Haynes Yamaha Xv V Twins Manual

4B-2 
Chapter 4 Part B Ignition system (XV700-1100 models)

1 General information

These motorcycles are equipped with a battery operated, fully

transistorized, breakerless ignition system. The system consists of the

following components:

Pick-up coil(s)

Igniter unit

Battery and fuse

Ignition coils

Spark plugs

Ignition (main), engine kill (stop), sidestand and neutral switches

Primary and secondary (HT) circuit wiring

The transistorized ignition system functions on the same principle

as a...

Chapter 4 Part B Ignition system (XV700-1100 models)

4B-3

3.6 To test the coil secondary resistance, connect the ohmmeter

between the spark plug wire (HT) terminal and one of

the primary terminals 
3.11 Disconnect the coil primary connectors and remove the

mounting nuts or bolts to separate them from the bracket

other primary terminal (see illustration).

5 Place the ohmmeter selector switch in the Rx1 position and

compare the measured resistance to the value listed in this Chapters...

4B-4 
Chapter 4 Part B Ignition system (XV700-1100 models)

Removal and installation

1 If youre working on a 1981 through 1983 model, remove the fuel

tank (see Chapter 3).

2 If youre working on a 1984 or later model, remove the seat, the

left side cover and the luggage box (see Chapter 7).

3 Unplug the electrical connector, remove the mounting screws and

take the igniter out (see illustration 4.3).

4 Installation is the reverse of the removal steps.

6 Pressure sensor (1984 and later XV1000 and...

5A-1

Chapter 5 Part A Steering,

suspension and final drive (XV535 models)

Contents

Section

Driveshaft and final drive - removal, inspection and installation.... 9

Fork oil change 3

Forks - disassembly, inspection and reassembly 5

Forks - removal and installation 4

General information 1

Handlebar - removal and installation 2 
Section

Rear shock absorbers - removal, inspection and installation 7

Steering head bearings - replacement 6

Swingarm bearings - check 8

Swingarm bearings - inspection...

5A-2 
Chapter 5 Part A Steering, suspension and final drive (XV535 models)

2.2a On early models, pry off the

rubber cover... 
2.2b ... later models use a pair of plugs 
2.2c Remove the Allen bolts to detach the

handlebar brackets; the arrow cast

in each bracket must face forward

when the bracket is reinstalled

1 General information

The front forks are of the conventional coil spring, hydraulically-

damped telescopic type.

The rear suspension consists of twin shock absorbers with coil

springs...

Chapter 5 Part A Steering, suspension and final drive (XV535 models)

5A-3

3.4a Press the spring seat down against

the spring pressure and pry out the

stopper ring (arrow) ... 
3.4b ... then remove the spring seat with

its O-ring and the spring 
3.5 Remove the fork drain screw (arrow)

3.8 Pour the specified amount of oil into the top of the fork

forks to pump out the remaining oil. An assistant will most likely be

required to do this.

7 Check the drain screw gasket and spring seat O-ring for...

5A-4 
Chapter 5 Part A Steering, suspension and final drive (XV535 models)

5.3 Pour the fork oil into a container

5.4a Pry the dust seal out of the outer fork tube 
5.4b Front fork (XV535 models) - exploded view

1 Fork cap

2 Stopper ring

3 Spring seat

4 O-ring

5 Fork spring

6 Teflon ring

7 Rebound spring

8 Damper rod 
9 Oil lock piece

10 Inner fork tube

11 Outer tube bushing

12 Dust cover

13 Retaining clip

14 Oil seal

15 Outer fork tube

16 Drain screw
Installation

8 Slide each fork leg...

Chapter 5 Part A Steering, suspension and final drive (XV535 models)

5A-5

5.6a This special Yamaha tool is used to keep the damper rod

from turning when its bolt is loosened or tightened

1 Handle 
2 Adapter 
5.6b Loosen the damper rod bolt with an Allen wrench .

5.6c ... and remove the bolt and its

copper washer - use a new copper

washer during reassembly 
5.7 Remove the damper rod and the

rebound spring - dont separate the

Teflon ring from the damper rod

unless you plan to replace it 
5.8 To...

5A-6 
Chapter 5 Part A Steering, suspension and final drive (XV535 models)

5.17 If you dont have the proper tool, a section of pipe can be

used the same way the special tool would be used to install the

outer tube guide bushing - as a slide hammer (be sure to tape

the ends of the pipe so it doesnt scratch the fork tube)

15 Install the inner fork tube in the outer fork tube.

16 Apply non-permanent thread locking agent to the damper rod

bolt, then install the bolt with its copper washer and tighten...

Chapter 5 Part A Steering, suspension and final drive (XV535 models)

5A-7

6.5a Steering head and bearings (XV535 models) - exploded view

1 Steering stem bolt

2 Upper triple clamp

3 Ring nut

4 Bearing cover

5 Upper bearing top race 
6 Steel balls (19 total)

Upper bearing bottom race

8 Lower bearing top race

9 Steel balls (19 total)

10 Steering stem 
6.5b The brake hose retainer bolt is accessible from

underneath the triple clamp

6.6a Undo the steering stem bolt with a box

wrench (ring...