Haynes Yamaha Xv V Twins Manual

2A-6 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

5.24 Support the engine with a jack and a

block of wood 
5.25a Remove the lower rear

mounting bolt... 
5.25b ... and the upper rear

mounting bolts...

5.25c ... (theres an upper rear mounting

bolt on each side of the engine) 
5.25d Unbolt the front cylinder head

bracket from the frame 
5.25e Unbolt the rear cylinder head

mounting brackets from the frame ...

5.25f ... (theres one on each side of the engine)
23 Remove the...

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

2A-7

6.2a A selection of brushes is required for

cleaning holes and passages in the engine

components 
6.2b Type HPG-1 Plastigage is needed to

check the connecting rod oil clearances 
6.3 An engine stand can be made from

short lengths of lumber and lag bolts

or nails

7.1 a Loosen the tensioner cap bolt with a socket or wrench, then

unscrew it from the engine (if youre removing both tensioners at

the same time, its a good idea to...

2A-8 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

7.2a Remove the tensioner Allen bolts , 
7.2b ... and remove the tensioner and gasket from the engine

7.3 Tensioner details

a) Cap bolt c) Spring

b) Sealing washer d) Tensioner body 
7.4 Lift the latch and compress the tensioner piston into the body

2 Remove the tensioner mounting bolts and take it off the engine

(see illustrations).

Installation

Refer to illustrations 7.3 and 7.4

3 Check the sealing washer on the cap bolt...

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

2A-9

8.4a Cylinder head and cylinder (XV535 models) -

exploded view

1) Cylinder head side cover

2) Intake rocker arm cover

3) O-ring

4) Exhaust rocker arm cover

5) Spark plug

6) Oil baffle plate (rear cylinder only)

7) Gasket

8) Cylinder head (rear shown)

9) Cam sprocket cover

10) Long retainer bolt

11) Short retainer bolt

12) Lockwasher

13) Retainer

14) Dowel

15) Cylinder (rear shown)

8.4b Remove both Allen bolts ......

2A-10 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

8.5 Unbolt the rocker arm covers and

take them off, together with their O-rings 
8.6a The line next to the T mark on the

alternator rotor should be aligned with the

notch in the timing window 
8.6b The punch mark on the sprocket

should be aligned with the arrowhead cast

in the cylinder head (arrows)

8.9 Hold the crankshaft turning bolt with

a socket and loosen the camshaft

sprocket bolt with another socket or a

box wrench...

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

2A-11

8.14a The cylinder heads are secured by two Allen

bolts (arrows)... 
8.14b ... and five nuts ...

a) Allen bolts c) Nut (in spark plug well)

b) Nuts

8.14c Use a socket and extension to

remove the nut in the spark plug well.. . 
8.14d ... and pull its washer out with

a magnet 
8.15a Lift the cylinder head off

8.15b If the head is stuck, tap it with a soft-faced mallet (dont tap

against the cooling fins or theyll break) 
8.16a...

2A-12 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

8.16b ... if theyre not in the cylinder,

they may have remained in the

head (arrow) 
8.16c Lift out the exhaust side chain

damper (arrow) 
8.22a Flatten the lockwasher tabs with a

hammer and chisel (take care not to strike

the cylinder head)...

8.22b ... undo the retainer bolts ... 
8.22c ... and remove the lockwasher

8.23a Pull the camshaft and bushing out

of the head ...

8.23b ... and take the bushing off the camshaft
17...

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

2A-13

8.23c Camshaft, timing chain and valves (XV535 models) - exploded view

1) Valve adjuster locknut

2) Valve adjuster

3) Rocker arm shaft

4) Rocker arm

5) Valve keepers (collets)

6) Valve spring retainer

7) Valve springs

8) Oil seal

9) Valve spring seat

10) Valve 
11) Camshaft

12) Camshaft bushing

13) Camshaft dowel

14) Cam sprocket

15) Oil baffle plate (rear cylinder only)

16) Cam chain tensioner

17) Cam chain damper...

2A-14 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

8.26a A slide hammer like this one is the

easiest way to remove the rocker shafts 
8.26b Pull the shaft partway out. 
8.26c ... then remove the rocker arm

8.27 Label the shafts according to

cylinder (front or rear) and side (intake

or exhaust) 
8.29a Check the lobes of the camshaft for

wear - heres a good example of damage

which will require replacement (or repair)

of the camshaft 
8.29b Measure the height of the cam

lobes...

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

2A-15

8.32 Check the sprockets for wear

and damage 
8.34 Check rocker arms for wear on the

adjuster surface, inside the bore and on

the cam contact surface (arrows) 
8.36 Hold the rocker arm in the installed

position and install the shaft, using a bolt

8.40a Slide the camshaft into its bearing

in the cylinder head ... 
8.40b ... then install the bushing and

align it as shown 
8.41a Install the retainer...

8.41b ... and the...