Haynes Yamaha Xv V Twins Manual

1-24 
Chapter 1 Tune-up and routine maintenance

23.10 Remove the steering stem bolt and

lift off the upper triple clamp 
23.11 Turn the ring nut to adjust steering

head bearing play 
23.17 Loosen the upper ring nut and

adjust steering head bearing play with the

lower ring nut

All models

19 Start the engine and let it run until it reaches normal operating

temperature.

20 Make sure there are no leaks in the vacuum gauge or manometer

setup, as false readings will result.

21 Start the engine and...

Chapter 1 Tune-up and routine maintenance

1-25

25.6 The fuel tap is secured to the tank by

two screws 
25.7 Examine and clean the filter stack 
25.8 Inspect the fuel tap diaphragm

17 Beneath the upper triple clamp are two ring nuts (see

illustration). Loosen the upper one with a spanner wrench (C-spanner)

so the lower nut is free to turn.

18 Tighten the lower ring nut a little at a time just enough to remove

any front-to-rear play in the steering head. Caution: Dont overtighten

the nut.

19 To...

1-26

Chapter 1 Tune-up and routine maintenance

25.11 Loosen the clamp and

disconnect the hose at each end of the

filter, then remove it from its bracket 
26.3 Check above and below the fork

seals (arrow) for signs

of oil leakage 
27.3 The linkage arms should be at right angles

to the rod

27.4 Loosen the locknuts and rotate the

rod to change its length; on some models,

the front nut has left-hand threads

(loosens clockwise) 
28.6a If theres an air hose between the

forks, add air through the...

Chapter 1 Tune-up and routine maintenance

1-27

adjustable. On XV920 models, front fork damping is also adjustable.

rear suspension unit damping and air pressure are adjustable.

3 On 1984 and later XV700 and 750 models, front fork air pressure

and rear spring preload are adjustable.

4 On 1984 and later XV1000 and 1100 models, front fork air

pressure is adjustable. Rear spring preload and rear shock absorber

damping are also adjustable.

1981 through 1983 models

Refer to illustrations 28.6a,...

1-28

Chapter 1 Tune-up and routine maintenance

28.9b Take up excessive freeplay with the cable adjusters 
28.12a Adjust rear spring preload on 1984 and later XV700

and 750 models with the adjuster on the bottom of each

shock absorber

Front fork

Air pressure

1

2

3

4 
39.2 ~ 78.5 kPa

(0.4-0.8 kg/cm2,

5.7-11.4 psi)

39.2 ~ 78.5 kPa

(0.4-0.8 kg/cm2,

5.7-11.4 psi)

58.8 - 98.1 kPa

(0.6-1.0 kg/cm2,

8.5-14.2 psi)

78.5-117.7 kPa

(0.8-1.2 kg/cm2,

11.4-17.1 psi) 
Rear shock absorber

Spring...

2A-1

Chapter 2 Part A

Engine, clutch and transmission

(XV535 models)

Contents

Section

Alternator rotor - removal and installation See Chapter 8

Cam chains and dampers - removal, inspection

and installation , 17

Camshaft chain tensioners - removal and installation 7

Clutch cable - replacement 15

Clutch and primary gears - removal, inspection

and installation 16

Compression test See Chapter 1

Connecting rods and bearings - removal, inspection,

bearing selection and installation 26...

2A-2 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

Specifications

General

Bore x stroke 76 x 59 mm (2.992 x 2.323 inches)

Displacement 535 cc

Compression ratio 9.0 to 1

Camshafts

Lobe height

Intake (standard) 39.73 mm (1.564 inch)

Intake (limit) 39.63 mm (1.560 inch)

Exhaust (standard) 39.77 mm (1.566 inch)

Exhaust (limit) 39.67 mm (1.562 inch)

Base circle

Intake (standard) 32.22 mm (1.269 inch)

Intake (limit) 31.22 mm (1.229 inch)

Exhaust (standard) 32.30 mm (1.272...

Chapter 2 Part A Engine, clutch and transmission (XV535 models)

2A-3

Piston-to-cylinder clearance

Standard 0.035 to 0.055 mm (0.0014 to 0.0022 inch)

Limit 0.1 mm (0.004 inch)

Ring side clearance

Top ring

Standard 0.03 to 0.07 mm (0.001 to 0.003 inch)

Limit . 0.12 mm (0.005 inch)

Second ring

Standard 0.02 to 0.06 mm (0.0008 to 0.0024 inch)

Maximum 0.12 mm (0.005 inch)

Oil ring Not specified

Ring thickness

Top ring 1.2 mm (0.05 inch)

Middle ring .... 1.5 mm (0.06 inch)

Oil ring (spacer and...

2A-4 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

Torque specifications (continued)

Clutch push lever screw 12 Nm (8.7 ft-lbs)

Connecting rod nuts 36 Nm (25 ft-lbs) (2)

Crankcase bolts (6 mm) 10 Nm (7.2 ft-lbs)

Crankcase bolts (8 mm) 24 Nm (17 ft-lbs)

Crankcase studs (8 mm) 13 Nm (9.4 ft-lbs)

Crankcase studs (10 mm) 20 Nm (14 ft-lbs)

Cylinder bolt 10 Nm (7.2 ft-lbs)

Cylinder head bolts (8 mm).... 20 Nm (14 ft-lbs)

Cylinder head nuts (8 mm).... 35 Nm (25 ft-lbs)

Cylinder...

Chapter 2 Part A Engine, clutch and transmission (XV535 models)

2A-5

5.16 Squeeze the hose clamp and pull the

breather hose off its fitting 
5.18 Remove the Allen bolt and

disconnect the ground wire, then loosen

the Allen bolts that secure wiring harness

retainers (arrows; two of four bolts shown)

and release the harness from the retainers 
5.21 Pull the driveshaft rubber boot away

from the middle gear

does not remedy the situation, major mechanical work is the only

solution.

6 An engine...