Haynes Yamaha Xv V Twins Manual

							
2B-16 
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

8.4b Cylinder heads (1984 and later models) -

exploded view

1

2

3

4

5

6

7

8

9 
Cam sprocket

Front cam chain guide

Cam chain

Cam chain tensioner

O-ring

Cam sprocket cover

Spark plug

Rocker arm cover

O-ring

8.4c Remove the cam sprocket cover;

use a new O-ring on installation 
8.5 Remove the rocker arm cover; use a

new O-ring on installation 
8.6a Align the line next to the T mark with

the pointer

5 Remove the rocker arm covers and their O-rings from the exhaust

side and intake side of the cylinder (see illustration).

Rear cylinder

Referto illustrations 8.6a, 8.6b, 8.13,8.14a, 8.14b, 8.15a, 8.15b, 8.16

and 8.17

6 Turn the engine so the rear cylinder is at top dead center on its

compression stroke (see Valve clearance - adjustment in Chapter 1).

When the rear cylinder is on its compression stroke, the line on the 
alternator rotor with a T mark next to it will be aligned with the notch in

the timing window (see illustration). Also, the camshaft sprocket mark

will be aligned with the mark inside the sprocket housing on the

cylinder head (see illustration).

7 Remove the cam chain tensioner for the rear cylinder (see Sec-

tion 7).

8 Place a piece of mechanics wire where you can reach it easily

during the next steps.

9 Hold the engine from turning with a socket on the alternator rotor

bolt. If the engine is in the frame, you can also keep it from turning by 
						

							
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

2B-17

8.6b Align the cast pointer in the cylinder head with the sprocket

timing mark

1 Cam sprocket

2 Cam chain

3 Washer 
4 Sprocket bolt

5 Cast pointer

6 Sprocket timing mark 
8.13 Drape the cam chain over the cylinder head to keep it on the

crankshaft sprocket; tie it up with wire if necessary

8.14a Remove the oil pipe union bolt at

the cylinder head ... 
8.14b ... and at the crankcase; use new

sealing washers on installation 
8.15a Four of the rear cylinder head nuts

also secure the engine mounting brackets

8.15b Cylinder head nut LOOSENING sequence

8.16 Support the cam chain while you lift the head off the studs

shifting the transmission into gear and having an assistant hold the

rear brake on.

10 While you hold the engine from turning, loosen and unscrew the

camshaft sprocket bolt.

11 Slide the sprocket off the camshaft, making sure the camshaft

dowel doesnt fall out of the camshaft.

12 Disengage the sprocket from the chain. Label the sprocket R

(for rear cylinder) and set it aside.

13 Drape the cam chain over the cylinder head (see illustration). At 
this point, the camshaft dowel should be aligned with the pointer cast

in the cylinder head.

14 Remove the external oil line (see illustrations).

15 Loosen the cylinder head nuts and bolts evenly in several stages

(see illustrations). Remove the nuts, washers, bolts and engine

mounting brackets.

16 Hold the cam chain and lift the cylinder head off the studs (see

illustration). If its stuck, tap it gently with a rubber or plastic mallet,

being careful not to break the cooling fins. Dont pry against the gasket 
						

							
2B-18 
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

8.17 Keep the cam chain supported and lift the front side chain

damper out 
8.20 Align the cast pointer in the cylinder head with the sprocket

timing mark and the oil baffle hole

1 Cam sprocket 5 Sprocket bolt

2 Cam chain 6 Cast pointer

3 Oil baffle 7 Sprocket timing mark

4 Washer 8 Oil baffle hole

8.23 With the camshaft dowel aligned

with the cast pointer in the cylinder head,

unbolt the retainer 
8.24 Slowly remove the camshaft from the

head; be careful not to nick or gouge the

bearing surfaces 
8.27a Tap against the Vise Grips to

withdraw the bolt and rocker shaft

surfaces or they will be gouged.

17 Remove the dqwels and front side chain damper (see

illustration). Support the cam chain so it doesnt drop down off the

lower sprocket.

