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 the speedometer housing

and remove the speedometer (see illustration).

7 If youre working on a 1984 or later model, lift the speedometer

away from the bracket and turn it over. Remove the self-tapping screw

and detach the speedometer from the housing (see illustration 13.5 in

Part A of this Chapter). Follow the speedometer wiring harness to its

connector (inside a rubber cover below the speedometer) and

disconnect it.

Installation

8 Installation is the reverse of the removal procedure. Be sure the

speedometer cable and wiring harness are routed so it doesnt cause

the steering to bind or interfere with other components. The squared-

off ends of the cable must fit into their spindles in the speedometer and

drive gear.

14 Instrument and warning light bulbs - replacement

Refer to illustrations 14.1a, 14.1b and 14.3

1 To replace a warning light bulb on an XV920 RH, XV920 RJ or

TR1, remove the warning light cover screws (see illustration). Pull the

bulb outof its socket (see illustration), push in a new one and install

the cover. 
2 To replace an instrument light bulb on an XV920 RH, XV920 RJ or

TR1, remove the speedometer or tachometer (see Section 13). Pull the

bulb socket from the back of the instrument, pull the bulb out of the

socket and push in a new one. Reinstall the instrument.

3 To replace bulbs on an XV920J, remove the instrument cluster

from its mounting bracket (see Section 13). Pull the bulb socket from

the bottom of the instrument cluster (see illustration), pull the bulb out

of the socket and push in a new one. Reinstall the instrument cluster.

4 To replace bulbs on an XV750, XV920K or XV920 MK, remove the

cluster partway and remove the lower cover (see Section 13). Pull the

bulb socket from the bottom of the instrument, pull the bulb out of the

socket and push in a,new one. Reinstall the instrument cluster.

15 Ignition main (key) switch - check and replacement

Check

Refer to illustration 15.2

1 Follow the wiring harness from the ignition switch (on the upper

triple clamp) to the connector and disconnect it.

2 Using an ohmmeter, check the continuity of the terminal pairs

indicated in the accompanying table (see illustration). Continuity

should exist between the terminals connected by a solid line when the

switch is in the indicated position. Note: Connect the ohmmeter to the

switch side of the connector, not the wiring harness side.

3 If the switch fails any of the tests, replace it.

14.3 On chain drive models, remove the instrument and pull the

bulb socket from its underside, then pull the bulb from the socket 
15.2 Ignition (main key) switch continuity diagram

1 XV920J, 1984-on 1000 and XV1100 only

2 XV920J only 
						

							
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

procedure.

16 Handlebar switches - check

Refer to illustration 16.2

1 Switch testing procedures are the same as for XV535 models (see

Part A of this Chapter).

2 Continuity diagrams are the same as for XV535 models (see

illustration 16.4 in Part A of this Chapter), except for the engine kill

switch (both terminals have red/white wires) and the hazard switch

used on XV1000 and XV1100 models (see illustration).

17 Handlebar switches - removal and installation

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

Chapter.

18 Neutral switch - check and replacement

Check

Refer to illustration 18.2

1 . Make sure the transmission is in neutral.

2 Locate the switch harness (see illustration), then unplug the

connector. 
3 Connect the terminal in the harness side of the connector to

ground/earth (bare metal on the motorcycle frame) with a short length

of wire.

a) If the light stays out, check the bulb and the wiring between the

ignition switch and neutral switch.

b) If the neutral indicator light comes on, the neutral switch may be

bad. Connect an ohmmeter between the terminal in the switch

side of the connector and ground. Shift through the gears. The

ohmmeter should indicate continuity (low resistance) in neutral

and no continuity (infinite resistance) in all other gears. If not,

replace the neutral switch.

Replacement

Refer to illustration 18.4

4 Loosen the small screw on the switch and detach the wire (see

illustration 18.2). Unscrew the switch from the crankcase (see

illustration). Remove the sealing washer and install a new one.

5 Installation is the reverse of the removal steps.

19 Sidestand switch - check and replacement

Testing and replacement procedures are the same as for XV535

models. Refer to Part A of this Chapter.

20 Clutch switch - check and replacement

Testing and replacement procedures are the same as for XV535

models. Refer to Part A of this Chapter.

