Deutsch English Click flag to select index language

XV750SE service manual


CHAPTER/TITLE SUBTITLE PAGES
Main Index   [Top of page]0‑a
 Introduction0‑b | 0‑c | 0‑d
 General Information1‑a
 Periodic Inspections and Adjustments2‑a | 2‑b
 Engine Overhaul3‑a | 3‑b
 Carburetion4‑a
 Chassis5‑a | 5‑b
 Electrical System6‑a | 6‑b
 Appendices7‑a
General Information   [Top of page]1‑a
Motorcycle Identification (A) Frame Serial Number1‑1
 (B) Engine Serial Number1‑2
Special Tools  1‑2
 (A) For Tune-up1‑3
 (B) For Engine Service1‑3 | 1‑4 | 1‑5 | 1‑6 | 1‑7 | 1‑8 | 1‑9
 (C) For Shaft Drive Service1‑10 | 1‑11 | 1‑12 | 1‑13 | 1‑14 | 1‑15 | 1‑16
 (D) For Cassis Service1‑17
 (E) For Electrical Components1‑18
Periodic Inspections and Adjustments   [Top of page]2‑a | 2‑b
Introduction  2‑1
Maintenance Interval Charts  2‑1 | 2‑2
[French]  2‑3 | 2‑4
[German] Maintenance Interval Charts  2‑5 | 2‑6
Engine (A) Valve Clearance2‑7 | 2‑8 | 2‑9
 (B) Spark Plug2‑10
 (C) Crankcase Ventilation System2‑11
 (D) Fuel Line2‑11
 (E) Exhaust System2‑11
 (F) Carburetor Synchronization2‑11 | 2‑12 | 2‑13
 (G) Idle Speed2‑14
 (H) Engine Oil2‑15 | 2‑16 | 2‑17 | 2‑18
 (I) Clutch Adjustment2‑19 | 2‑20
 (J) Checking Ignition Timing2‑21
 (K) Compression Pressure Measurements2‑22 | 2‑23
Chassis (A) Final Gear Oil2‑24
 (B) Air Filter2‑25
 (C) Front and Rear Brake2‑26 | 2‑27 | 2‑28
 (D) Cable Inspection and Lubrication2‑29
 (E) Brake, Change Pedals, Clutch Levers2‑30
 (F) Centerstand and Sidestand2‑30
 (G) Front Fork Oil Change2‑30 | 2‑31 | 2‑32 | 2‑33
 (H) Front Fork and Rear Shock Absorber Adjustment2‑34 | 2‑35 | 2‑36 | 2‑37
 (I) Steering Head Adjustment2‑38 | 2‑39
 (J) Wheel Bearings2‑40
 (K) Fuel Cock2‑41
 (L) Tires and Aluminum Wheels2‑42 | 2‑43 | 2‑44
Electrical (A) Battery2‑45 | 2‑46
 (B) Headlight2‑47 | 2‑48
 (C) Fuse2‑49
Engine Overhaul   [Top of page]3‑a | 3‑b
Engine Removal (A) Preparation for Removal3‑1
 (B) Seat and Fuel Tank Removal3‑2
 (C) Air Filter3‑2
 (D) Battery3‑3
 (E) Exhaust Pipes and Muffler3‑3
 (F) Brake Pedal, Footpegs and Muffler Brackets3‑4
 (G) Wires, Cables and Sidestand3‑5
 (H) Engine Removal3‑6
Engine Disassembly (A) Mixture Control Valve, Ignition Coils, Carburetors3‑7
 (B) Cylinder and Cylinder Head3‑8 | 3‑9 | 3‑10
 (C) Piston Pin and Piston3‑11
 (D) Crankcase Covers, Starter Drive, Starter Motor3‑12
 (E) Timing Gears3‑13
 (F) Flywheel3‑14 | 3‑15
 (G) Clutch and Primary Gears3‑16 | 3‑17
 (H) Shifter3‑18
 (I) Oil Pump3‑18
 (J) Crankcase3‑19 | 3‑20 | 3‑21
Inspection and Repair (A) Cylinder Head3‑22
 (B) Valves, Valve Guides, Valve Seats, Valve Springs3‑23 | 3‑24 | 3‑25 | 3‑26 | 3‑27 | 3‑28 | 3‑29 | 3‑30 | 3‑31 | 3‑32 | 3‑33 | 3‑34 | 3‑35
