Haynes Yamaha Xv V Twins Manual

							
5B-2 
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

Fork oil level (US)

1981 through 1983 models Not specified

XV700, XV750, XV1000 155 mm (6.1 inches) below top of inner fork tube*

XV1100 179 mm (7.0 inches) below top of inner fork tube*

Fork oil capacity (UK)

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)

XV920Kand 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)

1986 and later models. 396 cc (13.4 US fl oz, 13.9 Imp fl oz)

Fork oil level (UK)

1981 through 1983 models Not specified

1992-on XV750, 1994 XV1100 155 mm (6.1 inches) below top of inner fork tube*

1986 through 1993 XV1000 and 1100 179 mm (7.0 inches) below top of inner fork tube*

Rear suspension

Rear spring free length

1981 through 1983 XV750 167 mm (6.57 inches)

XV920 J, K, MK 168.5 mm (6.63 inches)

XV920 RH, RJ and TR1 172 mm (6.77 inches)

1984 and 1985 models (except TR1) 223 mm (8.78 inches)

1986-onXV700andXV750 224.5 mm (8.83 inches)

1986-onXV1100 216.5 mm (8.5 inches)

Rear spring sag limit 5 mm (0.20 inch)

Swingarm end play and side play limits 1 mm (0.04 inch)

*With spring removed and fork fully compressed.

Torque specifications

1981 through 1983 models

Front forks

Damper rod bolt 20 Nm (14 ft-lbs)**

Triple clamp pinch bolts 20 Nm (14 ft-lbs)

Handlebars and steering stem

Handlebar bracket to upper triple clamp nuts (XV920J only) 23 Nm (17 ft-lbs)

Handlebar pinch bolts (XV920J only)

Inner sections 30 Nm (22 ft-lbs)

Outer sections 13 Nm (9 ft-lbs)

Steering stem bolt

XV920 J, K, MK 50 Nm (36 ft-lbs)

All others 54 Nm (39 ft-lbs)

Steering head bearing ring nut see Chapter 1

Rear suspension unit pivot bolt 45 Nm (32.5 ft-lbs) . • •

Swingarm pivot bolt 78 Nm (56 ft-lbs)

Final drive unit to swingarm nuts 43 Nm (31 ft-lbs)

1984-on models

Front forks

Damper rod bolt 23 Nm (17 ft-lbs)**

Upper triple clamp pinch bolts 20 Nm (14 ft-lbs)

Lower triple clamp pinch bolts.... 23 Nm (17 ft-lbs)

Cap bolt 23 Nm (17 ft-lbs)

Handlebars and steering stem

Handlebar bracket to upper triple clamp nuts

All except 1988-on XV750 not specified

1988-onXV750 59 Nm (43 ft-lbs)

Handlebar pinch bolts 20 Nm (14 ft-lbs)

Steering stem nut 110 Nm (80 ft-lbs)

Steering head bearing ring nut see Chapter 1

Rear shock absorber upper bolts 20 Nm (14 ft-lbs)

Rear shock absorber lower bolts/nuts 30 Nm (22 ft-lbs)

Swingarm pivot shafts

Left pivot shaft 100 Nm (72 ft-lbs)

Right pivot shaft

All except 1988-on XV750 5.5 Nm (4 ft-lbs)

1988-on XV750 6 Nm (4.3 ft-lbs)

Right pivot shaft nut 100 Nm (72 ft-lbs)

Final drive unit to swingarm nuts

All except 1988-on XV750 43 Nm (32 ft-lbs)

1988-on XV750 42 Nm (30 ft-lbs)

**Apply non-permanent thread locking agent to the bolt threads. 
						

							
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

5B-3

2.2a Pry up the bolt cover, then remove the handlebar

cover bolt and cover

2.2b Remove the trim caps from the handlebar

bracket Allen bolts

1 General information

The front forks are of the conventional coil spring, hydraulically-

damped telescopic type. Fork air pressure is adjustable on all except

1984 and later XV700 and XV750 models.

The rear suspension on 1981 through 1983 models consists of a

single shock absorber with concentric coil spring and a swingarm.

Suspension damping and shock absorber air pressure are adjustable.

The rear suspension on 1984 and later models consists of twin

shock absorbers with concentric coil springs and a swingarm.

Chain final drive is used on XV920 RH, RJ and RK models, as well as

on 1981 through 1985 XV1000 (TR1) models sold in the UK. All other

motorcycles covered in this Chapter use shaft final drive.

2 Handlebar(s) - removal and installation

All models except XV920J

Refer to illustrations 2.2a through 2.26, 2.7a and 2.7b

1 The handlebar is a one-piece unit thats secured to the upper

triple clamp by a pair of brackets.

