Haynes Yamaha Xv V Twins Manual

0-20 
Troubleshooting

Engine doesnt start or is difficult to start

1 Starter motor does not rotate

1 Engine kill switch Off.

2 Fuse blown. Check fuse block (Chapter 8).

3 Battery voltage low. Check and recharge battery (Chapter 8).

4 Starter motor defective. Make sure the wiring to the starter is

secure. Test starter relay (Chapter 8). If the relay is good, then the fault

is in the wiring or motor.

5 Starter relay faulty. Check it according to the procedure in

Chapter 8.

6 Starter switch not...

Troubleshooting

0-21

7 Cylinder head gasket damaged. If one of the heads is allowed to

become loose, or if excessive carbon build-up on a piston crown and

combustion chamber causes extremely high compression, the head

gasket may leak. Retorquing the head is not always sufficient to

restore the seal, so gasket replacement is necessary (Chapter 2).

8 Cylinder head warped. This is caused by overheating or

improperly tightened head nuts and bolts. Machine shop resurfacing or

head replacement is...

0-22 
Troubleshooting

5 Brakes dragging. Usually caused by debris which has entered the

brake piston sealing boot, or from a warped disc or bent axle. Repair

as necessary (Chapter 6).

Poor running or no power at high speed

14 Firing incorrect

1 Air filter restricted. Clean or replace filter (Chapter 1).

2 Spark plug fouled, defective or worn out. See Chapter 1 for spark

plug maintenance.

3 Spark plug cap or secondary (HT) wiring defective. See Chapters

1 and 4 for details of the ignition...

Troubleshooting

0-23

that will dissolve the adhesive bonding the carbon particles to the

piston crowns and chambers is the easiest way to remove the build-

up. Otherwise, the cylinder heads will have to be removed and

decarbonized (Chapter 2).

20 Firing incorrect

1 Spark plug fouled, defective or worn out. See Chapter 1 for spark

plug maintenance.

2 Incorrect spark plug (see Chapter 1).

3 Faulty ignition coil(s) (Chapter 4).

21 Fuel/air mixture incorrect

1 Main jet clogged. Dirt, water and...

0-24 
Troubleshooting

3 Gear(s) stuck on shaft. Most often caused by a lack of lubrication

or excessive wear in transmission bearings and bushings. Overhaul the

transmission (Chapter 2).

4 Shift cam binding. Caused by lubrication failure or excessive

wear. Replace the cam and bearing (Chapter 2).

5 Shift lever return spring weak or broken (Chapter 2).

6 Shift lever broken. Splines stripped out of lever or shaft, caused

by allowing the lever to get loose or from dropping the machine.

Replace...

Troubleshooting 
0-25

Abnormal frame and suspension noise

38 Front end noise

1 Low fluid level or improper viscosity oil in forks. This can sound

like spurting and is usually accompanied by irregular fork action

(Chapter 5).

2 Spring weak or broken. Makes a clicking or scraping sound. Fork

oil, when drained, will have a lot of metal particles in it (Chapter 5).

3 Steering head bearings loose or damaged. Clicks when braking.

Check and adjust or replace as necessary (Chapter 5).

4 Fork triple...

0-26 
Troubleshooting

hard from age or being washed out by high pressure car washes.

Disassemble steering head and repack bearings (Chapter 5).

5 Steering stem bent. Caused by a collision, hitting a pothole or by

dropping the machine. Replace damaged part. Dont try to straighten

the steering stem (Chapter 5).

6 Front tire air pressure too low (Chapter 1).

47 Handlebar shakes or vibrates excessively

1 Tires worn or out of balance (Chapter 1 or 6).

2 Swingarm bearings worn. Replace worn bearings...

1-1

Chapter 1

Tune-up and routine maintenance

Contents

Section

Air filter element - servicing 14

Battery electrolyte level/specific gravity - check 4

Brake lever and pedal position and play - check and adjustment. 7

Brake pads and shoes - wear check 5

Brake system - general check 6

Carburetor synchronization - check and adjustment 20

Clutch - check and adjustment 10

Crankcase ventilation system - inspection 21

Cylinder compression - check 15

Drive chain and sprockets (chain drive models) -...

1-2

Chapter 1 Tune-up and routine maintenance

Specifications

XV535

Engine

Spark plugs

Type NGK BP7ES or ND W22EP-U

Gap 0.7 to 0.8 mm (0.028 to 0.032 inch)

Valve clearances (COLD engine)

Intake 0.07 to 0.12 mm (0.003 to 0.005 inch)

Exhaust 0.12 to 0.17 mm (0.005 to 0.007 inch)

Engine idle speed 1150 to 1250 rpm

Cylinder compression pressure (at sea level)

Standard 10.75 Bars (156 psi)

Maximum... 11.78 Bars (171 psi)

Minimum 9.78 Bars (142 psi)

Maximum difference between cylinders 0.96...

Chapter 1 Tune-up and routine maintenance

1-3

Viscosity

Consistently below 15 degrees C (60 degrees F) SAE 10W30

Consistently above 5 degrees C (40 degrees F) SAE 20W40

Capacity

With filter change 2.8 liters (3.0 US qt, 5.0 Imperial pt)

Oil change only 2.6 liters (2.7 US qt, 4.6 Imperial pt)

Brake fluid .. DOT 4

Final gear

Type SAE 80 API GL-4 hypoid gear oil

Capacity 0.19 liters (0.2 US qt, 0.34 Imp pt

Wheel bearings Medium weight, lithium-based multi-purpose grease

Swingarm pivot bearings...