 (C) Rocker Arms and Rocker Arm Shafts3‑36
 (D) Camshafts, Cam Chains and Cam Sprockets3‑37 | 3‑38
 (E) Cylinder3‑39
 (F) Piston and Piston Rings3‑40 | 3‑41 | 3‑42 | 3‑43
 (G) Crankshaft and Connection Rod3‑44 | 3‑45 | 3‑46 | 3‑47
 (H) Oil Pump3‑48
 (I) Primary Drive3‑49
 (J) Clutch3‑50 | 3‑51 | 3‑52
 (K) Transmission3‑53 | 3‑54
 (L) Starter3‑55
 (M) Crankcase3‑56
 (N) Bearings and Oil Seals3‑57 | 3‑58
Engine Assembly and Adjustment (A) Important Information3‑59 | 3‑60
 (B) Left-Side Crankcase3‑61 | 3‑62 | 3‑63 | 3‑64 | 3‑65 | 3‑66 | 3‑67 | 3‑68 | 3‑69
 (C) Right-Side Crankcase3‑70 | 3‑71
 (D) Crankcase Assembly3‑72 | 3‑73
 (E) Oil Pump3‑74 | 3‑75
 (F) Shifter3‑76 | 3‑77
 (G) Primary Gears and Clutch3‑78 | 3‑79 | 3‑80 | 3‑81 | 3‑82 | 3‑83
 (H) Flywheel3‑84 | 3‑85 | 3‑86
 (I) Timing Gears3‑87 | 3‑88 | 3‑89 | 3‑90 | 3‑91
 (J) Starter Motor, Starter Drive, Crankcase Cover3‑92 | 3‑93 | 3‑94 | 3‑95 | 3‑96
 (K) Pistons, Cam Chain Guides and Cylinders3‑97 | 3‑98 | 3‑99 | 3‑100
 (L) Cylinder Head, Rocker Arm and Camshaft3‑101 | 3‑102 | 3‑103 | 3‑104 | 3‑105 | 3‑106 | 3‑107 | 3‑108 | 3‑109 | 3‑110 | 3‑111 | 3‑112 | 3‑113
 (M) Carburetors, Ignition Coils, Mixture Control Valve3‑114 | 3‑115
 (N) Mounting the Engine3‑116 | 3‑117 | 3‑118 | 3‑119 | 3‑120 | 3‑121 | 3‑122 | 3‑123
Middle Gear Service  3‑124
 (A) Gear Lash Adjustment3‑125
 (B) Removal3‑126
 (C) Disassembly3‑126 | 3‑127 | 3‑128
 (D) Inspection3‑129
 (E) Assembly and Adjustment3‑129 | 3‑130 | 3‑131 | 3‑132 | 3‑133 | 3‑134 | 3‑135 | 3‑136 | 3‑137
Carburetion   [Top of page]4‑a
Carburetor  4‑1
 (A) Section View4‑2
 (B) Specifications4‑2
 (C) Disassembly4‑3 | 4‑4 | 4‑5
 (D) Inspection4‑6
 (E) Assembly4‑7
 (F) Adjustment4‑7 | 4‑8 | 4‑9
Air Cleaner, Crankcase Ventilation System  4‑10
Mixture Control Valve (A) Vacuum Line Routing4‑11
 (B) Inspection4‑11 | 4‑12
Chassis   [Top of page]5‑a | 5‑b
Front Wheel (A) Removal5‑1
 (B) Front Axle Inspection5‑2
 (C) Front Wheel Inspection5‑2
 (D) Replacing the Wheel Bearings5‑3
 (E) Installing the Front Wheel5‑4
Rear Wheel (A) Removal5‑5
 (B) Checking Brake Shoe Wear5‑6
 (C) Brake Drum5‑7
 (D) Brake Shoe Plate5‑7
 (E) Rear Axle Inspection5‑8
 (F) Replacing the Wheel Bearings5‑8
 (G) Rear Wheel Inspection5‑8
 (H) Installing the Rear Wheel5‑8
Front Brake  5‑9
 (A) Brake Pad Replacement5‑10
 (B) Caliper Disassembly5‑11
 (C) Master Cylinder Disassembly5‑12
 (D) Brake Inspection and Repair5‑13 | 5‑14
 (E) Brake Assembly5‑15 | 5‑16 | 5‑17 | 5‑18
Front Fork  5‑19
 (A) Removal and Disassembly5‑20 | 5‑21
 (B) Inspection5‑22
 (C) Assembly5‑23
Steering Head  5‑24
 (A) Adjustment5‑25
 (B) Removal5‑25 | 5‑26
 (C) Inspection5‑27
 (D) Assembly5‑27 | 5‑28
