Haynes Yamaha Xv V Twins Manual

5B-2 
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

Fork oil level (US)

1981 through 1983 models Not specified

XV700, XV750, XV1000 155 mm (6.1 inches) below top of inner fork tube*

XV1100 179 mm (7.0 inches) below top of inner fork tube*

Fork oil capacity (UK)

1981 through 1983 XV750 278 cc (9.40 US.fl oz, 9.78 Imp fl oz)

XV920J 303 cc (10.24 US fl oz, 10.66 Imp fl oz)

XV920Kand MK 290 cc (9.80 US fl oz, 10.20 Imp fl oz)

XV920 RH, RJ and TR1 264 cc (8.92 US fl oz,...

Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

5B-3

2.2a Pry up the bolt cover, then remove the handlebar

cover bolt and cover

2.2b Remove the trim caps from the handlebar

bracket Allen bolts

1 General information

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

damped telescopic type. Fork air pressure is adjustable on all except

1984 and later XV700 and XV750 models.

The rear suspension on 1981 through 1983 models consists of a

single shock...

5B-4 
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

2.2d Steering head and handlebar brackets (1984

and later models) - exploded view

1 Handlebar bracket bolt

2 Handlebar bracket (upper half)

3 Handlebar bracket (lower half)

4 Top nut

5 Washer

6 Upper triple clamp

7 Washer

8 Lockwasher

9 Nut

10 Safety clip

11 Lockwasher

12 Bearing locknut

13 Bearing washer

14 Bearing ring nut

15 Bearing cover

16 Upper and lower bearings

17 Steering stem/lower triple clamp...

Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

5B-5

2.7a The arrow mark on each handlebar bracket must point to

the front of the motorcycle 
2.7b Align the dot on the handlebar with the gap in the bracket;

the gaps at front and back of the bracket must be even

2.8 Handlebars (XV920J) - exploded view

1 Right mounting bracket

2 Left mounting bracket

3 Trim plates

4 Washer

5 Handlebar riser retaining bolt

6 Plastic cap

7 Pinch bolt

8 Trim plate

9 Screw

10 Left...

5B-6 
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

2.10 Steering head and handlebar bracket (XV920J) -

exploded view

1 Upper triple clamp 14 Upper bearing top race

2 Top bolt 15 Upper bearing balls

3 Handlebar bracket 16 Upper bearing bottom race

4 Steering stem inch bolt 17 Lower bearing top race

5 Fork pinch bolt 18 Lower bearing balls

6 Washer 19 Lower bearing bottom race

7 Nut 20 Dust seal

8 Washer 21 Steering stem/lower triple

9 Lockwasher clamp

10 Nut 22...

Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 
5B-7

4.13b ... and remove the nuts that secure

the headlight brackets and instrument

cluster to the upper triple clamp 
5.10a Remove the washer and the

lower ring nut 
5.10b Remove the bearing cover

XV920 and XV1000 (TR1) models

Refer to illustrations 4.13a and 4.13b

13 Unbolt the headlight brackets from the lower triple clamp (see

illustration). Remove the nut that attaches the top of each headlight

bracket to the...

5B-8 Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

5.11 a Lift the upper bearing out of the steering head ...

5.11 b ... and lower the steering stem out of the steering head

5.14 Drive out the upper race from below

with a punch 
5.15a The lower race may not leave room

for a punch to be placed against it... 
5.15b ... so instead, insert a special tool

like this one into the race and expand it so

it grips the race securely...

Inspection and installation

Refer to...

Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 
5B-9

5.18 Remove the lower bearing and its

grease seal (arrow) if they need

to be replaced 
5.20 Work the grease completely

into the rollers 
6.2 Remove the plastic cap from the fork

6.4 Unscrewing the air valve core on models with separate air

valves will provide an opening to add fork oil

from the steering stem with a bearing splitter and puller setup. These

can be rented. Tap the lower bearing on with a hammer and...

5B-10 
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

6.7 On XV920J models, unscrew the fork

cap; it should sit like this before its

installed - if it sits higher, reposition

the end of the damping adjusting rod 
6.9 Remove the drain screw from the

bottom of the fork leg 
6.12 Add the specified amount of fork oil

6.14 Pour the specified amount of oil into the top of the fork - on

later models, measure the oil level and adjust it as needed 
7.7a Remove the trim screw...

Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

5B-11

7.7b Front forks (XV750 and XV920 K and MK models) - exploded view

1 Outer fork tube 17 O-ring (XV750)

2 Drain screw 18 Air valve (XV750)

3 Gasket 19 Cap (XV750)

4 Oil seal 20 Bolt

5 Retainer 21 Nut

6 Dust seal 22 Lockwasher

7 Damper rod seat 23 Bolt

8 Inner fork tube 24 Air charging hose (XV920)

9 Damper rod 25 O-ring (XV920)

10 Rebound spring 26 Air valve (XV920)

11 Fork spring 27 O-ring (XV920)

12 O-ring...