Haynes Yamaha Xv V Twins Manual

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

5.5 Unscrew the banjo bolt (arrow);

theres a sealing washer on each side of

the fitting 
5.6 Remove the mounting bolts (arrows);

note the position of the UP mark, which

must be upright when the master cylinder

is installed 
5.7a Remove the locknut from the

lever pivot bolt...

Removal

5 Remove the wheel (see Section 11 for front wheel removal or

Section 12 for rear wheel removal). Caution: Dont lay the wheel down

and allow it to...

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

6A-7

5.7b ... and unscrew the bolt

5.7c Remove the lever spring

5.9 Remove the rubber boot

5.10a Remove the snap-ring from

the bore 
5.10b Piston component details

6.2a Remove the cotter pin and nut

and detach the brake rod from the

brake panel...

rubber cup seals in clean brake fluid for ten or fifteen minutes.

Lubricate the master cylinder bore with clean brake fluid, then carefully

insert the piston and related parts in the reverse...

6A-8 
Chapter 6 Part A Brakes, wheels and tires (XV535 models)

6.3 Remove the brake panel from

the wheel 
6.4a Fold the shoes in a V to release

spring tension, then remove them from

the panel 
6.4b Rear brake shoes and springs

6.8a Rear wheel and brake (XV535 models)

exploded view

1 Short spacer

2 Washer

3 Rear brake lever

4 Brake wear indicator

5 Brake panel

6 Brake cam

7 Brake shoes

8 Rear wheel bearing

9 Collar

10 Long spacer

11 Brake rod

12 Hub dust seal

13 Clutch hub 

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

6A-9

6.8b Check the brake cam and pivot post (arrows) for wear

or damage 
6.12 The assembled brake panel should look like this

3 Lift the brake panel out of the wheel (see illustration).

4 Fold the shoes toward each other to release the spring tension

(see illustration). Remove the shoes and springs from the brake panel

(see illustration).

Shoe inspection

Refer to illustrations 6.8a and 6.8b

5 Check the linings for wear, damage and signs...

6 A-10 
Chapter 6 Part A Brakes, wheels and tires (XV535 models)

8.5 Place a box wrench (ring spanner)

over the bleed valve, then connect a

length of clear plastic tubing to the valve 
i.2 Measure wheel runout with a dial

indicator, if one is available

1 Radial (up-and-down) runout

2 Axial (side-to-side) runout 
11.3a Loosen the axle pinch bolt,

16 To remove the pedal spring, unhook it from its post, then from the

pedal arm.

17 Installation is the reverse of the removal steps. Adjust the rear...

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

6A-11

11.3b ... and unscrew the axle

can be rotated to check the runout.

3 An easier, though slightly less accurate, method is to attach a stiff

wire pointer to the fork or the swingarm and position the end a fraction

of an inch from the wheel (where the wheel and tire join). If the wheel is

true, the distance from the pointer to the rim will be constant as the

wheel is rotated. Repeat the procedure to check the runout of the rear

wheel....

6A-12 
Chapter 6 Part A Brakes, wheels and tires (XV535 models)

11.5a Remove the collar from the

right side ... 
11.5b ... and the speedometer drive unit

from the left side 
11.8 Be sure the speedometer drive unit

notches align with the speedometer

clutch lugs (arrows)

12.3a Straighten the cotter pin and pull

it out... 
12.3b ... unscrew the axle nut. 
12.3c ... and remove the washer

12.4 Loosen the axle pinch bolt

5 Remove the collar from the right side and the speedometer drive

unit from the...

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

6A-13

12.5a Pull the axle out. . . 
12.5b ... remove the washer ... 
12.5c ... and the short spacer

12.5d Separate the wheel from the

final drive . . . 
12.5e ... and remove the long spacer 
12.8 Be sure the long spacer is in place

before installing the wheel

13.3 Pry out the grease seal on the brake disc side of the wheel

4 Loosen the axle pinch bolt (see illustration).

5 Support the wheel, slide the axle out and remove the washer and...

6A-14 
Chapter 6 Part A Brakes, wheels and tires (XV535 models)

13.4a Pry the grease seal loose ... 
13.4b ... and lift it out 
13.4c Lift out the speedometer

clutch retainer ...

13.4d ... and the speedometer clutch 
13.5 Drive out the opposite bearing with a

long rod 
13.6 Lift out the spacer

13.7 Drive out the remaining bearing 
13.10a Drive in the bearing with a

socket or bearing driver that contacts the

outer race ... 
13.10b The installed bearing should loc

like this

4 From the left side...

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

6A-15

13.10c Install the grease seal with its

closed side out 
13.11a Install the spacer

13.11b Drive in the remaining bearing

13.12a Install the speedometer clutch ...

13.12b ... and its retainer 
13.12c Install the remaining grease seal

10 Thoroughly clean the hub area of the wheel. Install the bearing

into the recess in the hub, with the marked or sealed side facing out.

Using a bearing driver or a socket large enough to contact the...