Swingarm  5‑29
 (A) Free Play Inspection5‑30
 (B) Removal5‑30
 (C) Inspection and Lubrication5‑31 | 5‑32
 (D) Assembly5‑33
Rear Shock Absorber  5‑34
 (A) Removal5‑35
 (B) Inspection5‑36
 (C) Installation and Adjustment5‑37
Cable and Fittings (A) Cable Maintenance5‑37
 (B) Throttle Maintenance5‑38 | 5‑39
Shaft Drive (A) Troubleshooting5‑40 | 5‑41 | 5‑42 | 5‑43 | 5‑44 | 5‑45 | 5‑46
 (B) Final Gear Removal5‑47
 (C) Gear Lash Check and Adjustment5‑47 | 5‑48
 (D) Final Gear Disassembly5‑49 | 5‑50 | 5‑51
 (E) Final Gear Assembly5‑52 | 5‑53 | 5‑54 | 5‑55 | 5‑56 | 5‑57 | 5‑58
Drive Shaft (A) Removal5‑59
 (B) Inspection5‑59
 (C) Installation5‑60
Electrical System   [Top of page]6‑a | 6‑b
XV750SE Wiring Diagram  6‑2 | 6‑3
Electric Starting System  6‑4 | 6‑5
Starting Circuit Operation  6‑6 | 6‑7
Starter Motor  6‑8
 (A) Removal6‑9
 (B) Inspection and Repair6‑9 | 6‑10
Starter Relay (A) Inspection6‑11
Starting-Circuit Cut-Off Relay (A) Inspection6‑12 | 6‑13
Starter Cut-Out Relay (A) Inspection6‑14 | 6‑15
Charging System  6‑16 | 6‑17
AC Generator and Voltage Regulator (A) Inspection6‑18
 (B) Battery Inspection6‑19
 (C) Stator Coil Inspection6‑19
 (D) Checking the Silicon Rectifier6‑20 | 6‑21
Ignition System  6‑22 | 6‑23
 (A) Description6‑24
 (B) Operation6‑24 | 6‑25
 (C) Troubleshooting6‑26 | 6‑27 | 6‑28 | 6‑29 | 6‑30 | 6‑31 | 6‑32
Lighting System  6‑34 | 6‑35
 (A) Lighting Tests and Checks6‑36 | 6‑37
Signal System  6‑38 | 6‑39
 (A) Signal System Tests and Checks6‑40 | 6‑41
 (B) Flasher Self-Cancelling Unit6‑42 | 6‑43
 (C) Switches6‑44 | 6‑45
 (D) Battery6‑46 | 6‑47
Appendices   [Top of page]7‑a
Specifications (A) General Specifications7‑1 | 7‑2 | 7‑3 | 7‑4 | 7‑5 | 7‑6 | 7‑7 | 7‑8 | 7‑9 | 7‑10
 (B) Chassis7‑11 | 7‑12 | 7‑13 | 7‑14
Tightening Torque  7‑15 | 7‑16 | 7‑17
General Torque Specifications  7‑17
Color Codes  7‑17
[French]  7‑18 | 7‑19 | 7‑20 | 7‑21 | 7‑22 | 7‑23 | 7‑24 | 7‑25 | 7‑26 | 7‑27 | 7‑28 | 7‑29 | 7‑30 | 7‑31 | 7‑32 | 7‑33 | 7‑34
[German] Specifications (A) General Specifications7‑35 | 7‑36 | 7‑37 | 7‑38 | 7‑39 | 7‑40 | 7‑41 | 7‑42 | 7‑43 | 7‑44
 (B) Chassis7‑45 | 7‑46 | 7‑47 | 7‑48
[German] Tightening Torque  7‑49 | 7‑50 | 7‑51
[German] General Torque Specifications  7‑51
[German] Color Codes  7‑51
Exploded Diagrams Cylinder Head/Valve7‑52
 Cam Chain7‑53
 Crankshaft/Connection Rod/Piston7‑54
 Transmission7‑55
 Middle Gear7‑56
 Frame7‑57
 Front Wheel7‑58
 Front Fork7‑59
 Front Brake Caliper7‑60
 Rear Wheel/Rear Brake7‑61
 Rear Shock Absorber7‑62
 Swingarm7‑63
 Final Gear/Drive Shaft7‑64
 Electrical Components7‑65 | 7‑66
Lubrication Diagrams  7‑67 | 7‑68 | 7‑69
Cable Routing  7‑70 | 7‑71 | 7‑72
Wiring Diagram  7‑73 | 7‑74