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Yamaha XV920 Virago Manual

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8A-18
Chapter 8 Part A Electrical system (XV535 models)
29.3a Compress the pin and spring (A)
and remove the roller (B)...
29.3b ... then remove the pin and spring
from their bore
29.6 Press the pin and spring into their
bore with a pointed tool and install
the roller
30.2 Free the wiring harness and hose, remove the screws and
remove the fuel tap (1) from the tank
2 Place the large starter driven gear in the starter clutch and try to
turn it. It should turn freely in one direction and not at all in the other. If
it turns both ways or neither way, remove the idler gear and
disassemble the starter clutch for inspection.
3 Compress the pin against its internal spring with a pointed tool
and take out the roller (see illustration). Remove the pin and spring
(see illustration).
4 Remove the remaining two pins, rollers and springs in the same
way.
5 Check all parts for wear and damage and replace parts with these
conditions. If the starter clutch needs to be replaced, unstake the ends
of its three bolts inside the alternator rotor and unscrew them to
separate the starter clutch body from the rotor. Position the new
starter clutch on the rotor and apply non-permanent thread locking
agent to the threads of the bolts. Install the bolts, tighten them to the
torque listed in this Chapter's Specifications and stake their ends on
the inside of the rotor.
6 Position the spring inside one of the pins. Place the spring and pin
in their bore, compress the pin against the spring with a pointed tool
(see illustration) and install the roller.
7 Install the remaining springs, pins and rollers in the same way.
8 The remainder of installation is the reverse of the removal steps.
When installing the starter driven gear, don't forget to install the thrust
washer first (see illustration 28.11c).
30 Fuel tap solenoid (1989 and later models) - removal,
testing and installation
Refer to illustration 30.2
1 Remove the main fuel tank (see Chapter 3). Pour the fuel into an
approved container.
2 Free the wiring harness and hose from their clips, remove the
screws and detach the fuel tap from the tank (see illustration).
3 Disconnect the hose from the fuel nozzle and connect a length of
clean rubber hose in its place.
4 Turn the fuel tap lever to On and try to blow air into the hose. It
should go through. If it doesn't, replace the fuel tap.
5 Connect a 12
l
volt battery (the motorcycle's battery will work) to
the solenoid wire terminals (positive to black/yellow; negative to black.
Try to blow air into the hose again. It shouldn't be possible with the
battery connected to the solenoid. If air willgo through, replace the
solenoid.
31 Carburetor heater (1994 UK models) - testing
1 Follow the wiring harness from the heater unit at the carburetor
assembly to the thermoswitch (it can be identified by its wire color).
Remove the thermoswitch from the wiring harness.
2 Immerse the thermoswitch in a container of water (suspend it so it
doesn't touch the sides or bottom of the container).
3 Connect an ohmmeter to the thermoswitch wires and heat the
water. Note the ohmmeter readings as the water heats, then cools
down.
a) Zero to 17+1- 5-degrees C (32 to 63 +/- 9-degrees F) -
continuity (little or no resistance)
b) 17 +/- 5 to 70-degrees C (63 +/- 9 to 158-degrees F) -
no continuity (infinite resistance)
c) 70 to 11 +/- 3-degrees C (158 to 52 +/- 5-degrees F) -
no continuity
d) Less than 11 +/- 3-degrees C (52 +/- 5-degrees F) - continuity
4 If the thermoswitch doesn't give the readings described, replace
it.
5 Disconnect the wiring from the heater unit at the carburetor
assembly. Connect an ohmmeter to the terminal on the heater unit
note the reading and compare it to the value listed in this Chapter's
Specifications. If the resistance reading is not with the specified range
replace the heater unit.
32 Wiring diagrams
Prior to troubleshooting a circuit, check the fuses to make sure
they're in good condition. Make sure the battery is fully charged and
check the cable connections.
When checking a circuit, make sure all connectors are clean, with
no broken or loose terminals or wires. When unplugging a connector
don't pull on the wires - pull only on the connector housings
themselves.
Refer to the table in Chapter 9 for the wire color codes.
… 321 …


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