Haynes Yamaha Xv V Twins Manual

6A-16 
Chapter 6 Part A Brakes, wheels and tires (XV535 models)

13.16b Drive out the bearings with a

long rod 
13.16c Lift out the spacer and collar (be

sure to reinstall both during assembly) 
13.16d Drive the clutch hub side bearing

into position with a bearing driver or

socket that bears on the outer race

14 Tubed tires - general information

1 Tires with tubes are used as standard equipment on this

motorcycle. They are generally easier to change than tubeless tires.

2 Before changing a tire...

TIRE CHANGING SEQUENCE - TUBED TIRES

Deflate tire. After push-

ing tire beads away

from rim flanges push

tire bead into well of rim

at point opposite valve.

Insert tire lever next to

valve and work bead

over edge of rim.

Use two levers to

work bead over edge

of rim. Note use of

rim protectors

Remove inner tube

from tire

When first bead is clear,

remove tire as shown

To install, partially

inflate inner tube

and insert in tire

Work first bead over rim

and feed valve through

hole in...

6A-18 
Chapter 6 Part A Brakes, wheels and tires (XV535 models)

Notes 

6B-1

Chapter 6 Part B

Brakes, wheels and tires (XV700-1100 models)

Contents

Section

Brake caliper - removal, overhaul and installation 3

Brake disc - inspection, removal and installation 4

Brake hoses - 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 information 1

Rear drum...

6B-2 
Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models)

Brakes (continued)

Rear brake drum inside diameter

1981 through 1983XV750

Standard 180 mm (7.087 inch)

Maximum.... Not specified

All others

Standard 200 mm (7.87 inches)

Maximum 201 mm (7.91 inches)

Rear brake shoe lining thickness

Standard 4 mm (0.16 inch)

Minimum 2 mm (0.08 inch)

*Refer to marks stamped into the disc (they supersede information printed here)

Wheels and tires

Wheel runout

Radial (up-and-down) 2.0 mm...

Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models)

6B-3

2.2 On 1981 through 1983 XV750 and XV920 K and MK models,

remove the coil spring, then pull out the pad pin ... 
2.3a ... and lower the pads out of the caliper

1 General information

The models covered in this Chapter are equipped with a hydraulic

disc brake at the front and a mechanical drum brake at the rear.

Several different front brake designs are used, varying according to

model. They may be equipped with wire spoke wheels...

6B-4 
Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models)

2.4a On chain drive XV920 and TR1

models, remove the bolt and detach

the caliper from the bracket... 
2.4b ... remove the brake pad retaining

screw and the pads 
2.5a Remove the anti-rattle spring

2.5b Front brake caliper (XV920 chain drive

and TR1 models) - exploded view

1 Right brake disc

2 Left brake disc

3 Disc mounting bolts

4 Lockwashers

5 Right caliper assembly

6 Left caliper assembly

7 Caliper mounting bolts

8...

Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) 
6B-5

2.7 Front brake caliper (XV920J) - exploded view

7 Right caliper assembly

2 Left caliper assembly

3 Caliper body

4 Mounting bracket

5 Shim

6 Retaining plate

7 Screw

8 Bleed valve and cap

9 Pad retaining pin

10 Pad retaining pin

11 Cotter pin

12 Spring clip

13 Anti-rattle spring

14 Brake pads

15 Piston seals

16 Piston

17 Caliper mounting bolts

18 Lockwashers

19 Washers

20 Brake disc mounting bolts

27 Lockwashers

22...

6B-6

Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models)

1984 and later models (except 1994 UK)

Refer to illustrations 2.9a and 2.9b

9 Remove the pad cover (see illustration). Remove the pad pin

clips, then pull out the pad pins and remove the anti-rattle spring (see

illustration).

10 Pull out the pads.

1994 UK models

Refer to illustration 2.11

11 Remove the lower caliper bolt and pivot the caliper upward (see

illustration).

12 Remove the pad spring and pull out the pads.

All...

Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) 
6B-7

15 Connect a length of rubber or plastic tubing to the caliper bleed

valve and place the other end in a container. Open the bleed valve and

push the pistons into the caliper as far as possible; displaced brake

fluid will flow through the tubing into the container. If you cant depress

the pistons with thumb pressure, try using a C-clamp (G-clamp). If the

piston sticks, remove the caliper and overhaul it as described in

Section 3....