Haynes Yamaha Xv V Twins Manual

							
2B-26

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

15.7d Lift off the remaining rotor housing

and oil pump shaft... 
15.7e ... and separate the shaft from

the rotors 
15.7f Note the marks on the rotors; they

must face in the same direction when the

pump is assembled .

15.9a Measure oil pump clearances with a feeler gauge

15.9b Oil pump measurement points

1 Inner rotor B Outer rotor to housing

2 Outer rotor clearance

3 Pump housing C Side clearance

A Inner to outer rotor clearance

15.13a Remove the oil pump sprocket from the crankshaft with

a puller (the sprocket must be replaced with a new one whenever

its removed)

8 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. 
9 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.

10 Lay a straightedge across the pump body and measure the side

clearance between the rotors and straightedge with a feeler gauge (see

illustration 15.9b). Replace the pump if the clearance is excessive.

11 If the pump is good, reverse the disassembly steps to reassemble

it. Make sure the pins are centered in the rotor shaft so they will align

with the slots in the inner rotors.

12 Inspect the oil pump drive chain and sprockets. Replace all three

components as a set if any one of them is worn or damaged.

13 To replace the oil pump drive sprocket, remove it from the

crankshaft with a puller (see illustration). Note: Removal will damage

the sprocket It must be replaced with a new one if its removed from

the crankshaft. Position the new sprocket on the crankshaft with the

teeth toward the crankcase (see illustration), then drive it all the way

on with a hammer and a piece of pipe (see illustration). 
						

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

2B-27

15.13b Place the new sprocket on the

crankshaft with its teeth toward

the crankcase ... 
15.13c ... and drive the sprocket all the

way on with a hammer and piece of pipe 
15.15 Make sure the dowel and both

O-rings are in position

15.17 Install the chain on the drive

sprocket, engage it with the driven

sprocket and bolt the driven sprocket to

the oil pump 
15.18 Push the arm of the chain cover

against the chain to tension it and tighten

the cover bolts 
16.1 Remove the Allen bolts (arrows) and

take the cover off the release mechanism

16.2 Loosen the cable adjuster at the handlebar, then slide the

cable out of the slot and free it from the lever

Installation

Refer to illustrations 15.15, 15.17 and 15.18

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

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

quickly. Caution: Also pour oil into the crankcase oil passages to 
prevent engine damage on start-up.

15 Be sure the oil feed pipe, dowel and O-rings are in position (see

illustration).

16 Position the pump on the engine and tighten its mounting bolts to

the torque listed in this Chapters Specifications.

17 Slip the chain over the crankshaft sprocket. Engage the chain

with the oil pump driven sprocket, then install the sprocket on the

pump (see illustration). Install the sprocket bolt and tighten it to the

torque listed in this Chapters Specifications.

18 Install the chain cover loosely. Push it against the chain to tension

it, then tighten the cover bolts to the torque listed in this Chapters

Specifications (see illustration).

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

16 Clutch cable replacement and release mechanism

removal and installation

Clutch cable replacement

Refer to illustrations 16.1, 16.2 and 16.3

1 Remove the cover from the release mechanism on the left side of

the engine (see illustration).

2 Loosen the cable locknut and adjuster at the handlebar (see

illustration). Disconnect the cable from the clutch lever. 
						

							
2B-28 
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

16.3 Bend back the metal tang on the

lever bracket and slip the end of the cable

out of the lever bracket 
16.9 Unhook the spring and remove the

nut from the operating lever 
16.10a Lift out the push screw .

16.10b ... and the thrust housing; the

locating pin on the thrust housing fits into

a hole in the alternator cover 
16.11 Pry out the old oil seal and install a

new one 
17.3 Remove the clutch cover; note the

locations of the dowels

17.4a Remove the pressure plate screws, washers

and springs... 
3 Bend back the metal tang and disconnect the lower end of the

clutch cable from the release lever (see illustration).

4 Attach a piece of string (somewhat longer than the clutch cable)

to one end of the cable. Free the cable from any retainers and remove

it from the motorcycle, pulling the string with it. The string will remain in

position and act as a guide to route the cable correctly during instal-

lation.

5 Installation is the reverse of the removal steps. If youre installing

a new cable, attach the string to it and pull the cable into position with

the string so its routed correctly.

6 Adjust the clutch free-play (see Chapter 1).

Release mechanism removal and installation

Refer to illustrations 16.9, 16.10a, 16.10b and 16.11

7 Disconnect the clutch cable at the engine (see above).

8 Remove the alternator cover (see Chapter 8).

9 Remove the nut and detach the clutch operating lever from the

push screw (see illustration).

10 Remove the push screw, ball retainer and thrust housing from the

alternator cover (see illustrations).

11 Pry the release mechanism oil seal out of the alternator cover (see

illustration). Install a new one. It should go in with thumb pressure, but

if necessary, tap it in with a hammer and a socket the same diameter

as the seal. 
						