18 Check the cylinder head gasket (and the separate O-ring around

the cam chain tunnel on 1981 through 1983 models) and the mating

surfaces on the cylinder head and cylinder for leakage, which could

indicate warpage. Refer to Section 10 and check the flatness of the

cylinder head.

19 Clean all traces of old gasket material from the cylinder head and

the top of the cylinder. Be careful not to let any of the gasket material

fall into the crankcase, the cylinder bore or the oil passages.

Front cylinder

Refer to illustration 8.20

20 Repeat Steps 6 through 19 to remove the front cylinder head,

noting that the front camshaft sprocket has an oil baffle. The hole in the

baffle should be aligned with the cast pointer when the rear cylinder is

at TDC on its compression stroke (see illustration).

Camshaft removal

Refer to illustrations 8.23 and 8.24

21 If you havent already done so, remove the rocker arm covers (see

illustrations 8.4b, 8.4c and 8.5).

22 Loosen the rocker arm locknuts and back off the adjusters. 
23 Remove the bolt and camshaft retainer plate (see illustration).

24 Remove the camshaft (see illustration).

Rocker arm removal

Refer to illustrations 8.27a and 8.27b

25 Remove the camshaft (see Steps 21 through 24).

26 Remove the rocker arm shaft retaining bolt and sealing washer.

27 Thread a slide hammer into the end of the rocker shaft. If you

dont have one, use a long bolt and a pair of Vise Grips (see

illustration). Thread the bolt into the rocker arm, grip it with the Vise

Grips, then tap against the Vise Grips with a hammer to pull the rocker

shaft out. Once the rocker shaft clears the rocker arm, take the rocker

arm out (see illustration).

28 Remove the remaining rocker shaft and arm, then label them

according to cylinder and position (for example, rear intake and rear

exhaust).

Camshaft, chain and cam sprocket inspection

29 This is the same as for XV535 models. Refer to Part A of this

Chapter for procedures and to this Chapters Specifications.

Rocker arm and shaft inspection

30 This is the same as for XV535 models. Refer to Part A of this

Chapter for procedures and to this Chapters Specifications. 
						

							
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

2B-19

8.27b When the rocker shaft is partway

out, remove the rocker arm 
8.35 Be sure the threads face out when

the shaft is installed, or there will be no

way to grip and remove the shaft 
8.38 Early models have an O-ring

(separate from the head gasket) around

the cam chain tunnel

8.41 Cylinder head nut and bolt TIGHTENING sequence

8.44 Align the dimple in the sprocket with the cast pointer in the

cylinder head
Camshaft installation

31 Apply a light coat of engine assembly lube or moly-based grease

to the camshaft journals. Position the camshaft bushing on the

camshaft.

32 Apply a light coat of engine assembly lube or moly-based grease

to the cam lobes.

33 Slide the camshaft into the cylinder head, then install the bushing

(see illustrations 8.24 and 8.23). Dont let the bushing tilt sideways

and jam in its bore. Align the bushing cutout with the retainer bolt hole

and align the camshaft dowel with the timing mark (see illustration

8.23).

34 Install the retainer (see illustration 8.23). Tighten the bolt to the

torque listed in this Chapters Specifications.

Rocker arm and shaft installation

Refer to illustration 8.35

35 Coat the rocker shafts and the rocker arm bores with clean engine

oil. Thread a bolt into the threads in the end of the exhaust rocker shaft

to use as a handle. Position the exhaust rocker shaft partway into its

hole with the threaded end facing out (see illustration). Install the

exhaust rocker arm and slide the shaft into the rocker arm. Repeat this

procedure to install the intake rocker arm.

36 Install the retaining bolt with a new sealing washer in the left hole

(as you face the cylinder head). The right hole is for the oil line union

bolt.

Cylinder head installation

Rear cylinder head

Refer to illustrations 8.38, 8.41 and 8.44

37 If both cylinder heads have been removed, install the rear cylinder

head first.

