Yamaha XV535 through 1100 Owners Workshop Manual by Alan Ahlstrand and John H Haynes Member of the Guild of Motoring Writers Models covered: USA: Yamaha XV535 Virago. 535cc. 1987 through 1990 and 1993 through 1994 Yamaha XV535S Virago. 535cc. 1994 Yamaha XV700 Virago. 699cc. 1984 through 1987 Yamaha XV750 Virago. 748cc. 1981 through 1983 and 1988 through 1994 Yamaha XV920 Virago. 920cc. 1982 and 1983 Yamaha XV920R (chain drive). 920cc. 1981 and 1982 Yamaha XV1000 Virago. 981 cc.
Acknowledgements Our thanks to Mitsui Machinery Sales (UK) Ltd for permission to reproduce certain illustrations used in this manual. We would also like to thank NGK Spark Plugs (UK) Ltd for supplying the color spark plug condition photos and the Avon Rubber Company for supplying information on tire fitting.
Contents Introductory pages About this manual Introduction to the Yamaha XV Identification numbers Buying parts General specifications Maintenance techniques, tools and working facilities Safety first! Motorcycle chemicals and lubricants Troubleshooting Chapter 1 Tune-up and routine maintenance 0-6 0-6 0-7 0-8 0-8 0-11 0-17 0-18 0-19 1-1 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 2A-1 Chapter 2 Part B Engine, clutch and transmission (XV700 through 1100 models) 2B-1 Chapter 3 Part
0-4 Yamaha XV The 1994 XV535S model The 1985 XV700 Virago model
Yamaha XV The TR1 model The 1994 XV1100 Virago model 0-5
0-6 About this manual Its purpose The purpose of this manual is to help you get the best value from your motorcycle. It can do so in several ways. It can help you decide what work must be done, even if you choose to have it done by a dealer service department or a repair shop; it provides information and procedures for routine maintenance and servicing; and it offers diagnostic and repair procedures to follow when trouble occurs. We hope you use the manual to tackle the work yourself.
0-7 Identification numbers The frame serial number is stamped into the right side of the frame and printed on a label affixed to the frame. The engine number is stamped into the right upper side of the crankcase. Both of these numbers should be recorded and kept in a safe place so they can be furnished to law enforcement officials in the event of a theft.
0-8 Buying parts Once you have found all the identification numbers, record them for reference when buying parts. Since the manufacturers change specifications, parts and vendors (companies that manufacture various components on the machine), providing the ID numbers is the only way to be reasonably sure that you are buying the correct parts. Whenever possible, take the worn part to the dealer so direct comparison with the new component can be made.
General specifications 1989-on UK models Wheelbase Overall length Overall width Flat handlebar Upright handlebar Overall height Flat handlebar Upright handlebar Seat height Ground clearance (minimum) Weight (with oil and full fuel tank) 1520 mm (59.8 inches) 2285 mm (90.0 inches) 725 mm (88.6 inches) 810 mm (31.9 inches) 1070 mm (42.1 inches) 1110 mm (43.7 inches) 720 mm (28.3 inches) 160 mm (6.
0-10 General specifications XV920 K and MK models Wheelbase Overall length Overall width Overall height Seat height Ground clearance (minimum) Weight 1520 mm (59.8 inches) 2230 mm (87.8 inches) 805 mm (31.7 inches) 1160 mm (45.7 inches) Not specified 145 mm (5.7 inches) 235 kg (518 lbs) XV920 RH and RJ models Wheelbase Overall length Overall width Overall height Seat height Ground clearance (minimum) Weight 1540 mm (60.6 inches) 2260 mm (89.0 inches) 930 mm (36.6 inches) 1170 mm (46.
0-11 Maintenance techniques, tools and working facilities Basic maintenance techniques There are a number of techniques involved in maintenance and repair that will be referred to throughout this manual. Application of these techniques will enable the amateur mechanic to be more efficient, better organized and capable of performing the various tasks properly, which will ensure that the repair job is thorough and complete.
0-12 Maintenance techniques, tools and working facilities Spark plug gap adjusting tool Feeler gauge set Control cable pressure luber Hand impact screwdriver and bits If a hose clamp is broken or damaged, do not reuse it. Also, do not reuse hoses that are cracked, split or torn. Tools Torque wrenches (left - click type; right - beam type) A selection of good tools is a basic requirement for anyone who plans to maintain and repair a motorcycle.
Maintenance techniques, tools and working facilities Snap-ring pliers (top - external; bottom - internal) Allen wrenches (left) and Allen head sockets (right) Valve spring compressor Piston ring removal/installation tool Piston pin puller Telescoping gauges 0-13
0-14 Maintenance techniques, tools and working facilities 0-to1-inch micrometer Cylinder surfacing hone Cylinder compression gauge Dial indicator set Multimeter (volt/ohm/ammeter) Adjustable spanner
Maintenance techniques, tools and working facilities Maintenance and minor repair tool kit The tools in this list should be considered the minimum required for performance of routine maintenance, servicing and minor repair work. We recommend the purchase of combination wrenches (box end and open end combined in one wrench); while more expensive than open-ended ones, they offer the advantages of both types of wrench.
0-16 Maintenance techniques, tools and working facilities Working facilities Not to be overlooked when discussing tools is the workshop. If anything more than routine maintenance is to be carried out, some sort of suitable work area is essential.
0-17 Safety first Professional mechanics are trained in safe working procedures. However enthusiastic you may be about getting on with the job at hand, take the time to ensure that your safety is not put at risk. A moment's lack of attention can result in an accident, as can failure to observe simple precautions.
Motorcycle chemicals and lubricants A number of chemicals and lubricants are available for use in motorcycle maintenance and repair. They include a wide variety of products ranging from cleaning solvents and degreasers to lubricants and protective sprays for rubber, plastic and vinyl. Contact point/spark plug cleaner is a solvent used to clean oily film and dirt from points, grime from electrical connectors and oil deposits from spark plugs. It is oil free and leaves no residue.
0-19 Troubleshooting Contents Symptom Section Engine doesn't start or is difficult to start Starter motor doesn't rotate... Starter motor rotates but engine does not turn over Starter works but engine won't turn over (seized) No fuel flow .
0-20 Troubleshooting Engine d o e s n ' t start or is difficult to start 1 Starter motor does not rotate 1 Engine kill switch Off. 2 Fuse blown. Check fuse block (Chapter 8). 3 Battery voltage low. Check and recharge battery (Chapter 8). 4 Starter motor defective. Make sure the wiring to the starter is secure. Test starter relay (Chapter 8). If the relay is good, then the fault is in the wiring or motor. 5 Starter relay faulty. Check it according to the procedure in Chapter 8.
Troubleshooting 7 Cylinder head gasket damaged. If one of the heads is allowed to become loose, or if excessive carbon build-up on a piston crown and combustion chamber causes extremely high compression, the head gasket may leak. Retorquing the head is not always sufficient to restore the seal, so gasket replacement is necessary (Chapter 2). 8 Cylinder head warped. This is caused by overheating or improperly tightened head nuts and bolts.
0-22 Troubleshooting 5 Brakes dragging. Usually caused by debris which has entered the brake piston sealing boot, or from a warped disc or bent axle. Repair as necessary (Chapter 6). Poor running or no p o w e r at high s p e e d 14 Firing incorrect 1 Air filter restricted. Clean or replace filter (Chapter 1). 2 Spark plug fouled, defective or worn out. See Chapter 1 for spark plug maintenance. 3 Spark plug cap or secondary (HT) wiring defective. See Chapters 1 and 4 for details of the ignition system.
Troubleshooting that will dissolve the adhesive bonding the carbon particles to the piston crowns and chambers is the easiest way to remove the buildup. Otherwise, the cylinder heads will have to be removed and decarbonized (Chapter 2). 0-23 pressure. Replace cam, bushing or cylinder head. Abnormal wear could be caused by oil starvation at high rpm from low oil level or improper viscosity or type of oil (Chapter 1). 4 Crankshaft and/or bearings worn. Same problems as paragraph 3.
0-24 Troubleshooting 3 Gear(s) stuck on shaft. Most often caused by a lack of lubrication or excessive wear in transmission bearings and bushings. Overhaul the transmission (Chapter 2). 4 Shift cam binding. Caused by lubrication failure or excessive wear. Replace the cam and bearing (Chapter 2). 5 Shift lever return spring weak or broken (Chapter 2). 6 Shift lever broken. Splines stripped out of lever or shaft, caused by allowing the lever to get loose or from dropping the machine.
Troubleshooting A b n o r m a l f r a m e a n d suspension noise 38 Front end noise 1 Low fluid level or improper viscosity oil in forks. This can sound like spurting and is usually accompanied by irregular fork action (Chapter 5). 2 Spring weak or broken. Makes a clicking or scraping sound. Fork oil, when drained, will have a lot of metal particles in it (Chapter 5). 3 Steering head bearings loose or damaged. Clicks when braking. Check and adjust or replace as necessary (Chapter 5).
0-26 Troubleshooting hard from age or being washed out by high pressure car washes. Disassemble steering head and repack bearings (Chapter 5). 5 Steering stem bent. Caused by a collision, hitting a pothole or by dropping the machine. Replace damaged part. Don't try to straighten the steering stem (Chapter 5). 6 Front tire air pressure too low (Chapter 1). 47 Handlebar shakes or vibrates excessively 1 Tires worn or out of balance (Chapter 1 or 6). 2 Swingarm bearings worn.
1-1 Chapter 1 Tune-up and routine maintenance Contents Section Air filter element - servicing 14 Battery electrolyte level/specific gravity - check 4 Brake lever and pedal position and play - check and adjustment.
1-2 Chapter 1 Tune-up and routine maintenance Specifications XV535 Engine Spark plugs Type Gap Valve clearances (COLD engine) Intake Exhaust Engine idle speed Cylinder compression pressure (at sea level) Standard Maximum... Minimum Maximum difference between cylinders Carburetor synchronization Vacuum at idle speed Maximum vacuum difference between cylinders Cylinder numbering (from rear to front of bike)... NGK BP7ES or ND W22EP-U 0.7 to 0.8 mm (0.028 to 0.032 inch) 0.07 to 0.12 mm (0.003 to 0.
Chapter 1 Tune-up and routine maintenance Viscosity Consistently below 15 degrees C (60 degrees F) Consistently above 5 degrees C (40 degrees F) Capacity With filter change Oil change only Brake fluid .. Final gear Type Capacity Wheel bearings Swingarm pivot bearings . Cables and lever pivots Sidestand/centerstand pivots Brake pedal/shift lever pivots Throttle grip 'In the UK, tread depth must be at least 1 mm over 3/4 of the tread breadth SAE 10W30 SAE 20W40 2.8 liters (3.0 US qt, 5.0 Imperial pt) 2.
1-4 Chapter 1 Tune-up and routine maintenance Tire pressures (cold) (continued) XV920RH and RJ Front Up to 90 kg (198 lbs) load 90 to 213 kg (198 to 470 lbs) load High speed riding Rear Up to 90 kg (198 lbs) 90 to 213 kg (198 to 470 lbs) High speed riding 1.79 Bars (26 psi) 1.93 Bars (28 psi) 1.93 Bars (28 psi) 1.93 Bars (28 psi) 2.20 bars (32 psi) 2.
Chapter 1 Tune-up and routine maintenance Cylinder compression pressure (at sea level) Standard Maximum Minimum . Maximum difference between cylinders Carburetor synchronization Vacuum at idle speed Maximum vacuum difference between cylinders Engine idle speed Cylinder numbering (from rear to front of bike) 10.75 Bars (156 psi) 11.78 Bars (171 psi) 8.8 Bars (128 psi) 0.96 Bars (14 psi) 180 +/-10 mm Hg (7.09 +/- 0.4 inch Hg) 10 mm Hg (0.
1-6 Chapter 1 Tune-up and routine maintenance 1 Yamaha XV Routine maintenance intervals Routine maintenance intervals Note: The pre-ride inspection outlined in the owner's manual covers checks and maintenance that should be carried out on a daily basis. It's condensed and included here to remind you of its importance. Always perform the pre-ride inspection at every maintenance interval (in addition to the procedures listed).
Chapter 1 Tune-up and routine maintenance 2.3a Decals at various locations on the motorcycle include such information as tire pressures . . . 2.3b . . . special precautions for airadjustable front forks . . . 3.3a Check the oil level in the window (this is an XV535)... 2 Introduction to tune-up and routine maintenance Refer to illustrations 2.3a, 2.3b and 2.3c This Chapter covers in detail the checks and procedures necessary for the tune-up and routine maintenance of your motorcycle.
1-8 Chapter 1 Tune-up and routine maintenance 3.4a Remove the filler plug (arrow)... 3.4b . . . and add oil to bring up the level in the window 3.7 Brake fluid should be above the Lower line in the window 3.9 To add fluid, remove the cover screws (arrows) and lift off the cover and diaphragm 4.4a Unclip the fuel hoses and move them aside . . . 4.4b . . .
Chapter 1 Tune-up and routine maintenance 4.5a Pull back the plastic caps (arrows) and undo the terminal screws (negative first, then positive) 4.5b Lift the battery out 1-9 4.5c The electrolyte level should be between the marks on the battery case 4.8 Check the specific gravity with a hydrometer 5.2 The caliper on chain drive models has a pad inspection window illustration).
1-10 Chapter 1 Tune-up and routine maintenance 5.3 If the raised corner of the pad backing metal (arrow) is close to the disc, the pad is worn and the full set of pads must be replaced (pad removed for clarity) 5.6 If the pointer is near the end of its travel with the brake pedal depressed, replace the shoes 3 On models so equipped, remove the pad cover (see illustration 2.9a in Chapter 6, Part B). Reach up and operate the brake lever while you look at the back of the caliper.
Chapter 1 Tune-up and routine maintenance 7.2 Loosen the locknut and turn the screw to change brake lever freeplay 7.4a Loosen the locknut and turn the bolt to change brake pedal freeplay (this is an X V 9 2 0 ) . . . 8.4 Check tire pressures with an accurate gauge 8 Tires/wheels - general check Refer to illustration 8.4 Routine tire and wheel checks should be made with the realization that your safety depends to a great extent on their condition.
1-12 Chapter 1 Tune-up and routine maintenance 10.3 Normal clutch cable adjustments are made at the handlebar - loosen the clutch cable lockwheel (left arrow) and turn the adjuster (right arrow); tighten the lockwheel after adjustment 9.9 Loosen the locknuts and adjust the accelerator and decelerator cables 1 2 Accelerator cable Decelerator cable 3 4 Locknuts Throttle pulley 6 If you're working on an XV535 model, remove the upper fuel tank (see Chapter 3) or the top cover (see Chapter 7).
Chapter 1 Tune-up and routine maintenance 10.8 The XV700 through 1100 can be adjusted with a screw on the side of the engine 11.3 Look through the viewing hole to measure chain slack 1-13 11.8 Remove the cotter pin and loosen the axle nut; the vertical lines in the frame below the nut are used for chain adjustment Do this every inch or so along the chain until you find the tightest point.
1-14 Chapter 1 Tune-up and routine maintenance 12.3 Remove the filler plug to check final drive oil level 12.4a The oil should be even with the top of the filler hole 12.4b Add oil through the filler hole in this Chapter's Specifications with a funnel or hose (see illustration), then reinstall the filler plug and tighten it to the torque listed in this Chapter's Specifications. Oil change 12.7a Remove the drain plug , Refer to illustrations 12.7a and 12.
Chapter 1 Tune-up and routine maintenance 1-15 13.4a The oil drain plug (arrow) is located on the left side of the engine (XV535 shown; others similar) 13.4b Loosen the drain plug with a socket... 13.4c . . . and let the oil drain into a pan 13.5a On XV535 models, remove the Allen bolts (arrows) . . . 13.5b . . . and remove the cover 13.5c On XV700 through 1100 models, remove the Allen bolts (arrows)... 13.6a . . . and remove the cover together with its two O-rings 13.
1-16 Chapter 1 Tune-up and routine maintenance 13.13 Make sure the washer is in position on the inner end of the filter element 14.2 Remove the screw (1), then lift the housing cover 14.5b . . . be careful not to lose the spacer tubes and washers 7 If you're working on an XV535 model, remove the O-ring from its groove in the cover (see illustration).
Chapter 1 Tune-up and routine maintenance 1-17 14.6 Separate the housing halves and take the filter element out 14.7a Check the seal between the filter housing and the frame . . . 14.7b . . . and the seals inside the filter housing; replace them if they're deteriorated or brittle 14.9 Loosen the clamp bolt and remove the Allen bolts, then detach the air filter case from the motorcycle 14.10a Remove the cover from the inside of the case 14.