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

2B-29

17.4b ... then take off the pressure plate 
12 Installation is the reverse of the removal steps.

13 Adjust clutch free-play (see Chapter 1).

17 Clutch and primary gears - removal, inspection and

installation

Removal

Refer to illustrations 17.3, 17.4a, 17.4b, 17.4c, 17.6. 17.7a. 17.7b

17.8, 17.9a through 17.9d, 17.11a, 17.11b, 17.12a, 17.12b and 17.13

1 Drain the engine oil and remove the oil filter (see Chapter 1).

2 Remove the footpeg and brake pedal, then loosen the right-hand

crankcase cover bolts in a criss-cross pattern, 1/4 turn at a time.

3 Once the bolts are all loose, remove the bolts and take the cover

off (see illustration). If its struck, pry gently at the pry points around

the cover. Dont pry anywhere else or the gasket surface may be

damaged.

4 If youre working on a coil spring clutch, loosen the pressure plate

screws evenly in a criss-cross pattern, then remove the screws and

springs and take off the pressure plate (see illustrations).

5 If youre working on a diaphragm spring clutch, remove the bolts.

plate washer, clutch spring, spring seat and pressure plate (see

illustration 17.4c).

17.4c Clutch (XV700-1100 models) -

exploded view

1 Clutch housing

2 Pushrod

3 Thrust washer

4 Clutch boss

5 Seat plate

6 Seat spring

7 Metal plate

8 Wire ring

9 Friction plates

10 Metal plates

11 Lockwasher

12 Nut

13 Push piece

14 Thrust bearing

15 Thrust washer

16 Pressure plate (coil spring clutch)

17 Spring (coil spring clutch)

18 Washers (coil spring clutch

19 Pressure plate screws

20 Woodruff key

21 Primary gear

22 Special washer

23 Lockwasher

24 Nut

25 Bolts (diaphragm spring clutch)

26 Plate washer (diaphragm spring clutch)

27 Diaphragm spring (diaphragm spring clutch)

28 Spring seat (diaphragm spring clutch)

29 Pressure plate (diaphragm spring clutch) 
						

							
2B-30 
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

17.6 Remove the thrust washer and

thrust bearing 
17.7a Remove the push piece ... 
17.7b ... and the pushrod

17.8 Remove the clutch plates 
17.9a Bend the lockwasher tab away from

the nut 
17.9b Youll need a tool to keep the clutch

from turning; this is one type of Yamaha

special tool...

17.9c ... this is another type 
17.9d Hold the clutch housing so it wont turn and loosen the nut

6 Remove the thrust washer and thrust bearing (see illustration).

7 Remove the push piece and pushrod (see illustrations).

8 Remove the clutch plates (a friction plate comes off first, followed

by a steel plate, then alternating friction and steel plates) (see

illustration).

9 Bend back the lockwasher on the clutch boss nut (see

illustration). Loosen the nut, using a special holding tool (Yamaha tool

no. YM-91402, part no. 90890-04086 or equivalent) to prevent the

clutch housing from turning (see illustrations). An alternative to these 
tool can be fabricated from some steel strap, bent at the ends and

bolted together in the middle (see Part A of this Chapter). You can also

make a holding tool by drilling through a steel plate and friction plate

and bolting them together (see Part A of this Chapter). Slip the bolted

plates into their normal installed position to lock the clutch housing

and clutch boss together. To keep the engine from turning, wedge a

rag between the teeth of the primary drive gear and the driven gear on

the clutch housing. Once the nut is loose, remove it.

10 Remove the lockwasher and discard it. Use a new one during

installation. 
						

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

2B-31

17.11a Remove the clutch boss ... 
17.11b ... and the thrust washer

17.12a With the primary gear nut loose.

slide off the clutch boss, then remove the

primary gear nut...

17.12b ... the lockwasher and the

special washer 
17.13 Take the primary drive gear and

Woodruff key off the crankshaft 
17.14 Push the ends of the wire ring

through the hole in the clutch boss

17.15 Inspect the clutch boss splines

17.16 Measure the free length of the clutch springs (coil

spring models)

11 Remove the clutch boss and thrust washer (see illustrations).

12 Bend back the lockwasher from the nut that secures the primary

drive gear. Wedge a rag between the driven gear and drive gear teeth

to keep the gears from turning, then loosen the nut. Once the nut is

loose, slide the clutch housing/driven gear off and remove the nut,

lockwasher and special washer (see illustrations).

13 Remove the primary drive gear and Woodruff key (see

illustration).

Inspection

Refer to illustrations 17.14, 17.15, 17.16, 17.17a, 17.17b, 17.18, 17.19,

17.21, 17.22, 17.23 and 17.24 
14 If the clutch has been chattering (juddering), remove the wire ring

(see illustration). Remove the steel plate, seat spring and seat plate

that make up the clutch damper (see illustration 17.4c). These parts

need not be removed if the clutch hasnt been chattering.

