User Guide

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.
Note: When reassembling the carburetors, be sure to use the new O-
rings, gaskets and other parts supplied in the rebuild kit.
58 Assembly is the reverse of the disassembly steps, with the
following additions.
a) Be sure the needle jet is pushed all the way into its bore. When
you install the vacuum piston, be sure the jet needle fits into the
needle jet.
b) Align the protrusion on the vacuum piston and diaphragm with the
notch in the carburetor body.
c) Install the carburetors (see Section 6) and check the fuel level (see
Section 8).
8 Carburetors - fuel level adjustment
Refer to illustration 8.3
Warning: Gasoline (petrol) is extremely flammable, so take extra
precautions when you work on any part of the fuel system. Don't smoke
or allow open flames or bare light bulbs near the work area, and don't
work in a garage where a natural gas-type appliance (such as a water
heater or clothes dryer) is present. If you spill any fuel on your skin,
rinse it off immediately with soap and water. When you perform any
kind of work on the fuel system, wear safety glasses and have a fire
extinguisher suitable for class B type fires (flammable liquids) on hand.
1 Support the bike securely in an upright position so it can't be
knocked over during this procedure.
2 Remove components as necessary for access to the float
chamber drain screws.
3 Attach Yamaha service tool no. YM-01312 (UK part no. 90890-
01312) to the drain fitting on the bottom of one of the carburetor float
chambers (both will be checked) (see illustration). This is a clear plastic
tube graduated in millimeters. An alternative is to use a length of clear
plastic tubing and an accurate ruler. Hold the graduated tube (or the free
end of the clear plastic tube) vertically against the float chamber cover.
4 Unscrew the drain screw at the bottom of the float chamber a
couple of turns, then start the engine and let it idle - fuel will flow into
the tube. Wait for the fuel level to stabilize, then note how far the fuel
level is below the line on the float chamber cover.
8.3 A gauge like this or a clear tube and ruler can be
used to measure fuel level
5 Measure the distance between the indicator line and the top of
the fuel level in the tube or gauge. This distance is the fuel level - write
it down on a piece of paper, tighten the drain screw, then move on to
the other carburetor and check it the same way.
6 Compare your fuel level readings to the value listed in this
Chapter's Specifications. If the fuel level in either carburetor is not
correct, remove the float chamber cover and bend the tang up or down
as necessary, then recheck the fuel level.
9 Throttle cables and grip - removal, installation and
adjustment
Refer to illustrations 9.1, 9.3a and 9.3b
Removal
1 Loosen the throttle cable(s) with the adjusters and remove the
throttle cable securing screw at the handlebar (see illustration).
2 Remove the handlebar switch mounting screws. Separate the
halves of the handlebar switch and detach the throttle cable(s) from the
throttle grip pulley (see Chapter 8).
3 Detach the throttle cables from the throttle pulley at the
carburetors (see illustrations). Remove the cables, noting how they
are routed.
4 Slide the throttle grip off the handlebar.
9.1 Loosen the cable locknuts (A) and
turn the adjusters to create slack;
remove the cable securing screw (B)
9.3a Pull the cable housing out of the
bracket and slip the cable through
the slot (arrow)...
9.3b ... then align the cable with the slot
in the throttle pulley fitting and
slip the cable end out