Haynes Yamaha Xv V Twins Manual

2B-46 
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

26.9h Transmission shafts (XV700-1100 models) -

exploded view

1 Mainshaft

2 Fourth pinion gear

3 Second-third pinion gear

4 Fifth pinion gear

5 Fifth wheel gear

6 Second wheel gear

7 Driveaxle

8 Third wheel gear

9 Fourth wheel gear

10 Middle drive gear

11 First wheel gear

12 Middle driveshaft

13 Middle driven shaft

14 Middle driven gear

15 Oil pump drive sprocket

26.10a Slide the fifth wheel gear off the...

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

2B-47

26.10c ... and the thrust washer ...

26.10d ... and slide second wheel

gear off 
26,1 Oe At the other end of the driveaxle,

slide off the middle drive gear ...

26.10f ... the first wheel gear ...

26.1 Og ... and the fourth wheel gear

26.10h Remove the snap-ring ...

26.101 ... and the thrust washer ...

26.10J ... and the third wheel gear ...

26.10k ... from the driveaxle

Driveaxle

Refer to illustrations 26.10a through...

2B-48 
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

26.12 Check the gear bushings (if

equipped) for wear or damage 
26.15 Check the teeth, splines and

bearing on the middle drive gear 
26.19 The stopper plate can be left in

position unless its loose or the

crankcases are to be replaced - if you

remove it, use Loctite Stud n Bearing

Mount or equivalent on the screw threads

noises. If any of these conditions are found, replace the bearing with a

blind hole puller (see...

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

2B-49

26.25 Engage the pin on the fifth pinion

gear shift fork with the groove in the

shift cam 
26.26 Install the remaining two shift forks

and engage their pins with the shift

cam grooves 
26.27a Slide the guide bar through

the forks ...

26.27b ... and align its flat with the teeth of the middle drive gear
them correctly. The forks are numbered from one to three, starting

from the left side of the engine.

24 Install the...

2B-50 
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

Notes 

3A-1

Chapter 3 Part A

Fuel and exhaust systems (XV535 models)

Contents

Section

Air induction system (1990-on US models) -

inspection and component replacement 13

Air filter element - servicing See Chapter 1

Carburetor overhaul - general information 5

Carburetors and intake joints - removal and installation 6

Carburetors - disassembly, inspection, cleaning

and reassembly 7

Carburetors - fuel level adjustment 8

Evaporation control system (California models) - inspection

and canister...

3A-2 
Chapter 3 Part A Fuel and exhaust systems (XV535 models)

Specifications

Carburetor

Type Mikuni BDS34 (two)

Jet sizes

Main jet

1987 and 1988 135

1989 through 1993

Front cylinder 137.5

Rear cylinder 135

1994 US

Front cylinder 137.5

Rear cylinder 135

1994 UK and Canada 135

Main air jet 140

Jet needle/clip position

1987 and 1988 US and Canada

Front cylinder 5DZ7-1

Rear cylinder 5DZ8-1

1990 through 1993 US and Canada

Front cylinder 5DZ17-1

Rear cylinder 5DZ18-1

1994 US

Front...

Chapter 3 Part A Fuel and exhaust systems (XV535 models) 
3A-3

2.4a Release the fuel hoses from the clips on top of the

battery cover

A Clips

B Hose clamps

C Tank mounting bolts 
D Battery positive cable

(always disconnect the

negative cable first)

2.4b Fuel tanks and lines (models with upper fuel tank)

1 Fuel lines

2 Fuel filter

3 Fuel pump 
4 Fuel tap

5 Lower fuel tank

6 Upper fuel tank

2.5a Remove the upper tank mounting bolt at the rear ...

2.5b ... and one on each side
1 General...

3A-4 
Chapter 3 Part A Fuel and exhaust systems (XV535 models)

2.6a Lift the tank and disconnect the

hoses from the fittings (arrows) . . . 
2.6b ... theres a fuel hose on each side

2.10 Remove the mounting bolts (arrows)

and take off the footpeg bracket

2.11 Fuel tank and lines (models without upper fuel tank)

1 Vapor hoses

2 Breather hose

3 Rollover valve

4 Fuel filter 
5 Fuel pump

6 Fuel tank

7 Rubber cover 
2.13 Work the drain fitting (arrow) free of the rubber cover and lift

the cover...

Chapter 3 Part A Fuel and exhaust systems (XV535 models)

3A-5

2.14a Remove the mounting bolts ... 
2.14b ... and detach the rubber dampers

from the brackets 
6.6 Free the hose from the retaining clips

Even after cleaning and flushing of the fuel system, explosive fumes

can remain and ignite during repair of the tank.

2 If the fuel tank is removed from the vehicle, it should not be

placed in an area where sparks or open flames could ignite the fumes

coming out of the tank. Be especially careful...