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...