Ac Generator And Voltage Regulator

Remove the right side cover and connect the pocket tester leads to the battery terminals. 3. Accelerate the engine to approximately 5,000 r min or more, and check the generator voltage. 4. If the indicated voltage cannot be reached, check all connections. If the connections are all good, check the battery, stator coil, and the regulator rectifier. If both the battery and stator coil are in working order, the regulator is defective and should be replaced. Never disconnect the wires from the...

Starter Relay

Disconnect the starter cables at the relay. 3. Connect the pocket tester leads to the relay terminals (ohmsxl scale). 4. Turn the ignition to the ON position and the engine stop switch to RUN. 5. Push the starter button. The starter relay should click once, and the scale on the tester should read zero. If it does not read zero, the relay must be replaced. 6. If the relay does not click, check the leads from the starter button and from the starting circuit cut-off relay (red white, blue white)....

Starter Motor

I 20 Nm (2.0 m kg, 14 ft lb) I STAKE I 1. See Chapter 3. ENGINE DISASSEMBLY. 1. Check the outer surface of the commutator. If its surface is dirty, clean it with 600 grit sandpaper. 2. The mica insulation between the commutator segments should be 1.6 -1.1 mm (0.06 0.04 in) below the segment level. If not, scrape the mica to proper limits with an appropriately shaped tool. (A hacksaw blade can be ground to fit.) The mica insulation of the commutator must be undercut to ensure proper operation of...

Electrical

XV500K WIRING ELECTRIC STARTING SYSTEM 62 STARTING CIRCUIT CUT-OFF SYSTEM 6 3 Starting Circuit STARTER MOTOR Inspection and STARTER Inspection STARTING CIRCUIT CUT-OFF RELAY 6 6 Inspection CHARGING SYSTEM AC GENERATOR AND VOLTAGE REGULATOR 6 9 Inspection Battery Stator Coil Checking the Silicon IGNITION Description Sidestand Relay LIGHTING Lighting Tests and SIGNAL Signal System Tests and Flasher Cancelling

C

Remove the guide collar, oil seal, and roller bearing from the main housing by using an appropriate press tool and a press. Use the appropriate supports for the main housing during this operation. The roller bearing may be reused if undamaged. Do not reuse the oil seal. 6. Final-drive-shaft roller bearing removal of this bearing is difficult and seldom necessary. Heat the bare housing to 150 C (302 F). Use an appropriately shaped punch to remove the roller bearing outer race. Remove the inner...

Cables And Fittings

See MAINTENANCE AND LUBRICATION interval charts. Cable maintenance is primarily concerned with preventing deterioration and providing proper lubrication to allow the cable to move freely within its housing. Cable removal is straight forward and uncomplicated. Removal is not discussed within this section. Cable routing is very important. For details of cable routing, see the CABLE ROUTING at the end of this manual. Improperly routed or adjusted cables may make the motorcycle unsafe for...

Swingarm

Remove the rear wheel and the shock absorber pivot shaft. Grasp the swingarm and try to move it from side to side as shown. There should be no noticeable side play. 2. The swingarm is mounted on needle bearings. Move the swingarm up and down as shown. The swingarm should move smoothly, without tightness, binding, or rough spots that could indicate damaged bearings. 1. Remove the rear wheel, seat, side covers, and fuel tank. 2. Remove the final gear assembly and the dirve shaft from the...

Removal

Remove the side covers, seat, and fuel tank. 2. Remove the T.C.I, unit bracket and rear frame securing bolt and nut from each muffler bracket. 3. Remove the cotter pin from the pivot shaft, drive out the shock absorber pivot shaft, and disconnect the shock absorber from the swingarm. Always wear a proper eye protection to prevent eye damage from escaping gas and or metal chips. 1. To install the shock absorber in the motorcycle, reverse the removal procedures. Shock absorber mount bolt 45 Nm...

Assembly

Grease the bearings and races with wheel bearing grease. 2. Install the steering stem, balls, and races. 3. Install the ring nut. Tighten it to approximately 20 Nm (2.0 m kg, 14 ft lb) and loosen it approximately 1 4 turn. 4. Continue assembly reverse the disassembly procedure. 5. When assembly is complete, check the steering stem by turning it from lock to lock. If there is any binding or looseness, readjust the tightness of the steering stem.

Adjustment

Refer to Assembly for steering head adjustment procedures. 1. Place the motorcycle on its centerstand. 2. Remove the side covers, seat, and fuel tank. 3. Remove the front wheel and front forks. 4. Remove the headlight lens unit, and disconnect all wiring connectors in the headlight shell. 7. Remove the headlight body bracket securing bolt and nuts. Remove the meter assembly and the headlight body bracket. 8. Remove the steering stem bolt, and remove the steering crown with the handlebar...

