Haynes Yamaha Xv V Twins Manual

							
2A-36 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

16.34 On models so equipped, align the

double notches in the friction plates (1)

with the marks on the clutch housing (2) . 
16.35 ... if tight friction plates impede

clutch movement, align the single

notches (3) with the marks (2) 
16.37a Loosen the adjuster

locknut (arrow)

16.37b Align the clutch lever mark with

the mark on the crankcase 
16.38a Remove the snap-ring , 
16.3&b ... and pry out the seal

16.38c Make sure the dowels are in position (arrows) and install

the gasket
32 If you removed the clutch damper, reverse Step 13 to install it.

The OUTSIDE mark on the seat spring faces out (away from the

engine). Make sure the wire ring is securely seated in its groove in the

clutch boss.

33 Coat the pushrods and steel ball with multipurpose grease. Install

the long pushrod and ball in the engine and the short pushrod in the

pressure plate (see illustrations 16.6b, 16.6a and 16.5b).

34 Coat one of the friction plates with engine oil and install it in the

clutch housing so its double notch aligns with the embossed marks on

the clutch housing (see illustration). If there arent any visible marks

on the clutch housing, align the double notches on all of the friction

plates with each other. Engage the tabs on the friction plate with the

slots in the clutch housing.

35 Coat a metal plate with engine oil and install it on top of the

friction plate with its rounded side in. Continue to install alternate

friction and metal plates, coated with engine oil (a friction plate is the

last one installed). Align the double notch on each remaining friction

plate with the clutch housing marks (if equipped) or with the double

notches on the previously installed friction plates. Note: If any of the

friction plates fit tightly in the clutch housing, remove all of the friction

and metal plates, then reinstall them so the single notches are aligned

with the clutch housing marks (see illustration).

36 Install the pressure plate, springs and screws. Tighten the screws

evenly in a criss-cross pattern to the torque listed in this Chapters

Specifications.

37 Loosen the locknut on the clutch mechanism freeplay adjuster

(see illustration). Push the lever by hand toward the front of the

engine as far as it will go, then note the positions of the lever mark and 
the match mark on the crankcase (see illustration). If they arent

aligned, turn the adjuster in or out until they are, then tighten the

locknut.

38 Remove the snap-ring and pry the seal out of the clutch cover

(see illustrations). Tap in a new seal with a socket the same diameter

as the seal, then install a new snap-ring. Make sure the clutch cover

dowels are in position and install a new gasket (see illustration). 
						

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

2A-37

17.2a Lift out the exhaust side chain

damper (arrow)... 
17.2b ... the bottom end fits into a slot in

the crankcase

a) Chain damper slot

b) Intake side chain damper bolts 
17.5 Take the intake side chain guide off

the crankcase

17.9 Remove the exhaust side chain

damper bolts (arrows) and lift the chain

damper out 
17.10 Slip the chain off the sprocket and

remove it 
17.12 Check the friction surface of each

damper for wear or scoring

39 Install the clutch cover over the dowels, then install and finger-

tighten the bolts. Four of the bolts retain wiring harness clamps.

40 Tighten the bolts in stages, using a criss-criss pattern, to the

torque listed in this Chapters Specifications.

41 Install a new oil filter (see Chapter 1).

42 Fill the crankcase with the recommended type and amount of

engine oil (see Chapter 1).

43 The remainder of installation is the reverse of the removal steps.

17 Cam chains and dampers - removal, inspection and

installation

Removal

1 Remove the cylinder head (see Section 8).

Rear cylinder

Refer to illustrations 17.2a, 17.2b and 17.5

2 Lift the exhaust side chain damper out of its slot (see

illustrations).

3 Remove the alternator and starter clutch (see Chapter 8).

4 Remove the idler gears (see Section 14).

5 Unbolt the intake side cam chain damper and lift it out (see

illustration 17.2b) and the accompanying illustration).

6 Slip the cam chain off the crankshaft sprocket and remove it. 
Front cylinder

Refer to illustrations 17.9 and 17.10

7 Remove the clutch and primary gears (see Section 16).

8 Lift the intake side chain damper out of its slot.

9 Unbolt the exhaust side cam chain damper and lift it out (see

illustration).

10 Slip the cam chain off the crankshaft sprocket and remove it (see

illustration).

Inspection

Refer to illustration 17.12

11 Check the chain for binding and obvious damage. If these

conditions are visible, or if the chain appears to be stretched, replace

it.

12 Check the dampers for deep grooves, cracking and other obvious

damage and replace them if necessary (see illustration).

13 Check the sprocket teeth for wear or damage. Replace the cam

sprockets if undesirable conditions are found. The entire crankshaft

must be replaced if the crankshaft sprockets are worn or damaged.