38 Install the dowels and the new head gasket on top of the cylinder

(see illustrations 8.4b and 8.4c). If youre working on a 1981 through

1983 model, install the O-ring in the groove around the cam chain

tunnel (see illustration). Never reuse the old head gasket and dont

use any type of gasket sealant.

39 Install the front side cam chain damper (if removed).

40 Position the cylinder head on the studs and guide the cam chain

damper through the cam chain tunnel (see illustration 8.16).

41 Install the cylinder head bolts and nuts together with the engine

mounting brackets (see illustration 8.15a). Four of the shorter nuts go

on the rear cylinder head; the longer nuts and the remaining four short

nuts go on the front cylinder head. Tighten the bolts and nuts evenly in

several stages, in the specified sequence, to the torque listed in this

Chapters Specifications (see illustration).

42 Make sure the camshaft locating dowel is aligned with the mark

on the cylinder head (see illustration 8.23).

43 Make sure the line on the timing rotor with a T mark next to it 
aligns with the notch in the timing window (see illustration 8.6a). If its

necessary to turn the crankshaft, hold the timing chain up while youre

turning so it doesnt fall off the crankshaft sprocket and become

jammed.

44 Engage the camshaft sprocket with the timing chain so its dowel

hole aligns with the dowel. Slip the sprocket onto the camshaft over

the dowel. The dimple in the sprocket should be aligned with the

pointer on the cylinder head (see illustration). 
						

							
2B-20 
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

8.51 Crankshaft timing mark for

front cylinder 
8.52a The longer nuts go on the front

cylinder head ... 
8.52b ... and the front engine mounting

bracket fits on the studs

8.53 Install the oil baffle next to the front cylinders cam sprocket,

facing in the direction shown

45 Turn the cam sprocket clockwise far enough to remove all slack in

the front run of the cam chain, but no farther. Insert a finger in the

tensioner hole and push against the chain damper. Make sure the

timing marks on the cam sprocket and crankshaft are aligned correctly

(see illustrations 8.6a and 8.6b).

46 With the marks correctly aligned, install the washer and cam

sprocket bolt and tighten to the torque listed in this Chapters Specifi-

cations.

47 Install the cam chain tensioner (see Section 7).

48 Adjust the valve clearances (see Chapter 1).

49 Install the rocker arm covers with new O-rings.

50 Install the cam sprocket cover, using a new O-ring.

Front cylinder head

Refer to illustrations 8.51, 8.52a, 8.52b and 8.53

51 Repeat Steps 38 through 40 to install the front cylinder head,

noting that the slot in the timing rotor must be aligned with the

crankcase pointer when the camshaft dowel is aligned with the

cylinder head mark (see illustration).

52 Install the washers, cylinder head nuts and bolts and engine

mounting bracket (see illustrations).

53 Repeat Steps 42 through 51 to finish installing the cylinder head,

noting that there is an oil baffle on the sprocket (see illustration).

54 Install the ignition coils and their bracket (see Chapter 4).

Both cylinder heads

55 Change the engine oil (see Chapter 1).

56 The remainder of installation is the reverse of the removal steps. 
9 Valves/valve seats/valve guides - servicing

1 Because of the complex nature of this job and the special tools

and equipment required, servicing of the valves, the valve seats and

the valve guides (commonly known as a valve job) is best left to a

professional.

2 The home mechanic can, however, remove and disassemble the

head, do the initial cleaning and inspection, then reassemble and

deliver the head to a dealer service department or properly equipped

motorcycle repair shop for the actual valve servicing. Refer to Section

8 for those procedures.

3 The dealer service department will remove the valves and springs,

recondition or replace the valves and valve seats, replace the valve

guides, check and replace the valve springs, spring retainers and

keepers/collets (as necessary), replace the valve seals with new ones

and reassemble the valve components.

4 After the valve job has been performed, the head will be in like-

new condition. When the head is returned, be sure to clean it again

very thoroughly before installation on the engine to remove any metal

particles or abrasive grit that may still be present from the valve service

operations. Use compressed air, if available, to blow out all the holes

and passages.