21 Horn - check and replacement

These models use two horns, mounted at the front of the

motorcycle. Testing and replacement procedures are the same as for

XV535 models. Refer to Part A of this Chapter.

22 Starter relay - check and replacement

Refer to illustration 22.2

1 An external starter relay is used on 1981 through 1983 models, as

well as 1984 and 1985 XV700 models.

2 Testing and replacement procedures are the same as for XV535

models (see Part A of this Chapter). The relay is mounted on the right

side of the motorcycle (see illustration).

18.2 The neutral switch is screwed into

the left crankcase half; the screw that

secures its wire is beneath a rubber cover 
18.4 Unscrew the switch; use a new

sealing washer on installation 
22.2 The relay is mounted on the right

side of the motorcycle; pull back the

rubber covers to expose the terminal nuts 
						

							
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 through 1983 models

Refer to illustrations 23.2 and 23.3

2 Connect an ohmmeter and 12-volt battery to the relay terminals

24.2 Pull back the cover, remove the nut and

disconnect the starter cable 
23.5 Cutoff relay test connections (1984 and later models)

(see illustration). The ohmmeter should indicate continuity (little or no

resistance) while the battery is connected, and infinite resistance (no

continuity) when the battery is disconnected.

3 Disconnect the battery and connect the ohmmeter between the

coil winding terminals (see illustration). Note the ohmmeter reading,

then switch the ohmmeter leads. The ohmmeter should indicate very

high resistance in one direction and very low resistance in the other

direction.

4 If the relay doesnt perform as described, replace it.

1984 and later models

Refer to illustration 23.5

5 Connect an ohmmeter and 12-volt battery to the relay terminals

(see illustration). The ohmmeter should indicate continuity (little or no

resistance) while the battery is connected, and infinite resistance (no

continuity) when the battery is disconnected.

6 If the relay doesnt perform as described, replace it.

24 Starter motor - removal and installation

Refer to illustrations 24.2, 24.3 and 24.4

Removal

1 Disconnect the cable from the negative terminal of the battery.

2 Pull back the rubber cover, remove the nut retaining the starter

cable to the starter and disconnect the cable (see illustration). 
						

							
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 worn teeth.

Installation

6 Apply a little engine oil to the O-ring and install the starter by

reversing the removal procedure. Tighten the starter mounting bolts to

the torque listed in this Chapters Specifications. 
25 Starter motor - disassembly, inspection and

reassembly

Refer to illustrations 25.2, 25.3a and 25.3b

1 Remove the starter motor (see Section 24).

2 All XV700 through 1100 models use a two-brush, reduction gear

starter (see illustration).

3 Disassembly, inspection and assembly procedures are generally

the same as for XV535 models (refer to Part A of this Chapter). In

addition, check the reduction gears and bushings for wear and

25.2 Starter motor - exploded view

1 Armature

2 Starter housing

3 Washer

4 O-ring

5 Washer

6 Drive gear

7 O-ring

8 Brushes (early design shown;

later design similar)

9 Screws (early design brushes)

10 Brush plate

11 O-ring

12 End cover

13 Through bolt

14 Mounting bolt 
						

							
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 regulator/rectifier). Note:

Before beginning the checks, make sure the battery is fully charged

and that all system connections are clean and tight.

2 Checking the output of the charging system and the performance

of the various components within the charging system requires the use

of special electrical test equipment. A voltmeter or a multimeter are the

absolute minimum tools required. In addition, an ohmmeter is generally

required for checking the remainder of the system.

3 When making the checks, follow the procedures carefully to

prevent incorrect connections or short circuits, as irreparable damage

to electrical system components may result if short circuits occur.

Because of the special tools and expertise required, it is

recommended that the job of checking the charging system be left to a

dealer service department or a reputable motorcycle repair shop.

27 Charging system - output test

Caution: Never disconnect the battery cables from the battery while

the engine is running. If the battery is disconnected, the alternator and

regulator/rectifier will be damaged.

1 To check the charging system output, you will need a voltmeter or

a multimeter with a voltmeter function.

