Yamaha Virago XV500K 1983–1984 Service Manual (P/N LIT-11616-03-51)

This Yamaha factory service manual covers the Virago XV500K (22U). Yamaha first issued the manual (P/N LIT-11616-03-51) in December 1982. This copy is the fourth printing, dated April 1986.

Printable Manual and Wiring Diagram

Both PDFs can be printed. Text search and PDF bookmarks are unavailable in both files. Small connector labels and wire-color codes are readable when enlarged. The separate landscape sheet lets you view the full wiring diagram without rotating the manual page.

The ZIP contains 209 PDF pages in two files: a 208-page service manual, including its covers, appendices, and one page of handwritten notes, plus a one-page landscape copy of the XV500K wiring diagram.

XV500K Workshop Coverage

These selected workshop topics show the range of procedures and reference data in the manual.

• Engine overhaul: Engine removal and installation, cylinder-head and valve work, cam-chain timing, piston and cylinder inspection, crankcase and bearing service, oil pump, clutch, transmission, and starter drive.
• Shaft drive: Middle-gear and final-drive troubleshooting, gear-lash measurement, shim selection, universal-joint and damper service, drive-shaft inspection, and final-drive assembly.
• Fuel and induction: Paired Mikuni BDS34 carburetors, front and rear calibration, fuel-level and synchronization checks, coasting enricher, fuel pump, and Y.I.C.S. and vacuum-line routing.
• Chassis and brakes: Wheel bearings, rear drum brake, front caliper and master cylinder, brake bleeding, fork seals, steering-head bearings, rear shocks, and swingarm adjustment.
• Electrical diagnosis: Starting and cut-off circuits, charging, T.C.I. ignition, lighting, and signals, with system diagrams and component tests.
• Shop references: Special-tool part numbers, tightening torques, wear limits, exploded views, lubrication diagrams, and cable-routing drawings.

Yamaha wrote this manual for dealer mechanics. It also suits experienced owners equipped for precision measurements, bearing work, carburetor synchronization, and electrical testing.

Engine Bearings, Timing, and Shaft Drive

The engine chapter pairs inspection procedures with service limits for valves and guides, camshafts, cylinders, pistons and rings, the crankshaft, and connecting rods. It covers crankcase main-bearing sizing, connecting-rod bearing color codes, Plastigage checks, and the press tooling for plain bearings. The sizing tables help you use the inspection results to select replacement bearings.

The front and rear cylinders have different camshaft indexing and cam-chain positions. The assembly notes also distinguish cylinder hardware, the rear-cylinder oil baffle, cam-sprocket covers, and intake and vacuum connections. The flywheel section flags the risk of distorting the starter clutch with puller bolts.

The drive chapters show how gear and housing markings relate to shim selection. They also cover thrust-clearance checks and final-drive leak diagnosis, with exploded views of the middle gear and final gear and drive shaft.

Carburetor and Fuel-Pump Service

A cross-section of the paired carburetors shows the vacuum pistons and diaphragms. The manual distinguishes front and rear jetting and covers floats, needle valves, and fuel-pump diaphragms and valves. The coasting-enricher section explains its role in limiting afterburn. Periodic-service coverage includes idle adjustment, ignition-timing checks, and compression testing.

Brakes and Suspension

The chassis chapter covers front-brake hydraulic overhaul, fork disassembly, and swingarm side-clearance setup. Rear-shock coverage includes removal, inspection, disposal, installation, and preload adjustment. Yamaha specifies replacement for an internally leaking shock. Detailed tubeless tire and aluminum wheel service is referred to a separate Yamaha manual, which is sold separately from this download.

Electrical Tests and Circuit Diagrams

Dedicated starting and ignition diagrams complement the full wiring schematic. Component tests cover the starter motor and relay, sidestand and clutch interlocks, stator, regulator/rectifier, pickup and ignition coils, switches, flasher relay, and self-canceling turn-signal unit. The separate schematic lets you keep the harness layout in view while following a component test in the manual.

Sample Settings for Gear Lash and Drain-Plug Torque

The shaft-drive chapter specifies 0.1–0.2 mm (0.004–0.008 in) of middle-gear lash, checked at four positions of the drive yoke. The periodic oil-change section specifies 43 N·m (31 ft-lb) for the engine oil drain plug.