Installation

14 Installation is the reverse of the removal steps. Be sure to align

the timing marks on the crankshaft sprocket and cam sprocket as

described in Section 8. 
						

							
2A-38 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

18.2a Remove the oil pump

mounting bolts ... 
18.2b ... and take the pump off... 
18.3 ... then remove the dowel with O-

ring and separate O-ring (arrow)

18.5a The cover screw (arrow) may be

tight enough to require an impact driver 
18.5b Lift off the cover ... 
18.6a ... the outer rotor .

18.6b ... and the inner rotor
18 Oil pump - removal, inspection and installation

Note: The oil pump can be removed with the engine in the frame.

Removal

Refer to illustrations 18.2a, 18.2b and 18.3

1 Remove the oil pump driven gear and the clutch (see Section 19).

2 Remove the oil pump mounting bolts and remove the pump (see

illustrations).

3 Remove the oil pump dowel and O-rings (see illustration).

Disassembly, inspection and reassembly

Refer to illustrations 18.5a, 18.5b, 18.6a, 18.6b, 18.6c, 18.8a, 18.8b,

18.9a through 18.9e and 18.10

4 Wash the oil pump in solvent, then dry it off.

5 Remove the pump housing screw (use an impact driver if its tight)

(see illustration). Lift off the housing (see illustration).

6 Lift off the rotors (see illustrations).

7 Check the pump body and rotors for scoring and wear. If any

damage or uneven or excessive wear is evident, replace the pump

(individual parts arent available). If you are rebuilding the engine, its a

good idea to install a new oil pump.

8 Measure the clearance between the inner and outer rotors and

between the outer rotor and housing (see illustrations). Replace the

pump if the clearance is excessive. 
9 Remove the screw and retaining plate, then take out the spring

and relief valve (see illustrations). Check the valve for scoring or

other damage and check the spring for weakness. Replace the oil

pump if any of the relief valve parts are in doubtful condition. 
						

							
Chapter 2 Part A Engine, clutch and transmission (XV535 models) 
2A-39

18.6c Pump body and rotors

A) Pump body C) Inner rotor

B) Drive pin D) Outer rotor 
18.8a Measure the tip clearance between the

inner and outer rotors

18.8b ... and the clearance between the outer rotor and housing 
18.9a Remove the screw (use an impact driver if its tight)...

18.9b take off the cover . 
18.9c ... dump out the spring . 
18.9d ... and the relief valve 
						

							
2A-40 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

18.9e Relief valve components 
18.10 Be sure the drive pin aligns with the slot in the inner

rotor (arrows)

18.12 Be sure the dowel pin and O-rings

(arrows) are in position; pour engine oil

into the passages before installing

the oil pump 
19.1 Remove the Allen bolts (arrows) and

take off the oil passage housing 
19.2a Pull the strainer out of

the housing ...

19.2b ... or out of the engine
10 If the pump is good, reverse the disassembly steps to reassemble

it. Make sure the pin is centered in the rotor shaft so it will align with

the slot in the inner rotor (see illustration).

Installation

Refer to illustration 18.12

11 Before installing the pump, prime it by pouring oil into it while

turning the shaft by hand - this will ensure that it begins to pump oil

quickly. Caution: Also pour oil into the crankcase oil passages to

prevent engine damage on start-up.

12 Installation is the reverse of removal, with the following additions:

a) Be sure the dowel and O-rings are in position (see illustration).

b) Tighten the pump mounting bolts to the torque listed in this

Chapters Specifications.

19 Oil strainer - removal, inspection and installation

Refer to illustrations 19.1, 19.2a, 19.2b, 19.4a, 19.4b and 19.5

1 Drain the engine oil (see Chapter 1) and unbolt the oil passage

housing from the engine (see illustration).

2 Take the oil passage housing off. If the strainer comes out with

the housing, pull them apart (see illustration). If it stays in the engine,

pull it out (see illustration).

3 Check all parts for visible wear or damage. If the strainer is so

clogged it cant be cleaned, replace it. 
4 Remove the O-rings and install new ones (see illustrations).

5 Push the strainer into the oil passage housing (see illustration).

6 Installation is the reverse of the removal steps. Make sure the end

of the strainer engages its tab in the far side of the crankcase. Tighten

the oil passage housing bolts to the torque listed in this Chapters

Specifications. Fill the engine oil. 
						

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

2A-41

19.4a Install new O-rings in the oil passage housing (arrows) 
19.4b ... and on the strainer

19.5 Push the strainer into the oil

passage housing until it seats securely 
20.2 There should be a punch mark next

to the shift lever slot (arrows); if not, make

your own 
20.8a Remove the circlip (arrow)...