Warning

Remove the cap and fork cap bolt from each inner fork tube. 6. Loosen the pinch bolts on the under bracket, and remove the fork(s). 7. Remove the collar, spring seat, and fork spring. Remove the cylinder securing bolt from the bottom of the fork assembly. Hold the damper rod with the front-fork-cylinder holder. Remove the damper rod assembly and inner fork tube. 4. Place an open container under each drain hole. Remove the drain screw from each outer tube. 5. Remove the emblem plate from the...

Rear Wheel

Place the motorcycle on its centerstand. 2. Remove the tension bar and the brake rod from the brake shoe plate. The tension bar can be removed by removing the cotter pin and nut from the tension bar bolt. The brake rod can be removed by removing the adjuster. 3. Remove the axle nut cotter pin and axle nut. Discard the old pin. 5. Move the wheel to the right side to separate it from the final gear case and remove the rear wheel. 1. Check the brake linings for damage and wear. If the thickness is...

Chassis

FRONT Front Axle Inspection Front Wheel Replacing the Wheel Installing the Front REAR Checking Brake Shoe Brake Brake Shoe Rear Axle Replacing the Wheel Rear Wheel Inspection Installing the Rear FRONT Brake Pad Caliper Master Cylinder Brake Inspection and Brake FRONT Removal and Inspection STEERING Inspection Inspection Note on Installation and SWINGARM Free Play Inspection and Lubrication CABLES AND Cable Throttle SHAFT Final Gear Removal Gear Lash Check and Final Gear Final Gear Assembly...

Note

Note the position of the tab on the gaskets. This tab must be placed in the recess in the fuel pump body during reassembly. 1. Examine the fuel pump body and fuel passage. If they are contaminated, wash the fuel pump body in a petroleum-based solvent. Blow out all passages with compressed air. 2. Inspect the fuel pump diaghragm, valve, and gasket for damage. If damaged, replace these components as a set. As shown below, a gap of 0.125 mm (0.005 in) is provided between the valve seat and the...

Fuel Pump

The fuel pump diaphragm is operated by variations in the pressure in the carburetor joint and thus produces a pumping action that pumps fuel from the fuel tank to the carburetor. Each individual spring is rigorously tested for its preload and therefore must not be broken down or adjusted in any way. If an afterburning sound is heard during normal riding, clean the pilot air jet, pilot jet, and bypass port by blowing air into them. 1. Remove the Y.I.C.S. chamber from the fuel pump. 2. Remove the...

Coasting Enricher

This model is eqipped with an afterburning protection device (coasting enricher). Afterburning is a phenomenon typical of the internal combustion engine. If throttle is precipitously closed on an engine revolving at high speed, a large amount of air mixed fuel spurts out of the pilot outlet (P.O.), resulting in incomplete burning in the combustion chamber. Such unburned elements are expelled together with exhaust gases and build up in the exhaust pipe or muffler. These elements, accumulated to...

Carburetors and Ignition Coils

Place the carburetors between the cylinders and tighten the clamps. 2. Install the ignition coils inside the engine-mounting bracket on the front cylinder. Secure each coil to the bracket with two mounting nuts. The coil with the shorter cable should be on the left side of the bracket. Torque the nuts to specification. 3. Install the change pedal onto the shift shaft. Torque the bolt to specification.

Primary Drive

The drive gear is mounted on the crankshaft the driven gear is mounted on the transmission main axle and integrated with the clutch assembly. 1. Check the drive gear and the driven gear for obvious signs of wear or damage from foreign material within the primary case. 2. If the primary drive is excessively noisy during operation, replace both the drive and the driven gears.

Caution

Motorcycle Mechanic Illustration

First align the shift cam segment key with the keyway in the crankcase, and install the right-side crankcase. 4. Install the crankcase bolts and the battery negative lead. Tighten the bolts in the tightening sequence shown in the illustration. After all the bolts are tight, torque them to specification. 1. Shift shaft 2. Stopper lever 3. Shift cam stopper 1. Shift shaft 2. Stopper lever 3. Shift cam stopper 1. Lightly grease then lips of the shift shaft oil seal at the left-side crankcase. 2....

Lighting System

HEADLIGHT I I DIMMER SWITCH The battery provides power for operation of the headlight, taillight, license light, and meter lights. If none of the above operates, always check battery voltage before proceeding further. Low battery voltage indicates either a faulty battery, low battery electrolyte, or a defective charging system. See CHARGING SYSTEM for checks of the battery and charging system. Also check fuse condition. Replace any open fuses. There are individual fuses for various circuits...

