring harness.

2 Immerse the thermoswitch in a container of water (suspend it so it

doesnt touch the sides or bottom of the container).

3 Connect an ohmmeter to the thermoswitch wires and heat the

water. Note the ohmmeter readings as the water heats, then cools

down.

a) Zero to 17+1- 5-degrees C (32 to 63 +/- 9-degrees F) -

continuity (little or no resistance)

b) 17 +/- 5 to 70-degrees C (63 +/- 9 to 158-degrees F) -

no continuity (infinite resistance)

c) 70 to 11 +/- 3-degrees C (158 to 52 +/- 5-degrees F) -

no continuity

d) Less than 11 +/- 3-degrees C (52 +/- 5-degrees F) - continuity

4 If the thermoswitch doesnt give the readings described, replace

it.

5 Disconnect the wiring from the heater unit at the carburetor

assembly. Connect an ohmmeter to the terminal on the heater unit

note the reading and compare it to the value listed in this Chapters

Specifications. If the resistance reading is not with the specified range

replace the heater unit.

32 Wiring diagrams

Prior to troubleshooting a circuit, check the fuses to make sure

theyre in good condition. Make sure the battery is fully charged and

check the cable connections.

When checking a circuit, make sure all connectors are clean, with

no broken or loose terminals or wires. When unplugging a connector

dont pull on the wires - pull only on the connector housings

themselves.

Refer to the table in Chapter 9 for the wire color codes. 
						

							
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 1

Handlebar switches - check 16

Handlebar switches - removal and installation 17

Headlight aim - check and adjustment 8

Headlight assembly - removal and installation 9

Headlight bulb - replacement 7 
Section

Horn - check and replacement 21

Ignition main (key) switch - check and replacement 15

Instrument and warning light bulbs - replacement 14

Lighting system - check 6

Neutral switch - check and replacement 18

Oil level switch - removal, check and installation 29

Sidestand switch - check and replacement 19

Speedometer and cable- removal and installation 13

Starter clutch - removal, inspection and installation 30

Starter relay - check and replacement 22

Starting circuit cut-off relay - check and replacement 23

Starter motor - disassembly, inspection and reassembly 25

Starter motor - removal and installation 24

Turn signal circuit - check 11

Turn signals and tail/brake light bulbs - replacement 10

Wiring diagrams 31

Specifications

Battery type

XV700, XV750 12 V, 16 Ah

XV920, XV1000, XV1100 12 V, 20 Ah

Fuse specifications

1981 through 1983 models

Main

XV920J, K, MX, TR1 30 amps

All others 20 amps

Headlamp 15 amps

Tail/brake lights 10 amps

Turn signals 15 amps

Ignition 10 amps 
						

							
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.... 28 mm (1.1 inch)

Minimum 27 mm (1.06 inch)

Mica undercut 0.5 mm (0.02 inch)

Starter brush length

Standard 12.5-1-/- 5 mm (0.492 +/- 0.02 inch)

Minimum 5.5 mm (0.217 inch)

Starter clutch spring clip turning force

Idle gear 2.2 to 2.5 kg (4.9 to 5.5 lbs)

Starter gear 2.0 to 2.3 kg (4.4 to 5.1 lbs)

Bulb specifications (1981 through 1983 models)

Headlight 60/55W

Tail/brake lights

. TR1 5/21W

All others 8/27W

Turn signals

TR1 21W

All others 27W

Running light (XV920J only) 8W

License plate light

XV750, XV920 K, MK 8W

XV920J 3.8W

Warning lights 3.4W

Pilot light (UK only) 3.4W

Bulb specifications (1984 and later US models)

Headlight.. 60/55W

Tail/brake lights 8/27W

Turn signals/running lights 27W

Instrument and warning lights 4W

Bulb specifications (1984 and later UK models)

Headlight 60/55W

Tail/brake lights 5/21W

Parking light 4W

Turn signals 21W

Instrument and warning lights .. 3W

Torque specifications

Alternator rotor nut

1981 through 1983 models..... 155 Nm (112 ft-lbs)

1984 and later models 175 Nm (125 ft-lbs)

Alternator cover bolts 7 Nm (5.1 ft-lbs)

Starter mounting bolts 10 Nm (7.2 ft-lbs)

Starter solenoid nuts 8 Nm (5.8 ft-lbs)*

Drive lever cover bolts 10 Nm (7.2 ft-lbs)

Drive lever collar screw 10 Nm (7.2 ft-lbs)*

*Apply non-permanent thread locking agent to the threads.

