Haynes Yamaha Xv V Twins Manual

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

20.10c Crankcase halves - shaft drive models

1 Crankcase halves

2 Dowels

3 Stud

4 Stud

5 Stud

6 Stud

7 O-ring

8 O-ring

9 Dowel

10 Bolt

11 Bolt

12 Bolt

13 Bolt

14 Bolt

15 Bolt

16 Sealing washer

17 Oil filler plug

18 O-ring

19 Clamp

20 Protector plate...

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...

2B-38 
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

21.4a Right crankcase half components

7 Crankshaft bearing

2 Transmission bearings

3 Middle gear bearings

4 O-ring

5 Oil pressure relief valve

6 Oil level switch

21.4b Use a slide hammer to remove the bearings if they dont lift

out easily ... 
21.4c ... the slide hammers puller attachment fits behind the

bearing like this

4 Spin the bearings in the crankcase halves (see illustration) with

fingers and check for...

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)

23.3b Crankshaft details

1 Crankshaft

2 Right main bearing

3 Woodruff key

4 Left main bearing

5 Oil pump drive sprocket

6 Washer

7 Nut

8 Piston 
9 Piston pin

10 Circlip

11 Piston rings

12 Connecting rod

13 Connecting rod bearings

14 Connecting rod studs

15 Connecting rod nuts 
23.5 Make sure the oil passage plugs are tight

Inspection

Refer to illustrations 23.5 and 23.7

4 If you havent already done so, mark and...

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

2B-41

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 thats braced against the outer race of the ball bearing

will transfer the installation force to the balls and retainers, damaging

the bearing. The same thing will happen if the...

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 
25.12 Tighten the cap nuts to the

specified torque in one continuous motion

off the condensed water and corrosive gases produced. These

products collect in the engine oil, forming acid and sludge. As...

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

2B-43

25.18a The number on each connecting rod is used for bearing

selection; the letter is used to align the rod and cap 
25.18b The letter on the crankshaft is used together with the

connecting rod number to select bearings

14 If the clearance is within the range listed in this Chapters Specifi-

cations and the bearings are in perfect condition, they can be reused. If

the clearance is greater than the wear limit, replace the...

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)

26.3 Lift the shock absorber assembly out of the crankcase

(chain drive models)

1

2

3

4

5

6

7 
Shock absorber shaft

Bearing

Oil seal

Engine sprocket

Splined lockwasher

Tab washer

Bolts 
8

9

10

11

12

13

14 
Collar

Spring

Spring end plate

Middle driven gear pinion

Thrust washer

Spring retaining collars

Bearing...

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 
26.9g First pinion gear is integral with the mainshaft

illustration).

5 Remove the two...