2 To remove the handlebar from its brackets, remove the trim cover

(if equipped) and remove the bolts that secure the top half of each

bracket (see illustrations). Lift the handlebar out. 
2.2c Steering head and handlebar brackets (1981 through 1983

models except XV920J) - exploded view

1 Upper triple clamp 18 Lower bearing bottom race

2 Top bolt 19 Dust seal

3 Steering stem pinch bolt 20 Steering stem/lower triple

4 Fork pinch bolt clamp

5 Washer 21 Bolt

6 Nut 22 Washer

7 Washer 23 Handlebar bracket (lower half)

8 Lockwasher 24 Handlebar bracket (upper half)

9 Nut 25 Bolt

10 Safety clip 26 Plug (chain drive models only)

11 Bearing locknut 27 Handlebar cover

12 Bearing cover 28 Washer

13 Upper bearing top race 29 Screw or bolt

14 Upper bearing balls 30 Trim cover

15 Upper bearing bottom race 31 Bearing ring nut

16 Lower bearing top race 32 Cable guide

17 Lower bearing balls 
						

							
5B-4 
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

2.2d Steering head and handlebar brackets (1984

and later models) - exploded view

1 Handlebar bracket bolt

2 Handlebar bracket (upper half)

3 Handlebar bracket (lower half)

4 Top nut

5 Washer

6 Upper triple clamp

7 Washer

8 Lockwasher

9 Nut

10 Safety clip

11 Lockwasher

12 Bearing locknut

13 Bearing washer

14 Bearing ring nut

15 Bearing cover

16 Upper and lower bearings

17 Steering stem/lower triple clamp

18 Screw

19 Trim

20 Bolt

21 Fork brace

22 Bolt

23 Lockwasher

24 Washer

25 Cable guide

26 Trim cap

3 If the handlebar must be removed for access to other

components, such as the forks or the steering head, its not necessary

to disconnect the cables, wires or hoses, but it is a good idea to

support the assembly with a piece of wire or rope, to avoid

unnecessary strain on the cables, wires and the brake hose.

4 If the handlebar is to be removed completely, refer to Chapter 2

for clutch cable removal procedures, Chapter 6 for the brake master

cylinder removal procedures, Chapter 3 for the throttle grip removal

procedure and Chapter 8 for the switch removal procedure.

5 To remove a bracket from the upper triple clamp, pull out the

safety clip and remove the nut, lockwasher and washer, then lift the

bracket out.

6 Check the handlebar and brackets for cracks and distortion and

replace them if any undesirable conditions are found. If the brackets 
were removed, check their rubber mounts for brittleness or deterioration.

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

additions:

a) Make sure the arrow cast in the top half of each bracket points

forward (see illustration).

b) Align the dot on the handlebar with the gap in the bracket (see

illustration). Tighten the nuts and bolts to the torques listed in

this Chapters Specifications and be sure the gaps at the front and

rear of each bracket are even.

XV920J models

Refer to illustrations 2.8 and 2.10

8 Pry the trim piece out of the handlebar cover, then remove the 
						

							
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

5B-5

2.7a The arrow mark on each handlebar bracket must point to

the front of the motorcycle 
2.7b Align the dot on the handlebar with the gap in the bracket;

the gaps at front and back of the bracket must be even

2.8 Handlebars (XV920J) - exploded view

1 Right mounting bracket

2 Left mounting bracket

3 Trim plates

4 Washer

5 Handlebar riser retaining bolt

6 Plastic cap

7 Pinch bolt

8 Trim plate

9 Screw

10 Left handlebar

11 Rubber boot

12 Handlebar pinch bolt

13 Handlebar

14 Trim cap

15 Allen bolt

16 Washer

17 Brake lever cover

18 Throttle grip

19 Handlebar cover

20 Washer

21 Screw

22 Trim piece

screw, the washer and the cover (see illustration).

9 Pry the plastic caps out of the handlebar riser retaining bolts, then

remove the retaining bolts and washers and loosen the pinch bolts.

10 Lift the handlebars off the mounting bracket (see illustration).

11 If the handlebar must be removed for access to other

components, such as the forks or the steering head, its not necessary

to disconnect the cables, wires or hoses, but it is a good idea to

support the assembly with a piece of wire or rope, to avoid

unnecessary strain on the cables, wires and the brake hose. 
12 If the handlebar is to be removed completely, refer to Chapter 2

for clutch cable removal procedures, Chapter 6 for the brake master

cylinder removal procedures, Chapter 3 for the throttle grip removal

procedure and Chapter 8 for the switch removal procedure.

