Haynes Yamaha Xv V Twins Manual

2A-16

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

8.42a Install new sealing washers on the

rocker shaft bolts 
8.42b Use a screwdriver to position the

rocker shafts so the bolts will line up

with them 
8.42c Install the bolts with their sealing

washers and tighten them to the torque

listed in this Chapters Specifications

8.44a Slip the O-ring onto the

large dowel.. 
8.44b ... and install the large dowel and

two small dowels in their bores ... 
8.44c ... and install the head...

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

2A-17

8.47a install the engine mounting bracket on the right side of the

rear cylinder head ... 
8.47b ... install the cylinder head cover bracket next and thread

two of the short nuts onto the studs on top of the

cover bracket...

8.47c ... On the left side of the engine, install the engine

mounting bracket (A) and two thin washers (B), then install two

short nuts ...

8.50 Fit the cam sprocket into the chain so its dowel hole will...

2A-18 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

8.57a Install a new O-ring on the cam

sprocket cover . .. 
8.57b ... and one on the oil baffle plate 
8.57c Align the hole in the oil baffle plate

with the locating pin in the

cover (arrows)...

8.57d ... then press the plate into the

cover and install a new gasket 
8.58a The line without a T mark next to it

must be aligned with the notch in the

timing window ...

55 Adjust the valve clearances (see Chapter 1).

56 Install the...

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

2A-19

8.59a On the left side of the front

cylinder head, install the cylinder head

cover bracket... 
8.59b ... install two washers on the

right side ... 
8.59c ... and install the four long nuts

(arrows) on top of the bracket and

washers (tighten the cylinder head nuts

and bolts at this point)

8.59d Install four thick washers over the long nuts ... 
8.59e ... install the mounting bracket, then install two thin

washers on the left...

2A-20

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

10.7b ... until the keepers/collets

are exposed 
10.7c Remove the keepers/collets with

a magnet 
10.7d Release the spring pressure and

remove the spring retainer ...

10.7e ... and the springs

10.7f Pull the valve into the combustion

chamber, but dont force it 
10.7g If the valve binds in the guide,

deburr the area above the keeper groove

10.9 Pull the valve stem seal (arrow) off the valve guide

head (see illustration), if...

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

2A-21

10.14 Check the cylinder head for warpage with a straightedge

and feeler gauge

10.16 Measure the valve guide inside diameter with a small hole

gauge, then measure the hole gauge with a micrometer

10.17 Check the valve face (A), stem (B) and keeper/collet groove

(C) for signs of wear and damage

10.18a Measure the valve stem diameter with a micrometer

10.18b Check the valve stem for bends with a V-block (or blocks,

as shown...

2A-22 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

10.19a Measure the free length of the

valve springs 
10.19b Check the valve springs

for squareness 
10.23 Apply the lapping compound very

sparingly, in small dabs, to the valve

face only

10.24 After lapping, the valve face should

have a uniform, unbroken contact

pattern (arrow) 
10.28a A small dab of grease will hold the

keepers/collets in place on the valve while

the spring is released 
10.28b With the keepers/collets...

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

2A-23

11.2 Remove the single Allen bolt that

secures the cylinder to the crankcase 
11.3a Lift the cylinder straight up off

the studs 
11.3b Note the locations of the three

dowels (arrows); the large dowel has

an O-ring

11.4 Remove the O-ring from the base of the cylinder 
11.7 Measure the cylinder bore at the specified distance from the

top of the cylinder (1); measure parallel to the crankshaft

centerline, then at right angles to...

2A-24

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

11.10 Move the hone rapidly up-and-down without stopping

11.13a Place the cylinder base gasket

in position

11.13b Make sure the two small dowel pins are in position and

install the large dowel pin with its O-ring 
11.15 If youre experienced and very careful, you can install the

cylinder over the piston rings without a compressor, but a

compressor will make the job easier

10 To perform the honing operation you will need the...

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

2A-25

12 Pistons - removal, inspection and installation

1 The pistons are attached to the connecting rods with piston pins

that are a slip fit in the pistons and rods.

2 Before removing the pistons from the rods, Stuff a clean shop

towel into each crankcase hole, around the connecting rods. This will

prevent the circlips from falling into the crankcase if they are inadver-

tently dropped.

Removal

Refer to illustrations 12.3a,...