Haynes Yamaha Xv V Twins Manual

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 its loose ... 
28.14b ... then remove the gear from

the shaft

28.15a Take off fifth pinion gear. .. 
28.15b ... and third pinion gear 
28.16a Remove the snap-ring .

28.16b ... the thrust washer ... 
28.16c ... and fourth pinion gear

main axle (see illustration). The...

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

28.23b Press second pinion gear onto the shaft until the gearset

is the specified length
Inspection

Refer to illustration 28.21

17 Wash all of the components in clean solvent and dry them off.

Rotate the ball...

2A-58

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

28.24a Install second wheel gear

28.24b ... the thrust washer ...

28.24c ... the snap-ring ...

28.24d ... and fifth wheel gear

28.25 Install third wheel gear on the main axle at the same time

you install the driveaxle in its bearing

28.26a When the gears are in the neutral position, the gear dogs

(arrows) are not engaged with the slots in the gears next to them

and the gears can be turned independently of each other...

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

2A-59

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 
the engine and any new parts installed have started to seat.

2 Even greater care is necessary if the engine has been...

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 . 14

Camshaft chain tensioners - removal and installation 7

Clutch and primary gears - removal, inspection

and installation 17

Clutch cable replacement and release mechanism removal

and installation 16

Compression test See Chapter 1

Connecting rod bearings - general note...

2B-2 
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

Specifications

XV700 and XV750 models

General

Bore x stroke

XV700 80.2x69.2 mm (3.16x2.72 inches)

XV750 . 83.0 x 69.2 mm (3.268 x 2.72 inches)

Displacement

XV700 ..... 699 cc

XV750.... 748 cc

Compression ratio

1981 though 1983 8.7 to 1

1984-on.. 9.0 to 1

Camshafts

Lobe height

Intake 39.17 mm (1.5421 inch)

Exhaust 39.20 mm (1.5433 inch)

Base circle

1981 through 1983

Intake . 32.00 mm (1.2598 inch)

Exhaust 32.00...

Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

2B-3

Bore measuring point

Through 1987 Top, center and bottom of cylinder

1988-on 35 mm (1.38 inch) from top of bore

Taper and out-of-round limit 0.05 mm (0.002 inch)

Pistons

Piston diameter (XV700)

Standard 80.135 to 80.185 mm (3.155 to 3.157 inches)

.First oversize 80.50 mm (3.17 inches)

Second oversize 81.00 mm (3.19 inches)

Piston diameter (XV750)

Standard 82.95 to 82.97 mm (3.266 to 3.267 inches)

First oversize ......

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 (8.7 ft-lbs)

Clutch boss nut 70 Nm (50 ft-lbs) (4)

Clutch cover...

Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

2B-5

Valve head diameter

RH models

Intake 43.0 to 43.02 mm (1.690 to 1.698 inch)

Exhaust 37.0 to 37.2 mm (1.460 to 1.468 inch)

J, K, MK models

Intake 47.0 to 47.2 mm (1.850 to 1.858 inch)

Exhaust 39.0 to 39.2 mm (1.540 to 1.548 inch)

Valve stem diameter

Intake 7.975 to 7.990 mm (0.311 to 0.314 inch)

Exhaust 7.960 to 7.975 mm (0.3134 to 0.3140 inch)

Valve head edge thickness limit 1.3 +/-0.2 mm (0.051 +/- 0.008 inch)

Valve...