13 To remove the brackets from the upper triple clamp, pull out the

safety clips and remove the nuts, lockwashers and washers (see

illustration 2.10), then lift the bracket out.

14 Check the handlebar and bracket for cracks and distortion and

replace them if any undesirable conditions are found. 
						

							
5B-6 
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

2.10 Steering head and handlebar bracket (XV920J) -

exploded view

1 Upper triple clamp 14 Upper bearing top race

2 Top bolt 15 Upper bearing balls

3 Handlebar bracket 16 Upper bearing bottom race

4 Steering stem inch bolt 17 Lower bearing top race

5 Fork pinch bolt 18 Lower bearing balls

6 Washer 19 Lower bearing bottom race

7 Nut 20 Dust seal

8 Washer 21 Steering stem/lower triple

9 Lockwasher clamp

10 Nut 22 Lockwasher

11 Safety clip 23 Bolt

12 Locknut 24 Bearing ring nut

13 Bearing cover

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

additions:

a) Adjust the handlebar position (see Section 3).

b) Tighten the nuts and bolts to the torques listed in this Chapters

Specifications.

3 Handlebar adjustment (XV920J models)

1 There are two handlebar adjustments: the risers can be rotated on

the bracket to one of three positions, and the handlebars themselves 
4.13a Unbolt the headlight brackets from the lower triple clamp ...

can be raised or lowered to one of three positions.

2 To adjust the risers, refer to Section 2 and detach the handlebars

from their bracket. Place the risers in one of the three adjustment

positions, then refer to Section 2 and install the risers.

3 To adjust the handlebars, remove the trim caps from the tops of

the risers (see illustration 2.8). Loosen the Allen bolts that secure the

handlebars in the risers and loosen the pinch bolts. Pull the handlebars

out of the risers far enough to rotate them to one of the three

adjustment positions, then push the handlebars all the way back in.

4. Tighten the Allen bolts to the torque listed in this Chapters

Specifications and install the trim caps. Warning: Dont adjust the

risers or the handlebars to any position other than the three positions

provided; this could cause loss of steering control.

4 Steering head bearings (1981 through 1983 models) -

replacement

1 Ball bearings are used in the steering head of 1981 through 1983

models. If the steering head bearing check/adjustment (see Chapter 1)

does not remedy excessive play or roughness in the steering head

bearings, the entire front end must be disassembled and the bearings

and races replaced with new ones.

Removal (all models except XV920J)

2 Remove the front wheel (see Chapter 6).

3 Refer to Section 7 and remove the front forks.

4 Disconnect the negative cable from the battery to prevent an

accidental short circuit while disconnecting electrical wiring.

5 Cover the fuel tank with a blanket to prevent damage.

6 Remove the handlebar and place it back out of the way. It

shouldnt be necessary to disconnect the cables or brake hose, but if

necessary, remove tie wraps to allow slack in the cables. Also, make

sure the master cylinder stays upright to prevent fluid leakage.

7 Remove the headlight lens (see Chapter 8) and disconnect the

wiring connectors within the headlight body.

XV750 models

8 Remove the single screw that controls vertical adjustment of the

headlight.

9 Unscrew the speedometer cable from the speedometer and

remove two Allen bolts that secure the instrument bracket. Pull the

headlight assembly and instrument cluster forward, away from the

upper triple clamp.

10 Remove the fuse holder cover and detach the fuse holder from

the lower triple clamp.

11 Remove the left horn (see Chapter 8), then detach the brake hose

from its retaining clip on the horn mounting bracket.

12 Disconnect the wires from the right horn, then detach the horn

mounting bracket from the lower triple clamp. 
						

							
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 
5B-7

4.13b ... and remove the nuts that secure

the headlight brackets and instrument

cluster to the upper triple clamp 
5.10a Remove the washer and the

lower ring nut 
5.10b Remove the bearing cover

XV920 and XV1000 (TR1) models

Refer to illustrations 4.13a and 4.13b

13 Unbolt the headlight brackets from the lower triple clamp (see

illustration). Remove the nut that attaches the top of each headlight

bracket to the instrument cluster studs at the upper triple clamp (see

illustration).

14 Disconnect the speedometer cable and electrical connectors

from the instrument cluster, then lift the cluster clear of the triple clamp

and pull the headlight assembly forward out of the way.

15 Remove the fuse holder and the horn, then unbolt the brake hose

joint from the lower triple clamp without disconnecting any hydraulic

lines.

All models

16 Check the steering stem and lower triple clamp to make sure

nothing is still attaching them to the motorcycle.