20.8b ... and the washer
20 External shift mechanism - removal, inspection and

installation

Shift lever and pedal

Refer to illustration 20.2

1 Support the bike securely so it cant be knocked over during this

procedure.

2 Look for a punch mark on the end of the lever shaft (see

illustration). This should align with the groove in the lever. If you cant

find it, make your own punch mark so the lever can be realigned

correctly during installation.

3 Remove the lever pinch bolt (see illustration 20.2). Pull the lever

off the shaft, together with the linkage rod.

4 If its necessary to separate the shift pedal from the footpeg

assembly, remove the assembly as described in Chapter 7.

5 Installation is the reverse of removal. Adjust the linkage as needed

with the nuts on the linkage shaft (see Chapter 1).

Shift mechanism removal

Refer to illustrations 20.8a, 20.8b, 20.9a, 20.9b, 20.9c and 20.10

6 Disconnect the shift lever from the shaft (Steps 1 through 3).

7 Remove the clutch housing/primary driven gear (see Section 16). 
Remove the alternator cover (see Chapter 8).

8 Remove the circlip and washer from the shift shaft (see

illustrations). 
						

							
2A-42 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

20.9a Pull the stopper lever in the

direction shown by the arrow ... 
20.9b ... and unhook the torsion spring

(arrow) from its post 
20.9c Pull the shift shaft out, taking care

not to lose the washer (A); check the

guide bar (B) for looseness

20.10 Put the washers and circlip back on

the shaft so they wont be lost 
20.15a Pry the shift shaft seal out of

the crankcase ... 
20.15b ... press a new seal in with

fingers or a socket the same diameter as

the seal

20.16 The external shift linkage should look like this when

its installed
9 Pull on the stopper lever to disengage it from the shift cam and

unhook the torsion spring from its post (see illustrations). Slide the

shift shaft and stopper lever out of the crankcase (see illustration).

Keep track of the washer on the shift shaft so it isnt lost.

10 Reassemble the components on the shaft to keep them in order

(see illustration).

Shift mechanism inspection

Refer to illustrations 20.15a and 20.15b

11 Inspect the shift shaft guide bar (see illustration 20.9c). If its

worn or damaged, replace it. If its loose, bend back its lockwasher,

unscrew it, reinstall it with a new lockwasher and tighten it securely.

Bend the new lockwasher against the nut to secure it.

12 Check the shift shaft for bends and damage to the splines. If the

shaft is bent, you can attempt to straighten it, but if the splines are

damaged it will have to be replaced. Inspect the pawls and springs on

the shift shaft and replace the shaft if theyre worn or damaged.

13 Check the condition of the stopper lever and spring. Replace the

stopper lever if its worn where it contacts the shift cam. Replace the

spring if its distorted.

14 Inspect the pins on the end of the shift cam. If theyre worn or

damaged, youll have to disassemble the crankcase to replace the shift

cam.

15 Inspect the shift shaft seal and replace it if its worn or damaged

(see illustrations). Its a good idea to replace the seal whenever the

shift shaft is removed. 
Installation

Refer to illustration 20.16

16 Remove the circlip and smaller washer from the shift shaft. Be

sure the larger washer is on the shift shaft, then install the shift shaft

and stopper lever in the crankcase. Engage the stopper lever with the

shift cam and position the torsion spring against its post (see

illustration). 
						

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

2A-43

21.2a Remove the Allen bolts (arrows)...

21.2b ... and take the middle driven gear

case off 
21.3a Remove four bolts ...

21.3b ... pull the middle driven gear back

from the crankcase ... 
21.3c ... pull out the shims and write

down their locations ... 
21.3d ... then pull the assembly out of

the engine

21.4 Remove the O-ring from the housing with a pointed tool
17 Install the plain washer and circlip on the other end of the shift

shaft (see illustrations 20.8b and 20.8a),

18 The remainder of installation is the reverse of the removal steps.

19 Adjust the shift pedal position (see Chapter 1).

20 Check the engine oil level and add some, if necessary (see

Chapter 1).

21 Middle driven gear - removal, inspection and

installation

Removal

Refer to illustrations 21.2a, 21.2b, 21.3a, 21.3b, 21.3c, 21.3d, 21.4

and 21.9

1 Remove the engine from the frame (see Section 5).

2 Unbolt the middle gear case from the engine (see illustrations).

3 Remove four bolts that secure the bearing housing to the case

(see illustration). Remove the bearing housing and any shims, writing

down the number and location of the shims for use during installation

(see illustrations).

4 Remove the O-ring from the bearing housing (see illustration).

Inspection

5 Check the universal joint and ball bearing on the middle driven

shaft for looseness or stiff movement.

6 Check the shaft splines and the teeth of the middle driven gear for

wear or damage. 
7 Check the damper spring for looseness or obvious damage such

as breakage.