2 The battery must be fully charged (charge it from an external

source if necessary) and the engine must be at normal operating

temperature to obtain an accurate reading.

3 Attach the positive (red) voltmeter lead to the positive (+) battery

terminal and the negative (black) lead to the battery negative (-)

terminal. The voltmeter selector switch (if equipped) must be in 0-to-20

DC volt range.

4 Start the engine.

5 The charging system output should be within the range listed in

this Chapters Specifications. Stop the engine as soon as the voltage

reading has been obtained, and turn the ignition key switch Off.

6 Follow the wiring harness from the alternator cover (on the left

side of the engine) to the electrical connector and disconnect the

connector containing the three white wires.

7 Connect the probes of an ohmmeter set to the R x 1 range

between each pair of white wires in the connector (the side that runs

back to the alternator, not the wiring harness side). Note the reading of

all three tests. 
25.3b ... and check the bushing inside the gear end plate

28.2 Note the locations of the locating dowels as you

remove the cover

8 If each reading is not within the range listed in this Chapters

Specifications, replace the stator (see Section 28).

9 If the reading is within the Specifications, refer to the Wiring

diagrams at the end of the book and check the charging circuit for

breaks or poor connections. If the wiring is good, replace the

regulator/rectifier (see Section 28). Note: No test details are providec

by the manufacturer for the regulator/rectifier unit. If the stator coils

and wiring check out OK, the regulator/rectifier is probably defective.

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

removal and installation

Cover

Refer to illustrations 28,2 and 28.6

1 Remove the outer crankcase cover from the left side of the

engine. Refer to Chapter 2 and disconnect the clutch cable at the

engine. Remove the left footpeg assembly if necessary for access.

2 Loosen the alternator cover mounting bolts evenly in a criss-cross

pattern and remove the cover (see illustration).

3 Clean all traces of old gasket sealer from the cover and its matin:

surface on the engine. •

4 Make sure there are no metal particles stuck to the rotor magnets

5 Position a new gasket over the dowels.

6 On XV1000 models, XV1100 models and 1986 and later XV70C

and XV750 models, hold the starter clutch thrust collar in with a flat

steel ruler or similar tool (see illustration). 
						

							
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 Alternator rotor and stator details

1 Rotor

2 Stator

3 Bolt

4 Pickup coils (dual

pickup model shown) 
5 Pickup coil screws

6 Washers

7 Pickup coil screws

(alternate locations)

8 Washers

8 Remove the stator screws and take the stator out (see

illustration).

9 Installation is the reverse of the removal steps. Tighten the stator

screws securely.

Rotor

Refer to illustrations 28.11, 28.12a, 28.12b, 28.13a, 28.13b and 28.13c

10 Remove the alternator cover as described above.

11 Shift the transmission into gear and have an assistant apply the

rear brake. Remove the rotor nut and washer (see illustration).

12 Thread a rotor puller such as Yamaha tool no. YU-33270 into the 

rotor. Remove the rotor from the end of the crankshaft and take the

Woodruff key out of its slot (see illustrations). Note: Dont take the

intermediate gear off the back of the rotor unless the gear or rotor is to

be replaced.

28.12b Remove the Woodruff key from the crankshaft 
						

							
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 is

lined up with the sighting hole in the rotor (see illustrations).

b) Be sure to reinstall the Woodruff key. Caution: Make sure no

metal objects have stuck to the magnets inside the rotor.

28.13c Tighten the rotor nut to the specified torque 
c) Aligning the rotor and intermediate gear must be done in a

specific way. Refer to the timing gear installation procedures in

Part B of Chapter 2.

d) Tighten the rotor nut to the torque listed in this Chapters Specifi-

cations (see illustration).

Regulator/rectifier

Refer to illustration 28.14

14 On 1981 through 1983 models, the regulator/rectifier unit is

mounted on the rear subframe (see illustration). On 1984 and later

models, it is mounted inboard of the luggage box behind the left side

cover.

15 Follow the wiring harness from the regulator/rectifier to the

connector. Disconnect the electrical connector and remove the

regulator/rectifier mounting fasteners.

16 Installation is the reverse of the removal steps.

29 Oil level switch - removal, check and installation

Refer to illustrations 29.3a and 29.3b

Removal

1 Drain the engine oil (see Chapter 1).

2 The oil level switch is mounted in the bottom of the crankcase.

Note how its wiring harness is routed, then unplug the electrical

connector.

3 Remove the cover, then-unscrew the switch (see illustrations).

Check

4 Connect an ohmmeter between the terminals of the switch

harness. With the switch in its normal installed position, the ohmmeter

should indicate infinite resistance.

5 Turn the switch upside down. The ohmmeter should now reac

zero ohms.

6 If the ohmmeter doesnt give the correct indication in Step 4 or 5

replace the switch.

Installation

7 Installation is the reverse of the removal steps. Use a new sealing

washer and tighten the switch to the torque listed in this Chapters

Specifications.

30 Starter clutch - removal, inspection and installation

1 Two different starter clutch designs are used, one on 1981

through 1985 XV750, XV700 and XV920 models, the other on XV100C

XV1100, and 1986 and later XV700 and XV750 models.

28.14 The voltage regulator/rectifier on 1981 through 1983

models is mounted on the rear subframe 
						

							
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 gear, idler wheel, compression spring,

30.4 Starter clutch details (1981 through 1985 XV700

and XV750; XV920)

1 Starter motor pinion

2 Spring clip

3 Snap-ring

4 Shaft

5 Idler wheel

6 Inner idler gear 
7 Outer idler gear

8 Spring clip

9 Thrust collars

10 Spring

11 Collar 
idler shaft, the remaining spring clip, two more idler,gears and the

washer (see illustration).

XV1000, XV1100 and 1986 and later XV700 and XV750

models

Refer to illustrations 30.5, 30.6, 30.7, 30.10a, 30.10b and 30.11

5 Remove the drive lever cover and gasket (see illustration).

6 Loosen the drive lever collar screw (see illustration).

30.5 Remove the drive lever cover and gasket

30.6 Loosen the collar screw 
						

							
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

7 Remove the thrust collar (see illustration). Remove the O-ring,

shaft, starter wheel, spring, outer idler gear, inner idler gear and

remaining thrust collar.

8 Remove the snap-ring, starter clutch and remaining snap-ring.

9 Remove the drive lever collar screw (see illustration 30.6).

10 Remove the two solenoid securing nuts. Remove the solenoid

screws, pull the solenoid out and remove the gasket (see

illustrations).

11 Remove the drive lever pivot bolt, then remove the drive lever,

collar and spring (see illustration).

Inspection

Refer to illustrations 30.12a, 30.12b, 30.13a, 31,13b and 30.13c

12 If youre working on a 1981 through 1985 XV700, XV750 or XV920

model, clean the starter clutch components and check them for wear

and damage (see illustration). Replace any worn or damaged parts.

Place the spring clips in position and try to rotate them. If the turn

easily, replace them. If youre in doubt about their condition, pull on

them with a spring scale and measure the force required to rotate them

(see illustration). If its less than the value listed in this Chapters

Specifications, replace them.

13 If youre working on a 1986 or later XV700 or XV750, an XV1000

or an XV1100 model, clean the drive assembly components and check 
30.11 Remove the pivot and starter drive lever 
						

							
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 
them for wear or damage (see illustration). Replace worn or damaged

parts. Check the starter clutch splines and bushing for wear or damage

and replace the starter clutch if problems are found (see illustrations).

Installation

1981 through 1985 XV700, XV750 and XV920 models

14 Install the washer and the idler gears and center them over the

idler shaft bushing.

15 Install the outer idler gear and spring clip. Position the end of the

spring clip in its channel in the crankcase.

16 Insert the shaft through the idler gears.

17 Install the spring on the idler wheel, then install them on the shaft.

18 Install the starter motor gear and secure it with the snap-ring.

19 Install the remaining spring clip and place its end in the crankcase

notch (see illustration 30.3).

XV1000, XV1100, and 1986 and later XV700 and XV750

models

Refer to illustrations 30.21, 30.23 and 30.24

20 Install the gasket and starter solenoid. Install the solenoid screws

and nuts.

21 Position the drive lever collar and spring on the alternator cover.