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Haynes Yamaha Xv V Twins Manual

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Page 191

3B-6 
Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models)

6.3 Squeeze the clip (arrow) and slide it down the fuel line, then

pry the fuel line off the fitting 
6.4 Loosen the air hose clamp screws (A) and the choke cable

retaining screw (B), then disconnect the choke cable (C)

from the carburetor

6 Carburetors and intake joints - removal and

installation

Warning: Gasoline (petrol) is extremely flammable, so take extra

precautions when you work on any part of the fuel system. Dont...

Page 192

Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models)

3B-7

7.1 Carburetors (XV700-1100,1981 through 1987 US and

all UK models) - exploded view

1 Vacuum chamber cover screws

2 Lockwashers

3 Upper bracket

4 Vacuum chamber cover

5 Piston spring

6 Vacuum piston

7 Jet needle

8 Spring

9 Plastic Allen screw

10 Needle jet

11 Choke control plate

12 Cotter pin

13 Washer

14 Screw

15 Lockwasher

16 Pilot adjustment screw

17 Spring

18 Spring

19 Screw

20 Washer

21 Throttle stop screw...

Page 193

3B-8 
Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models)

7.3 Remove the cotter pin and washer

and disconnect the choke linkage rod 
7.4 Remove the screws and detach the

bottom bracket 
7.5a Note carefully how the carburetors

fit together...

7.5b ... then pull them apart

7.6 Remove the E-clip and separate the linkage assembly

2 Remove the screws and detach the top bracket from the

carburetor assembly.

3 Remove the cotter pin and washer and disconnect the choke

linkage rod from the...

Page 194

Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models)

3B-9

7.9 Slip the choke control plate fingers

out of the groove in the choke plunger 
7.10 Unscrew the choke plunger cap

and take the plunger out of the

carburetor body 
7.11 Remove the float chamber

cover and gasket

7.12a Push the float pivot pin partway out

with a thin punch, then pull it clear ... 
7.12b ... and lift out the floats together

with the needle valve 
7.13 Unscrew the needle valve seat and

remove it together with its...

Page 195

3B-10 
Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models)

7.17a Remove the plastic Allen screw, the spring

and jet needle ... 
7.17b ... then separate the components

carburetor body. On US models, this screw is hidden behind a plug

which wili have to be removed if the screw is to be taken out. To do

this, drill a hole in the plug, being careful not to drill into the screw, then

pry the plug out or remove it with a small slide hammer. On all models,

turn the pilot screw in, counting the...

Page 196

Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models) 
3B-11

7.24 Remove the screws (1), the coasting enricher (2)

and the O-ring (3)

20 Check the carburetor body, float chamber cover and vacuum

chamber cover for cracks, distorted sealing surfaces and other

damage. If any defects are found, replace the faulty component,

although replacement of the entire carburetor will probably be

necessary (check with your parts supplier for the availability of

separate components).

21 Check the...

Page 197

3B-12 
Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models)

7.31 Carburetor (1987 and later US models)

- exploded view

1 Jet needle

2 Vacuum piston

3 Needle jet

4 Pilot air jet no. 1

5 Pilot air jet no. 2

6 Coasting enricher assembly

7 Main jet

8 Pilot jet

9 Float

10 Needle valve and seat

11 Throttle stop screw

12 Synchronizing screw

13 Choke plunger

14 Pilot screw

15 Spring

16 Choke plunger cap

17 Sealing washer

18 Main jet

19 Throttle pulley

20 Bottom bracket

21 Float...

Page 198

Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models)

3B-13

56 Check the needle valve seat for wear or damage. Check the filter

cap for clogging and clean or replace it as necessary. The sealing

washer should be replaced whenever the needle valve seat is removed.

Cleaning

57 Perform Steps 28 and 29 above to clean the carburetor

components.

Reassembly

Caution: When installing the jets, be careful not to over-tighten them -

theyre made of soft material and can strip or shear easily....

Page 199

3B-14

Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models)

10.1 Loosen the screw and detach the

cable housing from the bracket 
10.2 Remove the screw (arrow) and

detach the choke lever 
11.2 Remove the nuts that secure the

flange plate to the cylinder head

Installation

5 Clean the handlebar and apply a light coat of multi-purpose

grease.

6 Route the cable(s) into place, following the same route noted on

removal. Make sure they dont interfere with any other components

11.3a Exhaust...

Page 200

Chapter 3 Part B Fuel and exhaust systems (XV700-1100 models)

3B-15

11.3b Exhaust system (1981 through 1983 chain

drive models) - exploded view

1 Rear cylinder pipe

2 Bolt

3 Washer

4 Gasket

5 Washer

6 Bolt

7 . Left muffler/silencer

8 Mounting bracket

9 Bolt

10 Lockwasher

11 Right muffler/silencer

12 Mounting bracket

13 Bolt

14 Lockwasher

15 Gasket

16 Clamp

17 Bolt

18 Washer

19 Washer

20 Bolt

21 Front cylinder pipe

22 Bolt

23 Lockwasher

24 Washer

25 Sealing ring

26 Nut

27...
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