Haynes Yamaha Xv V Twins Manual

							
5A-8

Chapter 5 Part A Steering, suspension and final drive (XV535 models)

6.7a Loosen the ring nut with a ring nut

wrench (C-spanner) 
6.7b Take the ring nut off

the steering stem 
6.7c Lift off the bearing cover and the

upper bearing top race (arrow)

6.7d Remove the 19 steel balls

6.8 Lower the steering stem and lower

bearing balls out of the steering head 
6.10a Insert a long punch or rod from

below to tap out the upper

bearing bottom race ...

7 Remove the ring nut with a special wrench such as Yamaha tool

YU-33975 (part no. 90890-01403) (see illustration). Remove the

bearing cover, upper race and 19 steel balls (see illustrations).

8 Lower the steering stem partway out of the steering head and

remove the 19 steel balls from the lower bearing (see illustration).

Inspection

Refer to illustrations 6.10a, 6.10b, 6.11a, 6.11b, 6.11c, 6.116, 6.13,

6.14a, 6.14b and 6.14c

9 Check the bearings for wear. Look for cracks, dents, and pits in 
the races and flat spots, pitting or galling on the bearing balls. Replace

any defective parts with new ones. If a new bearing is required, replace

both bearings, their races and both dust seals as a set.

10 To remove the bearing races, drive them out of the steering head

with a hammer and long rod or punch (see illustrations). A slide

hammer with the proper internal-jaw puller will also work.

11 Since the races are an interference fit in the frame, installation will

be easier if the new races are left overnight in a refrigerator. This will

cause them to contract and slip into place in the frame with very little

effort. When installing the races, tap them gently into place with a

6.10b ... and from above to tap out the

lower bearing top race 
6.11a Position the lower bearing top race

in the steering head ... 
6.11b ... and tap it into position with a

socket just smaller in diameter

than the race 
						

							
Chapter 5 Part A Steering, suspension and final drive (XV535 models)

5A-9

6.11c Tap the upper bearing bottom race

into position with the same tools . . 
6.11d ... the race should look like

this when installed 
6.13 Tap the seal and lower bearing

bottom race off the steering stem

6.14a Install a new seal with its

concave side down . .. 
6.14b ... the seal should look like

this when installed 
6.14c Install the lower bearing bottom

race with its groove up

hammer and punch or a large socket (see illustrations). Do not strike

the bearing surface or the race will be damaged.

12 Inspect the steering stem/lower triple clamp for cracks and other

damage. Do not attempt to repair any steering components. Replace

them with new parts if defects are found.

13 Tap the seal and lower bearing race off the steering stem with a

hammer and punch (see illustration). The seal will be ruined during

this process, so dont remove it unless you plan to install a new one.

14 Install a new seal with its concave side down, then install the

lower bearing bottom race (see illustrations). 
Installation

Refer to illustrations 6.15a, 6.15b, 6.16a, 6.16b, 6.16c, 6.17, 6.18a,

6.18b and 6.18c

15 Pack the lower bearing bottom race with high-quality bearing

grease (preferably a moly-based grease). Stick 19 steel balls to the

grease around the race, then add more grease (see illustrations).

Note: A small hand-operated grease gun will make this job easier.

16 Pack the upper bearing and install the steel balls in the same way

as for the lower bearing (see illustrations).

6.15a Pack the race with grease and

install 19 steel balls ... 
6.15b ... then pack more grease

on top of the balls 
6.16a Apply a layer of grease to the upper

bearing bottom race .. . 
						

							
5A-10 
Chapter 5 Part A Steering, suspension and final drive (XV535 models)

6.16b . .. stick 19 steel balls to

the grease .. . 
6.16c ... then add more grease 
6.17 Slip the steering stem into the

steering head, taking care not

to dislodge the steel balls

6.18a Install the upper bearing top

race with its flat side up 
6.18b Install the bearing cover

over the race 
6.18c Install the ring nut and

adjust the bearings

17 Slip the steering stem into the steering head, taking care not to

dislodge any of the bearing balls (see illustration).

18 Install the top race on top of the upper bearing balls, then install

the bearing cover and the ring nut (see illustrations).

19 Refer to Chapter 1 and adjust the bearings.

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

7 Rear shock absorbers - removal, inspection and

installation

Removal

Refer to illustrations 7.2, 7,3a, 7.3b and 7.4

1 Support the bike securely so it cant be knocked over during this 
procedure. Place a jack beneath the frame to lift the rear tire off the

ground and support the swingarm so it cant drop.

2 Remove the cover from the top end of the shock absorber (see

illustration). On models so equipped, remove the backrest (see

Chapter 7).

3 Unbolt the top end of the shock from the frame (see illustrations).

4 Remove the bolt that secures the lower end of the right shock or

the nut that secures the lower end of the left shock (see illustration).

Rotate the top end of the shock toward the rear of the bike and take

it off.

Inspection

Refer to illustration 7.6

5 Check the shock for obvious physical damage and the coil spring

7.2 Remove the shock absorber cover fasteners (arrows); on

some models one of the fasteners also secures the backrest 
7.3a Remove the upper mounting bolt 
						

							
Chapter 5 Part A Steering, suspension and final drive (XV535 models)

5A-11

7.3b Rear shock absorber details (XV535 models)

1 Shock absorber

2 Mounting bushings

3 Collars

4 Mounting bolts

5 Mounting nut flower left only)

6 Swingarm

for looseness or signs of fatigue; replace both shock absorbers as a

pair if these conditions are found. Except for mounting bushings,

replacement parts are not available.

6 Check the shock for signs of oil or gas leaks and replace it if you

find any. Yamaha specifies releasing the nitrogen gas pressure before

throwing away the shock absorber. Warning: Wear eye protection 
while drilling to prevent injury from flying metal chips. To release the

gas pressure, drill a hole through the cylinder wall at a point 10 mm (0.4

inch) from the top of the nitrogen reservoir (see illustration). The hole

should be 2 to 3 mm (0.08 to 0.12 inch) in diameter.

7 Inspect the pivot hardware at the top and bottom of the shock

and replace any worn or damaged parts.

7.4 The bottom of the left shock absorber is secured by a nut 
7.6 A hole must be drilled in the nitrogen reservoir before

throwing the shock absorber away 
						

							
5A-12

Chapter 5 Part A Steering, suspension and final drive (XV535 models)

9.5a Remove the nuts and lockwashers ...

9.5b ... and take the final drive unit off the swingarm

9.5c Driveshaft and final drive unit

(XV535 models) - exploded view

1 Collar

2 Dust seal

3 Bearing housing

4 O-ring

5 Oil seal

6 Ring gear shim

7 Bearing

8 Ring gear

9 Thrust washer

10 Drive pinion gear

11 Final drive gear shim

12 Bearing retainer

13 Boot

14 Spring

15 Coupling gear

16 Snap-ring

17 Driveshaft

18 Universal joint

19 Bearing 
						

							
Chapter 5 Part A Steering, suspension and final drive (XV535 models)

5A-13

Installation

8 Coat the pivot points with a thin layer of multi-purpose lithium-

based grease. Install the shock with the tightly would spring coils

down. Tighten the top bolts, then the bottom right bolt, then the

bottom left nut to the torques listed in this Chapters Specifications.

8 Swingarm bearings - check

1 Refer to Chapter 6 and remove the rear wheel, then refer to

Section 7 and remove the rear shock absorbers.

2 Grasp the rear of the swingarm with one hand and place your

other hand at the junction of the swingarm and the frame. Try to move

the rear of the swingarm from side-to-side. Any wear (play) in the

bearings should be felt as movement between the swingarm and the

frame at the front. The swingarm will actually be felt to move forward

and backward at the front (not from side-to-side). If any play is noted,

the bearings should be replaced with new ones (see Section 11).

3 Next, move the swingarm up and down through its full travel. It

should move freely, without any binding or rough spots. If it does not

move freely, refer to Section 10 for servicing procedures.

9 Driveshaft and final drive - removal, inspection and

installation

Removal

Refer to illustrations 9.5a, 9.5b, 9.5c, 9.6, 9.7, 9.8a, 9.8b and 9.9

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

procedure.

2 Remove the exhaust system (see Chapter 3).

3 Remove the rear wheel (see Chapter 6).

4 Remove the rear shock absorbers (see Section 7).

5 Remove the nuts and lockwashers and detach the final gear

assembly from the swingarm (see illustrations).

6 Remove the spring from the end of the driveshaft (see

illustration).

7 Slide the driveshaft out of the swingarm (see illustration).

8 Slide the boot and coupling gear off the driveshaft (see

illustrations).

9 Slide the forward boot up the driveshaft slightly, remove the

snap-ring and slide the forward boot off (see illustration).

Inspection

10 Thoroughly clean the driveshaft and related parts with solvent.

Wipe the final gear assembly clean with a rag moistened in solvent.

11 Check all parts for obvious wear or damage and replace any worn

or damaged parts. 
9.6 Take out the spring

9.7 Pull the driveshaft backward and take it out of the swingarm

12 The final drive unit requires special tools to measure and adjust

gear backlash. The procedure is complicated and should be done by a

dealer service department or other qualified shop. Rotate the pinion

shaft (the one that mates with the driveshaft) by hand. The ring gear

splines (the part that mates with the rear wheel) should rotate

smoothly. If rotation feels rough or jerky or if its noisy, have the final

drive unit disassembled and inspected.

