Engine Removal

Battery

1. Disconnect the battery leads. NOTE: _

Disconnect the negative lead first.

Disconnect the negative lead first.

Yamaha Yics Starter Motor Chains

2. Disconnect the starter motor lead from the starter motor relay, and oil level switch lead.

Yamaha Yics Starter Motor Chains

3. Remove the battery-box-holding screw and remove the battery box from the frame.

NOTE:

Be sure to disconnect the brake switch rod from the brake pedal return spring before completely removing the battery box.

VAMaha

1. Brake switch rod

Exhaust Pipes and Mufflers

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 bolt at the rear cylinder.

4. Remove the muffler and passenger footrest securing bolt from each muffler bracket.

Remove the muffler assembly and the passenger footrests.

5. Remove the exhaust pipe flange nuts from the rear cylinder head.

Leads and Couplers

1. Remove the engine-mounting-bracket cover from the front cylinder. The cover is in three pieces: a centerpiece and two sidepieces. The upper part of each sidepiece hooks to the frame. Remove the securing screw, unhook each sidepiece, then remove the centerpiece.

2. Disconnect the following couplers and leads.

• Sidestand switch lead

• Pickup coil lead

• Neutral switch lead

• Ignition coil leads

• Wire harness negative lead

Cables and Pipes

1. Disconnect the following cables.

• Crankcase ventilation pipe

2. Remove the Y.I.C.S. chamber securing bolt and disconnect the throttle cable.

Footrests, Sidestand and Muffler Brackets

1. Remove the brake rod from the rear brake arm.

2. Remove the nuts and bolts shown in the illustration, and remove the front footrests and the muffler brackets.

RIGHT-SIDE

MUFFLER BRACKET

FOOTREST

MUFFLER BRACKET

FOOTREST

3. Remove the sidestand securing nut and remove the sidestand.

Engine Removal

1. Remove the engine mounts and remove the engine. There are two engine-mounting bolts on the front cylinder, two bolts on the rear cylinder, and an engine-mounting stud in the rear of the engine.

2. Finally, push the threaded stud through the frame and pull the engine forward. This will disengage the engine from the drive shaft, and the engine can be removed from the right-side of the frame.

ENGINE DISASSEMBLY

Engine-Mounting Bracket and Carburetors

1. Remove the ignition coils from the engine-mounting bracket, and remove the engine-mounting bracket and washers from the front cylinder.

2. Disconnect Y.I.C.S. pipe from each cylinder and disconnect the fuel pump pipe from the carburetor joint.

3. Loosen the carburetor outlet joint clamp on each carburetor, and remove the carburetors.

4. Remove the change pedal and spark plugs.

Cylinder Heads and Cylinders

1. Remove the timing plug and emblem from the left-side crankcase cover.

2. Remove the cam chain tensioner from each cylinder.

3. Turn the crankshaft clockwise, and align the "T" mark on the flywheel with the stationary pointer. This places the rear (# 1) piston at top dead center.

Honda Vt1100 Crank Tdc Front Cylinder

4. Remove the cam sprocket cover, oil baffle plate (rear cylinder only), and cam chain sprocket from the rear cylinder head; Hold the crankshaft end with the box wrench.

Yamaha Virago Xv500 Timing Marks

5. Rotate the crankshaft 290 degrees clockwise until the TDC mark for the front cylinder is opposite the stationary pointer.

Be sure to keep the rear cylinder cam chain taut while turning the crankshaft.

6. Remove the cam sprocket cover and cam sprocket from the front cylinder head.

7. Remove the cylinder securing bolt from each cylinder.

8. Remove each cylinder head and engine-mounting brackets. Loosen all the cylinder head nuts and bolts first. Each nut and bolt must be loose before any one is removed.

9. Remove the three dowels and O-ring from each cylinder. 10. Remove the rear cam chain guide from each cylinder.

11. Remove each cylinder.

Put a marking on the cylinder for reinstallation.

Piston Pin and Piston

1. Mark each piston so it can be reinstalled in the appropriate cylinder.

2. Remove the piston pin clip from the piston.

Before removing the piston pin clip, cover the crankcase with a clean rag so you will not accidentally drop the clip into the crankcase.

3. Remove the piston pin clip from the opposite side, then pull it out; use the special tool.

Before removing the piston pin, deburr the clip groove and pin hole.

Pump

1. Remove the oil filter cover bolts and remove the cover and oil filter element.

1. Oil filter cover

2. Remove the right-side crankcase cover bolts, and remove the crankcase cover and clamps.

3. Remove the two dowels from the right side crankcase.

4. Remove the circlip and oil pump driven gear.

1. Circlip

2. Oil pump driven gear

1. Circlip

2. Oil pump driven gear

5. Remove the oil pump assembly.

6. Remove the dowel and two O-rings from the crankcase.

2. Dowel

7. Remove the oil level switch assembly from the bottom of the crankcase.

■ i HMMuM! ii. .^T . 1. Oil level switch assembly

■ i HMMuM! ii. .^T . 1. Oil level switch assembly

8. Remove the left-side crankcase cover bolts and remove the cover and clutch cable bracket.

9. Remove the two dowels from the crankcase.

10. Remove the starter motor.

11. Remove the starter idle gear # 1 and idle gear shaft.

1. Starter idle gear #1 2. Idle gear shaft

1. Starter idle gear #1 2. Idle gear shaft

2. Dowel

12. Remove the neutral switch assembly from the left-side crankcase.

CAUTION:

1. Neutral switch

Flywheel

1. Remove the flywheel securing bolt; Hold the flywheel end with a 32 mm (1.26 in) wrench.

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2. Remove the flywheel. Place the 3-way universal puller with the puller attachment on the crankshaft, and remove the flywheel with the universal puller.