Front Brake

Disc brake components rarely require disassembly. Do not disassemble components unless absolutely necessary. If any hydraulic connection in the system is opened, the entire system should be disassembled, drained, cleaned, and then properly filled and bled upon reassembly. Do not use solvents on brake internal components. Solvents will cause seals to swell and distort. Use only clean brake fluid for cleaning. Use care with brake fluid. Brake fluid can injure your eyes, and it will damage painted...

General Torque Specifications

This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature.

Push

Tension body II. Install the tension body into the rear cylinder head. Use a new gasket and, torque the bolts to specification. 12. Install the tension spring into the tension body. Torque the end plug to specification. TIGHTENING TORQUE 20 Nm (2.0 m-kg, 14 ft-lb) 13. Install the cam sprocket cover onto the rear ( 1) cylinder head. The cam sprocket cover for the rear cylinder has a breather outlet. The cam sprocket cover for the front cylinder does not. Use the...

Ft

Install the camshaft bushing onto the camshaft. Be sure the bushing is completely seated in the cylinder head. The cut-out portion of the bushing must be flush with the cylinder head. Secure the bushing in the head with the securing plate. Torque the securing-plate bolt to specification, and bend the lock tab against a nut flat. Do not cock the bushing during installation. The bushing must be perpendicular to the camshaft during installation. The securing-plate bolts must be installed at the...

General Maintenancelubrication

Adjust the play Replace pads if necessary (front) Replace shoes if necessary (rear) Yamaha chain and cable lube or SAE 10W30 motor oil Yamaha chain and cable lube or SAE 10W30 motor oil Yamaha chain and cable lube or SAE 10W30 motor oil Drain completely Refill to specification Check bearings assembly for looseness Moderately repack every 16,000 km (10.000 mi) Check bearings for smooth rotation Replace if necessary Check breather pipe for proper operation Yamaha chain and cable lube or SAE 10W30...

Motorcycle Secondary Coil

Check resistance of ignition coil primary and secondary Primary 2.7fl 15 at 20 C 68 F Secondary 8.5 Kf2 15 at 20 C 68 F Check pickup coils for resistance Pickup coil 15512 10 at 20 C 68 F If the ignition system becomes inoperative or if the engine misfires at the minimum spark gap or at a smaller gap, there is a problem in the ignition system. Follow the troubleshooting chart until the source of the problem is located. 1. Remove the engine-mounting-bracket-covers and disconnect the ignition...

Oil Pump

Measure the rotor width on both trochoid gears. If the measurement exceeds specification, replace the pump. Crankshaft pump 6 mm 0.236 in Transmission pump 4 mm 0.157 in 2. Measure the clearance between the rotor and housing. Replace the pump assembly if the clearance exceeds specifications. Inner Outer clearance 0.12 mm 0.0047 in or less

Inspection

If the tube is severely scratched or bent, it should be replaced. 2. Inspect the outer surface of the fork seal seat in the outer fork tube. If this surface is damaged, replace the outer fork tube. If it is not damaged, replace the fork seal. 3. Check the outer fork tubes for dents. Replace the tube if it is dented. 4. Check the free length of the springs. 5. Check the O-ring on the cap bolt. If it's damaged, replace it. 1. Make sure all components are clean...

Motorcycle Identification

The engine serial number is stamped into the elevated part of the right rear section of the engine. The first three digits of these numbers are for model identification the remaining digits are the unit production number. The vehicle identification number is on the right side of the steering head pipe.

Starting Circuit Cutoff System

The starting circuit cut-off system is employed. Hence, the following description. The starting circuit on this model consists of the starter motor, starter relay, and the starting circuit cut-off relay. If the engine stop switch and the main switch are both on, the starter motor can operate only if The starting circuit cut-off relay prevents the starter from operating when neither of these conditions has been met. In this instance, the starting circuit cut-off relay is off so current cannot...

Gear Lash Measurement

Remove the middle gear case cover from the left-side crankcase. 2. Install the middle-drive-gear holder onto the crankcase. 5. Check the gear lash at four positions. Rotate the yoke 90 degrees each time, and repeat the gear lash check. 3. Tighten the holder bolts as tight as necessary to keep the middle gear from turning. 4. Set the dial gauge on the outside edge of yoke so that it is positioned over the centerline of the yoke bearing hole. Gently rotate the drive yoke back and forth. Note...

