Haynes Yamaha Xv V Twins Manual

5B-12 
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

7.7d Front forks (XV920J) - exploded view

1 Outer fork tube

2 Damper rod bolt and copper washer

3 Drain plug and gasket

4 Upper bushing

5 Spacer

6 Oil seal

7 Retainer

8 Dust seal

9 Damper rod seat

10 Lower bushing

11 Inner fork tube

12 Rebound spring

13 Damper rod

14 Teflon ring

15 Fork spring

16 O-ring

17 Cap bolt

18 Retainer

19 Rubber spacer

20 Steering stem/lower triple clamp

21 Bolt

22 Lockwasher...

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

5B-13

7.7e Front forks (1984 and later models) -

exploded view

1 Plastic cap

2 Cap bolt

3 O-ring

4 Spacer

5 Spring seat

6 Fork spring

7 Damper rod

8 Inner fork tube

9 Taper spindle

10 Dust seal cover

11 Dust seal

12 Retainer

13 Oil seal 

14 Washer

15 Guide bushing

16 Outer fork tube

17 Damper rod bolt

18 Rubber spacer (except XV700)

19 Air joint bracket (except XV700)

20 Stopper ring (except XV700)

8.2...

5B-14 
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

8.6b Take the damper rod seat

off the damper rod 
8.7 Remove the damper rod and rebound

spring from the inner fork tube 
8.8 Pry the oil seal out of the

lower fork tube

8.9a Inspect the inner and outer fork

tubes; they must be replaced if

worn or damaged 
8.9b Check the damper rod, its seat and

the rebound spring for wear or damage 
9.1a The remote adjuster handle

should turn freely

7 Pull out the damper rod and...

Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 5B-15

9.1b Rear suspension unit (1981 through

1983 models) - exploded view

1 Shock absorber

2 Upper bushing

3 Lower bushing

4 Sleeves

5 Upper spring seat

6 Spring

7 Lower spring seat

8 Seating ring

9 Retaining ring

10 Attachment pin

11 Pivot bolt

12 O-ring

13 Air hose

14 Control cables

15 O-rings

16 Remove adjuster unit upper half

17 Seal

18 O-ring

19 Allen bolt

20 Remote adjuster unit lower half

21 Remote...

5B-16 
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

9.6 Remove the pivot bolt 
9.7 Guide the suspension unit out

of the frame 
9.10 The adjuster ring should turn freely

9.12a Check the bushings and the metal sleeves for

wear and damage 
9.12b Fabricated bushing removal tool

1 High-strength nut

2 Thick washer

3 Metal tube (large enough for the bushing to fit inside)

4 Bushing sleeve

5 Thick washer

6 High-strength bolt

7 Bushing
5 Remove the two Allen bolts that...

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

5B-17

9.13 The spring can be detached from the suspension unit 
9.15 Secure the spring seat with the retaining clip, making sure

the clip seats securely in its groove

9.17 Make sure the cables and hose are clear of the suspension

unit and secure them in their clips 
10.2a The right shock absorber is secured by bolts at the top and

bottom (arrows); the left shock absorber is secured by a

bolt at the top and a nut at the...

5B-18 
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

10.2b Rear suspension (1984 and

later models) - exploded view

1 Shock absorbers

2 Swingarm

3 Bearing

4 Grease seal .

5 Collar

6 Lockwasher

7 Left pivot shaft

8 Pivot cover

9 Right pivot shaft

10 Nut

11 Rubber boot

6 Inspect the pivot hardware at the top and bottom of the shook

and replace any worn or damaged parts.

Installation

7 Coat the pivot points with a thin layer of multi-purpose lithium-

based...

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

5B-19

Inspection

Refer to illustrations 12.10a and 12.10b

8 Wipe the final gear assembly clean with a rag moistened in

solvent.

9 Check all parts for obvious wear or damage and replace any worn

or damaged parts.

10 Check the driveshaft splines for step wear. Make sure the snap-

ring at the rear end of the driveshaft is securely seated in its groove

(see illustrations).

11 The final drive unit requires special tools to...

5B-20 
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

12.10a Check the driveshaft splines

for step wear 
12.10b Make sure the snap-ring is

securely located in its groove 
13.3 Remove the left footpeg bracket,

together with the muffler/silencer

13.4 Loosen the screws on the

chain case clamps 
13.5a Loosen the cover bolts with an

Allen wrench ... 
13.5b ... evenly, in a criss-cross pattern

Installation

12 Installation is the reverse of the removal steps, with the...

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

5B-21

13.5c Final drive housing (chain drive models) -

exploded view

1 Rear sprocket housing

2 Upper chain case

3 Lower chain case

4 Front chain case clamps

5 Rear chain case clamps

6 Clamp screws

7 Sprocket housing cover bolts

8 O-ring

9 Access plug

10 Filler plug

11 Sealing washer

12 O-ring

13 Sprocket retaining ring

14 Grease seal

13.8 These two bolts secure the chain cases to the swingarm 
13.9 Remove the...