1981–1984 Yamaha Virago XV750SE / XV750 Service & Repair Manual (P/N 5G5-000101)

• Covers the XV750SE 5G5 build, with frame and engine serial numbers starting at 5G5-000101, plus the XV750H 4X7 revision section (MS612, revised 4/81) starting at 4X7-000101.
• Documents full engine removal, disassembly, inspection, reassembly, and installation, including cylinder heads, valves, cam chains and timing gears, crankshaft and connecting rods, oil pump, clutch, transmission, starter, and crankcases.
• Covers middle-gear and shaft-drive repair through gear-lash diagnosis, final-drive removal and teardown, shim selection, collapsible-collar setup, drive-shaft inspection, assembly, and final adjustment.
• Details twin-carburetor service, fuel-level checks, synchronization, mixture-control-valve testing, crankcase-ventilation routing, air-cleaner service, and fuel-line inspection.
• Includes the XV750SE wiring diagram, starter and cut-off relay diagnosis, charging and TCI ignition tests, lighting and signal checks, plus exploded views, lubrication diagrams, cable routing, and component-specific specification tables.

Model and Publication Scope

This 475-page PDF contains a Yamaha Motor Company factory service publication centered on the air-cooled V-twin, shaft-drive XV750SE 5G5. The main manual is presented in English, French, and German, including its procedures, specification tables, diagram legends, and safety cautions. The model-identification pages give 5G5-000101 as the starting number for both the frame and engine, so coverage is anchored to the 5G5 production build rather than a blanket multi-year range.

The separate English-language XV750H section is identified in its footer as MS612, revised 4/81. It provides revised identification, special-tool information, maintenance schedules, specifications, torque tables, and model-specific exploded views for the 4X7 build.

Important scope distinction: The appended 5H1 section specifies a 920 cc engine and drive-chain chassis. It belongs to a separate model group and should not be used as additional 5G5/4X7 XV750 shaft-drive data.

Engine, Fuel-System, and Chassis Repair

The engine chapter covers both routine service and full overhaul. It maps removal of the seat, fuel tank, air filter, battery, exhaust, foot controls, wiring, and cables before the engine is taken from the frame. Teardown and inspection coverage then follows the cylinders and heads, pistons and rings, crankshaft and connecting rods, rocker arms, camshafts, cam chains, timing gears, flywheel, primary drive, clutch, shifter, transmission, starter motor, oil pump, crankcases, bearings, and oil seals.

Reassembly sections cover crankcase joining, transmission and clutch installation, cam timing, cylinder and head installation, carburetor and ignition-coil refitting, and final engine mounting. Related tables provide the tightening torques, clearances, wear limits, lubrication data, and inspection specifications required for those assemblies.

Fuel-system work includes a carburetor section view, component identification, jetting and fuel-level specifications, carburetor separation and disassembly, passage and diaphragm inspection, float-valve checks, reassembly, fuel-level adjustment, synchronization, and idle setup. The air-cleaner, crankcase-ventilation, and mixture-control-valve pages show vacuum-line routing and functional testing, useful when drivability symptoms come from hose routing or control-valve operation rather than internal carburetor wear.

Chassis coverage includes front and rear wheel and bearing service, rear drum-brake inspection, front brake pad, caliper, and master-cylinder repair, brake bleeding and fluid requirements, front-fork disassembly and seal service, steering-head adjustment, swingarm inspection, rear-shock setup, control cables, and tubeless tire and aluminum-wheel checks. Periodic service charts also cover engine and final-drive oil, fork oil, suspension air-pressure adjustment, brake-fluid replacement, and electrical checks.

Shaft Drive, Electrical Diagnosis, and Factory Reference Data

The shaft-drive material includes symptom-based troubleshooting for acceleration or deceleration noise and vibration; middle-gear lash measurement; final-drive removal; ring-and-pinion inspection; shim calculation; guide-collar and bearing service; final-drive assembly; and drive-shaft removal, inspection, and installation.

Yamaha special tools are identified with part numbers, including the middle/final gear holding tool (P/N 90890-01229), final-gear lash measurement tool (P/N 90890-01230), dial gauge (P/N 90890-03097), and final-drive bearing-retainer wrench (P/N 90890-04050).

Electrical coverage follows complete circuits rather than isolated component specifications: electric starting and interlock operation, starter motor and relays, charging-system output, AC generator and stator, voltage regulator and silicon rectifier, TCI ignition, pickup and ignition coils, lighting, signals, and the self-canceling flasher unit. Continuity charts, test diagrams, and fault-isolation flowcharts are paired with the XV750SE wiring diagram.

Key appendix drawings include the Cylinder Head/Valve, Transmission, Middle Gear, Final Gear/Drive Shaft, Front Brake Caliper, and Electrical Components exploded views. Separate lubrication, cable-routing, and color-code references support final assembly. The specification chapter consolidates engine, chassis, and electrical maintenance data, component-specific tightening torques, general torque guidance, capacities, clearances, wear limits, and electrical test values.

Shop Notes That Matter

The middle-gear procedure treats the collapsible collar as a one-use part; tightening past the lash target damages it and requires replacement. The carburetor diaphragm locating tab must sit in its body recess, or the diaphragm can be pinched and damaged under the cover. The brake-caliper section warns against prying out the piston because scoring the piston or bore can compromise the hydraulic seals.

Brake hydraulics, compressed-air piston removal, engine handling, and final-drive setup require proper support, protective equipment, and technician-level mechanical judgment. The manual assumes users already understand motorcycle repair fundamentals.