Engine

Motorcycle Mechanics Institute

Adjust the valve clearance as follows Valve clearance must be measured when the engine is cool to the touch. 1. Remove the seat, side covers, and fuel tank. 2. Remove the T.C.I regulator holding bracket. 3. Remove the intake and exhaust valve covers. 4. Remove the emblem and timing plug from the left-side crankcase cover. 5. Align the T mark for the rear cylinder on the flywheel with the stationary pointer on the crankcase cover. The pointer can be viewed through the timing window in the...

Master Cylinder Disassembly

Remove the master cylinder cup assembly. Note that the cylinder cups are installed with the larger diameter lips inserted first. 3. Replace the piston seals if damaged. Replace the seals every two years. 4. Inspect the master cylinder body replace if scratched. Clean all the passages with new brake fluid. 5. Inspect the brake hoses. Replace the hoses every four years or immediately if cracked, frayed, or damaged. 6. Check for wear and deflection of the disc. If the disc is worn beyond...

Shaft Drive

FINAL GEAR OIL 1 0.19 L 0.17 Imp qt, 0.20 US qt I GEAR LASH 0.1 -0.2 mm 0.004 - 0.008 in The following conditions may indicate damaged shaft drive components 1. A pronounced hesitation or jerky movement during acceleration, deceleration, or sustained speed. This must not be confused with engine surging or transmission characteristics. 2. A rolling rumble noticeable at low speed a high-pitched whine a clunk from a shaft drive component or area. 3. A locked-up condition of the shaft drive...

Periodic Inspections And Adjustments

MAINTENANCE INTERVALS CHARTS 2-1 CONTROL GENERAL MAINTENANCE LUBRICATION 2 2 Valve Clearance Spark Crankcase Ventilation Fuel Exhaust Carburetor Idle Engine Clutch Checking Ignition Final Gear Air Front Brake Rear Brake Brake Fluid Cable Inspection and Brake and Change Pedals Brake and Clutch Levers 2-13 Centerstand and Front Fork Oil Rear Shock Absorber Adjustment 2-14 Steering Head Wheel Front Rear Wheel Fuel Battery

Middle Gear Service

0.15 mm 0.0059 in 0.20 mm 0.0079 in 0.30 mm 0.012 in 0.40 mm 0.016 in 0 50 mm 0.020 in 0.15 mm 0.0059 in 0.20 mm 0.0079 in 0.30 mm 0.012 in 0.40 mm 0.016 in 0 50 mm 0.020 in 0.10 mm 0.0039 in 0.15 mm 0.0059 in 0.20 mm 0.0079 in 0.30 mm 0.012 in 0.40 mm 0.016 in 0.50 mm 0.020 in 5. Check the gear lash at four positions. Rotate the yoke 90 degrees each time, and repeat the gear lash check. 6. If the measurement exceeds the specified gear lash at any of the four points, the gear lash must be...

Front Wheel

Loosen the pinch bolt securing the axle. 5. Remove the axle shaft and the front wheel. In this case, make sure the motorcycle is properly supported. Remove the speedometer cable holder securing bolts. 1. Place the motorcycle on its centerstand. 2. Remove the cotter pin and wheel axle nut. Remove the speedometer cable holder securing bolts. When using tube-type tires, be sure to install the proper tube also. Loosen the pinch bolt securing the axle. 5. Remove the axle shaft and the front wheel....

Mounting the Engine

Place the rear-cylinder exhaust pipe in the frame. 2. Place the engine on a block or other suitable engine stand, and lower the frame over the engine. It is easier if you approach the engine from the right-hand side. 3. Align the splines of the U-joint with those of the drive shaft, then move the engine into place in the frame. 4. Install the rear, lower engine-mounting stud. TIGHTENING TORQUE 20 Nm 2.0 m-kg, 14 ft lb TIGHTENING TORQUE 55 Nm 5.5 m-kg, 40 ft-lb 5. Using the rear, lower...

Important Information

Connecting Rod Bearing Cap Alignment

All gaskets and seals should be replaced when an engine is overhauled. All gasket surfaces and oil seal lips must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip, make sure that the sharp edged corner is positioned opposite to the thrust it receives. See the sectional view below. Lock washers plates...

Carburetor

500 Carburettors

The pilot screw settings are adjusted for maximum performance at the factory with special equipment. DO NOT attempt to change these settings. If all other engine systems are functioning correctly, any changes will decrease performance and cause increased exhaust emissions. When you separate the carburetors, the small spring may fall out. This spring is connecting the both throttle levers. Do not lose this spring. 1. Remove the two starter link securing screws, and remove the starter link and starter levers from the carburetors. 2. Remove the upper bracket securing screws and remove the upper bracket with fuel pump. 3. Remove the lower brackets from the carburetors and separate the carburetors. 4. Remove the vacuum chamber cover, and remove the spring, O-ring, and diaphragm. The vacuum piston will come out with the diaphragm. Note the position of the tab on the diaphragm. This tab must be placed in the recess in the 5. Remove the starter plunger from the carburetor body. 7. Remove the...