8 If any of the above conditions exist, have the middle driven gear

disassembled and repaired by a Yamaha dealer or other qualified

motorcycle repair shop.

9 Spin the middle driven gear bearing in the crankcase with fingers 
						

							
2A-44 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

21.9 Inspect the ball bearing in the

engine; have it replaced if its worn

or damaged 
21.10 Install a new O-ring on the middle

driven gear case 
22.8 Position the shift cam so it aligns

with the notches in the crankcase

22.9a Loosen the crankcase bolts in

sequence, starting with the highest

numbered bolts (in the right side of

the crankcase)... 
22.9b ... and working to the lowest (in the

left side of the crankcase) 
22.9c The engine protector bracket is

bolted to the front of the crankcase

and check for looseness, excessive noise or rough movement (see

illustration). If these conditions are found, have the bearing replaced

by a Yamaha dealer or other qualified motorcycle repair shop.

Installation

Refer to illustration 21.10

10 Installation is the reverse of the removal steps, with the following

additions:

a) If the middle driven gear was disassembled, have gear lash

adjusted by a Yamaha dealer or other qualified motorcycle repair

shop. If not, reinstall the shims in their original positions,

bj Use new O-rings on the bearing housing and middle driven gear

case (see illustration).

22 Crankcase - disassembly and reassembly

1 To examine and repair or replace the crankshaft, middle

driveshaft, connecting rods, bearings, or transmission components,

the crankcase must be split into two parts.

Disassembly

Refer to illustrations 22.8, 22.9a, 22.9b, 22.9c, 22.10a,. 22.10b,

22.10c, 22.10d, 22.11a, 22.11b and 22.12

2 Remove the cylinder heads, cylinders, pistons and cam chains 
(see Sections 8,11,12 and 17).

3 Remove the alternator (Chapter 8) and pick-up coil (Chapter 4).

4 Remove the clutch and primary gears, oil pump and idler gears

(see Sections 16,18 and 14).

5 Remove the external shift linkage (see Section 20).

6 Remove the middle driven gear (see Section 21).

7 Remove the oil strainer (see Section 19).

8 The shift cam must be positioned so it doesnt hang up on the

crankcase when separating the halves (see illustration). Rotate it to

the correct position if necessary.

9 Remove the crankcase bolts in the reverse of the tightening

sequence (start with the highest-numbered bolt and work to the

lowest) (see illustrations). Note that one bolt secures the engine

protector bracket (see illustration).

10 Carefully separate the crankcase halves (see illustration). As you

lift, pry gently and evenly at the pry points around the crankcase seam

(see illustrations). Tap alternately on the transmission shafts, front

engine mounting boss and shift cam. If the halves wont separate

easily, make sure all fasteners have been removed. Dont pry against

the crankcase mating surfaces or theyll leak.

11 Look for the O-ring and dowels (see illustrations). If theyre not in

one of the crankcase halves, locate them.

12 If the right crankcase half needs to be replaced, remove the oil

baffle (see illustration). Otherwise, it can be left in position.

13 Refer to Sections 24 through 28 for information on the internal

components of the crankcase. 
						

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

2A-45

22.10a Lift the right crankcase half off

the left half... 
22.10b ... prying gently at the pry points

if necessary .. . 
22.10c ... (these are spaced around

the crankcase)

22.10d ... insert a screwdriver in each

pry point and apply gentle pressure 
22.11a Remove the small dowels (theres

one at each end of the crankcase)... 
22.11b ... and the large dowel with

its O-ring

22.12 The oil baffle plate can be left in

position unless the crankcase half is to

be replaced 
22.15a Install a new O-ring .

22.15b ... the large dowel and the two

small dowels

Reassembly

Refer to illustrations 22.15a and 22.15b

14 Make sure the crankshaft and transmission shafts are correctly

positioned in the upper crankcase half (see Sections 25 and 28).

15 Remove all traces of sealant from the crankcase mating surfaces.

Be careful not to let any fall into the case as this is done. Check to

make sure the large dowel (with a new O-ring) and the two small

dowels are in place (see illustrations). 
16 Pour some engine oil over the transmission gears, the crankshaft

main bearings and the shift cam. Also pour oil into the exposed internal

oil passages. Dont get any oil on the crankcase mating surfaces.

17 Apply a thin, even bead of Yamaha Bond or Quick Gasket sealant

(part no. ACC-11001-05-01) or equivalent to the crankcase mating

surfaces. Caution: Dont apply an excessive amount of sealant.

18 Check the position of the shift cam. Make sure its turned

wont obstruct assembly of the cases (see illustration 22.8).

19 Carefully assemble the crankcase halves over the d: