Haynes Yamaha Xv V Twins Manual
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Page 171
3A-6 Chapter 3 Part A Fuel and exhaust systems (XV535 models) 6.8 If this wiring harness obstructs removal, detach it from its clip (arrow) and move it out of the way 6.9 Loosen the clamp and pull the fuel line off the fitting 6.10a Loosen the clamping band screws on the air cleaner joints ... 6.10b ... insert a flat-bladed screwdriver between the joint and carburetor (arrow) and push the joint up into the air cleaner cavity 6.11 a Loosen the clamping band screws (upper arrows); an...
Page 172
Chapter 3 Part A Fuel and exhaust systems (XV535 models) 3A-7 7.1 Carburetors (XV535 models) - exploded view 1 Jet needle assembly 2 Vacuum piston 3 Main nozzle 4 O-ring 5 No. 2 pilot air jet 6 No. 1 pilot air jet 7 Drain screw 8 Float 9 Needle valve 10 Choke plunger assembly 11 Coasting enricher diaphragm 12 Main jet 13 Main bleed pipe 14 Pilot jet 15 Throttle stop screw 7.2a Remove the float chamber cover screws and take off the cover ... illustrations). Note: You can also unbolt...
Page 173
3A-8 Chapter 3 Part A Fuel and exhaust systems (XV535 models) 7.2b ... remove the other float chamber cover ... 7.2c ... disconnect the fuel and vent lines and set them aside 7.3a Pull out the float... 7.3b ... and lift out the needle valve 7.4a Unscrew the main Jet.., 7.4b ... and the main nozzle holder ... 7.4c ... remove the O-ring with a pointed tool... 7.4d ... remove the jet block screws ... 7.4e ... then lift out the jet block and remove its gasket off both float chamber covers,...
Page 174
Chapter 3 Part A Fuel and exhaust systems (XV535 models) 3A-9 7.5a Pull the two rubber plugs out of their passages . 7.5b ... unscrew the pilot jet... 7.5c ... and the main bleed pipe 7.5d Jet block components A Jet block B Pilot jet C Rubber plug D Rubber plug E Main bleed pipe F Main jet G Main nozzle holder 7.6a Remove the screws and lift off the coasting enricher valve cover ... 7.6b ... then lift out the spring and diaphragm
Page 175
3A-10 Chapter 3 Part A Fuel and exhaust systems (XV535 models) 7.7a Note the locations of the hose clips and remove the cover screws . .. 7.7b ... one of the screws requires a Torx bit 7.8a Lift off the cover ... 7.8b ... and remove the spring 7.8c Carefully separate the diaphragm from the carburetor body without tearing it... 7.8d ... and remove the O-ring 7.9a Remove the O-ring from the main nozzle ... 7.9b ... then push the main nozzle into the throttle bore (arrow) and remove it...
Page 176
Chapter 3 Part A Fuel and exhaust systems (XV535 models) 3A-11 7.10b ... and the no. 1 pilot air jet from the throttle bore (arrow) 7.11a Loosen the choke link securing screws (theres one for each carburetor)... 7.11b ... remove the choke lever pivot screw . 7.11c ... its spring and washers 7.11d Remove the clip and washers ... 7.11e ... and take off the choke lever
Page 177
3A-12 Chapter 3 Part A Fuel and exhaust systems (XV535 models) 7.12a Remove the clip from the end of the choke link with a pointed tool... 7.12b ... remove the spring retainer ... 7.12c ... the spring . 7.12d ... and pull out the choke link 7.13a Pry the washer and bushing loose with a pointed tool... 7.13b ... and remove them from the choke shaft passage 7.15a Detach the upper stay plate ... 7.15b ... and the lower stay plate ... 7.15c ... note carefully how the synchronizing screw fits...
Page 178
Chapter 3 Part A Fuel and exhaust systems (XV535 models) 3A-13 7.15d ... and pull the carburetors apart 7.16a Unscrew the choke plunger ... 7.16b ... and take it out of the housing 7.16c Remove the housing mounting screws ... 7.16d ... and take the housing and gasket off the carburetor body 7.17 Remove two screws and take the throttle pulley assembly off 7.19 Pilot screw components A Pilot screw B Spring C Washer D O-ring 7.20 Remove the O-ring from each float chamber cover with a...
Page 179
3A-14 Chapter 3 Part A Fuel and exhaust systems (XV535 models) 7.26a Remove the screw from inside the vacuum piston ... 7.26b ... and lift out the jet needle , 7.26c ... together with the spring, washer, clip and O-ring 7.28 Check the coasting enricher solenoid diaphragms for cracks or brittleness 21 Check the operation of the choke plunger. If it doesnt move smoothly, replace it, along with the return spring. Inspect the needle on the end of the choke plunger and replace it if its worn. 22...
Page 180
Chapter 3 Part A Fuel and exhaust systems (XV535 models) 3A-15 7.32a Align the choke shaft screws with the dimples in the shaft (arrows) 7.32b Align the protrusion in the diaphragm with the notch in the carburetor body (arrow) 7.32c Align the tab on the coasting enricher diaphragm with the notch in the carburetor body (arrow) 8.3 Connect the tool to one of the drain fittings (arrows) 8.4 Loosen the float chamber drain screw 8.6 Bend the float tang to change fuel level 8 Carburetors - fuel...