Starting Circuit Cutoff Relay

Cut Off Relay

Remove the starting circuit cut-off relay from the rubber clamp, and disconnect the connector. 1. When the battery is connected 2. When the battery is disconnected 1. When the battery is connected 2. When the battery is disconnected 3. Check the resistance of the relay coil windings with the pocket tester. If the resistance is not within specification, replace the relay. 5. Check the diode in the starting circuit cutoff relay with the pocket tester as shown in the illustration. Replace the...

Ignition System

Yamaha Sidestand Switch Wiring Diagram

This circuit diagram shows the ignition circuit in the wiring diagram. CLUTCH SWITCH MAIN SWITCH I ENGINE STOP SWITCH R.H. STARTING CIRCUIT CUT-OFF RELAY SIDESTAND SWITCH T.C.I. UNIT SIDESTAND RELAY This model is equipped with a battery operated, fully transistorized, breakerless ignition system. By using magnetic pickup coils, the need for contact breaker points is eliminated. This adds to the dependability of the system by eliminating frequent cleaning and adjustment of points and ignition...

Signal System

How Motorcycle Clutch Works

Circuit diagram shows only the signal circuit in the wiring diagram. The battery provides power for operation of the horn, brake light, indicator lights, and flasher light. If none of the above operates, always check the battery voltage before proceeding further. Low battery voltage indicates either a faulty battery, low battery electrolyte, or a defective charging system. See page 6-8 CHARGING SYSTEM for checks of the battery and charging system. Also check the fuse condition. Replace any open...

Inspection And Repair

Runout Measurement Block

Remove the intake and exhaust valve covers from each cylinder head. 2. Loosen the valve adjuster on both valves, and flatten the lock washer. 3. Remove the camshaft bearing securing bolts, washer, and plate. 4. Remove each camshaft and camshaft bearing with a slide hammer. 5. Remove the rocker-arm-shaft-union bolts. 6. Remove each rocker arm shaft with a slide hammer, then remove the rockers. 7. Mount the valve spring compressor on the head and depress each valve spring. Remove the valve...

Specifications

Dimensions Overall Length Overall Width Overall Height Seat Height Wheelbase Engine Type Cylinder Arrangement Displacement Bore x Stroke Compression Ratio Compression Pressure Starting System 2,135mm 84.1 in 825mm 32.5in 1,160mm 45.7in 745mm 29.3in 1,410mm 55.5in 155mm 6.1 in 4-stroke, gasoline, DOHC V-2 cylinder 494 cm' 1,079 kPa 11 kg cm2, 156 psi Electric starter Oil Capacity Engine Oil Periodic Oil Change With Oil Filter Replacement Total Amount Final Gear Case Oil Amount Yamalube 4-cycle...

Engine Removal

Honda Vt1100 Crank Tdc Front Cylinder

NOTE _ 2. Disconnect the starter motor lead from the starter motor relay, and oil level switch lead. 3. Remove the battery-box-holding screw and remove the battery box from the frame. Be sure to disconnect the brake switch rod from the brake pedal return spring before completely removing the battery box. 1. Remove the exhaust pipe flange nuts from the front cylinder head. 2. Loosen the muffler clamp bolt and remove the exhaust pipe. 3. Loosen the muffler clamp...

Special Tools

Demontage Drague Final Drive Gear

The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. Inductive tachometer P N. YU-08036 Inductive timing light P N. YU-08037 Fuel level gauge P N. YM-01312 Compression gauge P N. YU-33223 This gauge is needed for carburetor synchronization. This gauge is needed for carburetor synchronization. Universal clutch holder P N. YM-91042 This tool is...

Engine Overhaul

ENGINE Preparation for Fuel Air Exhaust Pipes and Leads and Couplers Cables and Footrests, Sidestand and Muffler Brackets 3-3 Engine ENGINE Engine-Mounting Bracket and Carburetors .3-5 Cylinder Heads and Piston Pin and Piston Crankcase Covers, Starter Motor, and Oil Pump 3-6 .3-8 Clutch and Primary Shifter and Oil Crankcase INSPECTION AND REPAIR 3-13 Cylinder Head Cylinder Valves, Valve Guides, Valve Seats, and Valve Springs 3-14 Rocker Arms and Rocker Arm Camshafts, Cylinder Head Assembly and...