**Apply non-permanent thread locking agent to the threads and stake the bolts. 
						

							
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. This

produces alternating current, which is converted to direct current by

the regulator/rectifier. The regulator/rectifier also controls the charging

system output..

An electric starter mounted to the front of the engine is standard

equipment. The starter on all models has two brushes and uses

reduction gears. The starting system includes the motor, the battery,

the relay and the various wires and switches. If the engine kill switch

and the ignition (main key) switch are both in the On position, the

circuit relay allows the starter motor to operate only if the transmission

is in Neutral (Neutral switch on) or the clutch lever is pulled to the

handlebar (clutch switch on) and, on all US models and later UK

models, the sidestand is up (sidestand switch on).

Note: Keep in mind that electrical parts, once purchased, cant be

returned. To avoid unnecessary expense, make very sure the faulty

component has been positively identified before buying a replacement

part.

2 Electrical troubleshooting

This is the same as for XV535 models. Refer to Part B of this

Chapter.

5.3 The accessory fuse block on 1984 and later models is

beneath the warning light panel 
3 Battery - inspection and maintenance

These procedures are the same as for XV535 models, except that

the XV920J has a long-life battery. This battery has a single filler hole

for the electrolyte and a sensor that indicates electrolyte level and

activates a warning light on the instrument panel when it drops too low.

If the sensor isnt working properly, put on eye protection and

rubber gloves and remove,. Jt from the battery. Clean the sensor

thoroughly with water, then sand any corrosion from its surface and

reinstall it. Warning: Battery electrolyte is diluted sulfuric acid. It can

cause burns and eye injury. Dont let it touch your skin.

4 Battery - charging

This is the same as for XV535 models. Refer to Part A of this

Chapter.

5 Fuses - check and replacement

Refer to illustrations 5.1, 5.2 and 5.3

1 The main fuse on all XV700 through 1100 models is located

beneath the seat (see illustration).

2 The fuse block on 1981 through 1983 models is behihd a cover on

the lower triple clamp (see illustration).

3 The fuse block on 1984 and later models is located under the

warning light panel (see-illustration).

4 The fuse block contains spare fuses and accessory fuses. Fuse

functions and ratings are listed in this Chapters Specifications. Fuse

ratings are marked on the fuses.

5 If you have a test light, the accessory fuses can be checked

without removing them. Turn the ignition key to the On position,

connect one end of the test light to a good ground, then probe each

terminal on top of the fuse. If the fuse is good, there will be voltage

available at both terminals. If the fuse is blown, there will only be

voltage present at one of the terminals.

6 The fuses can also be tested with an ohmmeter or self-powered

test light. Remove the fuse and connect the tester to the ends of the

fuse. If the ohmmeter shows continuity or the test lamp lights, the fuse

is good. If the ohmmeter shows infinite resistance or the test lamp

stays out, the fuse is blown.

7 The fuses can be removed and checked visually. If you cant pull

the fuse out with your fingertips, use a pair of needle-nose pliers. A

blown fuse is easily identified by a break in the element.

8 If a fuse blows, be sure to check the wiring harnesses very 
						

							
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

obvious reason. Corrosion of the fuse ends and fuse block terminals

may occur and cause poor fuse contact. If this happens, remove the

corrosion with a wire brush or emery paper, then spray the fuse end

and terminals with electrical contact cleaner.

6 Lighting system - check

1 The battery provides power for operation of the headlight,

taillight, brake light, license plate light, instrument and warning lights. If

none of the lights operate, always check battery voltage before

proceeding. Low battery voltage indicates either a faulty battery, low

battery electrolyte level or a defective charging system. Refer to

Chapter 1 for battery checks and Sections 26 and 27 for charging

system tests. Also, check the condition of the fuses and replace any

blown fuses with new ones.