1. 3 way universal puller

2. Puller attachment

1. 3 way universal puller

2. Puller attachment

The starter clutch assembly can become severely distorted if the flywheel-magneto-puller bolts are inserted too far.

The starter clutch has three rollers, three springs, and three spring caps. Use care so that they don't fall out when removing the flywheel.

3. Remove the woodruf key and idle gear #2 from the crankshaft.

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4. Remove the cam chain guide securing bolts, and remove the cam chain guide and cam chain.

4. Remove the cam chain guide securing bolts, and remove the cam chain guide and cam chain.

Clutch and Primary Gears

1. Clutch pressure plate

4. Ball

5. Clutch friction plate

6. Clutch plate

7. Clutch boss

8. Thrust washer

9. Clutch housing

11. Gasket

12. Washer

13. Oil seal

14. Bearing

Clutch and Primary Gears

4. Place a small piece of rolled rag or a small piece of lead between the gears, and remove the primary drive gear securing nut, lock washer, washer, and key.

5. Flatten the lock tab, and remove the clutch boss securing nut; use the universal clutch hub holder.

3. Flatten the lock tab on the primary drive gear securing nut.

6. Remove the lock washer, clutch boss, thrust washer, and the clutch housing from the transmission main axle.

7. Remove the key, oil pump drive gear, and primary drive gear from the crankshaft.

8. Remove the front cam chain guide securing bolts and remove the cam chain guide and cam chain.

Shifter and Oil Strainer

1. Remove the shifter shaft circlip and washer from the left-side crankcase.

1. Clutch pressure plate

4. Ball

5. Clutch friction plate

6. Clutch plate

7. Clutch boss

8. Thrust washer

9. Clutch housing

11. Gasket

12. Washer

13. Oil seal

14. Bearing

Remove the five clutch springs, then remove the clutch pressure plate, friction plates, and clutch plates. Remove the ball and push rod #2 from the transmission main shaft.

1. Universal clutch hub holder

2. Disengage the shift lever from the shift drum pins, and remove the shift shaft assembly.

1. Shift shaft assembly.

3. Remove the oil passage housing securing bolts, and remove the housing, O-rings, and oil strainer from the left-side crank-case.

1. Shift shaft assembly.

3. Remove the oil passage housing securing bolts, and remove the housing, O-rings, and oil strainer from the left-side crank-case.

1. Oil passage housing 2. Oil strainer

Crankcase

1. Remove all the crankcase bolts and battery negative (-) lead from the crankcase.

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1. Battery negative ( - ) lead

2. Remove the right-side crankcase from the left-side, and remove the three dowels and O-rings.

CAUTION: _

When separating the crankcase, be sure the shiftdrum star aligns with its corresponding contours in the crankcase.

1. Segment

1. Segment

If the right crankcase has to be replaced, remove the oil baffle plate; otherwise, the removal of the oil baffle plate is unnecessary.

1. Oil baffle plate

3. Remove the crankshaft from the left-side crankcase.

1. Crankshaft

4. Remove the shift fork guide bars first, then remove the shift levers and shift cam.

The following steps are necessary only if you must service the middle gears or replace the crankcase.

1. Circlip

2. Washer

3. 2nd wheel

6. Remove the circlip, washer, and 2nd wheel from the drive axle.

1. Circlip

2. Washer

3. 2nd wheel

1. Drive axle 2. 3rd wheel 3. 5th wheel 4. 2nd wheel 5. Main axle subassembly

1. Shift fork 2. Shift fork guide 3. Shift cam

5. Remove the 1st wheel, 4th wheel, circlip, washer, and 5th wheel from the drive axle. Remove the main axle subassembly from the crankcase.

1. Drive axle 2. 3rd wheel 3. 5th wheel 4. 2nd wheel 5. Main axle subassembly

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)

Bearing stopper bolt:_

Mechanics Shim

125 Nm (2.5 m • kg, 18 ft^lbTj | Apply LOCTITE* & STAKE)-

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1. Bearing

2. Shim

3. Middle drive pinion gear

4. Bearing

5. Damper spring retainer

6. Spring seat

7. Damper spring

8. Damper cam

9. Middle driven pinion gear

10. Shim

11. O-ring

12. Bearing housing

13. Oil seal

14. Universal joint

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)

Bearing stopper bolt:_

125 Nm (2.5 m • kg, 18 ft^lbTj | Apply LOCTITE* & STAKE)-

v. iiiiii iu.woj in/

Remove the middle-gear-case cover securing bolts and middle-drive-shaft bearing-housing securing bolts. Remove the middle-drive-shaft assembly and shims from the left-side crankcase.

1. Middle-drive-shaft assembly

2. Shim

11. Remove the bearing stopper plates, bear ing and shims.

1. Shim

1. Middle-drive-shaft assembly

2. Shim

8. Secure the drive axle in a vice or other support.

9. Remove the middle drive gear and crankcase from the drive axle; With the drift punch, flatten the punched portion of the drive gear securing nut. Remove the drive gear securing nut.

1. Middle drive gear

1. Middle drive gear

10. Remove the drive-axle-bearing-stopper bolts; use the torx driver.

1. Torx driver

2. Stopper bolt

1. Torx driver

2. Stopper bolt

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Responses

  • stephanie
    How do i remove the crank cover on yamaha virago?
    4 years ago
  • mark
    How to disengage drive shafts universal joint virago?
    4 years ago
  • proserpio sagese
    How to remove rear cylinder virago 125?
    7 months ago

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