Haynes Yamaha Xv V Twins Manual

5B-22 
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

13.16 Chain case internal rib measurement

1 Chain case 2 Rib height 
13.18 The engine sprocket is secured by

two bolts and a lockwasher 
13.35 Coat the mating surface of the

engine sprocket housing with

silicone sealant

16 Check the chain cases for cracks or.brittleness and replace as

necessary. Measure the height of the internal ribs and compare it to

the value listed in this Chapters Specifications (see...

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

5B-23

14.7b The pivot bolt head on 1981 through 1983 shaft drive

models is secured by a lockwasher

22 Lift out the bearing. If it wont come easily, tap it out from the

wheel side of the coupling toward the sprocket side.

23 Pack a new bearing with grease and tap it in from the sprocket

side. Use a bearing driver or a socket that bears against the bearing

outer race.

24 Install the spacer and tap in a new grease seal with...

5B-24 
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

14.8b Swingarm (chain drive models) - exploded view

1 Swingarm

2 Pivot bolt

3 Dust cap

4 Thrust washer

5 Bearing

6 Bushing 
7 Pivot bolt nut

8 Washer

9 Bolt

10 Lockwasher

11 Washer

14.12 Check the swingarm for cracks and bending

14.13 If the pivot bolt holes are worn to an oval shape,

replace the swingarm

1984 and later models

9 Pry off the pivot cover on each side of the swingarm (see

illustration 10.2b)....

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

5B-25

14.14 Check the rubber boot for hardness or cracks

14.16 Tighten the pivot bolt, then bend the lockwasher

tabs against the bolt head

15.2 Pry the dust caps off the frame

15.3 Pull out the bushing

b) Tighten the pivot bolt, nut or shafts to the torque listed in this

Chapters Specifications (see illustration). On 1984 and later

models, tighten the right side, then the left side. On all shaft drive

models, bend the...

5B-26 
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

15.5 Check the dust cap, thrust washer and seal for

wear and damage

15.6 Swingarm side clearance measurement

(1981 through 1983 models)

A Bushing length

B1 Thrust washer thickness

B2 Thrust washer thickness

C Frame mounting point length
5 Check the dust caps, thrust washers and seals for wear or

damage and replace them as necessary (see illustration).

6 Calculate the swingarm side clearance. Measure the length of...

6A-1

Chapter 6 Part A

Brakes, wheels and tires (XV535 models)

Contents

Section

Brake caliper - removal, overhaul and installation 3

Brake check See Chapter 1

Brake disc - inspection, removal and installation 4

Brake hose - inspection and replacement 7

Brake light switches - check and adjustment See Chapter 1

Brake pads -replacement 2

Brake system bleeding 8

Front brake master cylinder - removal, overhaul and installation.. 5

Front wheel - removal and installation 11 
Section

General...

6A-2 
Chapter 6 Part A Brakes, wheels and tires (XV535 models)

Wheels and tires

Wheel runout

Radial (up-and-down) 2.0 mm (0.08 inch)

Axial (side-to-side) 2.0 mm (0.08 inch)

Tire pressures See Chapter 1

Tire sizes

Front 3.00S-19 4PR

Rear 140/90-15M/C 70S

Torque specifications

Caliper lower mounting bolt (to bracket) 18 Nm (13 ft-lbs)

Caliper bracket bolts (to fork leg) . 35 Nm (25 ft-lbs)

Front axle 58 Nm (42 ft-lbs)

Front axle pinch bolt 20 Nm (14 ft-lbs)

Brake disc mounting bolts 20 Nm...

Chapter 6 Part A Brakes, wheels and tires (XV535 models)

6A-3

2.3b Remove the pad springs

2.6a Special lubricants are required in the UK (and recommended

anywhere salt is used on the roads) to prevent corrosion

A Apply Duckhams Copper 10 or equivalent to the

shaded areas

B Apply Shin-Etsu G-40M or equivalent silicone grease to

the shaded areas

2.6b Apply the recommended lubricants to the pad friction areas

inside the caliper and to the exposed portion of the

caliper pistons

A Duckhams Copper...

6A-4 
Chapter 6 Part A Brakes, wheels and tires (XV535 models)

3.2a Unscrew the banjo bolt; theres a sealing washer on each

side of the fitting

Caution: Dont use too much Copper 10. Make sure no Copper 10

contacts the brake discs or the pad friction surfaces.

7 Install the pads and springs in the caliper. The rounded edge of

the pad faces the rear of the motorcycle (see illustration 2.3a).

8 Refill the master cylinder reservoir (see Chapter 1) and install the

diaphragm and cover.

9 Operate the...

Chapter 6 Part A Brakes, wheels and tires (XV535 models) 
6A-5

3.3 Remove the mounting bolts and

separate the caliper from the fork leg 
3.5a Carefully blow air into the fluid outlet

to push the piston out; keep your fingers

out of the way to prevent injury 
3.5b Remove the piston from the bore

3.7 Remove the dust seal with fingers or

a wood or plastic tool 
3.8 Remove the piston seal from its

groove (a toothpick can be used as a

removal tool) 
4.3 Position a dial indicator against

the disc and...