Headlight

2 If the headlight is out when the engine is running (US models) or it

wont switch on (UK models), check the fuse first with the key or switch

On (see Section 5), then unplug the electrical connector for the

headlight and use jumper wires to connect the bulb directly to the

battery terminals (see Section 7). If the light comes on, the problem lies

in the wiring or one of the switches in the circuit. Refer to Section 17

for the switch testing procedures, and also the wiring diagrams at the

end of this Chapter.

Taillight/license plate light

3 If the taillight fails to work, check the bulbs and the bulb terminals

first, then check for battery voltage at the taillight electrical connector.

If voltage is present, check the ground/earth circuit for an open or poor

connection.

4 If no voltage is indicated, check the wiring between the taillight

and the ignition switch, then check the switch. On UK models, check

the lighting switch as well.

Brake light

5 See Section 12 for the brake light switch checking procedure.

Neutral indicator light

6 If the neutral light fails to operate when the transmission is in

Neutral and the key switch is On, check the fuses and the bulb (see 
7.1b ... on XV920J models, dont confuse them with the

adjuster screws

1 Headlamp assembly 6 Spring clip

2 Rim 7 Adjusting screw

3 Reflector 8 Spring

4 Bulb retaining ring 9 Nut

5 Cover 10 Headlamp bulb

Section 14 for bulb removal procedures). If the bulb and fuses are in

good condition, check for battery voltage at the connector attached to

the neutral switch on the left side of the engine. If battery voltage is

present, refer to Section 18 for the neutral switch check and

replacement procedures.

7 If no voltage is indicated, check the wiring between the switch

and the bulb for open circuits and poor connections.

7 Headlight bulb - replacement

Refer to illustrations 7.1a, 7.1b, 7.1c, 7.2a, 7.2b and 7.5

Warning: If the bulb has just burned out, allow it to cool. It will be hot

enough to burn your fingers.

1 Remove the headlight cover screws (see illustrations). Tilt the

cover forward out of the headlight assembly and disconnect the

electrical connector (see illustration).

2 On models so equipped, turn the bulb retainer counterclockwise

(anti-clockwise) (see illustration). Remove the bulb (see illustration).

3 On models with a wire bulb retainer, unclip the retainer and

remove the bulb.

4 When installing the new bulb, reverse the removal procedure. Be

sure not to touch the bulb glass with your fingers - oil from your skin

will cause the bulb to overheat and fail prematurely. If you do touch the

bulb, wipe it off with a clean rag dampened with rubbing alcohol.

5 The parking light bulb holder (auxiliary light) on UK models is

either a push fit in the grommet set in the rear of the reflector or has a

bayonet-type socket (see illustration). Access may be possible via

the cutout in the headlight housing, but if not remove the headlight as

described in Step 1. Twist the bulb counterclockwise (anti-clockwise)

to release it from its bulb holder.

8 Headlight aim - check and adjustment

1 An improperly adjusted headlight may cause problems for

oncoming traffic or provide poor, unsafe illumination of the road ahead.

Before adjusting the headlight, be sure to consult with local traffic laws

and regulations.

2 The headlight beam can be adjusted both vertically and

horizontally. Before performing the adjustment, make sure the fuel tank

is at least half full and have an assistant sit on the seat. 
						

							
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

chain drive models, loosen the

mounting bolts ...

1981 through 1983 models

Refer to illustrations 8.3. 8.5a and 8.5b

3 Turn the Phillips screw to change horizontal adjustment (see

illustration 7.1b or the accompanying illustration).

4 If youre working on an XV920J model, turn the adjusting screw in

8.5b ... and the securing screw, then tilt the headlight assembly

as needed and retighten the fasteners 
the lower edge of the retaining ring to change vertical adjustment.

5 If youre working on an XV920 RH or RJ or a TR1, loosen the

mounting bolts and securing screw, then pivot the headlight assembly

to change vertical adjustment (see illustrations).

6 If youre working on an XV750 or XV920 K or MK, loosen the

securing screw at the bottom of the headlight assembly and use the

pivot at the top of the assembly to change headlight adjustment.

1984 and later models

7 The horizontal adjusting screw is at the upper left of the headlight

cover. The vertical adjusting screw is located at the lower right. Turn

the screws to change adjustment as needed.