10 Cylinder head and valves - disassembly, inspection

and reassembly

These procedures are the same as for XV535 models. Refer to

Part A of this Chapter for procedures and Part B for specifications.

11 Cylinders - removal, inspection and installation

Removal

Refer to illustrations 11.2, 11.3 and 11.4

1 Following the procedure given in Section 8, remove the cylinder

head.

2 Remove the cylinder bolts (see illustration).

3 Lift the cylinder straight up to remove it, supporting the cam chain

as you do so (see illustration). If its stuck, tap around its perimeter

with a soft-faced hammer, taking care, not to break the cooling fins.

Dont attempt to pry between the cylinder and the crankcase, as you

will.ruin the sealing surfaces. As you lift, note the location of the dowel

pins and O-ring. Be careful not to let these drop into the engine.

4 Stuff clean shop towels around the pistons and remove the

gasket and all traces of old gasket material from the surfaces of the 
						

							
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

2B-21

11.2 Remove the three Allen bolts to detach the cylinder from

the crankcase 
11.3 Support the timing chain and pull the cylinder off the studs

11.4 Cylinder (XV700-1100 models) - exploded view

1

2

3

4

5

6

7

8

9 
Cylinder

O-ring

Damping block

Locating dowel

Bolt

Cylinder base gasket

Cover

Gasket

Bolt

cylinder, cylinder head and crankcase. Remove the O-ring from the

oase of the cylinder (see illustration). Note: Dont remove the rubber

sleeves from the cylinder studs.

Inspection

Refer to illustration 11.7

5 Dont attempt to separate the liner from the cylinder.

6 Check the cylinder wall carefully for scratches and score marks.

7 Using the appropriate precision measuring tools, check each

cylinders diameter. Measure parallel to the crankshaft axis and across

the crankshaft axis, at the depth from the top of the cylinder listed in

this Chapters Specifications (see illustration). Average the two

measurements and compare the results to this Chapters Specifi-

cations. If the cylinder walls are tapered, out-of-round, worn beyond

the specified limits, or badly scuffed or scored, have them rebored and

honed by a dealer service department or a motorcycle repair shop. If a

rebore is done, oversize pistons and rings will be required as well.

8 As an alternative, if the precision measuring tools are not

available, a dealer service department or motorcycle repair shop will 
11.7 On 1981 through 1987 models, measure the cylinder

diameter at the top, center and bottom of the bore; on 1988

and later models, measure at the specified distance from the

top of the bore 
						

							
2B-22 
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

14.3 Remove the bolt and locknut and lift

the cam chain damper out 
14.4a Remove the bolt and pull out the

retaining plate ... 
14.4b ... then pull out the spindle and

remove the intermediate gear

make the measurements and offer advice concerning servicing of the

cylinders.

9 If they are in reasonably good condition and not worn to the

outside of the limits, and if the piston-to-cylinder clearances can be

maintajned properly (see Section 12), then the cylinders do not have to

be rebored; honing is all that is necessary.

To perform the honing operation refer to Chapter 2, Part A.

Installation

11 Lubricate the cylinder bore and piston with plenty of clean engine

oil.

12 Install a new O-ring around the base of the cylinder (see

illustration 11.4). Place a new cylinder base gasket on the crankcase.

Install a new O-ring on the large dowel pin, install it in its bore and

make sure the two small dowel pins are in position.

13 Attach a piston ring compressor to the piston and compress the

piston rings. A large hose clamp can be used instead - just make sure

it doesnt scratch the piston, and dont tighten it too much. Note: If

youre experienced and very careful, you can install the cylinder without

using a ring compressor, but the compressor will make the job easier

and reduce the chance of breaking a ring,

14 Install the cylinder block over the pistons and carefully lower it

down until the piston crown fits into the cylinder liner (see illustra-

tion 11.3). While doing this, pull the camshaft chain up, using a hooked

tool or a piece of coat hanger if necessary. Also keep an eye on the

cam chain guide to make sure it doesnt wedge against the cylinder.

