Description
This 1981-1982 Yamaha XV750 Virago Seca XV920 Virago Motorcycle Service Manual is a reproduction of the original, out of print manual. This manual provides detailed service information, step-by-step repair instruction and maintenance specifications for the following Yamaha motorcycles:
1981 Yamaha XV920RH Virago repair
1981 Yamaha XV750RH Seca repair
1981 Yamaha XV750H Virago repair
1982 Yamaha XV920J Virago repair
Table of Contents
CHAPTER 1. GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION.
A. Frame Serial Number
B. Engine Serial Number.
C. Vehicle Identification Number
SPECIAL TOOLS.
A. For Tune-up
B. For Engine Service.
C. For Shaft Drive Service
D. For Chassis Service
E. For Electrical Components
F. XV750 Tool Kit
CHAPTER 2.
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION
MAINTENANCE INTERVALS CHARTS.
ENGINE.
A. Valve Clearance Adjustment
B. SparkPlug.
C. Crankcase Ventilation System
D. Fuel Line.
E. Exhaust System
F. Carburetor Synchronization
G. Idle Speed
H. Engine Oil
I. Clutch Adjustment.
J. Checking Ignition Timing
K. Compression Pressure Measurement
CHASSIS
A. Final Gear Oil
B. Air Filter
C. Front and Rear Brake
D. Cable Inspection and Lubrication
E. Brake and Change Pedals/ Brake and Clutch Levers.
F. Centerstands and Sidestands.
G. Front Fork Oil Change.
H. Front Fork and Rear Shock Absorber Adjustment.
I. Steering Head Adjustment
J. Wheel Bearings
K. Fuel Petcock
L. Tubeless Tires and Aluminum Wheels
ELECTRICAL.
A. Battery.
B. Headlight.
C. Fuse .
CHAPTER 3. ENGINE OVERHAUL
ENGINE REMOVAL
A. Preparation For Removal
B. Seat and Fuel Tank.
C. Air Filter.
D. Battery
E. Exhaust Pipes and Muffler
F. Brake Pedal, Footpegs, and Muffler Brackets
G. Wires, Cables, and Sidestand
H. Engine Removal
ENGINE DISASSEMBLY
A. Mixture Control Valve, Ignition Coils, and Carburetors
B. Cylinder and Cylinder Head.
C. Piston Pin and Piston
D. Crankcase Covers, Starter Drive, and Starter Motor
E. Timing Gears.
F. Flywheel.
G. Clutch and Primary Gears.
H. Shifter
I. Oil Pump.
J. Crankcase .
INSPECTION AND REPAIR.
A. Cylinder Head.
B. Valves, Valve Guides, Valve Seats, and Valve Springs
C. Rocker Arms and Rocker Arm Shafts.
D. Camshafts, Cam Chains, and Cam Sprockets
E. Cylinder
F. Piston and Piston Rings.
G. Crankshaft and Connecting Rod.
H. Oil Pump
I. Primary Drive.
J. Clutch
K. Transmission
L. Starter.
M. Crankcase.
N. Bearings and Oil Seals
ENGINE ASSEMBLY AND ADJUSTMENT
A. Important Information
B. Left-Side Crankcase
C. Right-Side Crankcase.
D. Crankcase Assembly.
E. Oil Pump.
F. Shifter
G. Primary Gears and Clutch.
H. Flywheel.
I. Timing Gears.
J. Starter Motor, Starter Drive, and Crankcase Covers
K. Pistons, Cam Chain Guides, and Cylinders.
L. Cylinder Head, Rocker Arm, and Camshaft
M. Carburetors, Ignition Coils, and Mixture Control Valve
N. Mounting the Engine
MIDDLE GEAR SERVICE.
A. Gear Lash Measurement
B. Removal
C. Disassembly
D. Inspection.
E. Assembly and Adjustment
CHAPTER 4. CARBURETION
CARBURETOR
A. Section View.
B. Specifications.
C. Disassembly
D. Inspection.
E. Assembly.
F. Adjustment.
AIR CLEANER AND CRANKCASE VENTILATIN SYSTEM
MIXTURE CONTROL.
A. Vacuum Line Routing
B. Inspection.
CHAPTER 5. CHASSIS
FRONT WHEEL.
A. Removal
B. Front Axle Inspection.
C. Front Wheel Inspection .
D. Replacing The Wheel Bearings
E. Installing the Front Wheel
REAR WHEEL
A. Removal
B. Checking Brake Shoe Wear
C. Brake Drum.
D. Brake Shoe Plate.
E. Rear Axle Inspection.
F. Replacing The Wheel Bearings
G. Rear Wheel Inspection
H. Installing The Rear Wheel
FRONT BRAKE.
A. Brake Pad Replacement
B. Caliper Disassembly
C. Master Cylinder Disassembly.
D. Brake Inspection and Repair
E. Brake Assembly.
FRONT FORK
A. Removal and Disassembly
B. Inspection
C. Assembly.
STEERING HEAD
A. Adjustment.,
B. Removal_
C. Inspection.
D. Assembly.
SWINGARM
A. Free Play Inspection .
B. Removal
C. Inspection and Lubrication.
D. Assembly
REAR SHOCK ABSORBER.
A. Removal
B. Inspection.
C. Installation and Adjustment
CABLES AND FITTINGS.
A. Cable Maintenance
B. Throttle Maintenance.
SHAFT DRIVE.
A. Troubleshooting.
B. Final Gear Removal.
C. Gear Lssh Check and Adjustment
D. Final Gear Disassembly.
E. Final Gear Assembly
DRIVE SHAFT.
A. Removal
B. Inspection.
C. Installation.
CHAPTER 6. ELECTRICAL
XV750H WIRING DIAGRAM.
ELECTRIC STARTING SYSTEM
STARTING CIRCUIT OPERATION
STARTER MOTOR.
A. Removal
B. Inspection and Repair
STARTER RELAY.
STARTING-CIRCUIT CUT-OFF RELAY
STARTER CUT-OUT RELAY.
CHARGING SYSTEM.
AC GENERATOR AND VOLTAGE REGULATOR
A. Inspection.
B. Battery Inspection.
C. Stator Coil Inspection.
D. Checking the Silicon Rectifier.
IGNITION SYSTEM.
A. Description
B. Operation
C. Troubleshooting
LIGHTING SYSTEM.
A. Lighting Tests and Checks
HEADLIGHT RELAY.
SIGNAL SYSTEM.
A. Signal System Tests and Checks.
B. Flasher Self-Cancelling Unit.
C. Switches
D. Battery
CHAPTER 7. APPENDICES
SPECIFICATIONS.
TIGHTENING TORQUE
GENERAL TORQUE SPECIFICATIONS
COLOR CODES
CONVERSION TABLES
EXPLODED DIAGRAMS
Cylinder Head/Valve.
Cam Chain.
Crankshaft/Connecting Rod/Piston.
Transmission.
Middle Gear.
Frame
Front Wheel.
Front Fork
Front Brake Caliper.
Rear Wheel/Rear Brake.
Rear Shock Absorber
Swingarm
Final Gear/Drive Shaft
Electrical Components.
LUBRICATION DIAGRAMS
CABLE ROUTING
WIRING DIAGRAM