9 Headlight assembly - removal and installation

1981 through 1983 models

1 Remove the headlight cover (see Section 7). If youre planning to

take the headlight assembly completely off the motorcycle, disconnect

any electrical connectors inside the headlight assembly.

2 If youre working on an XV750, XV920K or XV920MK, Remove the

two mounting bolts, collars and grommets that secure the headlight

assembly brackets. Remove the pivot bolt at the top of the headlight

assembly and take the assembly off.

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

mounting bolts and securing screws and take the assembly off (see

illustrations 8.5a and 8.5b). 
						

							
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 models without a retaining bolt,

unscrew the cable from the drive unit

4 If youre working on an XV920J, remove the mounting bolt and

nut on each side and take the assembly off.

5 Installation is the reverse of the removal steps. Be sure to reinstall

all washers, lockwashers, grommets and collars.

1984 and later models

6 This is the same as for XV535 models, described in Part A of this

Chapter. Note that the two lower mounting bolts also secure the brake

hose union.

10 Turn signals and tail/brake light bulbs - replacement

Procedures are the same as for XV535 models, although the

shapes of the taillight lenses differ slightly. Refer to Part A of this

Chapter.

11 Turn signal circuit - check

Refer to illustration 11.3

1 The battery provides power for operation of the signal lights, so if

they do not operate, always check the battery voltage and specific

gravity first. Low battery voltage indicates either a faulty battery, low

electrolyte level or a defective charging system. Refer to Chapter 1 for

battery checks and Sections 26 and 27 for charging system tests.

Also, check the fuses (see Section 5). 
2 Most turn signal problems are the result of a burned out bulb or

corroded socket. This is especially true when the turn signals function

properly in one direction, but fail to flash in the other direction. Check

the bubs and the sockets (see Section 10).

3 If the bulbs and sockets check out okay, check for power at the

turn signal relay with the ignition On. On 1981 through 1983 models,

this is a separate unit (see illustration). On 1984 and later models, its

incorporated into the relay assembly. Refer to the Wiring diagrams at

the end of the book to identify the correct relay and its power source

terminal.

4 If the relay is okay, check the wiring between the turn signal relay

and the turn signal lights (see the Wiring diagrams at the, end of the

book).

5 If the wiring checks out okay, replace the turn signal relay.

12 Brake light switches - check and replacement

Circuit check

1 Before checking any electrical circuit, check the fuses (see

Section 5).

2 Using a test light connected to a good ground, check for voltage

at the brake light switch. If theres no voltage present, check the wire

between the switch and the fuse box (see the Wiring diagrams at the

end of the book).

3 If voltage is available, touch the probe of the test light to the other 
						

							
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

27 Bolt

terminal of the switch, then pull the brake lever or depress the brake

pedal - if the test light doesnt light up, replace the switch.

4 If the test light does light, check the wiring between the switch and

the brake lights (see the wiring diagrams at the end of this Chapter).

Switch replacement

Front brake lever switch

5 This is the same as for XV535 models. Refer to Part A of this

Chapter.

Rear brake pedal switch

Refer to illustration 12.7

6 Unplug the electrical connector in the switch harness.

7 Unhook the switch spring (see illustration).

8 Either compress the retainer prongs and slide the switch and its

adjusting nut out of the bracket or unscrew the switch completely from

the adjusting nut (see illustration 12.7).

9 Install the switch by reversing the removal procedure, then adjust

the switch by following the procedure described in Chapter 1. 
13 Speedometer and cable - removal and installation

Speedometer cable removal

Refer to illustrations 13.1, 13.2a and 13.2b

1 Unscrew the speedometer cable end and pull the cable from the

speedometer (see illustration). If necessary for access, lower the

headlight assembly (see Section 9).

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

the drive gear at the left front fork. On early XV750 models, remove the

cable retaining bolt and detach the cable from the guide (see

illustration). On all others, unscrew the knurled nut from the

speedometer drive unit (see illustration).

Speedometer removal

Refer to illustrations 13.4a, 13.4b, 13.4c and 13.6

3 Disconnect the cable from the speedometer (see illustration 13.1).

4 Remove the mounting fasteners and detach the speedometer

housing or instrument cluster (see illustrations). 
						

							
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 Lockwasher

32 Nut 
						

							
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

29 Lockwasher

30 Nut

31 Speedometer cable