83 Virago 500 Service Manual

  



  • The Virago is no different than any other motorcycle manufacturer when it comes to having defects in design or manufacturing. In Yamaha’s case, it is the starter employed by the Virago that has become the primary complaint. In fairness to Yamaha, many starter problems are created by the owner. There are all types of repair designed by Virago owners. Those repairs along with suggestions from Yamaha are the subject of this report.

By Alan Ahlstrand and John H Haynes. Member of the Guild of Motoring Writers. Models covered: USA: Yamaha XV535 Virago. 1987 through 1990 and 1993 through 1994. Virago 750 Service Manual 82 Yamaha Virago 750 Service Manual Yeah, reviewing a ebook 82 yamaha virago 750 service manual could ensue your near friends listings. This is just one of the solutions for you to be successful. As understood, talent does not recommend that you have Page 1/27. Yamaha xv virago v twins 81 to 03 haynes service and repair manual Oct 10, 2020 Posted By Dan Brown Media Publishing TEXT ID 26640a5b Online PDF Ebook Epub Library sales brochures 1995 lit 3mc 0107010 95e gbp999 yamaha xv virago v twins 81 03 haynes service repair manual 72 bpm on yamaha custom wood 5 inch motorcycle. Yamaha XV500 Virago XV 500 Workshop Service Repair Manual HERE. Yamaha XV535 Virago XV 535 Exploded View Parts List Diagram Schematics HERE. Yamaha XV535 Virago XV 535 B Owners Maintenance Instruction Manual 1991 HERE. Yamaha XV535 Virago XV 535 D Owners Maintenance Instruction Manual 1992 HERE.

  1. First we have the symptoms. You know, those things that either happen or don’t happen when you hit the starter button. Things like: the starter slips, spins out and does not turn the engine, turns slow, runs continuously, noisy or delayed engagement, makes a clicking sound and motor will not turn etc. Well, luckily there is a fix of some kind for all these problems. Before you spend your hard-earned dollars replacing parts, there are some things you should check.
  2. Make sure your carbs are adjusted properly. Too much fuel will flood the engine causing fouled plugs and too little fuel will create hard starting. Carbs that are out of sync will cause hard starts also. Use proper procedures when starting your engine. Many new Virago owners do not understand the importance of this and they either foul plugs or cause other staring problems. To start your Virago you: turn the choke on (cold starting only), make sure the bike is in neutral, turn the key to the on position, turn the kill switch to the on position, using one finger push the starter button. If your engine is tuned properly, it will start in less than three revolutions.
    DO NOT ROLL THE THROTTLE!!!! Be sure your charging system is to spec. Make sure the water/acid level is at the proper level. If you have an OHM meter and know how to use it, then check the charge rate as specified in your owner’s manual. A low battery can create all kinds of starting problems such as:
  3. The starter makes a rapid clicking noise when you push the starter button.
    (Low voltage will cause the starter relay not to engage the starter gear into the flywheel.)

    Symptom: Starter Motor Slippage (XV-920, XV-1000, XV-1100)
  4. The starter clutch located inside the left side cover is the worn part. It is designed to protect the engine from backfiring, when starting. This part eventually wears out and is relatively easy to replace. However, if you are not mechanically inclined, do not attempt this repair. Adding three shims, part number 156-11563-00, in the starter nose will take up any wear caused by prolonged use while this symptom existed.
  5. The XV-700’s and 750’s require a different repair because they do not have the starter clutch. Yamaha suggests changing the large tension clip, P/N 904-68291-06-00, on the idler gear. Look for wear in the clip groove. Hand grind smooth. Replace the idler gear also. A dealer would use a spring gauge to check the tension of the spring clip. It should be 4.9-5.1 lbs. per inch. If the groove is worn excessively, then install washer P/N 902-01356-68-00 between the idler gears. Again. I would not recommend this repair to a person who is not mechanically inclined.

Symptom: Delayed or Noisy Disengagement

Replace the idler gear compression spring, P/N 905-01156-36-00, and starter gear tension clip, P/N 904-68291-14-00. These parts are located inside the left side cover.

Starter Trouble Shooting Guide

Symptoms(S) Probable Cause(P) Remedy(R)

(S)Starter will not start

(P)Low battery

(R)Recharge battery
(P)Worn brushes

(R)Replace brushes
(P)Defective relay

(R)Repair or replace
(P)Defective switch

(R)Repair or replace
(P)Defective wiring

Virago

(R)Repair or replace
(P)Internal short circuit

(R)Repair or replace

(S)Starter action weak

(P)Low Battery

(R)Recharge Battery
(P)Pitted relay contacts

(R)Clean or replace relay
(P)Worn brushes

(R)Replace Brushes
(P)Defective connection

(R)Clean and tighten
(P)Short circuit in commutator

(R)Replace armature

(S)Starter runs continuously

83 Virago 500 Service Manual Transmission

(P)Stuck relay

(R)Replace relay
(P)Starter button sticks

(R)Clean and lubricate

(S)Starter turns but engine does not turn

(P)Defective starter clutch

83 Virago 500 Service Manual Download

(R)Replace starter clutch

  • Yamaha does not recommend welding the starter ring gear because if the engine should backfire you could do serious damage to the case. I know that this method of repair worked for many club members, but if locking-in the ring gear was a design requirement, I’m sure that Yamaha would have avoided this flaw.
  • In most cases using 3 or 4 shims will do the trick.

Bug Notes:

Yamaha
  • 1) When installing shims use a tacky substance to hold them in place and do not use adhesives.
  • 2) Always lubricate the housing o-ring before re-assembly or replace if stretched.
  • 3) Do not perform these repairs unless you are confident with your knowledge of motorcycles.
  • 4) Make sure your engine is tuned before challenging the starter.
  • 5) Check your charging system and battery prior to starter evaluation.

Compliments of BUG!

Copyright © BUG All Rights Reserved
Rev. 1/06

Note: This Tech Article was created from the VOC site data.(Virago Owners Club)

1983 yamaha virago 500 parts

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