Push down on the cylinder, making sure the piston doesnt get cocked

sideways, until the bottom of the cylinder liner slides down past the

piston rings. A wood or plastic hammer handle can be used to gently

tap the cylinder down, but dont use too much force or the piston will

be damaged.

15 Remove the piston ring compressor or hose clamp, being careful

not to scratch the piston.

16 Repeat the procedure to install the remaining cylinder.

17 The remainder of installation is the reverse of removal.

12 Pistons - removal, inspection and installation

Removal, inspection and installation procedures for the pistons

are the same as for XV535 models. Refer to Part A of this Chapter for

procedures and this Chapters Specifications.

13 Piston rings - installation

Piston ring installation procedures are the same as for XV535

models. Refer to Part A of this Chapter for procedures and to this

Chapters Specifications. 
14 Cam chains and intermediate gears - removal,

inspection and installation

Removal

Refer to illustrations 14.3, 14.4a and 14.4b

1 Remove the engine (see Section 5). .

2 Remove the cylinder head(s) and cylinder(s) (see Sections 8

and 11).

3 If youre working on the front cylinder, remove the retaining bolt

and lift out the rear cam chain damper (see illustration).

4 Remove the bolt and stopper plate (see illustration). Pull out the

spindle, then remove the intermediate gear and timing chain (see

illustration). Label the parts (F for front cylinder or R for rear cylinder).

5 If youre working on the rear cylinder, remove the retaining bolt

and lift out the rear cam chain damper.

Inspection

6 Thoroughly clean all parts in solvent and blow them dry with

compressed air.

7 Check the cam chain(s) for obvious wear and damage and

replace it if these conditions are found. Note how far the cam chain

tensioner has extended; if its near the end of its travel, the cam chain

is stretched and should be replaced. Note: If the chain is replaced, the

intermediate gear and its drive gear on the crankshaft should also be

replaced. Replacing only one of the components will cause rapid wear

of the other two.

8 Check the intermediate gear(s) for worn or damaged teeth and

replace them if these conditions are found. The two plates that make

up the gear should move separately from each other against the

pressure of the three springs built into the gear, then return to their

original relationship by spring pressure. If the plates dont move

separately or dont return, replace the intermediate gear. Also replace

the gear if the springs are loose or damaged.

9 Check the chain dampers for deep grooves or separation from

the steel backing and replace them if these conditions are found.

Installation

Refer to illustration 14.10

10 If the intermediate gears werent marked for location during

removal, identify the front and rear cylinder intermediate gears by the

location of the spring stoppers (see illustration).

Rear cylinder

Refer to illustrations 14.11, 14.12, 14.13, 14.15a, 14.5b and 14.16

11 Install the rear cam chain damper. Tighten its bolt to the torque

listed in this Chapters Specifications, then tighten the locknut against

the crankcase to secure the bolt (see illustration).

12 Note: This procedure assumes the alternator rotor is installed on 
						

							
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

2B-23

14.10 The correct locations of the

intermediate gears can be determined by

looking at the spring stoppers 
14.11 Tighten the chain guide bolt to the

specified torque, then tighten the locknut

to the specified torque to secure the bolt

(front cylinder shown) 
14.12 Align the sighting hole in the

alternator rotor with the centerlines of the

crankshaft and the intermediate gear

spindle hole

14.13 With the cam chain on the sprocket

teeth of the gear, lower the gear

into position 
14.15a Pry the two plates of the

intermediate gear into alignment with

a punch inserted through the

alignment holes 
14.15b The alignment mark on the

gear must be aligned with the

crankshaft keyway

14.16 With the alternator rotor installed, look through the sighting

hole (arrow) to make sure the intermediate gear alignment mark is

positioned correctly

the engine. If it isnt, ignore the steps which dont apply. Align the

sighting hole in the alternator rotor with the centerlines of the

crankshaft and the intermediate gear spindle hole (see illustration).