1-18 Chapter 1 Tune-up and routine maintenance 16.2 On XV535 models, remove the Allen bolts and lift off the cylinder head side covers 16.3a Twist and pull the spark plug caps to detach them from the plugs . . . 16.3b . . . check the rubber seals for brittleness and the plastic for cracks 16.3c The spark plugs are inside wells in the cylinder heads, so you'll need a socket with a rubber insert to grip the plug 16.
For a COLOR version of this spark plug diagnosis page, please see the inside rear cover of this manual CARBON DEPOSITS NORMAL Symptoms: Dry sooty deposits indicate a rich mixture or weak ignition. Causes misfiring, hard starting and hesitation. Recommendation: Check for a clogged air cleaner, high float level, sticky choke and worn ignition points. Use a spark plug with a longer core nose for greater anti-fouling protection. Symptoms: Brown to grayishtan color and slight electrode wear.
1-20 Chapter 1 Tune-up and routine maintenance 17.2a Lubricate the brake pedal pivot... 17.2b . . . the footpeg and shift linkage pivots (arrows) - XV1100 shown . . . 17.2c . . . and the brake and clutch lever pivots (brake lever shown; clutch lever similar) 17.3a Lubricating a cable with a pressure lube adapter (make sure the tool seats around the inner cable) 8 Since the cylinder head is made of aluminum, which is soft and easily damaged, thread the plugs into the heads by hand.
Chapter 1 Tune-up and routine maintenance 18.7a Remove the cover bolts (arrows)... 18.7b . . . and lift the cover off 1-21 18.8 Unscrew the timing plug (upper arrow) and the crankcase cover plate (lower arrow) 18.9b XV535 timing marks 1 2 3 Rear cylinder top dead center mark Frornt cylinder firing range mark Front cylinder top dead center mark 18.
1-22 Chapter 1 Tune-up and routine maintenance 18.14 The single line on the edge of the alternator rotor is the top dead center mark for the front cylinder 18.22 Lift off the rocker cover 18.23 Remove the crankcase outer cover 18.24b XV700 through 1100 timing marks 1 2 3 Rear cylinder top dead center mark Front cylinder top dead center mark Rear cylinder firing range mark XV700 through 1000 models 18.
Chapter 1 Tune-up and routine maintenance 19.3 Turn the throttle stop screw to set idle speed (1981 through 1987 XV700 through 1100 shown; XV535 and 1988-on XV750 and 1100 similar) 20.7 Remove the rubber caps and connect the vacuum gauges or manometer to the fittings (A); turn the synchronizing screw (B) to obtain even vacuum readings (XV535 shown; others similar) back-and-forth and see if the idle speed changes as this is done.
1-24 Chapter 1 Tune-up and routine maintenance 23.10 Remove the steering stem bolt and lift off the upper triple clamp 23.11 Turn the ring nut to adjust steering head bearing play 23.17 Loosen the upper ring nut and adjust steering head bearing play with the lower ring nut All models Check 19 Start the engine and let it run until it reaches normal operating temperature. 20 Make sure there are no leaks in the vacuum gauge or manometer setup, as false readings will result.
Chapter 1 Tune-up and routine maintenance 25.6 The fuel tap is secured to the tank by two screws 25.7 Examine and clean the filter stack 17 Beneath the upper triple clamp are two ring nuts (see illustration). Loosen the upper one with a spanner wrench (C-spanner) so the lower nut is free to turn. 18 Tighten the lower ring nut a little at a time just enough to remove any front-to-rear play in the steering head. Caution: Don't overtighten the nut.
1-26 Chapter 1 Tune-up and routine maintenance 25.11 Loosen the clamp and disconnect the hose at each end of the filter, then remove it from its bracket 27.4 Loosen the locknuts and rotate the rod to change its length; on some models, the front nut has left-hand threads (loosens clockwise) 26.3 Check above and below the fork seals (arrow) for signs of oil leakage 27.3 The linkage arms should be at right angles to the rod 28.
1-27 Chapter 1 Tune-up and routine maintenance adjustable. On XV920 models, front fork damping is also adjustable. rear suspension unit damping and air pressure are adjustable. 3 On 1984 and later XV700 and 750 models, front fork air pressure and rear spring preload are adjustable. 4 On 1984 and later XV1000 and 1100 models, front fork air pressure is adjustable. Rear spring preload and rear shock absorber damping are also adjustable.
1-28 Chapter 1 Tune-up and routine maintenance 28.12a Adjust rear spring preload on 1984 and later XV700 and 750 models with the adjuster on the bottom of each shock absorber 28.9b Take up excessive freeplay with the cable adjusters Front fork Air pressure Rear shock absorber Spring seat Damping adjuster 1 39.2 ~ 78.5 kPa (0.4-0.8 kg/cm 2 , 5.7-11.4 psi) 1-2 1 -2 2 39.2 ~ 78.5 kPa ( 0 . 4 - 0 . 8 kg/cm2, 5.7-11.4 psi) 3-5 2-3 3 58.8 - 98.1 kPa ( 0 . 6 - 1 . 0 kg/cm2, 8.5-14.
2A-1 Chapter 2 Part A Engine, clutch and transmission (XV535 models) Contents Section Alternator rotor - removal and installation See Chapter 8 Cam chains and dampers - removal, inspection and installation , 17 Camshaft chain tensioners - removal and installation 7 Clutch cable - replacement 15 Clutch and primary gears - removal, inspection and installation 16 Compression test See Chapter 1 Connecting rods and bearings - removal, inspection, bearing selection and installation 26 Crankcase components - insp
2A-2 Chapter 2 Part A Engine, clutch and transmission (XV535 models) Specifications General Bore x stroke Displacement Compression ratio 76 x 59 mm (2.992 x 2.323 inches) 535 cc 9.0 to 1 Camshafts Lobe height Intake (standard) Intake (limit) Exhaust (standard) Exhaust (limit) 39.73 39.63 39.77 39.67 mm mm mm mm (1.564 (1.560 (1.566 (1.
Chapter 2 Part A Engine, clutch and transmission (XV535 models) Piston-to-cylinder clearance Standard Limit Ring side clearance Top ring Standard Limit Second ring Standard Maximum Oil ring Ring thickness Top ring Middle ring Oil ring (spacer and rails) Ring end gap (standard) Top and second rings Oil ring Ring end gap (limit) Top ring Second ring Oil ring Ring width Top ring Second ring Oil ring 0.035 to 0.055 mm (0.0014 to 0.0022 inch) 0.1 mm (0.004 inch) 0.03 to 0.07 mm (0.001 to 0.003 inch) 0.
2A-4 Chapter 2 Part A Engine, clutch and transmission (XV535 models) Torque specifications (continued) Clutch push lever screw 12 Nm (8.7 ft-lbs) Connecting rod nuts 36 Nm (25 ft-lbs) (2) Crankcase bolts (6 mm) 10 Nm (7.2 ft-lbs) Crankcase bolts (8 mm) 24 Nm (17 ft-lbs) Crankcase studs (8 mm) 13 Nm (9.4 ft-lbs) Crankcase studs (10 mm) 20 Nm (14 ft-lbs) Cylinder bolt 10 Nm (7.2 ft-lbs) Cylinder head bolts (8 mm).... 20 Nm (14 ft-lbs) Cylinder head nuts (8 mm)....
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 5.16 Squeeze the hose clamp and pull the breather hose off its fitting 5.18 Remove the Allen bolt and disconnect the ground wire, then loosen 2A-5 5.21 Pull the driveshaft rubber boot away from the middle gear the Allen bolts that secure wiring harness retainers (arrows; two of four bolts shown) and release the harness from the retainers does not remedy the situation, major mechanical work is the only solution.
2A-6 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 5.24 Support the engine with a jack and a block of wood 5.25a Remove the lower rear mounting b o l t . . . 5.25b . . . and the upper rear mounting b o l t s . . . 5.25c . . . (there's an upper rear mounting bolt on each side of the engine) 5.25d Unbolt the front cylinder head bracket from the frame 5.25e Unbolt the rear cylinder head mounting brackets from the frame . . . 23 Remove the starter motor (see Chapter 8).
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 6.2a A selection of brushes is required for cleaning holes and passages in the engine components 6 6.2b Type HPG-1 Plastigage is needed to check the connecting rod oil clearances 2A-7 6.3 An engine stand can be made from short lengths of lumber and lag bolts or nails Engine disassembly and reassembly - general information Refer to illustrations 6,2a, 6.2b and 6.
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 2A-8 7.2a Remove the tensioner Allen bolts , 7.4 Lift the latch and compress the tensioner piston into the body 7.3 Tensioner details a) b) Cap bolt Sealing washer c) d) Spring Tensioner body 2 Remove the tensioner mounting bolts and take it off the engine (see illustrations). Installation Refer to illustrations 7.3 and 7.4 3 Check the sealing washer on the cap bolt for cracks or hardening (see illustration).
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 2A-9 8.4a Cylinder head and cylinder (XV535 models) exploded view 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) Cylinder head side cover Intake rocker arm cover O-ring Exhaust rocker arm cover Spark plug Oil baffle plate (rear cylinder only) Gasket Cylinder head (rear shown) Cam sprocket cover Long retainer bolt Short retainer bolt Lockwasher Retainer Dowel Cylinder (rear shown) 8.4b Remove both Allen bolts . . . 8.4c . . .
2A-10 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 8.5 Unbolt the rocker arm covers and take them off, together with their O-rings 8.6a The line next to the T mark on the alternator rotor should be aligned with the notch in the timing window 8.6b The punch mark on the sprocket should be aligned with the arrowhead cast in the cylinder head (arrows) 8.
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 8.14a The cylinder heads are secured by two Allen bolts (arrows)... 8.14c Use a socket and extension to remove the nut in the spark plug w e l l . . . 8.14b . . . and five nuts . . . a) b) Allen bolts Nuts 8.14d . . . and pull its washer out with a magnet 8.
2A-12 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 8.16b . . . if they're not in the cylinder, they may have remained in the head (arrow) 8.16c Lift out the exhaust side chain damper (arrow) 8.22a Flatten the lockwasher tabs with a hammer and chisel (take care not to strike the cylinder h e a d ) . . . 8.22b . . . undo the retainer bolts . . . 8.22c . . . and remove the lockwasher 8.23a Pull the camshaft and bushing out of the head . . .
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 2A-13 8.
2A-14 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 8.26a A slide hammer like this one is the easiest way to remove the rocker shafts 8.27 Label the shafts according to cylinder (front or rear) and side (intake or exhaust) 8.26b Pull the shaft partway out. 8.29a Check the lobes of the camshaft for wear - here's a good example of damage which will require replacement (or repair) of the camshaft 8.26c . . . then remove the rocker arm 8.
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 2A-15 8.32 Check the sprockets for wear and damage 8.34 Check rocker arms for wear on the adjuster surface, inside the bore and on the cam contact surface (arrows) 8.36 Hold the rocker arm in the installed position and install the shaft, using a bolt 8.40a Slide the camshaft into its bearing in the cylinder head . . . 8.40b . . . then install the bushing and align it as shown 8.41a Install the retainer... each rocker arm.
2A-16 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 8.42a Install new sealing washers on the rocker shaft bolts 8.42b Use a screwdriver to position the rocker shafts so the bolts will line up with them 8.42c Install the bolts with their sealing washers and tighten them to the torque listed in this Chapter's Specifications 8.44a Slip the O-ring onto the large dowel.. 8.44b . . . and install the large dowel and two small dowels in their bores . . . 8.44c . . .
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 2A-17 8.47a install the engine mounting bracket on the right side of the rear cylinder head . . . 8.47b . . . install the cylinder head cover bracket next and thread two of the short nuts onto the studs on top of the cover bracket... 8.47c . . . On the left side of the engine, install the engine mounting bracket (A) and two thin washers (B), then install two short nuts . . . 8.47d . . . the installed brackets should look like this 8.
2A-18 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 8.57a Install a new O-ring on the cam sprocket cover . .. 8.57b . . . and one on the oil baffle plate 8.57c Align the hole in the oil baffle plate with the locating pin in the cover (arrows)... 8.57d . . . then press the plate into the cover and install a new gasket 8.58a The line without a T mark next to it must be aligned with the notch in the timing window . . . 8.58b . . .
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 8.59a On the left side of the front cylinder head, install the cylinder head cover bracket... 8.59b . . . install two washers on the right side . . . 8.59d Install four thick washers over the long nuts . . . 2A-19 8.59c . . . and install the four long nuts (arrows) on top of the bracket and washers (tighten the cylinder head nuts and bolts at this point) 8.59e . . .
2A-20 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 10.7b . . . until the keepers/collets are exposed 10.7c Remove the keepers/collets with a magnet 10.7e . . . and the springs 10.7f Pull the valve into the combustion chamber, but don't force it 10.7d Release the spring pressure and remove the spring retainer . . . 10.
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 2A-21 10.14 Check the cylinder head for warpage with a straightedge and feeler gauge 10.16 Measure the valve guide inside diameter with a small hole gauge, then measure the hole gauge with a micrometer 10.17 Check the valve face (A), stem (B) and keeper/collet groove (C) for signs of wear and damage 10.18a Measure the valve stem diameter with a micrometer 10.
2A-22 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 10.19a Measure the free length of the valve springs 10.19b Check the valve springs for squareness 10.23 Apply the lapping compound very sparingly, in small dabs, to the valve face only 10.24 After lapping, the valve face should have a uniform, unbroken contact pattern (arrow) 10.28a A small dab of grease will hold the keepers/collets in place on the valve while the spring is released 10.
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 11.2 Remove the single Allen bolt that secures the cylinder to the crankcase 11.3a Lift the cylinder straight up off the studs 11.4 Remove the O-ring from the base of the cylinder 29 Support the cylinder head on blocks so the valves can't contact the workbench top, then very gently tap each of the valve stems with a soft-faced hammer. This will help seat the keepers/collets in their grooves.
2A-24 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 11.10 Move the hone rapidly up-and-down without stopping 11.13a Place the cylinder base gasket in position 11.13b Make sure the two small dowel pins are in position and install the large dowel pin with its O-ring 11.
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 12.3a The EX mark on top of the piston faces the exhaust side of the cylinder (front side of the front cylinder, rear side of the rear cylinder) 12 Pistons - removal, inspection and installation 1 The pistons are attached to the connecting rods with piston pins that are a slip fit in the pistons and rods. 2 Before removing the pistons from the rods, Stuff a clean shop towel into each crankcase hole, around the connecting rods.
2A-26 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 12.4a Push the piston pin partway out, then grasp it and pull it the rest of the way 12.6 Remove the piston rings with a ring removal and installation tool 12.4b The piston pins should come out with hand pressure - if they don't, this removal tool can be fabricated from readily available parts 1) Bolt 5).
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 12.14 Measure the piston diameter with a micrometer A B Specified distance from bottom of piston Piston diameter 12.17a Slip the circlip into its bore with its gap away from the removal notch in the piston . . . 12.15 Slip the pin into the piston and try to wiggle it back-andforth; if it's loose, replace the piston and pin 12.17b . . .
2A-28 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 13.5 If the end gap is too small, clamp a file in a vise and file the ring ends (from the outside in only) to enlarge the gap slightly 13.9a Install the oil ring expander first 13.9b Installing an oil ring side rail - don't use a ring installation tool to do this 13.11b The top and middle rings can be identified by their profiles 13.11a Install the middle ring with its identification mark up Top ring 13.
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 2A-29 14.2 Pull off the shaft and no. 1 idler gear 14.3a Pull out the Woodruff k e y . . . 14.3b .. .take the no. 2 idler gear off the crankshaft... 14.3c . . . and locate the washer (it may have stuck to the back of the no. 2 idler gear) 15.1 Remove the cotter pin, disconnect the cable from the release lever and loosen the locknuts 15.
2A-30 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 16.2a Loosen the cover bolts 1/4 turn at a time in a criss-cross pattern; note that some of the bolts secure wiring harness retainers 16.2b Separate the clutch cover from the crankcase . 16.2c . . . if it's difficult to remove, use the pry points at the f r o n t . . . 16.2d . . . and at the rear 16.3 Remove the snap-ring (arrow) and take off the oil pump driven gear 16.
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 16.
2A-32 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 16.5a Take off the pressure plate . . . 16.5b . . . together with the push piece (A) and short pushrod (B) 16.5c The friction plates and metal plates can be removed as a set 16.6a Pull out the steel ball with a magnet... 16.6b . . . then pull out the long pushrod 16.7a Bend back the lockwasher 16.7b You'll need a tool to keep the clutch hub from turning; this is the Yamaha special t o o l . . .
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 2A-33 16.7d A holding tool can also be made by bolting an old metal plate and friction plate together 16.7e Remove the n u t . . . 16.8 . . . and the lockwasher 16.9a Pull the clutch boss o f f . . . 16.9b . . . and remove the holding plate 16.10a Bend back the lockwasher (arrow)... 16.10b . . . then wedge a rag between the drive and driven gears to keep them from turning and loosen the nut 16.11a Remove the lockwasher . . . 16.11b .
2A-34 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 16.11c . . . the oil pump drive gear. . 16.13a Pull one end of the wire circlip out of its hole in the clutch boss . . . 16.13d .... the seat spring . . . 16.12a . . . the primary drive gear . . . 16.13b . . . and work the circlip out of its groove 16.13e . . . and the seat plate 12 Remove the primary drive gear and Woodruff key (see illustrations). Inspection Refer to illustrations 16.13a through 16.13e, 16.15, 16.16 and 16.
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 2A-35 16.16 Measure the thickness of the friction plates 16.17 Check the metal plates for warpage 16.28 With the nut tightened to the specified torque, bend the lockwasher against one of the flats '6.29 Install the oil pump driven gear and secure it with a new snap-ring 16.30 Install the clutch boss lockwasher 16.
2A-36 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 16.34 On models so equipped, align the double notches in the friction plates (1) with the marks on the clutch housing (2) . 16.37b Align the clutch lever mark with the mark on the crankcase 16.35 . . . if tight friction plates impede clutch movement, align the single notches (3) with the marks (2) 16.38a Remove the snap-ring , 32 If you removed the clutch damper, reverse Step 13 to install it.
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 17.2a Lift out the exhaust side chain damper (arrow)... 17.2b . . . the bottom end fits into a slot in the crankcase a) b) 17.9 Remove the exhaust side chain damper bolts (arrows) and lift the chain damper out 17.5 Take the intake side chain guide off the crankcase Chain damper slot Intake side chain damper bolts 17.
2A-38 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 18.2a Remove the oil pump mounting bolts . . . 18.2b . . . and take the pump o f f . . . 18.5a The cover screw (arrow) may be tight enough to require an impact driver 18.5b Lift off the cover . . . 18 18.3 . . . then remove the dowel with Oring and separate O-ring (arrow) 18.6a . . . the outer rotor . Oil pump - removal, inspection and installation Note: The oil pump can be removed with the engine in the frame.
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 18.8a Measure the tip clearance between the inner and outer rotors 18.6c Pump body and rotors A) B) Pump body Drive pin C) D) Inner rotor Outer rotor 18.8b . . . and the clearance between the outer rotor and housing 18.9b take off the cover . 2A-39 18.9a Remove the screw (use an impact driver if it's tight)... 18.9c . . . dump out the spring . 18.9d . . .
2A-40 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 18.9e Relief valve components 18.12 Be sure the dowel pin and O-rings (arrows) are in position; pour engine oil into the passages before installing the oil pump 18.10 Be sure the drive pin aligns with the slot in the inner rotor (arrows) 19.1 Remove the Allen bolts (arrows) and take off the oil passage housing 19.2a Pull the strainer out of the housing . . . 10 If the pump is good, reverse the disassembly steps to reassemble it.
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 19.4a Install new O-rings in the oil passage housing (arrows) 19.5 Push the strainer into the oil passage housing until it seats securely 2A-41 19.4b . . . and on the strainer 20.2 There should be a punch mark next to the shift lever slot (arrows); if not, make your own 20.8a Remove the circlip (arrow)... 20 External shift mechanism - removal, inspection and installation Shift lever and pedal Refer to illustration 20.
2A-42 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 20.9a Pull the stopper lever in the direction shown by the arrow . . . 20.9b . . . and unhook the torsion spring (arrow) from its post 20.9c Pull the shift shaft out, taking care not to lose the washer (A); check the guide bar (B) for looseness 20.10 Put the washers and circlip back on the shaft so they won't be lost 20.15a Pry the shift shaft seal out of the crankcase . . . 20.15b . . .
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 2A-43 21.2a Remove the Allen bolts (arrows)... 21.2b . . . and take the middle driven gear case off 21.3a Remove four bolts . . . 21.3b . . . pull the middle driven gear back from the crankcase . . . 21.3c . . . pull out the shims and write down their locations . . . 21.3d . . . then pull the assembly out of the engine 17 Install the plain washer and circlip on the other end of the shift shaft (see illustrations 20.8b and 20.
2A-44 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 21.9 Inspect the ball bearing in the engine; have it replaced if it's worn or damaged 22.9a Loosen the crankcase bolts in sequence, starting with the highest numbered bolts (in the right side of the crankcase)... 21.10 Install a new O-ring on the middle driven gear case 22.8 Position the shift cam so it aligns with the notches in the crankcase 22.9b . . . and working to the lowest (in the left side of the crankcase) 22.
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 2A-45 22.10a Lift the right crankcase half off the left h a l f . . . 22.10b . . . prying gently at the pry points if necessary .. . 22.10c . . . (these are spaced around the crankcase) 22.10d . . . insert a screwdriver in each pry point and apply gentle pressure 22.11a Remove the small dowels (there's one at each end of the crankcase)... 22.11b . . . and the large dowel with its O-ring 22.
2A-46 Chapter 2 Part A Engine, clutch and transmission (XV535 models) Caution: The crankcase halves should fit together completely without being forced. If they're slightly apart, DO NOT force them together by tightening the crankcase bolts. 20 Install the crankcase bolts in their holes (see illustrations 22.9a and 22.9b). Bolts 1 through 12 have steel washers. 21 Tighten the bolts in numerical order, starting with the lowestnumbered bolt and working to the highest.
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 2A-47 25.6 Place the crankshaft in V-blocks or a holding fixture and check for runout with a dial indicator 25.7a Measure journal diameter with a micrometer 25.7b Measure main bearing diameter with a hole gauge . . . 25.7c . . . then measure the gauge diameter with a micrometer several times - if a journal picks up copper from the coin, it's too rough. Replace the crankshaft.
2A-48 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 25.11a This special Yamaha tool is used to press in the main bearings . . . 25.11b . . . the bearing fits over the support... 25.11c . . . and the plate fits on top of the support with its flat aligned with the bearing locating tab; a handle is threaded into the support to contact the press ram 25.11 d Align the locating tab with the notch and press the bearing into its bore 25.
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 26.1 Measure big end play between the two rods and between the rods and crankshaft 2A-49 26.2 Label the rods and caps according to their position on the crankshaft (left or right) 26.3a Undo the connecting rod nuts 26.3b . . . and take off the caps locations. Wash the parts in solvent and dry them with compressed air, if available. Inspection 26.
2A-50 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 26.11 Lay a strip of Plastigage on the journal, parallel to the crankshaft centerline 26.13 Place the Plastigage scale next to the flattened Plastigage to measure the bearing clearance 26.18a The number on the connecting rod (A) is used for bearing selection; the letter (B) is used to align the cap and rod during reassembly 26.18b The number on the rod is used together with the number on the crankshaft to select rod bearings 26.
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 2A-51 26.20b Coat the bearings with assembly lube or moly-based grease 26.21a The Y mark on the connecting rod (arrow) faces the outside of the engine 26.21b If the halves of the letter stamped on the rod and cap don't fit together perfectly, the wrong cap is on the rod (or the cap is on backwards) 26.22 Tighten to the specified torque in stages (see text) 27.2a Lift the guide bars o u t . . . 27.2b . . .
2A-52 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 27.4 Pull the shift cam out of its bore in the crankcase 27.5 Check for wear at the fork tips (A) and guide pins (B) 27.8a Oil the end of the shift cam and slip it into its bore in the crankcase 27.8b Position the shift fork marked L in the left-hand gear groove with its letter facing the right side of the engine . 27.8c . . . place the shift fork marked R in the groove next to the fork marked L . . . 27.8d . . .
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 27.8f Install the shift fork marked C in its groove with the letter facing the right side of the engine . . . 27.8g . . . and install the shorter guide bar through the f o r k . . . 2A-53 27.8h . . . (the assembled fork and guide bar should look like this) 28.
2A-54 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 28.3b Remove first wheel gear 28.4 Take the fourth wheel gear off the driveaxle 28.5a Remove the snap-ring . . . 28.5b . . . and the thrust washer 28.6 Remove the third wheel gear and main axle assembly together 28.7 Remove the fifth wheel gear 28.8b . . . and the thrust washer 28.9 Remove the second wheel gear 28.
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 28.10a Bend back the staked portion of the locknut with a hammer and punch or small chisel 28.10b Place the driveaxle in a vise with padded jaws to prevent damage to the splines . . . 2A-55 28.10c . . . remove the locknut.. 28.1 Od . . . and lift the driveaxle out of the crankcase 28.11a If the bearing needs to be replaced, remove one short retainer screw (A) and three longer screws ( B ) . . . 28.11b . . .
2A-56 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 28.13 Measure the length of the gearset on the main axle assembly and compare to the Specifications 28.14a Press the main axle out of second pinion gear until it's loose . . . 28.15a Take off fifth pinion gear. .. 28.15b . . . and third pinion gear 28.14b . . . then remove the gear from the shaft 28.16a Remove the snap-ring . 28.16b . . . the thrust washer . . . 28.16c . . . and fourth pinion gear main axle (see illustration).
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 2A-57 28.21 Check the shafts for runout with V-biocks and a dial indicator 28.22a Stake the bearing retainer screws . . . 28.22b . . . and the middle drive gear locknut 28.23a The assembled main axle should look like this Inspection Refer to illustration 28.21 17 Wash all of the components in clean solvent and dry them off.
2A-58 Chapter 2 Part A Engine, clutch and transmission (XV535 models) 28.24a Install second wheel gear 28.24b . . . the thrust washer . . . 28.24d . . . and fifth wheel gear 28.24c . . . the snap-ring . . . 28.25 Install third wheel gear on the main axle at the same time you install the driveaxle in its bearing 24 Install the second wheel gear, thrust washer, snap-ring and fifth wheel gear on the driveaxle (see illustrations). 25 Install the third wheel gear and main axle together (see illustration).
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 28.26b The assembled gears and shafts should look like this 30 Recommended break-in procedure 1 Any rebuilt engine needs time to break-in, even if parts have been installed in their original locations. For this reason, treat the machine gently for the first few miles to make sure oil has circulated throughout 2A-59 the engine and any new parts installed have started to seat.
2A-60 Chapter 2 Part A Engine, clutch and transmission (XV535 models) Notes
2B-1 Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) Contents Section Alternator rotor - removal and installation See Chapter 8 Cam chains and intermediate gears - removal, inspection and installation .
2B-2 Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) Specifications XV700 and XV750 models General Bore x stroke XV700 XV750 Displacement 80.2x69.2 mm (3.16x2.72 inches) 83.0 x 69.2 mm (3.268 x 2.72 inches) . XV700 ..... XV750.... Compression ratio 1981 though 1983 1984-on.. 699 cc 748 cc 8.7 to 1 9.
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) Bore measuring point Through 1987 1988-on Taper and out-of-round limit Pistons Piston diameter (XV700) Standard .First oversize Second oversize Piston diameter (XV750) Standard First oversize Second oversize Diameter measuring point Piston-to-cylinder clearance.
2B-4 Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) Torque specifications (continued) Alternator rotor nut See Chapter 8 Cam chain damper bolt 8 Nm (5.8 ft-lbs) Cam chain damper bolt locknut 12 Nm ((8.7 ft-lbs) Cam chain tensioner bolts 10 Nm (7.2 ft-lbs) Cam sprocket bolt 55 Nm (40 ft-lbs) Cam sprocket cover bolts 10 Nm (7.2 ft-lbs) Camshaft retainer bolts 20 Nm (14 ft-lbs) Clutch push screw locknut 12 Nm (8.
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) Valve head diameter RH models Intake Exhaust J, K, MK models Intake Exhaust Valve stem diameter Intake Exhaust Valve head edge thickness limit Valve guide inside diameter Valve seat width limit Valve face width Valve inner spring free length Valve inner spring installed length Valve inner spring bend limit Valve outer spring free length Valve outer spring installed length Valve outer spring bend limit 43.0 to 43.02 mm (1.690 to 1.
2B-6 Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) Transmission Driveaxle and mainshaft runout limit 0.08 mm (0.0031 inch) Torque specifications Alternator cover bolts 10 Nm (7.2 ft-lbs) Alternator cover screws 7 Nm (5.1 ft-lbs) Alternator rotor nut , See Chapter 8 Cam chain damper bolt 8 Nm (5.8 ft-lbs) Cam chain damper bolt locknut 12 Nm ((8.7 ft-lbs) Cam chain tensioner bolts 10 Nm (7.2 ft-lbs) Cam sprocket bolt 55 Nm (40 ft-lbs) Cam sprocket cover bolts 10 Nm (7.
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) Valve stem diameter Intake Exhaust Valve head edge thickness limit Valve guide inside diameter Valve seat width limit Valve face width Valve inner spring free length Valve inner spring installed length Valve inner spring bend limit Valve outer spring free length Valve outer spring installed length Valve outer spring bend limit . 7.975 to 7.990 mm (0.311 to 0.314 inch) 7.960 to 7.975 mm (0.3134 to 0.3140 inch) 1.3 +/- 0.2 mm (0.051 +/- 0.
2B-8 Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) Torque specifications (continued) Cam chain damper bolt Cam chain damper bolt locknut Cam chain tensioner bolts Cam sprocket bolt Cam sprocket cover bolts Camshaft bushing bolts Clutch push screw locknut Clutch boss nut Clutch cover bolts.... Clutch pressure plate screws Connecting rod nuts Crankcase bolts (6 mm)....
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 2B-13 e) Adjust the rear brake rod, clutch cable and throttle cable(s) following the procedures in Chapter 1 and Chapter 3. f) Be sure to refill the engine oil before starting the engine. 6 7.
2B-14 Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 7.2a If the engine has Type B tensioners, unscrew the tensioner from the body and take it out 7.2b Remove the Allen bolts and take the tensioner body out of the cylinder 7.3 Cam chain tensioner keeper dimensions 8.3 engine mounting brackets 1 7.
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 8.
2B-16 Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 8.4b Cylinder heads (1984 and later models) exploded view 1 Cam sprocket 2 Front cam chain guide 3 Cam chain 4 Cam chain tensioner 5 O-ring 6 Cam sprocket cover 7 Spark plug 8 Rocker arm cover 9 O-ring 8.4c Remove the cam sprocket cover; use a new O-ring on installation 8.
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 2B-17 8.6b Align the cast pointer in the cylinder head with the sprocket timing mark 1 2 3 Cam sprocket Cam chain Washer 4 5 6 8.14a Remove the oil pipe union bolt at the cylinder head . . . Sprocket bolt Cast pointer Sprocket timing mark 8.13 Drape the cam chain over the cylinder head to keep it on the crankshaft sprocket; tie it up with wire if necessary 8.14b . . .
2B-18 Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 8.20 Align the cast pointer in the cylinder head with the sprocket timing mark and the oil baffle hole 8.17 Keep the cam chain supported and lift the front side chain damper out 8.23 With the camshaft dowel aligned with the cast pointer in the cylinder head, unbolt the retainer 1 2 3 4 Cam sprocket Cam chain Oil baffle Washer 8.
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 8.27b When the rocker shaft is partway out, remove the rocker arm 8.35 Be sure the threads face out when the shaft is installed, or there will be no way to grip and remove the shaft 2B-19 8.38 Early models have an O-ring (separate from the head gasket) around the cam chain tunnel Camshaft installation 31 Apply a light coat of engine assembly lube or moly-based grease to the camshaft journals.
2B-20 Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 8.51 Crankshaft timing mark for front cylinder 8.52a The longer nuts go on the front cylinder head . . . 9 8.53 Install the oil baffle next to the front cylinder's cam sprocket, facing in the direction shown 45 Turn the cam sprocket clockwise far enough to remove all slack in the front run of the cam chain, but no farther. Insert a finger in the tensioner hole and push against the chain damper.
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 11.2 Remove the three Allen bolts to detach the cylinder from the crankcase 2B-21 11.3 Support the timing chain and pull the cylinder off the studs 11.4 Cylinder (XV700-1100 models) - exploded view 1 2 3 4 5 6 7 8 9 Cylinder O-ring Damping block Locating dowel Bolt Cylinder base gasket Cover Gasket Bolt cylinder, cylinder head and crankcase. Remove the O-ring from the oase of the cylinder (see illustration).
2B-22 Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 14.3 Remove the bolt and locknut and lift the cam chain damper out 14.4a Remove the bolt and pull out the retaining plate . . . make the measurements and offer advice concerning servicing of the cylinders.
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 2B-23 14.10 The correct locations of the intermediate gears can be determined by looking at the spring stoppers 14.11 Tighten the chain guide bolt to the specified torque, then tighten the locknut to the specified torque to secure the bolt (front cylinder shown) 14.12 Align the sighting hole in the alternator rotor with the centerlines of the crankshaft and the intermediate gear spindle hole 14.
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 2B-24 14.19 The alignment mark on the front cylinder's intermediate gear must align with the mark on the drive gear 15.
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 15.4a Remove the Allen bolts (A) to detach the pump; the screw (B) holds the pump together' 15.6b Remove three Phillips screws and detach the pick-up from the pump 15.4b Pull the pump out of the engine, taking care not to damage the strainer screen 15.7a Lift off the rotor housing . 2B-25 15.6a Separate the strainer screen from the pick-up 15.7b . . . the outer rotor .
2B-26 Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 15.7d Lift off the remaining rotor housing and oil pump s h a f t . . . 15.7e . . . and separate the shaft from the rotors 15.7f Note the marks on the rotors; they must face in the same direction when the pump is assembled . 15.9a Measure oil pump clearances with a feeler gauge 15.9b Oil pump measurement points 1 2 3 A 15.
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 2B-27 15.13b Place the new sprocket on the crankshaft with its teeth toward the crankcase . . . 15.13c . . . and drive the sprocket all the way on with a hammer and piece of pipe 15.15 Make sure the dowel and both O-rings are in position 15.17 Install the chain on the drive sprocket, engage it with the driven sprocket and bolt the driven sprocket to the oil pump 15.
2B-28 Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 16.3 Bend back the metal tang on the lever bracket and slip the end of the cable out of the lever bracket 16.9 Unhook the spring and remove the nut from the operating lever 16.10b . . . and the thrust housing; the locating pin on the thrust housing fits into a hole in the alternator cover 16.11 Pry out the old oil seal and install a new one 16.10a Lift out the push screw . 17.
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 12 13 2B-29 Installation is the reverse of the removal steps. Adjust clutch free-play (see Chapter 1). 17 Clutch and primary gears - removal, inspection and installation Removal 17.4b . . . then take off the pressure plate 17.
2B-30 Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 17.6 Remove the thrust washer and thrust bearing 17.7a Remove the push piece . . . 17.7b . . . and the pushrod 17.8 Remove the clutch plates 17.9a Bend the lockwasher tab away from the nut 17.9b You'll need a tool to keep the clutch from turning; this is one type of Yamaha special t o o l . . . 17.9d Hold the clutch housing so it won't turn and loosen the nut 17.9c . . .
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 2B-31 17.11a Remove the clutch boss . . . 17.11b . . . and the thrust washer 17.12a With the primary gear nut loose. slide off the clutch boss, then remove the primary gear n u t . . . 17.12b . . . the lockwasher and the special washer 17.13 Take the primary drive gear and Woodruff key off the crankshaft 17.14 Push the ends of the wire ring through the hole in the clutch boss 17.
2B-32 Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 17.17a Measure the free height of the diaphragm spring with a vernier catiper . . . 1 17.17b . . . and check it for warpage with a feeler gauge 17.18 Check the amount of wear on each clutch friction plate 17.21 Check the slots in the clutch housing for uneven wear 17.22 Check the driven gear teeth for wear or damage Diaphragm spring 17.
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 17.24 Check the push piece, thrust bearing and washer for wear and damage 18.3 Loosen the pinch bolt and detach the shift lever from the shift shaft (rearset shift linkage shown) 25 Clean all traces of old gasket material from the clutch cover and ts mating surface on the crankcase. Installation Refer to illustration 17.38 26 Install the primary drive gear Woodruff key, then install the primary drive gear (see illustration 17.13).
2B-34 Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 18.7a Pull the lever in the direction of the arrow until it clears the shift cam, then slide the shift mechanism out of the engine Shift mechanism removal Refer to illustrations 18.7a and 18.7b 5 Disconnect the shift lever from the shaft (Steps 1 through 3). 6 Remove the alternator cover (see Chapter 8).
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 18.11 Check the stopper arm roller and spring for wear and damage 18.13 Pry the oil seal out of the cover and tap a new one in 2B-35 18.15 The legs of the shaft return spring should be on either side of the shift shaft guide bar 20.8 Crankcase bolt TIGHTENING sequence the shift cam. Replace the spring if it's distorted. 12 Inspect the pins on the end of the shift cam.
2B-36 Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 20.9 With all fasteners removed, lift the right crankcase half off the left crankcase half 20.10a Locate the orange O-ring 20.10b . . . and the black O-ring 20.
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 2B-37 20.1 Od Crankcase halves - chain drive models 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Crankcase halves Dowels Stud Stud Stud O-ring Dowel Bolt Bolt Bolt Bolts Bolt Bolts Sealing washer Oil filler plug O-ring Protective plate Plug Grommet Sprocket guard Bolts Clamp 13 Remove all traces of sealant from the crankcase mating surfaces. Be careful not to let any fall into the case as this is done.
2B-38 Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 21.4a Right crankcase half components 7 2 3 4 5 6 Crankshaft bearing Transmission bearings Middle gear bearings O-ring Oil pressure relief valve Oil level switch 21.4b Use a slide hammer to remove the bearings if they don't lift out easily . . . 4 Spin the bearings in the crankcase halves (see illustration) with fingers and check for looseness, roughness or excessive noise. Replace the bearings if these conditions are found.
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 2B-39 21.5a Pry the oil seal out of the bearing bore . . . 21.5b . . . make sure the oil passage is clear and tap in a new seal 21.6a Push the bearing sU
2B-40 Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 23.5 Make sure the oil passage plugs are tight 23.3b Crankshaft details 1 2 3 4 5 6 7 8 Crankshaft Right main bearing Woodruff key Left main bearing Oil pump drive sprocket Washer Nut Piston 9 10 11 12 13 14 15 Piston pin Circlip Piston rings Connecting rod Connecting rod bearings Connecting rod studs Connecting rod nuts Inspection Refer to illustrations 23.5 and 23.
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 2B-41 24 Connecting rod bearings - general note 23.11 Set up a puller like this one to pull the crankshaft into the left main bearing the crankshaft with a sleeve nut. This can be fabricated (see illustration), but the puller must apply force to the inner race of the ball bearing. A puller that's braced against the outer race of the ball bearing will transfer the installation force to the balls and retainers, damaging the bearing.
2B-42 Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 25.3 Remove the nuts and separate the cap from the connecting rod 25.10 Make sure the tab aligns with the notch; when installing the bearing upper half, make sure the oil holes in the bearing and connecting rod are aligned off the condensed water and corrosive gases produced. These products collect in the engine oil, forming acid and sludge.
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 25.18a The number on each connecting rod is used for bearing selection; the letter is used to align the rod and cap 14 If the clearance is within the range listed in this Chapter's Specifications and the bearings are in perfect condition, they can be reused. If the clearance is greater than the wear limit, replace the bearing inserts with new inserts that have the same color code, then check the clearance once again.
2B-44 Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 26.2 Lift the middle driven gear pinion off the middle gear driveshaft (shaft drive models) 26.
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 2B-45 26.7 Lift the shift cam out of the crankcase 26.9a Remove the snap-ring and thrust washer . . . 26.9b . . . slide the fifth pinion gear off the mainshaft . . . 26.9c . . . and slide second-third pinion gear off the shaft 26.9d Remove the snap-ring . . . 26.9e . . . and the thrust washer . . . 26.9f . . . and slide off fourth pinion gear illustration). 5 Remove the two uppermost shift forks from the gear grooves.
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 2B-46 26.9h Transmission shafts (XV700-1100 models) exploded view 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Mainshaft Fourth pinion gear Second-third pinion gear Fifth pinion gear Fifth wheel gear Second wheel gear Driveaxle Third wheel gear Fourth wheel gear Middle drive gear First wheel gear Middle driveshaft Middle driven shaft Middle driven gear Oil pump drive sprocket 26.10a Slide the fifth wheel gear off the driveaxle 26.
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 26.10c . . . and the thrust washer . . . 2B-47 26.10d . . . and slide second wheel gear off 26,1 Oe At the other end of the driveaxle, slide off the middle drive gear . . . 26.10f . . . the first wheel gear . . . 26.1 Og . . . and the fourth wheel gear 26.10h Remove the snap-ring . . . 26.101 . . . and the thrust washer . . . 26.10J . . . and the third wheel gear . . . Driveaxle Refer to illustrations 26.10a through 26.
2B-48 Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 26.12 Check the gear bushings (if equipped) for wear or damage 26.15 Check the teeth, splines and bearing on the middle drive gear noises. If any of these conditions are found, replace the bearing with a blind hole puller (see illustrations 21.4b and 21.4c). Check the oil seal behind the mainshaft bearing; it's a good idea to replace it as a precaution (see Section 21).
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 26.25 Engage the pin on the fifth pinion gear shift fork with the groove in the shift cam 26.26 Install the remaining two shift forks and engage their pins with the shift cam grooves 2B-49 26.27a Slide the guide bar through the forks . . . them correctly. The forks are numbered from one to three, starting from the left side of the engine.
2B-50 Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) Notes
3A-1 Chapter 3 Part A Fuel and exhaust systems (XV535 models) Contents Section Air induction system (1990-on US models) inspection and component replacement 13 Air filter element - servicing See Chapter 1 Carburetor overhaul - general information 5 Carburetors and intake joints - removal and installation 6 Carburetors - disassembly, inspection, cleaning and reassembly 7 Carburetors - fuel level adjustment 8 Evaporation control system (California models) - inspection and canister replacement 14 Exhaust syst
3A-2 Chapter 3 Part A Fuel and exhaust systems (XV535 models) Specifications Carburetor Type Jet sizes Main jet 1987 and 1988 1989 through 1993 Front cylinder Rear cylinder 1994 US Front cylinder Rear cylinder 1994 UK and Canada Main air jet Jet needle/clip position 1987 and 1988 US and Canada Front cylinder Rear cylinder 1990 through 1993 US and Canada Front cylinder Rear cylinder 1994 US Front cylinder Rear cylinder Mikuni BDS34 (two) 135 137.5 135 137.
3A-3 Chapter 3 Part A Fuel and exhaust systems (XV535 models) 2.4a Release the fuel hoses from the clips on top of the battery cover A B C Clips Hose clamps Tank mounting bolts D Battery positive cable (always disconnect the negative cable first) 2.4b Fuel tanks and lines (models with upper fuel tank) 1 2 3 4 5 6 Fuel lines Fuel filter Fuel pump Fuel tap Lower fuel tank Upper fuel tank 2.5a Remove the upper tank mounting bolt at the rear . . .
3A-4 Chapter 3 Part A Fuel and exhaust systems (XV535 models) 2.6a Lift the tank and disconnect the hoses from the fittings (arrows) . . . 2.6b . . . there's a fuel hose on each side 2.10 Remove the mounting bolts (arrows) and take off the footpeg bracket 2.13 Work the drain fitting (arrow) free of the rubber cover and lift the cover out 2.
Chapter 3 Part A Fuel and exhaust systems (XV535 models) 2.14a Remove the mounting bolts . . . 2.14b . . . and detach the rubber dampers from the brackets Even after cleaning and flushing of the fuel system, explosive fumes can remain and ignite during repair of the tank. 2 If the fuel tank is removed from the vehicle, it should not be placed in an area where sparks or open flames could ignite the fumes coming out of the tank.
3A-6 Chapter 3 Part A Fuel and exhaust systems (XV535 models) 6.8 If this wiring harness obstructs removal, detach it from its clip (arrow) and move it out of the way 6.9 Loosen the clamp and pull the fuel line off the fitting 6.10a Loosen the clamping band screws on the air cleaner joints . . . 6.10b . . . insert a flat-bladed screwdriver between the joint and carburetor (arrow) and push the joint up into the air cleaner cavity 6.
Chapter 3 Part A Fuel and exhaust systems (XV535 models) 3A-7 7.2a Remove the float chamber cover screws and take off the cover . . . Installation 14 Engage the carburetor assembly with the intake joints. Lightly lubricate the ends of the throttle cables (or cable) with multi-purpose grease and attach them to the throttle pulley. Make sure the accelerator cable (and decelerator cable if equipped) are in their proper positions. .
3A-8 Chapter 3 Part A Fuel and exhaust systems (XV535 models) 7.2b . . . remove the other float chamber cover . . . 7.2c . . . disconnect the fuel and vent lines and set them aside 7.3a Pull out the f l o a t . . . 7.3b . . . and lift out the needle valve 7.4a Unscrew the main Jet.., 7.4b . . . and the main nozzle holder . . . 7.4c . . . remove the O-ring with a pointed t o o l . . . 7.4d . . . remove the jet block screws . . . 7.4e . . .
3A-9 Chapter 3 Part A Fuel and exhaust systems (XV535 models) 7.5a Pull the two rubber plugs out of their passages . 7.5b . . . unscrew the pilot j e t . . . 7.5d Jet block components 7.5c . . . and the main bleed pipe 7.6a Remove the screws and lift off the coasting enricher valve cover . . . A B C D Jet block Pilot jet Rubber plug Rubber plug E F G Main bleed pipe Main jet Main nozzle holder 7.6b . . .
3A-10 Chapter 3 Part A Fuel and exhaust systems (XV535 models) 7.7a Note the locations of the hose clips and remove the cover screws . .. 7.7b . . . one of the screws requires a Torx bit 7.8a Lift off the cover . . . 7.8b . . . and remove the spring 7.8c Carefully separate the diaphragm from the carburetor body without tearing i t . . . 7.8d . . . and remove the O-ring 7.9a Remove the O-ring from the main nozzle . . . 7.9b . . .
Chapter 3 Part A Fuel and exhaust systems (XV535 models) 7.10b . . . and the no. 1 pilot air jet from the throttle bore (arrow) 7.11b . . . remove the choke lever pivot screw . 7.11d Remove the clip and washers . . . 3A-11 7.11a Loosen the choke link securing screws (there's one for each carburetor)... 7.11c . . . its spring and washers 7.11e . . .
3A-12 Chapter 3 Part A Fuel and exhaust systems (XV535 models) 7.12a Remove the clip from the end of the choke link with a pointed t o o l . . . 7.12b . . . remove the spring retainer . . . 7.12d . . . and pull out the choke link 7.13a Pry the washer and bushing loose with a pointed t o o l . . . 7.13b . . . and remove them from the choke shaft passage 7.15a Detach the upper stay plate . . . 7.15b . . . and the lower stay plate . . . 7.15c . . .
Chapter 3 Part A Fuel and exhaust systems (XV535 models) 3A-13 7.15d . . . and pull the carburetors apart 7.16a Unscrew the choke plunger . . . 7.16b . . . and take it out of the housing 7.16c Remove the housing mounting screws . . . 7.16d . . . and take the housing and gasket off the carburetor body 7.17 Remove two screws and take the throttle pulley assembly off 7.
3A-14 Chapter 3 Part A Fuel and exhaust systems (XV535 models) 7.26a Remove the screw from inside the vacuum piston . . . 7.26b . . . and lift out the jet needle , 7.26c . . . together with the spring, washer, clip and O-ring opens and closes smoothly. If it doesn't, replace the carburetor. 28 Check the coasting enricher diaphragm for tears or brittleness (see illustration). Replace them if their condition is in doubt. 29 Check the floats for damage.
Chapter 3 Part A Fuel and exhaust systems (XV535 models) 7.32a Align the choke shaft screws with the dimples in the shaft (arrows) 7.32b Align the protrusion in the diaphragm with the notch in the carburetor body (arrow) 3A-15 7.32c Align the tab on the coasting enricher diaphragm with the notch in the carburetor body (arrow) 8.4 Loosen the float chamber drain screw 8.3 Connect the tool to one of the drain fittings (arrows) 8 Carburetors - fuel level adjustment Refer to illustrations 8.3, 8.4 and 8.
3A-16 Chapter 3 Part A Fuel and exhaust systems (XV535 models) 9.1 Loosen the throttle cable adjuster locknuts and loosen the adjusters (arrows) 9.3b . . . and disengage the end from the pulley 9 9.2 Remove the screw that secures the throttle cables to the housing 9.4a Pull the end of the cable out of the socket and slip the cable sideways through the slot to disengage i t . . . Throttle cables and grip - removal, installation and adjustment 9.3a Slip the cable out of its groove . 9.4b . . .
Chapter 3 Part A Fuel and exhaust systems (XV535 models) 3A-17 5 Support the muffler/silencer chamber with a jack and unbolt it from the frame (see illustration). Lower the exhaust system away from the bike and take it out. 6 Installation is the reverse of removal, with the following additions: a) Use new gaskets at the cylinder head (see illustration). b) Tighten all fasteners to the torque settings listed in this Chapter's Specifications. 11 10.
3A-18 Chapter 3 Part A Fuel and exhaust systems (XV535 models) 11.6 Connect the positive lead (1) of a 0-20 volt voltmeter to the red/white wire terminal of the connector (2) and the negative lead to ground/earth (3) 11.10 Connect a short jumper wire (arrow) between the red/white and blue/black wire terminals 11.11 Connect the voltmeter positive (1) lead to the back of the blue-black wire terminal (2) and the negative lead to ground/earth (3) relay connector.
3A-19 Chapter 3 Part A Fuel and exhaust systems (XV535 models) 11.14 Connect the terminals in the harness side of the fuel sender connector to each other with a short jumper wire 12.2 Disconnect the wiring connector and remove the fuel pump relay 12.5 Loosen the fuel line clamps (A), disconnect the connector (B), remove the mounting bolts (C) and take the pump out; loosen the clamp screw (D) to remove the pump from its bracket Start switch and note the voltmeter reading.
3A-20 Chapter 3 Part A Fuel ahd exhaust systems (XV535 models) 13.3a Pipe connections at the cylinder heads are secured by screw-type hose clamps 13.3b The pipes are attached to the right side of the engine with two Allen bolts (arrows) 13.3c Hose-to-pipe connections are secured by spring-type clamps 2 Check the hoses for loose connections, damage and deterioration. Tighten or replace loose or damaged hoses. 3 To replace system components, remove the left side cover (see Chapter 7).
3B-1 Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models) Contents Section Air filter element - servicing See Chapter 1 Air induction system (XV1000, XV1100 and 1988 and laterXV750) - inspection and component replacement....
3B-2 Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models) Carburetors Type Main jet Main air jet Jet needle (US models) Rear cylinder Front cylinder Jet needle (UK models) Rear cylinder Front cylinder Needle jet Pilot air jet US UK Pilot jet Pilot screw Valve seat size Starter jet Fuel level Rear cylinder Front cylinder Hitachi HSC40 (two) 122 50 . .... Y-23 Y-22 Y-21 Y-20 Not specified . 185 180 41 Preset (turns out not specified) 2.0 40 . 1.0 +/- 1.0 mm (0.039 +/-0.039 inch) 2.0 +/-1.
Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models) Fuel level Rear cylinder Front cylinder 1.0 +/-1.0 mm (0.039 +/- 0.039 inch) 2.0 +/-1.0 mm (0.078 +/- 0.039 inch) :.. Tightening torques Carburetor joint bolts Exhaust pipe-to-cylinder head nuts 10 Nm (7.2 ft-lbs) 20 Nm (14 ft-lbs) XV920 chain drive models Fuel tank capacity Total Reserve ... .... 19 liters (5.02 US gal, 4.18 Imperial gal) 3.2 liters (0.84 US gal, 0.
3B-4 Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models) Main jet Rear cylinder Front cylinder Main air jet Jet needle Rear cylinder Front cylinder Needle jet Pilot air jet Pilot jet Pilot screw Valve seat size Starter jet Fuel level Rear cylinder Front cylinder . 126 124 50 . .... . Y-21 Y-20 Not specified 175 43 Preset (turns out not specified) 2.0 40 1.0 +/-1.0 mm (0.039 +/- 0.039 inch) 2.0 +/-1.0 mm (0.078 +/- 0.
Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models) 1 3B-5 General information The fuel system consists of the fuel tank, the fuel tap and filter, the carburetors and the connecting lines, hoses and control cables. XV1000 and XV1100 models use an electric fuel pump. The carburetors used on these motorcycles are two Hitachis (1981 through 1987) or Mikunis (1988 and later) with butterfly-type throttle valves.
3B-6 Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models) 6.4 Loosen the air hose clamp screws (A) and the choke cable retaining screw (B), then disconnect the choke cable (C) from the carburetor 6.3 Squeeze the clip (arrow) and slide it down the fuel line, then pry the fuel line off the fitting 6 Carburetors and intake joints - removal and installation Warning: Gasoline (petrol) is extremely flammable, so take extra precautions when you work on any part of the fuel system.
Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models) 3B-7 7.
3B-8 Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models) 7.3 Remove the cotter pin and washer and disconnect the choke linkage rod 7.4 Remove the screws and detach the bottom bracket 7.5a Note carefully how the carburetors fit together... 7.5b . . . then pull them apart 7.6 Remove the E-clip and separate the linkage assembly 2 Remove the screws and detach the top bracket from the carburetor assembly.
Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models) 7.9 Slip the choke control plate fingers out of the groove in the choke plunger 7.12a Push the float pivot pin partway out with a thin punch, then pull it clear . . . 7.10 Unscrew the choke plunger cap and take the plunger out of the carburetor body 7.12b . . . and lift out the floats together with the needle valve 8 Taking care not to tear the diaphragm, lift the piston and jet needle out of the carburetor (see illustration).
3B-10 Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models) 7.17a Remove the plastic Allen screw, the spring and jet needle . . . 7.17b . . . then separate the components carburetor body. On US models, this screw is hidden behind a plug which wili have to be removed if the screw is to be taken out. To do this, drill a hole in the plug, being careful not to drill into the screw, then pry the plug out or remove it with a small slide hammer.
Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models) 3B-11 25 Check the floats for damage. This will usually be apparent by the presence of fuel inside one of the floats. If the floats are damaged, they must be replaced. 26 Check the needle valve for wear or damage (see illustration). If there's a pronounced groove around the tip of the valve, replace it. 27 Check the needle valve seat for wear or damage (see illustration). Check the filter cap for clogging and clean or replace it as necessary.
3B-12 Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models) 7.31 Carburetor (1987 and later US models) - exploded view 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 32 Remove the screws and detach the top bracket. 33 Disconnect the choke link that fits between the choke shafts. 34 Carefully note how they're assembled, then remove the synchronizing screw and spring.
Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models) 3B-13 56 Check the needle valve seat for wear or damage. Check the filter cap for clogging and clean or replace it as necessary. The sealing washer should be replaced whenever the needle valve seat is removed. Cleaning 57 Perform Steps 28 and 29 above to clean the carburetor components. Reassembly Caution: When installing the jets, be careful not to over-tighten them they're made of soft material and can strip or shear easily.
3B-14 Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models) 10.1 Loosen the screw and detach the cable housing from the bracket 10.2 Remove the screw (arrow) and detach the choke lever Installation 5 Clean the handlebar and apply a light coat of multi-purpose grease. 6 Route the cable(s) into place, following the same route noted on removal. Make sure they don't interfere with any other components 11.
Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models) 3B-15 11.3b Exhaust system (1981 through 1983 chain drive models) - exploded view 1 Rear cylinder pipe 2 Bolt 3 Washer 4 Gasket 5 Washer 6 Bolt 7 . Left muffler/silencer 8 Mounting bracket 9 Bolt 10 Lockwasher 11 Right muffler/silencer 12 Mounting bracket 13 Bolt 14 Lockwasher 15 Gasket 16 Clamp 17 Bolt 18 Washer 19 Washer 20 Bolt 21 Front cylinder pipe 11.
3B-16 Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models) 12.2 Fuel pump circuit 1 2 3 4 5 6 Fuel pump controller Fuel pump Fuel reserve switch (Res position) Fuel reserve switch (On position) Igniter unit Fuel warning light switched on (with the fuel warning light on or off).
Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models) 3B-17 12.27a Fuel pump controller terminal identification voltage. a) If it's still more than 11 volts, test the fuel pump (see Step 24 below). b) If it's less than 11 volts, go to Step 15. 15 Connect a 0-20 volt voltmeter between the red/green wire at the fuel pump controller and a good ground/earth connection (bare metal on the motorcycle). a) If there's no voltage, test the reserve switch (see Chapter 8).
3B-18 Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models) 13.2 Fuel pump hoses (XV1000 and 1100 models) 1 2 3 4 Fuel pump Hose clamps Outlet hose Inlet hose 13 Fuel pump - replacement Refer to illustrations 13.1 and 13.2 1 Remove the cover from the fuel pump (see illustration). 2 Loosen the fuel line clamps and push the ends of the fuel lines off the pump fittings (see illustration). 3 Disconnect the pump electrical connector. Remove the mounting bolts and take the pump out.
Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models) 3B-19 14.5 Unclip the mixture control valve and disconnect its hoses 2 If you're working on a 1984 or 1985 XV700, remove the case cover (on the left side of the motorcycle between the cylinders). 3 Start the engine and let it idle. Hold a strip of paper next to the inlet side of the valve. 4 Raise engine speed to 5,000 rpm. The paper should be pulled toward the valve by air flow.
3B-20 Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models) 15.2c Air induction system hose routing (1988 and later XV750 models) 1 2 3 4 5 6 Face clamp ends inward To fuel tap Face clamp ends downward Place hose bend projection in square hole Face white paint mark toward air cut valve Face arrow mark toward air cut valve 16 Evaporation control system (California models) inspection and canister replacement 3 To replace system components, remove the left side cover.
4A-1 Chapter 4 Part A Ignition system (XV535 models) Contents General information Igniter - check, removal and installation Ignition coils - check, removal and installation Section 1 5 3 Ignition system - check Pick-up coil - check, removal and installation Spark plugs - replacement Specifications Ignition coil 1987 through 1993 US models Primary resistance Secondary resistance 1994 US models Primary resistance3.6 to 4.
4A-2 1 Chapter 4 Part A Ignition system (XV535 models) General information This motorcycle is equipped with a battery operated, fully transistorized, breakerless ignition system.
Chapter 4 Part A Ignition system (XV535 models) 4A-3 3.4 To test the coil primary resistance, connect the ohmmeter leads between the primary terminals in the coil connector 3.6 To test the coil secondary resistance, connect the ohmmeter between the spark plug wire (HT) terminal and one of the primary terminals checked. Mark the locations of all wires before disconnecting them.
4A-4 Chapter 4 Part A Ignition system (XV535 models) 4.1b The pick-up coil connector on 1994 and later models is in the wiring harness; it can be identified by its wire colors 1 Gray 2 Black 4.1a The pick-up coil connector on 1987 through 1993 models is on the underside of the igniter at the rear (arrow); if necessary, remove the igniter for access at the igniter (see illustration).
4B-1 Chapter 4 Part B Ignition system (XV700-1100 models) Contents General information Igniter - check, removal and installation Ignition coils - check, removal and installation Ignition system - check Sect/on 1 5 3 2 Section Pick-up coils - check, removal and installation 4 Spark plugs - replacement See Chapter 1 Pressure sensor (1984 and later XV1000 and XV1100 models) testing, removal and installation 6 Specifications Ignition coil 1981 through 1983 models Primary resistance Secondary resistance 19
4B-2 1 Chapter 4 Part B Ignition system (XV700-1100 models) General information These motorcycles are equipped with a battery operated, fully transistorized, breakerless ignition system.
Chapter 4 Part B Ignition system (XV700-1100 models) 4B-3 3.11 Disconnect the coil primary connectors and remove the mounting nuts or bolts to separate them from the bracket 3.6 To test the coil secondary resistance, connect the ohmmeter between the spark plug wire (HT) terminal and one of the primary terminals other primary terminal (see illustration). 5 Place the ohmmeter selector switch in the Rx1 position and compare the measured resistance to the value listed in this Chapter's Specifications.
4B-4 Chapter 4 Part B Ignition system (XV700-1100 models) Removal and installation 1 If you're working on a 1981 through 1983 model, remove the fuel tank (see Chapter 3). 2 If you're working on a 1984 or later model, remove the seat, the left side cover and the luggage box (see Chapter 7). 3 Unplug the electrical connector, remove the mounting screws and take the igniter out (see illustration 4.3). 4 Installation is the reverse of the removal steps.
5A-1 Chapter 5 Part A Steering, suspension and final drive (XV535 models) Contents Section Driveshaft and final drive - removal, inspection and installation.... 9 Fork oil change 3 Forks - disassembly, inspection and reassembly 5 Forks - removal and installation 4 General information 1 Handlebar - removal and installation 2 Rear shock absorbers - removal, inspection and installation Steering head bearings - replacement Swingarm bearings - check Swingarm bearings - inspection and replacement ...
5A-2 Chapter 5 Part A Steering, suspension and final drive (XV535 models) 2.2a On early models, pry off the rubber cover... 2.2b . . . later models use a pair of plugs 2.2c Remove the Allen bolts to detach the handlebar brackets; the arrow cast in each bracket must face forward when the bracket is reinstalled The front forks are of the conventional coil spring, hydraulicallydamped telescopic type. The rear suspension consists of twin shock absorbers with coil springs and a swingarm.
Chapter 5 Part A Steering, suspension and final drive (XV535 models) 3.4a Press the spring seat down against the spring pressure and pry out the stopper ring (arrow) . . . 3.4b . . . then remove the spring seat with its O-ring and the spring 5A-3 3.5 Remove the fork drain screw (arrow) fork with the fork fully compressed and without the spring in position (see illustration). Compare it to the value listed in this Chapter's Specifications. Add or remove oil as necessary.
5A-4 Chapter 5 Part A Steering, suspension and final drive (XV535 models) 5.3 Pour the fork oil into a container 5.4b Front fork (XV535 models) - exploded view 5.4a Pry the dust seal out of the outer fork tube Installation 8 Slide each fork leg into the lower triple clamp. 9 Slide the fork legs up, installing the tops of the tubes into the upper triple clamp. Position the top of the fork tube so that it is level with the top surface of the upper triple clamp.
Chapter 5 Part A Steering, suspension and final drive (XV535 models) 5A-5 5.6a This special Yamaha tool is used to keep the damper rod from turning when its bolt is loosened or tightened 1 Handle 5.6c . . . and remove the bolt and its copper washer - use a new copper washer during reassembly 2 Adapter 5.6b Loosen the damper rod bolt with an Allen wrench . 5.
5A-6 Chapter 5 Part A Steering, suspension and final drive (XV535 models) 5.17 If you don't have the proper tool, a section of pipe can be used the same way the special tool would be used to install the outer tube guide bushing - as a slide hammer (be sure to tape the ends of the pipe so it doesn't scratch the fork tube) 15 Install the inner fork tube in the outer fork tube.
Chapter 5 Part A Steering, suspension and final drive (XV535 models) 5A-7 6.5b The brake hose retainer bolt is accessible from underneath the triple clamp 6.5a Steering head and bearings (XV535 models) - exploded view 1 2 3 4 5 Steering stem bolt Upper triple clamp Ring nut Bearing cover Upper bearing top race 6 Steel balls (19 total) Upper bearing bottom race 8 Lower bearing top race 9 Steel balls (19 total) 10 Steering stem 6.6b . . . and lift it off. 6.
5A-8 Chapter 5 Part A Steering, suspension and final drive (XV535 models) 6.7a Loosen the ring nut with a ring nut wrench (C-spanner) 6.7b Take the ring nut off the steering stem 6.7c Lift off the bearing cover and the upper bearing top race (arrow) 6.7d Remove the 19 steel balls 6.8 Lower the steering stem and lower bearing balls out of the steering head 6.10a Insert a long punch or rod from below to tap out the upper bearing bottom race . . .
Chapter 5 Part A Steering, suspension and final drive (XV535 models) 5A-9 6.11c Tap the upper bearing bottom race into position with the same tools . . 6.11d . . . the race should look like this when installed 6.13 Tap the seal and lower bearing bottom race off the steering stem 6.14a Install a new seal with its concave side down . .. 6.14b . . . the seal should look like this when installed 6.
5A-10 Chapter 5 Part A Steering, suspension and final drive (XV535 models) 6.16b . .. stick 19 steel balls to the grease .. . 6.16c . . . then add more grease 6.17 Slip the steering stem into the steering head, taking care not to dislodge the steel balls 6.18a Install the upper bearing top race with its flat side up 6.18b Install the bearing cover over the race 6.
Chapter 5 Part A Steering, suspension and final drive (XV535 models) 5A-11 7.3b Rear shock absorber details (XV535 models) 1 2 3 4 5 6 Shock absorber Mounting bushings Collars Mounting bolts Mounting nut flower left only) Swingarm for looseness or signs of fatigue; replace both shock absorbers as a pair if these conditions are found. Except for mounting bushings, replacement parts are not available. 6 Check the shock for signs of oil or gas leaks and replace it if you find any.
5A-12 Chapter 5 Part A Steering, suspension and final drive (XV535 models) 9.5a Remove the nuts and lockwashers . . . 9.5c Driveshaft and final drive unit (XV535 models) - exploded view 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Collar Dust seal Bearing housing O-ring Oil seal Ring gear shim Bearing Ring gear Thrust washer Drive pinion gear Final drive gear shim Bearing retainer Boot Spring Coupling gear Snap-ring Driveshaft Universal joint Bearing 9.5b . . .
Chapter 5 Part A Steering, suspension and final drive (XV535 models) 5A-13 Installation 8 Coat the pivot points with a thin layer of multi-purpose lithiumbased grease. Install the shock with the tightly would spring coils down. Tighten the top bolts, then the bottom right bolt, then the bottom left nut to the torques listed in this Chapter's Specifications. 8 Swingarm bearings - check 1 Refer to Chapter 6 and remove the rear wheel, then refer to Section 7 and remove the rear shock absorbers.
5A-14 Chapter 5 Part A Steering, suspension and final drive (XV535 models) 9.13 Be sure the spring is in position before installing the final drive unit 10.6b . . . and remove the pivot shaft 10.6a Bend back the lockwasher tabs (arrows)... Installation Refer to illustration 9.13 13 Installation is the reverse of the removal steps, with the following additions: . a) Lubricate the driveshaft splines with multi-purpose lithium-based grease.
Chapter 5 Part A Steering, suspension and final drive (XV535 models) 10.9 Bend the lockwasher tabs against the head of the pivot shaft 10 Swingarm - removal and installation 5A-15 11.2 Pry the thrust cover loose and pull it off b) Install the swingarm without the driveshaft, then install the driveshaft as described in Section 9. c) Use a new lockwasher and be sure its tab engages the slot in the swingarm.
5A-16 Chapter 5 Part A Steering, suspension and final drive (XV535 models) Notes
5B-1 Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) Contents Section Drive chain, sprockets and coupling bearing (chain drive models) removal, inspection and installation 13 Driveshaft and final drive (shaft drive models) - removal, inspection and installation 12 Fork oil change 6 Forks - disassembly, inspection and reassembly 8 Forks - removal and installation 7 General .
5B-2 Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) Fork oil level (US) 1981 through 1983 models XV700, XV750, XV1000 XV1100 Fork oil capacity (UK) 1981 through 1983 XV750 XV920J XV920Kand MK XV920 RH, RJ and TR1 1986 and later models. Fork oil level (UK) 1981 through 1983 models 1992-on XV750, 1994 XV1100 1986 through 1993 XV1000 and 1100 Not specified 155 mm (6.1 inches) below top of inner fork tube* 179 mm (7.0 inches) below top of inner fork tube* 278 cc (9.40 US.fl oz, 9.
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 5B-3 2.2a Pry up the bolt cover, then remove the handlebar cover bolt and cover 2.2b Remove the trim caps from the handlebar bracket Allen bolts 1 General information The front forks are of the conventional coil spring, hydraulicallydamped telescopic type. Fork air pressure is adjustable on all except 1984 and later XV700 and XV750 models.
5B-4 Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 2.2d Steering head and handlebar brackets (1984 and later models) - exploded view 3 If the handlebar must be removed for access to other components, such as the forks or the steering head, it's not necessary to disconnect the cables, wires or hoses, but it is a good idea to support the assembly with a piece of wire or rope, to avoid unnecessary strain on the cables, wires and the brake hose.
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 2.7a The arrow mark on each handlebar bracket must point to the front of the motorcycle 5B-5 2.7b Align the dot on the handlebar with the gap in the bracket; the gaps at front and back of the bracket must be even 2.8 Handlebars (XV920J) - exploded view 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 screw, the washer and the cover (see illustration).
5B-6 Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 4.13a Unbolt the headlight brackets from the lower triple clamp . . . can be raised or lowered to one of three positions. 2 To adjust the risers, refer to Section 2 and detach the handlebars from their bracket. Place the risers in one of the three adjustment positions, then refer to Section 2 and install the risers. 3 To adjust the handlebars, remove the trim caps from the tops of the risers (see illustration 2.8).
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 4.13b . . . and remove the nuts that secure the headlight brackets and instrument cluster to the upper triple clamp 5.10a Remove the washer and the lower ring nut XV920 and XV1000 (TR1) models Refer to illustrations 4.13a and 4.13b 13 Unbolt the headlight brackets from the lower triple clamp (see illustration).
5B-8 Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 5.11 a Lift the upper bearing out of the steering head . . . 5.14 Drive out the upper race from below with a punch 5.11 b . . . and lower the steering stem out of the steering head 5.15a The lower race may not leave room for a punch to be placed against i t . . . 5.15b . . . so instead, insert a special tool like this one into the race and expand it so it grips the race securely...
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 5.18 Remove the lower bearing and its grease seal (arrow) if they need to be replaced 5.20 Work the grease completely into the rollers 5B-9 6.2 Remove the plastic cap from the fork based grease) (see illustration). Coat the outer races with grease also. 21 Insert the steering stem/lower triple clamp into the steering head. Install the upper bearing and lower ring nut. Refer to Chapter 1 and adjust the bearings.
5B-10 Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 6.7 On XV920J models, unscrew the fork cap; it should sit like this before it's installed - if it sits higher, reposition the end of the damping adjusting rod 6.9 Remove the drain screw from the bottom of the fork leg 6.
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 5B-11 7.
5B-12 Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 7.
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 5B-13 7.7e Front forks (1984 and later models) exploded view 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Plastic cap Cap bolt O-ring Spacer Spring seat Fork spring Damper rod Inner fork tube Taper spindle Dust seal cover Dust seal Retainer Oil seal ' Washer Guide bushing Outer fork tube Damper rod bolt Rubber spacer (except XV700) Air joint bracket (except XV700) Stopper ring (except XV700) 8.2 Remove the fork spring 8.
5B-14 Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 8.6b Take the damper rod seat off the damper rod 8.7 Remove the damper rod and rebound spring from the inner fork tube 8.8 Pry the oil seal out of the lower fork tube 8.9a Inspect the inner and outer fork tubes; they must be replaced if worn or damaged 8.9b Check the damper rod, its seat and the rebound spring for wear or damage 9.
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 5B-15 9.1b Rear suspension unit (1981 through 1983 models) - exploded view 9.3a Remove the rubber cover.. . 9.3b . . . and remove the cotter pin 22 Install the fork by following the procedure outlined in Section 7. If you won't be installing the fork right away, store it in an upright position. 9 Rear suspension unit (1981 through 1983 and all TR1 models) - inspection, removal and installation Removal Refer to illustrations 9.
5B-16 Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 9.6 Remove the pivot bolt 9.7 Guide the suspension unit out of the frame 9.10 The adjuster ring should turn freely 9.12b Fabricated bushing removal tool 9.12a Check the bushings and the metal sleeves for wear and damage 5 Remove the two Allen bolts that secure the remote adjuster to the frame.
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 5B-17 9.13 The spring can be detached from the suspension unit 9.15 Secure the spring seat with the retaining clip, making sure the clip seats securely in its groove 9.17 Make sure the cables and hose are clear of the suspension unit and secure them in their clips 10.
5B-18 Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 10.2b Rear suspension (1984 and later models) - exploded view 1 2 3 4 5 6 7 8 9 10 11 Shock absorbers Swingarm Bearing Grease seal . Collar Lockwasher Left pivot shaft Pivot cover Right pivot shaft Nut Rubber boot 6 Inspect the pivot hardware at the top and bottom of the shook and replace any worn or damaged parts. Installation 7 Coat the pivot points with a thin layer of multi-purpose lithiumbased grease.
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 5B-19 Inspection Refer to illustrations 12.10a and 12.10b 8 Wipe the final gear assembly clean with a rag moistened in solvent. 9 Check all parts for obvious wear or damage and replace any worn or damaged parts. 10 Check the driveshaft splines for step wear. Make sure the snapring at the rear end of the driveshaft is securely seated in its groove (see illustrations).
5B-20 Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 12.10a Check the driveshaft splines for step wear 12.10b Make sure the snap-ring is securely located in its groove 13.3 Remove the left footpeg bracket, together with the muffler/silencer 13.4 Loosen the screws on the chain case clamps 13.5a Loosen the cover bolts with an Allen wrench . . . 13.5b . . .
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 5B-21 13.5c Final drive housing (chain drive models) exploded view 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Rear sprocket housing Upper chain case Lower chain case Front chain case clamps Rear chain case clamps Clamp screws Sprocket housing cover bolts O-ring Access plug Filler plug Sealing washer O-ring Sprocket retaining ring Grease seal 13.
5B-22 Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 13.16 Chain case internal rib measurement 1 Chain case 2 13.18 The engine sprocket is secured by two bolts and a lockwasher Rib height 16 Check the chain cases for cracks or.brittleness and replace as necessary. Measure the height of the internal ribs and compare it to the value listed in this Chapter's Specifications (see illustration). If the ribs are worn, replace the chain cases.
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 14.7b The pivot bolt head on 1981 through 1983 shaft drive models is secured by a lockwasher 5B-23 between the lower chain case and the rear sprocket. This will provide access to reconnect the chain permanently. 33 Install the chain cases and rear sprocket housing on the bike, engaging the chain with the engine sprocket, and tighten their mounting bolts loosely.
5B-24 Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 14.8b Swingarm (chain drive models) - exploded view 1 2 3 4 5 6 Swingarm Pivot bolt Dust cap Thrust washer Bearing Bushing 7 8 9 10 11 Pivot bolt nut Washer Bolt Lockwasher Washer 14.12 Check the swingarm for cracks and bending 14.13 If the pivot bolt holes are worn to an oval shape, replace the swingarm 1984 a n d later models 9 Pry off the pivot cover on each side of the swingarm (see illustration 10.2b).
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 5B-25 14.14 Check the rubber boot for hardness or cracks 14.16 Tighten the pivot bolt, then bend the lockwasher tabs against the bolt head 15.2 Pry the dust caps off the frame 15.3 Pull out the bushing b) Tighten the pivot bolt, nut or shafts to the torque listed in this Chapter's Specifications (see illustration). On 1984 and later models, tighten the right side, then the left side.
5B-26 Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 15.5 Check the dust cap, thrust washer and seal for wear and damage 5 Check the dust caps, thrust washers and seals for wear or damage and replace them as necessary (see illustration). 6 Calculate the swingarm side clearance. Measure the length of the bushing and the frame crossmember (see illustration). Measure the thickness of the two thrust washers.
6A-1 Chapter 6 Part A Brakes, wheels and tires (XV535 models) Contents Section Brake caliper - removal, overhaul and installation 3 Brake check See Chapter 1 Brake disc - inspection, removal and installation 4 Brake hose - inspection and replacement 7 Brake light switches - check and adjustment See Chapter 1 Brake pads -replacement 2 Brake system bleeding 8 Front brake master cylinder - removal, overhaul and installation..
6A-2 Chapter 6 Part A Brakes, wheels and tires (XV535 models) Wheels and tires Wheel runout Radial (up-and-down) Axial (side-to-side) Tire pressures Tire sizes Front Rear 2.0 mm (0.08 inch) 2.0 mm (0.08 inch) See Chapter 1 3.
Chapter 6 Part A Brakes, wheels and tires (XV535 models) 6A-3 2.3b Remove the pad springs 2.6a Special lubricants are required in the UK (and recommended anywhere salt is used on the roads) to prevent corrosion A B Apply Duckhams Copper 10 or equivalent to the shaded areas Apply Shin-Etsu G-40M or equivalent silicone grease to the shaded areas 2.
6A-4 Chapter 6 Part A Brakes, wheels and tires (XV535 models) 3.2a Unscrew the banjo bolt; there's a sealing washer on each side of the fitting Caution: Don't use too much Copper 10. Make sure no Copper 10 contacts the brake discs or the pad friction surfaces. 7 Install the pads and springs in the caliper. The rounded edge of the pad faces the rear of the motorcycle (see illustration 2.3a). 8 Refill the master cylinder reservoir (see Chapter 1) and install the diaphragm and cover.
Chapter 6 Part A Brakes, wheels and tires (XV535 models) 3.3 Remove the mounting bolts and separate the caliper from the fork leg 3.7 Remove the dust seal with fingers or a wood or plastic tool 3.5a Carefully blow air into the fluid outlet to push the piston out; keep your fingers out of the way to prevent injury 3.8 Remove the piston seal from its groove (a toothpick can be used as a removal tool) groove in the caliper bore. Make sure it isn't twisted and seats completely.
6A-6 Chapter 6 Part A Brakes, wheels and tires (XV535 models) 5.5 Unscrew the banjo bolt (arrow); there's a sealing washer on each side of the fitting 5.6 Remove the mounting bolts (arrows); note the position of the UP mark, which must be upright when the master cylinder is installed Removal 5 Remove the wheel (see Section 11 for front wheel removal or Section 12 for rear wheel removal). Caution: Don't lay the wheel down and allow it to rest on the disc - the disc could become warped.
Chapter 6 Part A Brakes, wheels and tires (XV535 models) 6A-7 5.7b . . . and unscrew the bolt 5.7c Remove the lever spring 5.9 Remove the rubber boot 5.10a Remove the snap-ring from the bore 5.10b Piston component details 6.2a Remove the cotter pin and nut and detach the brake rod from the brake p a n e l . . . rubber cup seals in clean brake fluid for ten or fifteen minutes.
6A-8 Chapter 6 Part A Brakes, wheels and tires (XV535 models) 6.3 Remove the brake panel from the wheel 6.4a Fold the shoes in a V to release spring tension, then remove them from the panel 6.4b Rear brake shoes and springs 6.
Chapter 6 Part A Brakes, wheels and tires (XV535 models) 6.8b Check the brake cam and pivot post (arrows) for wear or damage 3 4 (see (see Lift the brake panel out of the wheel (see illustration). Fold the shoes toward each other to release the spring tension illustration). Remove the shoes and springs from the brake panel illustration). 6A-9 6.12 The assembled brake panel should look like this (skimmed) by a dealer to correct the surface.
6 A-10 Chapter 6 Part A Brakes, wheels and tires (XV535 models) i.2 Measure wheel runout with a dial indicator, if one is available 8.5 Place a box wrench (ring spanner) over the bleed valve, then connect a length of clear plastic tubing to the valve 1 2 Radial (up-and-down) runout Axial (side-to-side) runout 16 To remove the pedal spring, unhook it from its post, then from the pedal arm. 17 Installation is the reverse of the removal steps. Adjust the rear brake (see Chapter 1).
6A-11 Chapter 6 Part A Brakes, wheels and tires (XV535 models) 11.3b . . . and unscrew the axle can be rotated to check the runout. 3 An easier, though slightly less accurate, method is to attach a stiff wire pointer to the fork or the swingarm and position the end a fraction of an inch from the wheel (where the wheel and tire join). If the wheel is true, the distance from the pointer to the rim will be constant as the wheel is rotated. Repeat the procedure to check the runout of the rear wheel.
6A-12 Chapter 6 Part A Brakes, wheels and tires (XV535 models) 11.5a Remove the collar from the right side . . . 11.5b . . . and the speedometer drive unit from the left side 12.3a Straighten the cotter pin and pull it o u t . . . 12.3b . . . unscrew the axle nut. 11.8 Be sure the speedometer drive unit notches align with the speedometer clutch lugs (arrows) 12.3c . . . and remove the washer fine emery cloth. 7 Check the condition of the wheel bearings (see Section 13).
Chapter 6 Part A Brakes, wheels and tires (XV535 models) 6A-13 12.5a Pull the axle out. . . 12.5b . . . remove the washer . . . 12.5c . . . and the short spacer 12.5d Separate the wheel from the final drive . . . 12.5e . . . and remove the long spacer 12.8 Be sure the long spacer is in place before installing the wheel additions: a) Apply a light coat of multi-purpose lithium-based grease to the lips of the oil seals and to the splines on the final drive and wheel hub.
6A-14 Chapter 6 Part A Brakes, wheels and tires (XV535 models) 13.4a Pry the grease seal loose . . . 13.4b . . . and lift it out 13.4c Lift out the speedometer clutch retainer . . . 13.4d . . . and the speedometer clutch 13.5 Drive out the opposite bearing with a long rod 13.6 Lift out the spacer 13.7 Drive out the remaining bearing 13.10a Drive in the bearing with a socket or bearing driver that contacts the outer race . . .
Chapter 6 Part A Brakes, wheels and tires (XV535 models) 6A-15 13.10c Install the grease seal with its closed side out 13.11a Install the spacer 13.11b Drive in the remaining bearing 13.12a Install the speedometer clutch . . . 13.12b . . . and its retainer 13.12c Install the remaining grease seal 10 Thoroughly clean the hub area of the wheel. Install the bearing into the recess in the hub, with the marked or sealed side facing out.
6A-16 Chapter 6 Part A Brakes, wheels and tires (XV535 models) 13.16b Drive out the bearings with a long rod 14 13.16c Lift out the spacer and collar (be sure to reinstall both during assembly) Tubed tires - general information 1 Tires with tubes are used as standard equipment on this motorcycle. They are generally easier to change than tubeless tires. 2 Before changing a tire yourself, check with your local dealership 13.
TIRE CHANGING SEQUENCE - TUBED TIRES Deflate tire. After pushing tire beads away from rim flanges push tire bead into well of rim at point opposite valve. Insert tire lever next to valve and work bead over edge of rim. Use two levers to work bead over edge of rim. Note use of rim protectors Remove inner tube from tire When first bead is clear, remove tire as shown To install, partially inflate inner tube and insert in tire Work first bead over rim and feed valve through hole in rim.
6A-18 Chapter 6 Part A Brakes, wheels and tires (XV535 models) Notes
6B-1 Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) Contents Section Brake caliper - removal, overhaul and installation 3 Brake disc - inspection, removal and installation 4 Brake hoses - inspection and replacement 7 Brake light switches - check and adjustment See Chapter 1 Brake pads - replacement 2 Brake system bleeding 8 Front brake master cylinder - removal, overhaul and installation..
6B-2 Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) Brakes (continued) Rear brake drum inside diameter 1981 through 1983XV750 Standard 180 mm (7.087 inch) Maximum.... Not specified All others Standard 200 mm (7.87 inches) Maximum 201 mm (7.91 inches) Rear brake shoe lining thickness Standard 4 mm (0.16 inch) Minimum 2 mm (0.08 inch) *Refer to marks stamped into the disc (they supersede information printed here) Wheels and tires Wheel runout Radial (up-and-down) Axial (side-to-side)..
Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) 2.2 On 1981 through 1983 XV750 and XV920 K and MK models, remove the coil spring, then pull out the pad pin . . . 1 General information The models covered in this Chapter are equipped with a hydraulic disc brake at the front and a mechanical drum brake at the rear. Several different front brake designs are used, varying according to model. They may be equipped with wire spoke wheels and tubed tires or alloy wheels and tubetess tires.
6B-4 Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) 2.4a On chain drive XV920 and TR1 models, remove the bolt and detach the caliper from the bracket... 2.4b . . . remove the brake pad retaining screw and the pads 2.5a Remove the anti-rattle spring 2.
Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) 6B-5 2.
6B-6 Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) 1984 and later models (except 1994 UK) Refer to illustrations 2.9a and 2.9b 9 Remove the pad cover (see illustration). Remove the pad pin clips, then pull out the pad pins and remove the anti-rattle spring (see illustration). 10 Pull out the pads. 1994 UK models Refer to illustration 2.11 11 Remove the lower caliper bolt and pivot the caliper upward (see illustration). 12 Remove the pad spring and pull out the pads.
Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) 15 Connect a length of rubber or plastic tubing to the caliper bleed valve and place the other end in a container. Open the bleed valve and push the pistons into the caliper as far as possible; displaced brake fluid will flow through the tubing into the container. If you can't depress the pistons with thumb pressure, try using a C-clamp (G-clamp). If the piston sticks, remove the caliper and overhaul it as described in Section 3.
6B-8 Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) 3.2a Remove the union bolt (arrow); this type of caliper is used on 1981 through 1983 shaft drive models . . . 3.2b . . . and this type is used on 1984 and later models (except 1994 UK) 3.3a If you're working on a 1981 through 1983 XV750, an XV920K or an XV920 MK, remove the nut and washer . . . 3.3b . .. and slide the caliper off the pivot post 3.4 Remove the caliper mounting bolts and detach the caliper from the fork 4.
Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) 6B-9 Installation 15 Install the caliper, tightening the mounting bolts or nut to the torque listed in this Chapter's Specifications. 16 Connect the brake hose to the caliper, using new sealing washers on each side of the fitting. The neck of the hose union should fit between the two cast lugs on the caliper body. Tighten the banjo fitting bolt to the torque listed in this Chapter's Specifications.
6B-10 Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) 5.3b Master cylinder (chain drive XV920 and TR1 models) exploded view 1 2 3 4 5 6 7 8 Sealing washers Union bolts Hose joint Piston assembly Hose guides Bolt Rubber boot Master cylinder assembly 9 10 11 12 13 14 15 5.
Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) 6.4 Lift the rear brake panel out of the wheel 6.5b Rear wheel and brake details (shaft drive models) 1 Rear wheel 2 Dust seal 3 Screw and washer 4 Drive pinion 5 Bolts 6 O-ring 7 Left wheel bearing 8 Left wheel bearing 9 Washer 10 Cotter pin 11.
6B-12 Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) 6.
Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) 6.8a Loosen the pinch bolt and remove the brake lever. . . 6.8b . . . remove the wear indicator pointer . . . 6B-13 6.8c . . . and withdraw the cam from the brake panel 13 Hook the springs to the shoes. Position the shoes in a V on the panel, then fold them down into position (see illustration 6.5a). Make sure the ends of the shoes fit correctly against the cam and on the pivot post (see illustration 6.4).
6B-14 Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) 11.3a Front wheel (1981 through 1983 shaft drive models) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Front wheel Axle Collar Grease seal Right bearing Spacer Hub trim (except XV920J) Flanged spacer Left bearing Speedometer clutch Retaining ring Grease seal Speedometer drive unit Washer Castellated nut Cotter pin 11.
Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) 8 Brake system bleeding 10 6B-15 Wheels - alignment check This is the same as for XV535 models. Refer to Part A of this Chapter. This is the same as for XV535 models. Refer to Part A of this Chapter. 9 11 Wheels - inspection and repair 1 For models equipped with wire spoke wheels, this is the same as for XV535 models. Refer to Part A of this Chapter.
6B-16 Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) 11.4a Remove the nut and pinch bolt; if the axle has a round head like this one, insert a bar through the removal hole and pull it o u t . . . 11.4b . . . if the axle has a hex head like this one, unscrew it 11.5b . . . and the speedometer drive unit 11.8a Make sure the dogs on the speedometer clutch . . . threads directly into the left fork leg. 4 Support the wheel. Loosen the axle pinch bolt.
Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) 6B-17 12.2a Unscrew the nut and disconnect the brake rod 12.2b Remove the cotter pin, washer and nut and disconnect the brake rod 12.3 Remove the cotter pin and nut 12.4 Loosen the axle pinch bolt (if equipped) 12.5 Pull out the axle 12.6 On chain drive models, remove the spacer that fits between the brake panel and the swingarm 12.
6B-18 Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) 12.11c Make sure the tire clears the swingarm 13.4 If necessary, unbolt the clutch hub and remove it d) Tighten the axle nut to the torque listed in this Chapter's Specifications. Install a new cotter pin, tightening the axle nut an additional amount, if necessary, to align the hole in the axle with the castellations on the nut. e) Tighten the axle pinch bolt to the torque listed in this Chapter's Specifications.
TIRE CHANGING SEQUENCE - TUBELESS TIRES Deflate tire. After releasing beads, push tire bead into well of rim at point opposite valve. Insert lever next to valve and work bead over edge of rim. Use two levers to work bead over edge of rim. Note use of rim protectors. When first bead is clear, remove tire as shown. Before installing, ensure that tire is suitable for wheel. Take note of any sidewall markings such as direction of rotation arrows. Work first bead over the rim flange.
6B-20 Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) 14 Tires - general information Tubed tires 1 Tires with tubes are used on models equipped with wire spoke wheels. Information and tire changing procedures for tubed tires are provided in Part A of this Chapter. Tubeless tires 13.5e Drive in new bearings with a bearing driver or a socket the same diameter as the bearing outer race 2 Tubeless tires are used as standard equipment on models with cast wheels.
7A-1 Chapter 7 Part A Frame and bodywork (XV535 models) Contents Backrest and shock absorber cover - removal and installation Footpegs and pads - removal and installation Frame - inspection and repair Front fender/mudguard - removal and installation General information Lower left frame cover - removal and installation 1 Section 10 3 2 11 1 4 General information The XV535 models use a steel frame composed of round-section tubing and a pressed steel backbone which incorporates the air cleaner housing.
7A-2 Chapter 7 Part A Frame and bodywork (XV535 models) 3.5 Remove the footpeg mounting bolts (early models) 3.6 Remove the clip, washer and clevis pin (arrow) 3.7 The rear footpegs are bolted to the brackets; the brackets are bolted to the frame A B 3.8a Make sure there are match marks on the shift shaft and lever, then loosen the pinch bolt (arrow); remove the rear mounting n u t . . . 3 3.8b . . . and front mounting b o l t . . . Footpeg mounting bolt Bracket bolts 3.8c . . .
Chapter 7 Part A Frame and bodywork (XV535 models) 7A-3 3.9a Detach the pedal return spring, disconnect the brake cable and remove the snap-ring to detach the brake pedal from the bracket 3.9b Follow the wiring harness from the brake light switch and disconnect the connector; remove the mounting nut (arrow)... 3.9c . . . and the mounting bolt at the front 4.2a Remove the nut at the bottom . . . 4.2b . . . and the bolt at the top to detach the lower left frame cover from the frame 5.
7A-4 Chapter 7 Part A Frame and bodywork (XV535 models) 7.1 Remove one of the mounting bolts . . . 7.2a . . . pull out the clip, remove the washer and separate the support from its bracket... 7.2b . . . then remove the other mounting bolt to detach the seat 7.4 Lift t h e p a s s e n g e r s e a t o f f . . . 7.5 . . . and remove the mounting bolts to detach the rider's seat 8.
Chapter 7 Part A Frame and bodywork (XV535 models) 7A-5 9.2a Remove the mounting bolts (arrows). . . 9.2b . . . and pull the hoses (if equipped) off the fittings on the back side of the bracket 9.3a Remove the mounting bolt at the upper rear . . . 9.3b . . . and at the lower front 10.1a Remove the backrest mounting bolts on each side . . . 10.1b . . . don't lose the washer and spacers 10.2a Remove the mounting bolt at the rear on each side . . .
7A-6 Chapter 7 Part A Frame and bodywork (XV535 models) 10.3 Remove the screw and washer to detach the shock absorber cover 11.2a The fender mounting bolts are accessible from inside the fender 12.3a Unbolt the inner rear fender panel at the bottom . . . 3 The shock absorber covers are retained by two screws and washers on each side. On models with a backrest, the rear screw forms the backrest front mounting (see illustration). 4 Installation is the reverse of the removal steps.
7B-1 Chapter 7 Part B Frame and bodywork (XV700-1100 models) Contents Footpegs and pads - removal and installation Frame - inspection and repar Front fender/mudguard - removal and installation General information Rear fender/mudguard - removal and installation .
7B-2 Chapter 7 Part B Frame and bodywork (XV700-1100 models) 4.1 Remove one mounting nut, detach the prop rod and remove the other mounting nut 5.1a The sidestand spring must be properly connected and in good condition removing the right rear footpeg assembly on an early shaft drive model, support the exhaust system and unbolt the footpeg from the frame (the same boit also secures an exhaust bracket).
Chapter 7 Part B Frame and bodywork (XV700-1100 models) 8 7B-3 Front fender/mudguard - removal and installation Early models Refer to illustrations 8.1 and 8.2 1 The front fender/mudguard on early models is bolted to the forks (see illustration). If the upper fender/mudguard bolts will come all the way out without striking the wheel rim, it won't be necessary to remove the front wheel. If they won't, remove the front wheel (see Chapter 6).
7B-4 Chapter 7 Part B Frame and bodywork (XV700-1100 models) Notes
8A-1 Chapter 8 Part A Electrical system (XV535 models) Contents Section Alternator Cover, stator. rotor and regulator/rectifier - removal and installation 28 Battery - charging 4 Battery - inspection and maintenance 3 Brake light switches - check and replacement 12 Carburetor heater (1994 UK models) - testing 31 Charging system - output test 27 Charging system testing - general information and precautions...
8A-2 Chapter 8 Part A Electrical system (XV535 models) Specifications Battery type 12 v, 12 Ah Fuse specifications Main 1987 through 1990 models 1991-on models All others 1987 through 1990 models 1991-on models 20 amps 30 amps 10 amps 15 amps Charging system Statorcoil resistance Charging system output 0.34 to 0.42 ohms 14 to 15 volts at 5,000 rpm Starter Starter commutator diameter Standard Minimum Mica undercut Starter brush length Standard Minimum 28 mm (1.1 inch) 27 mm (1.06 inch) 1.6 mm (0.
8A-3 Chapter 8 Part A Electrical system (XV535 models) 1 General information The machines covered by this manual are equipped with a 12-volt electrical system. The charging system on XV535 models uses a rotor with permanent magnets that rotates around a stator coil of copper wire. This produces alternating current, which is converted to direct current by the regulator/rectifier. The regulator/rectifier also controls the charging system output.
8A-4 Chapter 8 Part A Electrical system (XV535 models) 5.1a The main and accessory fuses are located in a fuse block under the seat (this is an early m o d e l ) . . . 5.1b . . . and this is a later model brush or knife and emery paper. Reconnect the cables and apply a thin coat of petroleum jelly to the connections to slow further corrosion. 5 The battery case should be kept clean to prevent current leakage, which can discharge the battery over a period of time (especially when it sits unused).
Chapter 8 Part A Electrical system (XV535 models) 7.1a Remove the headlight cover screws (arrows) .. . 7.1b . . . tilt the cover out of the headlight assembly and disconnect the wiring connector 8A-5 7.2a Unscrew the retainer, 4 If no voltage is indicated, check the wiring between the taillight and the ignition switch, then check the switch. On UK modeis, check the lighting switch as well. Brake light 5 See Section 12 for the brake light switch checking procedure.
8A-6 Chapter 8 Part A Electrical system (XV535 models) 8.3 The headlight adjusting screws are located on either side of the headlight assembly; the vertical adjusting screw is at the lower right (arrow); the horizontal adjusting screw is at the upper left 9.2 Remove the pivot bolt and nut at the bottom (arrows) and the mounting bolt inside the headlight assembly 10.2 Press the bulb into the socket and turn it counterclockwise (anti-clockwise to remove cover (see illustration).
Chapter 8 Part A Electrical system (XV535 models) 11.3 The turn signal relay/cancel unit is located behind the right front side cover; it's part of the relay assembly and can be identified by its wire colors 11 12.5 To remove the brake light switch, insert a tool into the hole under the bracket and release the retainer 8A-7 12.
8A-8 Chapter 8 Part A Electrical system (XV535 models) 13.2 . . . and from the drive unit on the left fork leg 13.4 Remove the speedometer mounting nuts... 13.5 . . . and the mounting screws, then detach the speedometer from the housing I 2 Note how it's routed, then unscrew the speedometer cable from the drive gear at the left front fork (see illustration). Speedometer removal Refer to illustrations 13.4 and 13.5 3 Disconnect the cable from the speedometer (see illustration 13.1).
Chapter 8 Part A Electrical system (XV535 models) 8A-9 14.6b . . . and pull the bulb out of the socket 14.6a Pull the bulb socket out of the speedometer . 15.3b Continuity table for the ignition switch (UK models) 15.3a Continuity table for the ignition switch (US models) 15 Ignition main (key) switch - check and replacement Check Refer to illustration 15.3 1 Lift the seat (single seat models) or remove the seat (dual seat models) (see Chapter 7).
8A-10 Chapter 8 Part A Electrical system (XV535 models) should not be overlooked. If breakage does occur, the entire switch and related wiring harness will have to be replaced with a new one, since individual parts are not usually available. 2 The switches can be checked for continuity with an ohmmeter or a continuity test light. Always disconnect the battery negative cable, which will prevent the possibility of a short circuit, before making the checks.
Chapter 8 Part A Electrical system (XV535 models) 17.1a The handlebar switches are held together by screws (arrows); this is the throttle side . . . 17.1b . . . the clutch side switches are also held together by screws (arrows) 18.5a Loosen the small screw (arrow) and disconnect the wire; remove the three mounting screws . . . 17 Handlebar switches - removal and installation Refer to illustrations 17.1a, 17.1b and 17.1c 1 The handlebar switches are composed of two halves that clamp around the bars.
8A-12 Chapter 8 Part A Electrical system (XV535 models) 19.5 Sidestand switch mounting screws 20.4 Insert a pointed tool into the hole (arrow), compress the prong and pull out the clutch switch 21.1 Disconnect the horn wires (A) and remove the bracket bolt (B)" 3 With the sidestand in the down position, the meter should indicate infinite resistance. 4 If the switch fails either of these tests, replace it. Replacement Refer to illustration 19.
Chapter 8 Part A Electrical system (XV535 models) 8A-13 23.2 Starting circuit cut-off relay test 1 2 3 Ohmmeter Blue/white terminal Blue/white terminal 4 5 6 Red/white terminal (red/ black on 1994 models) Black/yellow terminal 12-volt battery cables) directly from the battery positive terminal to the disconnected end of the cable. Warning: Make the connection at the battery first and at the cable last; sparks are likely to occur, and if they occur near the battery they could cause it to explode.
Chapter 8 Part A Electrical system (XV535 models) 8A-14 25.5 Two-brush starter - exploded view 25.2 Four-brush starter motor - exploded view 1 2 3 4 5 Through-bolt Lockwasher Brush end cover Brush plate Plastic brush housing 6 7 8 9 10 Cable O-rings Starter housing O-ring Armature 1 2 3 4 5 6 Cable Terminal nuts and washers Brush end cover _, Brush plate O-ring Mounting bolt 7 8 9 10 11 Washer O-ring Through-bolt Armature Starter housing Disassembly Four-brush starter Refer to illustration 25.