15 Examine the splines on both the inside and the outside of the

clutch boss (see illustration). If any wear is evident, replace the clutch

boss with a new one.

16 If youre working on a coil spring clutch, measure the free length

of the clutch springs (see illustration). Replace the springs as a set if

any one of them is not within the values listed in this Chapters Specifi-

cations.

17 If youre working on a diaphragm spring clutch, measure the free 
						

							
2B-32

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

17.17a Measure the free height of

the diaphragm spring with a

vernier catiper ...

1 Diaphragm spring 
17.17b ... and check it for warpage with a

feeler gauge 
17.18 Check the amount of wear on each

clutch friction plate

17.19 Check the metal plates for warpage

with a feeler gauge 
17.21 Check the slots in the clutch

housing for uneven wear 
17.22 Check the driven gear teeth for

wear or damage

17.23 Check the pressure plate for wear and damage (coil spring

pressure plate shown)
height and warpage of the diaphragm spring (see illustrations).

Replace the spring if its sagged or warped.

18 If the lining material of the friction plates smells burnt or if its

glazed, new parts are required. If the metal clutch plates are scored or

discolored, they must be replaced with new ones. Measure the

thickness of each friction plate (see illustration) and compare the

results to this Chapters Specifications. Replace the friction plates as a

set.if any are near the wear limit.

19 Lay the metal plates, one at a time, on a perfectly flat surface

(such as a piece of plate glass) and check for warpage by trying to slip

a gauge between the flat surface and the plate (see illustration). The

feeler gauge should be the same thickness as the warpage limit listed

in this Chapters Specifications. Do this at several places around the

plates circumference. If the feeler gauge can be slipped under the

plate, it is warped and should be replaced with a new one.

20 Check the tabs on the friction plates for excessive wear and

mushroomed edges. They can be cleaned up with a file if the

deformation is not severe.

21 Check the edges of the slots in the clutch housing for

indentations made by the friction plate tabs (see illustration). If the

indentations are deep they can prevent clutch release, so the housing

should be replaced with a new one. If the indentations can be removed

easily with a file, the life of the housing can be prolonged to an extent.

22 Check the teeth on.the primary drive gear and driven gear for

wear or damage and replace them if defects are found. The driven gear

is replaced together with the clutch housing (see illustration).

Check the bearing surface in the center of the clutch housing and

replace the clutch housing if its worn or damaged. 
23 Check the pressure plate for wear and damage (see illustration).

Replace any worn or damaged parts.

24 Check the push piece, thrust bearing and washer for wear or

damage (see illustration). Check the pushrod, especially at the ends.

Replace any parts that show wear or damage. 
						

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

2B-33

17.24 Check the push piece, thrust bearing and washer for wear

and damage 
17.38 Several of the bottom clutch cover bolts secure wiring

harness clips

18.3 Loosen the pinch bolt and detach the shift lever from the

shift shaft (rearset shift linkage shown)

25 Clean all traces of old gasket material from the clutch cover and

ts mating surface on the crankcase.

Installation

Refer to illustration 17.38

26 Install the primary drive gear Woodruff key, then install the

primary drive gear (see illustration 17.13).

27 Install the special washer and a new lockwasher on the primary

drive gear. Make sure the lockwasher tabs fit into the notches in the

special washer (see illustration 17.12b), then install the nut.

28 Coat the clutch housing bearing surface with clean engine oil,

then slip the clutch housing onto the crankshaft (see illus-

tration 17.12a).

29 Wedge a rag between the primary drive gear and the driven gear

on the clutch housing so they cant turn, then tighten the primary drive

gear nut to the torque listed in this Chapters Specifications. Bend the

lockwasher against the nut.

30 Install the thrust washer, then the clutch boss (see illustrations

17.11b and 17.11a). Install a new lockwasher. Install the nut with its

recessed side toward the clutch boss and tighten it slightly (see

illustration 17.9a).

31 Hold the clutch boss and housing from turning with one of the

methods described in Step 9. Tighten the clutch boss nut to the torque

listed in this Chapters Specifications, then bend the lockwasher

against the nut to secure it. 
32 If you removed the clutch damper, reverse Step 14 to install it. If

theres an OUTSIDE mark on the seat spring, face it out (away from the

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

clutch boss.

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

clutcTi housing. Engage the tabs on the friction plate with the slots in

the clutch housing.

34 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 pfates, coated with engine oil (a friction plate is the

last one installed).

35 Coat the pushrod with multi-purpose grease and install it in the

engine (see illustration 17.7b).