9.8a Slide the boot off the coupling gear

9.8b Slide the coupling gear off the shaft 
9.9 Remove the snap-ring, then slide

the forward boot off 
						

							
5A-14 
Chapter 5 Part A Steering, suspension and final drive (XV535 models)

9.13 Be sure the spring is in position

before installing the final drive unit 
10.6a Bend back the lockwasher

tabs (arrows)... 
10.6b ... and remove the pivot shaft

10.8a Pull the swingarm back to remove it 
Installation

Refer to illustration 9.13

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

additions: .

a) Lubricate the driveshaft splines with multi-purpose lithium-based

grease.

b) Apply silicone sealant to the mating surfaces of the swingarm and

final drive unit.

c) Make sure the spring is in place in the end of the driveshaft (see

illustration).

d) Use new lockwashers and tighten the final drive-to-swingarm nuts

to the torque listed in this Chapters Specifications.

e) Check the oil level in the final drive unit and top up as needed (see

Chapter 1).

10.8b Swingarm (XV535 models) - exploded view

1 Pivot shaft

2 Lockwasher

3 Thrust cover

4 Plain washer

5 Needle roller bearing

6 Bushing 
						

							
Chapter 5 Part A Steering, suspension and final drive (XV535 models)

5A-15

10.9 Bend the lockwasher tabs against the head of the pivot shaft

11.2 Pry the thrust cover loose and pull it off

10 Swingarm - removal and installation

Refer to illustrations 10.6a, 10.6b, 10.8a, 10.8b and 10.9

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

procedure.

2 Remove the exhaust system (see Chapter 3).

3 Remove the rear wheel and disconnect the rear brake pedal and

rod, noting that the cable must be detached from its slot in the

swingarm (see Chapter 6).

4 Remove the rear shock absorbers (see Section 7).

5 Remove the right rear side cover (see Chapter 7).

6 Bend back the tabs on the lockwasher that secures the swingarm

pivot shaft head (see illustration). Unscrew the swingarm pivot shaft

and take it out (see illustration).

7 Remove the final gear assembly and driveshaft (see Section 9).

8 Pull the swingarm off the motorcycle (see illustrations).

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

additions:

a) Apply multi-purpose lithium grease to the driveshaft splines. 
b) Install the swingarm without the driveshaft, then install the

driveshaft as described in Section 9.

c) Use a new lockwasher and be sure its tab engages the slot in the

swingarm. Tighten the pivot shaft to the torque listed in this

Chapters Specifications, then bend the lockwasher against the

flats on the shaft head (see illustration).

11 Swingarm bearings - inspection and replacement

Refer to illustrations 11.2, 11.3 and 11.4

1 Remove the swingarm (see Section 10).

2 Pry off the thrust cover and remove the plain washer from each

side of the frame (see illustration).

3 Slide the bushing out (see illustration).

4 Inspect the bearings (see illustration). If theyre dry, lubricate

them with lithium base waterproof wheel bearing grease. If theyre

worn or damaged, take the motorcycle to a Yamaha dealer or

motorcycle repair shop for bearing replacement.

11.3 Pull out the bushing

11.4 The bearings may require a blind hole puller for removal 
						

							
5A-16

Chapter 5 Part A Steering, suspension and final drive (XV535 models)

Notes 
						

							
5B-1

Chapter 5 Part B

Steering, suspension and

final drive (XV700-1100 models)

Contents

Section

Drive chain, sprockets and coupling bearing (chain drive models) -

removal, inspection and installation 13

Driveshaft and final drive (shaft drive models) - removal,

inspection and installation 12

Fork oil change 6

Forks - disassembly, inspection and reassembly 8

Forks - removal and installation 7

General .information 1

Handlebar adjustment (XV920J models) 3

Handlebar(s) - removal and installation 2 
Section

Rear shock absorbers (1984 and later models) - removal,

inspection and installation 10

Rear suspension unit (1981 through 1983 models) - inspection,

removal and installation 9

Steering head bearings (1981 through 1983 models) -

replacement 4

Steering head bearings (1984 and later models) - replacement 5

Suspension adjustments See Chapter 1

Swingarm bearings - check 11

Swingarm bearings - inspection and replacement 15

Swingarm - removal, inspection and installation 14

Specifications

Front suspension

Fork spring length

1981 through 1983 XV750 635 mm (25.0 inches)

XV920J, KandMK 624.7 mm (24.6 inches)

XV920 RH, RJ and TR1 577.5 mm (22.7 inches)

1984 and 1985 models (except TR1) 508 mm (20.0 inches)

1986-on models 513 mm (20.2 inches)

Fork oil capacity (US)

1981 through 1983 XV750 278 cc (9.40 US fl oz, 9.78 Imp fl oz)

XV920J 303 cc (10.24 US fl oz, 10.66 Imp fl oz)

XV920 K and MK 290 cc (9.80 US fl oz, 10.20 Imp fl oz)

XV920 RH, RJ and TR1 : 264 cc (8.92 US fl oz, 9.30 Imp fl oz)

1984 and 1985 XV700 389 cc (13.1 US fl oz, 13.7; Imp fl oz)

1986-on XV700 and 750 396 cc (13.4 US fl oz, 13.9 Imp fl oz)

1984-on XV1000 and 1100 372 cc (12.6 US fl oz, 13.1 Imp fl oz)