Haynes Yamaha Xv V Twins Manual

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) . 
16.35 ... if tight friction plates impede

clutch movement, align the single

notches (3) with the marks (2) 
16.37a Loosen the adjuster

locknut (arrow)

16.37b Align the clutch lever mark with

the mark on the crankcase 
16.38a Remove the snap-ring , 
16.3&b ... and pry out the seal

16.38c Make sure the...

Chapter 2 Part A Engine, clutch and transmission (XV535 models)

2A-37

17.2a Lift out the exhaust side chain

damper (arrow)... 
17.2b ... the bottom end fits into a slot in

the crankcase

a) Chain damper slot

b) Intake side chain damper bolts 
17.5 Take the intake side chain guide off

the crankcase

17.9 Remove the exhaust side chain

damper bolts (arrows) and lift the chain

damper out 
17.10 Slip the chain off the sprocket and

remove it 
17.12 Check the friction surface of each

damper for wear...

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 off... 
18.3 ... then remove the dowel with O-

ring and separate O-ring (arrow)

18.5a The cover screw (arrow) may be

tight enough to require an impact driver 
18.5b Lift off the cover ... 
18.6a ... the outer rotor .

18.6b ... and the inner rotor
18 Oil pump - removal, inspection and installation

Note: The oil pump can be removed with the engine in the...

Chapter 2 Part A Engine, clutch and transmission (XV535 models) 
2A-39

18.6c Pump body and rotors

A) Pump body C) Inner rotor

B) Drive pin D) Outer rotor 
18.8a Measure the tip clearance between the

inner and outer rotors

18.8b ... and the clearance between the outer rotor and housing 
18.9a Remove the screw (use an impact driver if its tight)...

18.9b take off the cover . 
18.9c ... dump out the spring . 
18.9d ... and the relief valve 

2A-40 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

18.9e Relief valve components 
18.10 Be sure the drive pin aligns with the slot in the inner

rotor (arrows)

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 
19.1 Remove the Allen bolts (arrows) and

take off the oil passage housing 
19.2a Pull the strainer out of

the housing ...

19.2b ... or out of the engine
10 If the pump is good, reverse the...

Chapter 2 Part A Engine, clutch and transmission (XV535 models)

2A-41

19.4a Install new O-rings in the oil passage housing (arrows) 
19.4b ... and on the strainer

19.5 Push the strainer into the oil

passage housing until it seats securely 
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)...

20.8b ... and the washer
20 External shift mechanism - removal, inspection and

installation

Shift lever and pedal

Refer to...

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 wont be lost 
20.15a Pry the shift shaft seal out of

the crankcase ... 
20.15b ... press a new seal in with

fingers or a...

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

21.4 Remove the O-ring from the housing with a pointed tool
17 Install the plain washer and circlip on the other end of the...

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 its worn

or damaged 
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

22.9a Loosen the crankcase bolts in

sequence, starting with the highest

numbered bolts (in the right side of

the crankcase)... 
22.9b ... and working to the lowest (in the

left side of the crankcase) 
22.9c...

Chapter 2 Part A Engine, clutch and transmission (XV535 models)

2A-45

22.10a Lift the right crankcase half off

the left half... 
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 (theres

one at each end of the crankcase)... 
22.11b ... and the large dowel with

its O-ring

22.12 The oil baffle plate can be left in

position...