1983 Yamaha XV500K Virago Motorcycle Service Manual

Description

This 1983 Yamaha XV500K Virago Service Manual is a reproduction of the original out of print 1983 Yamaha XV500K Virago Motorcycle Service Manual.  It provides detailed service information, step-by-step repair instruction and maintenance specifications for 1983 Yamaha XV500K Virago motorcycles.  This book has a color cover as shown and is bound together using a sturdy lay-flat binding so you can put it down on your workbench and it will stay open to the page you need.

Table of Contents

GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
Engine Serial Number
Vehicle Identification Number
SPECIAL TOOLS
For Tune-Up
For Engine Service
For Chassis Service
For Middle Gear Service
For Shaft Drive Service
For Electrical Components

PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION
MAINTENANCE INTERVALS CHARTS
PERIODIC MAINTENANCE EMISSION
CONTROL SYSTEM
GENERAL MAINTENANCE/LUBRICATION
ENGINE
Valve Clearance Adjustment
Spark Plug
Crankcase Ventilation System
Fuel Line
Exhaust System
Carburetor Synchronization
Idle Speed
Engine Oil
Clutch Adjustment
Checking Ignition Timing
Compression Pressure Measurement
CHASSIS
Final Gear Oil
Air Filter
Front and Rear Brake
Brake Light Switch Adjustment
Front Brake Pad
Rear Brake Shoe
Brake Fluid
Cable Inspection and Lubrication
Brake and Change Pedals/Brake and Clutch Levers
Centerstand and Sidestand
Front Fork Oil Change
Rear Shock Absorber Adjustment
Steering Head Adjustment
Wheel Bearings
Front Wheel
Rear Wheel
Fuel Cock
Tubeless Tires and Aluminum Wheels
ELECTRICAL
Battery
Headlight
Fuse

ENGINE OVERHAUL
ENGINE REMOVAL
Preparation for Removal
Fuel Tank
Air Filter
Battery
Exhaust Pipes and Mufflers
Leads and Couplers
Cables and Pipes
Footrests, Sidestand and Muffler Brackets
Engine Removal
ENGINE DISASSEMBLY
Engine-Mounting Bracket and Carburetors
Cylinder Heads and Cylinders
Piston Pin and Piston
Crankcase Covers, Starter Motor, and Oil Pump
Flywheel
Clutch and Primary Gears
Shifter and Oil Strainer
Crankcase
INSPECTION AND REPAIR
Cylinder Head Disassembly
Cylinder Head
Valves, Valve Guides, Valve Seats, and Valve Springs
Rocker Arms and Rocker Arm Shafts
Camshafts, Cylinder Head Assembly and Cam Sprockets
Cylinder Head Assembly
Cam Sprocket
Cylinder
Piston, Piston Rings, and Piston Pin
Crankcase
Bearings and Oil Seals
Crankshaft and Connecting Rod
Oil Pump
Primary Drive
Clutch
Transmission
Starter Drives
ENGINE ASSEMBLY AND ADJUSTMENT
Important Information
Left-Side Crankcase
Right-Side Crankcase
Crankcase Assembly
Shifter
Front-Cylinder Cam Chain and Drive Gears
Clutch
Rear-Cylinder Cam Chain and Flywheel
Starter Motor and Starter Idle Gear #1
Crankcase Covers, Oil Filter, and Oil Strainer
Pistons, Cam Chain Guides, and Cylinders
Cylinder Head, Rocker Arm, and Camshaft
Carburetors and Ignition Coils
Mounting the Engine
MIDDLE GEAR SERVICE
Gear Lash Measurement
Gear Lash Adjustment
Removal
Disassembly
Inspection
Assembly and Adjustment

CARBURETION
CARBURETOR
Section View
Specifications
Disassembly
Inspection
Assembly
Adjustment
COASTING ENRICHER
Operation
Maintenance
FUEL PUMP
Operation
Disassembly
Inspection
Assembly
AIR CLEANER AND CRANKCASE
VENTILATION SYSTEM

CHASSIS
FRONT WHEEL
Removal
Front Axle Inspection
Front Wheel Inspection
Replacing the Wheel Bearings
Installing the Front Wheel
REAR WHEEL
Removal
Checking Brake Shoe Wear
Brake Drum
Brake Shoe Plate
Rear Axle Inspection
Replacing the Wheel Bearings
Rear Wheel Inspection
Installing the Rear Wheel
FRONT BRAKE
Brake Pad Replacement
Caliper Disassembly
Master Cylinder Disassembly
Brake Inspection and Repair
Brake Assembly
FRONT FORK
Removal and Disassembly
Inspection
Assembly
STEERING HEAD
Adjustment
Removal
Inspection
Assembly
REAR SHOCK ABSORBER
Removal
Inspection
Note on Disposal
Installation and Adjustment—-
SWINGARM
Free Play Inspection
Removal
Inspection and Lubrication
Assembly
CABLES AND FITTINGS
Cable Maintenance
Throttle Maintenance
SHAFT DRIVE
Troubleshooting
Final Gear Removal
Gear Lash Check and Adjustment
Final Gear Disassembly
Final Gear Assembly
DRIVE SHAFT
Removal
Inspection
Installation

ELECTRICAL
XV500K WIRING DIAGRAM
ELECTRIC STARTING SYSTEM
STARTING CIRCUIT CUT-OFF SYSTEM
Starting Circuit Operation
STARTER MOTOR
Removal
Inspection and Repair
STARTER RELAY
Inspection
STARTING CIRCUIT CUT-OFF RELAY
Inspection
CHARGING SYSTEM
AC GENERATOR AND VOLTAGE REGULATOR
Inspection
Battery Inspection
Stator Coil Inspection
Checking the Silicon Rectifier
IGNITION SYSTEM
Description
Operation
Sidestand Relay Operation
Troubleshooting
LIGHTING SYSTEM
Lighting Tests and Checks
SIGNAL SYSTEM
Signal System Tests and Check
Flasher Cancelling Unit
Switches
Battery

APPENDICES
SPECIFICATIONS
General Specification
Maintenance Specification
CONSUMER INFORMATION
GENERAL TORQUE SPECIFICATIONS
DEFINITION OF UNITS
CONVERSION TABLES
EXPLODED DIAGRAMS
Cylinder Head/Valve
Cylinder
Cam Chain
Crankshaft/Connecting Rod/Piston
Transmission
Middle Gear
Front Wheel
Front Fork
Front Brake Caliper
Rear Wheel/Rear Brake
Swingarm
Final Gear/Drive Shaft
Electrical Components
LUBRICATION DIAGRAMS
CABLE ROUTING