1981-1982 Yamaha XV750 XV920 Virago Seca Motorcycle Service Manual

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. Spark Plug
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 VENTILATION 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 Lash 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