13 Place the cam chain on the sprocketteeth of the intermediate 
gear. Position the intermediate gear in light contact with its drive gear

on the crankshaft (see illustration).

14 Theres an alignment hole in each of the plates that make up the

intermediate gear. The holes are used to align the gear teeth on each

plate with each other when the intermediate gear is installed. The holes

are slightly offset from each other when the intermediate gear is not

installed.

15 Insert a center punch through the offset holes in the two plates.

Use a prying motion to align the holes (which will align the gear teeth

on the two plates) (see illustration). Hold the plates in the aligned

position and mesh the intermediate gear with the crankshaft drive gear

so the timing marks on the gears are aligned (see illustration).

16 Install the spindlein the intermediate gear and secure it with the

stopper plate and bolt (see illustration). Look through the sighting

hole in the alternator rotor to be sure the intermediate gear and timing

gear holes are correctly aligned.

17 Make sure the cam chain is still engaged with the sprocket on the

intermediate gear and support it so it wont fall off (tie it to part of the

engine with wire).

Front cylinder

Refer to illustrations 14.19 and 14.20

18 Place the cam chain on the sprocket teeth of the intermediate

gear. Position the intermediate gear in light contact with its drive gear

on the crankshaft.

19 Align the teeth on the front cylinders intermediate gear as 
						

							
2B-24 
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

14.19 The alignment mark on the front

cylinders intermediate gear must align

with the mark on the drive gear 
14.20 Install the stopper plate and tighten

the bolt to the specified torque 
15.2 Remove the oil pump chain cover

15.3 Oil pump and delivery pipes (XV700-1100

models) - exploded view

1 Oil pump

2 Locating dowel

3 O-rings

4 Pump mounting bolt

5 Driven sprocket

6 Sprocket bolt

7 Oil pump chain cover

8 Chain cover bolt

9 Oil pump chain

10 Oil feed pipe

11 O-rings

12 Bolts

13 Rear cylinder oil feed pipe

14 Pipe guide

15 Mounting bracket

16 Front cylinder oil feed pipe

17 Union bolts

18 Sealing washers

19 Union bolt

20 Sealing washers

21 Pipe guide

22 Oil drain bolt

23 Sealing washer 
						

							
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

2B-25

15.4a Remove the Allen bolts (A) to

detach the pump; the screw (B) holds the

pump together 
15.4b Pull the pump out of the engine,

taking care not to damage the

strainer screen 
15.6a Separate the strainer screen from

the pick-up

15.6b Remove three Phillips screws and

detach the pick-up from the pump 
15.7a Lift off the rotor housing . 
15.7b ... the outer rotor .

15.7c ... and the inner rotor

described in Steps 13 and 14 above, then engage the gear with its

drive pinion so the timing marks are aligned (see illustration).

20 Install the spindle and secure it with the retaining plate and bolt

(see illustration).

21 Make sure the cam chain is still engaged with the sprocket on the

intermediate gear, then install the front cylinders rear cam chain

damper (see illustrations 14.3 and 14.11). Tighten the bolt and

locknut to the torque listed in this Chapters Specifications. 
All models

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

15 Oil pump and pick-up - removal, inspection and

installation

Removal

Refer to illustrations 15.2. 15.3. 15.4a and 15.4b

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

2 Unbolt the oil pump chain cover and take it off (see illustration).

3 Unbolt the oil pump driven sprocket and separate it from the

pump (see illustration). Lift the chain off the crankshaft sprocket.

4 Unbolt the oil pump and pull it away from the engine, taking care

not to damage the strainer screen on the pick-up (see illustrations).

Remove the pump dowel and two O-rings.

Disassembly, inspection and reassembly

Refer to illustrations 15.6a, 15.6b, 15.7a through 15.7f, 15.9a, 15.9b,

15.13a, 15.13b and 15.13c

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

6 Separate the strainer screen from the pickup (see illustration).

Remove three screws and detach the pick-up from the pump (see

illustration).

7 Remove the screw that holds the pump housings together. Lift off

the housings and both sets of rotors (see illustrations).