Haynes Yamaha Xv V Twins Manual

2A-46

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

25.2 Lift the crankshaft and connecting rods out of the crankcase
Caution: The crankcase halves should fit together completely without

being forced. If theyre 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 lowest-...

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

25.10 Press the main bearing out; apply pressure from the side

opposite the locating tab
several times - if a journal picks up copper from the coin, its too...

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 
25.14 Coat the bearing with assembly lube

or...

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

2A-49

26.1 Measure big end play between the two rods and between

the rods and crankshaft 
26.2 Label the rods and caps according to their position on the 2A

crankshaft (left or right)

26.3a Undo the connecting rod nuts

26.3b ... and take off the caps

26.5 Slip the piston pin into the rod and rock it back-and-forth to

check for looseness

and cap, relative to its position on the crankshaft (left or right) (see

illustration).

3...

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...

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 dont 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 out... 
27.2b ... and disengage the forks from...

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 ... install the...

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

2A-53

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 fork... 
27.8h ... (the assembled fork and guide

bar should look like this)

28.3a Transmission gears and shafts (XV535

models)

1) Bearing

2) First wheel gear

3) Fourth wheel gear

4) Snap-ring

5) Thrust washer

6) Third wheel gear

7) Fifth wheel gear

8)...

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

28.8a Remove the snap-ring ,

28.8b ... and the thrust washer 
28.9 Remove the second wheel gear

gears on a rod in order as they are removed so they can be

reassembled in the same order...

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

2A-55

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 ... 
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 ... be sure to use the proper

Torx...