Haynes Yamaha Xv V Twins Manual

6B-8 
Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models)

3.2a Remove the union bolt (arrow); this

type of caliper is used on 1981 through

1983 shaft drive models ... 
3.2b ... and this type is used on 1984 and

later models (except 1994 UK) 
3.3a If youre working on a 1981 through

1983 XV750, an XV920K or an XV920 MK,

remove the nut and washer ...

3.3b . .. and slide the caliper off

the pivot post 
3.4 Remove the caliper mounting bolts

and detach the caliper from the fork 
4.3 Set up...

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

6B-9

Installation

15 Install the caliper, tightening the mounting bolts or nut to the

torque listed in this Chapters Specifications.

16 Connect the brake hose to the caliper, using new sealing washers

on each side of the fitting. The neck of the hose union should fit

between the two cast lugs on the caliper body. Tighten the banjo fitting

bolt to the torque listed in this Chapters Specifications.

17 Fill the master cylinder with the...

6B-10 
Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models)

5.3b Master cylinder (chain drive XV920 and TR1 models)

exploded view

1 Sealing washers 9 Handlebar clamp

2 Union bolts 10 Bolts

3 Hose joint 11 Lockwashers

4 Piston assembly 12 Master cylinder body

5 Hose guides 13 Diaphragm

6 Bolt 14 Reservoir cover

7 Rubber boot 15 Screws

8 Master cylinder assembly 
5.3c Master cylinder (XV920J models) - exploded view

1 Master cylinder body 9 Bolts

2 Piston assembly 10 Rubber boot

3...

Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) 
6B-11

6.4 Lift the rear brake panel out of the wheel 
6.5a Fold the shoes together to detach them from

the brake panel

6.5b Rear wheel and brake details

(shaft drive models)

1 Rear wheel

2 Dust seal

3 Screw and washer

4 Drive pinion

5 Bolts

6 O-ring

7 Left wheel bearing

8 Left wheel bearing

9 Washer

10 Cotter pin

11. Castellated nut

12 Axle

13 Washer

14 Brake lever

15 Pinch bolt

16 Wear indicator plate

17 Brake panel

18...

6B-12 
Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models)

6.5c Rear wheel and brake details

(shaft drive models)

1 Rear wheel

2 O-ring

3 Left wheel bearing

4 Coupling (cush drive) damper

5 Coupling

6 Sprocket

7 Drive chain

8 Sprocket stud

9 Lockwasher

10 Nut

11 Coupling bearing

12 Left spacer

13 Oil seal

14 Snap-ring

15 Chain adjuster

16 Locknut

17 Adjusting bolt

18 Washer

19 Castellated nut

20 Axle

21 Cotter pin

22 Right spacer

23 Brake panel

24 Brake cam

25...

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

6B-13

6.8a Loosen the pinch bolt and remove

the brake lever. . . 
6.8b ... remove the wear

indicator pointer ... 
6.8c ... and withdraw the cam from

the brake panel

6.16 Note the position of the alignment marks (A), unhook the

brake light switch spring (B) and loosen the pinch bolt (C)

7.2 Remove the union bolts (A); note the position of the banjo

fitting neck next to the cast lug (B)

10 Check the brake cam for looseness in the...

6B-14 
Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models)

11.3a Front wheel (1981 through

1983 shaft drive models)

1 Front wheel

2 Axle

3 Collar

4 Grease seal

5 Right bearing

6 Spacer

7 Hub trim (except XV920J)

8 Flanged spacer

9 Left bearing

10 Speedometer clutch

11 Retaining ring

12 Grease seal

13 Speedometer drive unit

14 Washer

15 Castellated nut

16 Cotter pin

11.3b Front wheel details (1981 through

1983 chain drive models)

1 Front wheel

2 Center spacer

3 Right...

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

6B-15

8 Brake system bleeding

This is the same as for XV535 models. Refer to Part A of this

Chapter.

9 Wheels - inspection and repair

1 For models equipped with wire spoke wheels, this is the same as

for XV535 models. Refer to Part A of this Chapter.

2 Wheel runout for alloy wheels is measured in the same way as for

wire spoke wheels (refer to Part A of this Chapter). Alloy wheels with

excessive runout must be replaced with new...

6B-16

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

11.4a Remove the nut and pinch bolt; if

the axle has a round head like this one,

insert a bar through the removal hole and

pull it out... 
11.4b ... if the axle has a hex head like

this one, unscrew it 
11.5a Remove the collar.

11.5b ... and the speedometer drive unit

11.8a Make sure the dogs on the

speedometer clutch ... 
11.8b ... engage the slots in the

drive unit

threads directly into the left fork leg.

4 Support the...

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

6B-17

12.2a Unscrew the nut and disconnect

the brake rod 
12.2b Remove the cotter pin, washer and

nut and disconnect the brake rod 
12.3 Remove the cotter pin and nut

12.4 Loosen the axle pinch bolt

(if equipped) 
12.5 Pull out the axle

12.6 On chain drive models, remove the

spacer that fits between the brake panel

and the swingarm

12.10 On chain drive models, replace the

coupling dampers with new ones if theyre

deteriorated, worn...