Chapter 8 Part A Electrical system (XV535 models) 8A-15 25.9 Check the commutator for cracks and discoloring, then measure the diameter and compare it with the minimum diameter listed in this Chapter's Specifications 25.10a Continuity should exist between the commutator bars 25.10b There should be no continuity between the commutator bars and the armature shaft 25.11 There should be almost no resistance (0 ohms) between the brushes and the brush plate 25.
8A-16 Chapter 8 Part A Electrical system (XV535 models) 27.7 Measure stator coil resistance between 1 and 2,1 and 3, then 2 and 3 28.1a Remove the cover bolts (arrows)... 28.1b . . . and pry gently at the pry points (not between the gasket surfaces); there : one at the bottom . . . 28.1c . . . and another at the top 28.3 Be sure there are no metal fragments stuck to the rotor magnets (arrow) 28.
Chapter 8 Part A Electrical system (XV535 models) 28.5 Guide the wiring harness out through the back of the cover 28.11a Use a tool like this one to separate the rotor from the crankshaft. 8A-17 28.7 Remove the screws (A) to detach the stator; the other screws (B) secure the ignition pick-up coil and its wiring harness 28.10 Loosen the rotor bolt with a socket, then unscrew the bolt and remove the washer 28.11 b . . . then take the rotor off and lift the Woodruff key (arrow) out of its slot 28.
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 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.
8B-1 Chapter 8 Part B Electrical system (XV700-1100 models) Contents Section Alternator cover, stator, rotor and regulator/rectifier - removal and installation 28 Battery - charging 4 Battery - inspection and maintenance 3 Brake light switches - check and replacement 12 Charging system - output test 27 Charging system testing - general information and precautions...
8B-2 Chapter 8 Part B Electrical system (XV700-1100 models) 1984 and 1985 models Main Headlight Turn signals Ignition Tail/brake lights 1986 and later models Main Headlight Turn signals Ignition Tail/brake lights 20 amps 15 amps 15 amps 10 amps 10 amps : 30 amps 15 amps 15 amps 10 amps 10 amps Charging system Statorcoil resistance Charging system output 0.5 ohms+/ 10 percent at 20-degrees C (68-degrees F) 14.3 to 15.3 volts at 2,000 rpm Starter Starter commutator diameter Standard....
Chapter 8 Part B Electrical system (XV700-1100 models) 5.1 The main fuse is located beneath the seat; separate the halves of the fuse holder to expose the fuse 1 General information The machines covered by this manual are equipped with a 12-volt electrical system. The charging system models uses a rotor with permanent magnets that rotates around a stator coil of copper wire. This produces alternating current, which is converted to direct current by the regulator/rectifier.
8B-4 Chapter 8 Part B Electrical system (XV700-1100 models) 7.1a Remove the headlight cover screws . carefully for evidence of a short circuit. Look for bare wires and chafed, melted or burned insulation. If a fuse is replaced before the cause is located, the new fuse will blow immediately. 9 Never, under any circumstances, use a higher rated fuse or bridge the fuse block terminals, as damage to the electrical system could result.
Chapter 8 Part B Electrical system (XV700-1100 models) 8B-5 7.1c Tilt the headlight cover forward, remove the rubber dust cover and unplug the connector 7.2a If the headlight bulb is secured by a retainer ring, turn it counterclockwise (anti-clockwise) arid remove i t . . . 7.2b . . . then lift out the bulb (but make sure it has cooled first) 7.5 UK models have a parking light bulb in the headlight reflector 8.3 Horizontal adjustment is controlled by a screw 8.
8B-6 Chapter 8 Part B Electrical system (XV700-1100 models) 11.3 The turn signal relay on 1981 through 1983 models is a separate unit 12.7 Disconnect the electrical connector and the spring, then either remove the nut from the bracket or unscrew the switch from the nut 13.2a On models so equipped, remove the speedometer cable retainer bolt 13.
Chapter 8 Part B Electrical system (XV700-1100 models) 8B-7 13.
8B-8 Chapter 8 Part B Electrical system (XV700-1100 models) 13.
8B-9 Chapter 8 Part B Electrical system (XV700-1100 models) 13.
8B-10 Chapter 8 Part B Electrical system (XV700-1100 models) 13.6 Remove the speedometer securing nut and lift the speedometer out 14.1a Remove the warning light cover screws and lift off the cover . . . 5 If you're working on a 1981 through 1983 XV750, an XV920J, or an XV920 K or MK, disassemble the cluster as necessary for access to speedometer, 6 If you're working on an XV920 RH, XV920 RJ or TR1.
Chapter 8 Part B Electrical system (XV700-1100 models) 16.2 Hazard switch terminals (1984-on XV1000 and XV1100) 8B-11 3 Connect the terminal in the harness side of the connector to ground/earth (bare metal on the motorcycle frame) with a short length of wire. a) If the light stays out, check the bulb and the wiring between the ignition switch and neutral switch. b) If the neutral indicator light comes on, the neutral switch may be bad.
8B-12 Chapter 8 Part B Electrical system (XV700-1100 models) 23.1 The starting circuit cutoff relay is located beneath the seat (early XV750 shown); it can be identified by its wire colors 23.2 Cutoff relay test connections (1981 through 1983 models) 23.3 Cutoff relay diode test connections (1981 through 1983 models) 23.5 Cutoff relay test connections (1984 and later models) 23 Starting circuit cut-off relay - check and replacement Refer to illustration 23.
8B-13 Chapter 8 Part B Electrical system (XV700-1100 models) 24.3 Remove the mounting bolts (arrows) 3 Remove the starter mounting bolts (see illustration). 4 Lift the end of the starter up a little bit and slide the starter out of the engine case (see illustration). 5 Check the condition of the O-ring on the end of the starter and replace it if necessary. Also check the starter pinion gear and the driven gear inside the engine for chipped or worn teeth.
8B-14 Chapter 8 Part B Electrica! system (XV700-110Q models) 25.3a Check the reduction gears for wear or damage . . . 25.3b . . . and check the bushing inside the gear end plate damage (see illustrations). The gears aren't available separately, so the starter will have to be replaced if they're worn or damaged.
Chapter 8 Part B Electrical system (XV700-1100 models) -8B-15 28.6 Hold the thrust collar in with a flat steel ruler or similar tool while installing the cover 28.8 Alternator rotor and stator details 1 2 3 4 Rotor Stator Bolt Pickup coils (dual pickup model shown) 5 6 7 8 Pickup coil screws Washers Pickup coil screws (alternate locations) Washers 8 Remove the stator screws and take the stator out (see illustration). 9 Installation is the reverse of the removal steps.
8B-16 Chapter 8 Part B Electrical system (XV700-1100 models) c) Aligning the rotor and intermediate gear must be done in a specific way. Refer to the timing gear installation procedures in Part B of Chapter 2. d) Tighten the rotor nut to the torque listed in this Chapter's Specifications (see illustration). Regulator/rectifier Refer to illustration 28.14 14 On 1981 through 1983 models, the regulator/rectifier unit is mounted on the rear subframe (see illustration).
Chapter 8 Part B Electrical system (XV700-1100 models) 29.3a Remove the oil level switch cover . . . 29.3b .. .and unscrew the switch from the crankcase Removal 2 Remove the starter motor (see Section 24) and the alternator cover (see Section 28). 8B-17 30.3 The spring clips must fit into the notches in the crankcase idler shaft, the remaining spring clip, two more idler,gears and the washer (see illustration).
8B-18 Chapter 8 Part B Electrical system (XV700-1100 models) 30.10a Remove the solenoid screws and nuts ., 30.7 Starter clutch details (XV1000, XV1100 and 1986 and later XV700 and XV750 models) 1 2 3 4 5 6 7 8 9 Starter clutch Snap-ring Shaft Starter wheel Inner idler gear Outer idler gear Thrust collar Spring Collar - 10 11 12 13 14 15 16 17 18 Drive lever shaft Oil seal Collar Screw Drive lever return spring Pivot bolt Gasket Nut 30.10b . . .
Chapter 8 Part B Electrical system (XV700-1100 models) 8B-19 30.12a Check the components for wear and damage (XV920 and 1981 through 1985 XV700 and XV750) 30.12b Measure the tightness of the spring clips by rotating them with a spring scale; replace them if they turn too easily 30.13a Check the components for wear and damage (XV1000, XV1100 and 1986 and later XV700 and XV750 models) 30.13b Check the bushing in the starter clutch for wear or damage . . . them for wear or damage (see illustration).
8B-20 Chapter 8 Part B Electrical system (XV700-1100 models) 30.21 Appiy non-permanent thread locking agent to the threads of the pivot bolt 30,23 Install the starter drive assembly Apply non-permanent thread locking agent to the pivot bolt, then install it and tighten it securely (see illustration). 22 Install the starter motor (see Section 24). 23 Install the thrust collar, idler gear, drive lever shaft, idler gear, spring, starter wheel, shaft and thrust collar (see illustration).
Wiring diagram - XV535 (1987 and 1988 US models) Chapter 9 Wiring diagrams 9-1
Wiring diagram - XV535 (1989 and later US models) 9-2 Chapter 9 Wiring diagrams
1 2 3 4 5 6 7 8 9 10 Right handlebar switch Lighting switch Start switch Engine kill switch Fuel switch Horn Ignition coil Sparkplug Main switch Diode 11 12 13 14 15 16 17 18 19 20 Fuel pump Rectifier/regulator Fuel sender Battery Starter relay Starter motor Right rear turn signal Tail/brake light Left rear turn signal Sidestand relay 21 22 23 24 25 26 27 28 29 30 Rear brake switch Neutral switch Pickup coil Alternator Fuse block Sidestand relay Relay assembly Fuel pump relay Igniter unit Left handleba
1 2 3 4 5 6 7 8 9 Right handlebar switch Start switch Lighting switch Engine kill switch Fuel switch Horn Ignition coil Spark plug Main switch 10 11 12 13 14 15 16 17 18 Diode Fuel pump Solenoid valve Rectifier/regulator Battery Starter relay Starter motor Right rear turn signal Tail/brake light 19 20 21 22 23 24 25 26 27 Left rear turn signal Sidestand switch Neutral switch Pickup coil Alternator Rear brake switch Fuse block Turn signal relay Sidestand relay 28 29 30 31 32 33 34 35 36 Wiring diagram
Horn Front right-hand turn signal 3 Right-hand handlebar switch 4 Engine kill switch 5 Starter switch 6 Lighting switch 7 Front brake switch 8 Ignition coil 9 TCI unit 10 Starter motor 11 Oil level switch 12 Starter solenoid 13 Battery 14 Main fuse 15 Regulator/rectifier 16 Rear brake switch 17 Rear right-hand turn signal 18 Tail/stop lamp 19 Rear left-hand turn signal 20 Turn signal cancelling unit 21 Starter circuit cut-out relay 22 Starter relay 23 Turn signal relay 24 Neutral switch 25 Pickup coil 26 Al
Wiring diagram - XV750H, J, K and MK models 9-6 Chapter 9 Wiring diagrams
Wiring diagram - XV920 J model Chapter 9 Wiring diagrams 9-7
Wiring diagram - XV920K and MK models 9-8 Chapter 9 Wiring diagrams
Wiring diagram - XV920 RH and RJ models Chapter 9 Wiring diagrams 9-9
9-10 Chapter 9 Wiring diagrams Wiring diagram - XV700 and 1000 (1984 and 1985 US models) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Alternator Rectifier/regulator Main key switch Ignition fuse Engine kill switch Starter motor Starter relay (XV700) or solenoid switch (XV1000) Battery Main fuse Headlight fuse Starter switch Signal fuse Clutch switch Sidestand switch Sidestand relay 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Oil level indicator light Igniter unit Oil level switch Pickup coil Ignition coil T
Wiring diagram (1986 and later US XV700 and XV750 models) Chapter 9 Wiring diagrams 9-11
Wiring diagram (1986 and later US XV1100 models) 9-12 Chapter 9 Wiring diagrams
7 2 3 4 5 6 7 8 9 10 Ma/n switch Neutral switch Alternator Rectifier regulator Main fuse Battery Solenoid relay Starter motor Starting circuit cutoff relay Lighting switch 11 12 13 14 15 16 17 18 19 20 Engine kill switch Start switch Diode Oil level switch Clutch switch Sidestand switch Igniter unit Ignition coil Sparkplug Pickup coil 21 22 23 24 25 26 27 28 29 30 Carburetor heater Thermoswitch Relay unit Turn signal switch Flasher light Horn Horn switch Dimmer switch Passing switch Headlight 31 32 33
1 2 3 4 5 6 7 8 9 10 11 Left front turn signal Right front turn signal Turn signal switch Clutch switch Horn switch Passing switch Dimmer switch Headlight Auxiliary light Fuse block High beam indicator light 12 13 14 15 16 17 18 19 20 21 22 Oil level indicator light Neutral indicator light Turn indicator light Tachometer Fuel warning indicator light Instrument illumination Reed switch Horn Main switch Front brake switch Engine kill switch 23 24 25 26 27 28 29 30 31 32 33 Start switch Lighting switch Fu
Conversion factors Length (distance) Inches (in) Feet (ft) Miles X 25.4 X 0.305 X 1.609 = Millimetres (mm) = Metres (m) = Kilometres (km) Volume (capacity) Cubic inches (cu in; in3) Imperial pints (Imp pt) Imperial quarts (Imp qt) Imperial quarts (Imp qt) US quarts (US qt) Imperial gallons (Imp gal) Imperial gallons (Imp gal) US gallons (US gal) X X X X X X X X = = = = = = = = X X X 0.0394 3.281 0.621 = Inches (in) = Feet (ft) = Miles X X X X X X X X 0.061 1.76 0.88 0.833 1.057 0.22 0.833 0.
IND-1 Index A About this manual, 0-5 Acknowledgements, 0-2 Air filter, element, servicing, 1-16 Alternator, removal and installation XV535 models, 8A-16 XV700 through 1100 models. 8B-14 B Battery charging, 8A-4 inspection and maintenance. 1 -8 Bearings connecting rod. general note. XV700 through 1100 models, 2B-41 connecting rod, inspection and selection XV535 models. 2A-48 XV700 through 1100 models, 2B-42 main, inspection and selection XV535 models.
Index clutch, see Clutch cable throttle, adjustment, 1-11 throttle, removal and installation XV535 models, 3A-16 XV700 through 1100 models, 3B-13 Caliper (brake), removal, overhaul and installation, see Brake caliper Camshaft chain, removal, inspection and installation XV535 models, 2A-37 XV700 through 1100 models, 2B-22 chain tensioner, removal and installation XV535 models, 2A-7 XV700 through 1100 models, 2B-13 removal, inspection and installation XV535 models, 2A-9 XV700 through 1100 models, 2B-14 Carbur
IND-3 oil pressure relief valves, removal, check and installation, see Oil oil pump, pressure check, removal, inspection and installation, see Oil Piston rings, installation, see Piston Pistons, removal, inspection and installation, see Piston removal and installation XV535 models, 2A-5 XV700 through 1100 models, 2B-11 Engine fuel and exhaust systems XV535 models, 3A-1 XV700 through 1100 models, 3B-1 Exhaust system check, 1-24 removal and installation XV535 models, 3A-16 XV700 through 1100 models^ 3B-14 Ext
Index bulb, replacement XV535 models, 8A-5 XV700 through 1100 models, 8B-4 Horn, check and replacement XV535 models, 8A-12 XV700 through 1100 models, 8B-11 Hoses, brake, inspection and replacement, see Brake IND-4 N Neutral switch, check and replacement, see Switch o Oil I Identification numbers, 0-16 Idle fuel/air mixture adjustment, general information XV535 models, 3A-5 XV700 through 1100 models, 3B-5 Idle speed, check and adjustment, 1-22 Igniter, removal, check and installation XV535 models, 4A-4 X
IND-5 Index Side covers, removal and installation XV535 models, 7A-4 XV700 through 1100 models, 7B-2 Sidestand switch, check and replacement, see Switch Spark plugs, replacement, 1-18 Specifications, general, 0-7 Speedometer and cable, removal and installation, XV535 models, 8A-7 Sprockets (chain drive models), check and replacement, 5B-20 Starter clutch, removal, inspection and installation XV535 models, 8A-17 XV700 through 1100 models, 8B-16 motor disassembly, inspection and reassembly XV535 models, 8A-
Common spark plug conditions NORMAL Symptoms: Brown to grayish-tan color and slight electrode wear. Correct heat range for engine and operating conditions. Recommendation: When new spark plugs are installed, replace with plugs of the same heat range. WORN Symptoms: Rounded electrodes with a small amount of deposits on the firing end. Normal color. Causes hard starting in damp or cold weather and poor fuel economy. Recommendation: Plugs have been left in the engine too long.