36 If youre working on a coil spring clutch, 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 If youre working on a diaphragm spring clutch, install the

pressure plate, spring seat, spring and plate washer (see illustr-

tion 17.4c). Install the plate washer bolts and tighten them evenly, in a

criss-cross pattern, to the torque listed in this Chapters Specifi-

cations.

38 Install the clutch cover over the dowels and a new gasket, then

install and finger-tighten the bolts. Some of the bolts along the bottom

retain wiring harness clamps (see illustration).

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

torque listed in this Chapters Specifications.

40 Install a new oil filter and fill the crankcase with the recommended

type and amount of engine oil (see Chapter 1).

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

18 External shift mechanism - removal, inspection and

installation

Shift lever and pedal

Refer to illustration 18.3

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. This should

align with the groove in the lever or pedal. If you cant find it, make your

own punch mark so the lever or pedal can be realigned correctly

during installation.

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

lever or pedal off the shaft, together with the linkage rod.

4 Installation is the reverse of removal. Adjust the linkage (if

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

							
2B-34

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

18.7a Pull the lever in the direction of the arrow until it clears the

shift cam, then slide the shift mechanism out of the engine 
18.7b Remove the C-clip at each end of the shaft and slide the

parts off for inspection

Shift mechanism removal

Refer to illustrations 18.7a and 18.7b

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

6 Remove the alternator cover (see Chapter 8).

7 Pull the lever on the shift mechanism away from the shift cam,

then slide the shift mechanism out of the crankcase (see illustrations).

Shift mechanism inspection

Refer to illustrations 18.9, 18.11 and 18.13

8 Inspect the shift shaft guide bar in the crankcase. 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.

9 Remove the C-clips from each end of the shift shaft, then

separate the components from the shaft (see illustration).

10 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.

11 Check the condition of the stopper lever and spring (see

illustration). Replace*the stopper lever if its worn where it contacts

18.9 External shift mechanism (XV700-

1100 models) - exploded view

1 Shift arm and shaft

2 Return spring

3 Stopper lever

4 Shaft return spring

5 C-clip

6 Stopper lever spring

7 Washer

8 Bushing (if equipped)

9 Washer

10 Washer

11 Oil seal

12 Rear boot

13 Pedal pad

14 Thrust washer

75 Bushing

16 Nut

17 Linkage end piece

18 Front boot

19 Pinch bolt

20 Linkage rod

21 Rear adjusting nut

22 Front adjusting nut

23 Shift pedal and linkage -

rearset type

24 Shift pedal - direct type

25 Shift pedal

26 Pedal pad

27 Pinch bolt 
						

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

2B-35

18.11 Check the stopper arm roller and

spring for wear and damage 
18.13 Pry the oil seal out of the cover and

tap a new one in 
18.15 The legs of the shaft return spring

should be on either side of the shift shaft

guide bar

20.8 Crankcase bolt TIGHTENING sequence

the shift cam. Replace the spring if its distorted.

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

damaged, youll have to disassemble the crankcase to replace them.

13 Pry the shift pedal oil seal out of the alternator cover (see

illustration). Install a new seal so its open side will face into the engine

when the cover is installed. You should be able to push the new seal in

with thumbs, but if it wont go, tap it in with a hammer and a socket the

same diameter as the seal.

14 Reassemble the shift mechanism components on the shaft.

Installation

Refer to illustration 18.15

15 Be sure the washers are on the shift shaft, then install the shift

shaft in the crankcase. Engage the stopper lever with the shift cam and

position the torsion spring against its post (see illustration).

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

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

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

Chapter 1).

19 Middle gears and shafts (shaft drive models)

The middle driveshaft and middle driven shaft on these models

are mounted in the left crankcase casting. Access to the shafts is

gained by splitting the crankcase. Removal of the shafts for inspection

is a complicated procedure which requires a number of special tools.

For this reason, removal and disassembly of the shafts should be done 
by a Yamaha dealer or other qualified repair shop.

You can probably save considerable money on labor charges by

removing the engine and doing most of the engine disassembly

yourself. However, be sure to check with the shop firstto find out how

much disassembly to do. Some shops may not be willing to work on a

partially disassembled engine.

20 Crankcase - disassembly and reassembly

1 To examine and repair or replace the crankshaft, middle drive and

driven shafts, connecting rods, bearings, or transmission components,

the crankcase must be split into two parts.

Disassembly

Refer to illustrations 20.8, 20.9 and 20.10a through 20.10d

2 Remove the cylinder heads, cylinders, pistons and cam chains

(see Sections 8, 11, 12 and 14).

3 Remove the alternator, starter motor and starter drive (see

Chapter 8).

4 Remove the oil level switch and neutral switch (see Chapter 8).

5 Remove the oil pump and oil feed line (see Section

6 Remove the clutch and primary gear (see Section 1 7

7 Remove the external shift linkage (see Section 18).

8 Remove the crankcase bolts in the reverse of the tightening

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

lowest) (see illustration).