17 The bearing balls may fall out and be lost during the next steps.

Its a good idea to place a blanket on the floor to prevent them from

bouncing and rolling. Try to catch the balls with a magnet as the

steering stem is lowered. This will be easier if an assistant is available.

18 Loosen the steering stem pinch bolt and remove the top bolt (see

illustration 2.2c). Lift the upper triple clamp away from the steering

stem.

19 Remove the steering stem locknut with a spanner wrench

(C-spanner).

20 Remove the bearing ring nut with the spanner wrench

(C-spanner). Remove the upper bearing top race and collect the 19

bearing balls with a magnet.

21 Slowly lower the lower triple clamp away from the steering head

until the lower bearing balls are exposed. Try to catch them with the

magnet (there are 19).

22 Lower the steering stem out of the steering head.

Removal (XV920J)

23 Remove the front wheel (see Chapter 6).

24 Refer to Section 7 and remove the front forks.

25 Disconnect the negative cable from the battery to prevent an

accidental short circuit while disconnecting electrical wiring.

26 Cover the fuel tank with a blanket to prevent damage.

27 Detach the handlebar risers from the bracket on the upper triple

clamp and lace them back out of the way (see Section 3). It shouldnt

be necessary to disconnect the cables or brake hose, but if necessary,

remove tie wraps to allow slack in the cables. Also, make sure the

master cylinder stays upright to prevent fluid leakage.

28 Remove the headlight lens (see Chapter 8) and disconnect the

wiring connectors within the headlight body.

29 Remove the plastic trim piece from the lower triple clamp, then

unbolt the headlight bracket from the lower triple clamp.

30 Remove the instrument cluster (see Chapter 8).

31 Remove the top bolt and the upper triple clamp (see illustra-

tion 2.10). Move the headlight assembly out of the way. 
32 Remove the fuse holder, horns and brake hose joint from the

lower triple clamp.

33 Perform Steps 16 through 22 above to remove the steering stem

and bearings from the steering head.

Inspection

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

Chapter.

Installation

34 Installation of the bearings and steering stem in the steering head

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

35 Refer to Chapter 1 and adjust the bearings.

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

5 Steering head bearings (1984 and later models) -

replacement

1 Tapered roller bearings are used in the steering head of 1984 and

later models. If the steering head bearing check/adjustment (see

Chapter 1) does not remedy excessive play or roughness in the

steering head bearings, the entire front end must be disassembled and

the bearings and races replaced with new ones.

Removal

Refer to illustrations 5.10a, 5.10b, 5.11a and 5.11b

2 Remove the front wheel (see Chapter 6).

3 Refer to Section 7 and remove the front forks.

4 Disconnect the negative cable from the battery to prevent an

accidental short circuit while disconnecting electrical wiring.

5 Cover the fuel tank with a blanket to prevent damage.

6 Remove the handlebar and place it back out of the way. It

shouldnt be necessary to disconnect the cables or brake hose, but if

necessary, remove tie wraps to allow slack in the cables. Also, make

sure the master cylinder stays upright to prevent fluid leakage.

7 Remove the headlight lens (see Chapter 8) and disconnect the

wiring connectors within the headlight body. Remove the headlight

assembly mounting bolts, one inside the headlight body and two that

attach the headlight body and brake hose joint to the lower triple

clamp. Move the headlight assembly out of the way.

8 Disconnect the instrument cluster electrical connectors.

9 Remove the steering stem nut and lift off the upper triple clamp,

together with the instrument cluster (see illustration 2.2d).

10 Remove the lockwasher, bearing locknut and second washer

from the steering stem. Remove the lower ring nut and bearing cover

(see illustrations).

11 Remove the upper bearing (see illustration), then lower the

steering stem and lower triple clamp assembly out of the steering head

(see illustration). If its stuck, tap gently on top of the steering stem

with a plastic mallet or a hammer and a wood block. 
						

							
5B-8 Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

5.11 a Lift the upper bearing out of the steering head ...

5.11 b ... and lower the steering stem out of the steering head

5.14 Drive out the upper race from below

with a punch 
5.15a The lower race may not leave room

for a punch to be placed against it... 
5.15b ... so instead, insert a special tool

like this one into the race and expand it so

it grips the race securely...

Inspection and installation

Refer to illustrations 5.14, 5.15a, 5.15b, 5.15c, 5.18 and 5.20

12 Clean all the parts with solvent and dry them thoroughly, using

compressed air, if available. If you do use compressed air, dont let the

bearings spin as theyre dried - it could ruin them. Wipe the old grease

out of the frame steering head and bearing races.

13 Examine the races in the steering head for cracks, dents and pits.

If even the slightest amount of wear or damage is evident, the races

should be replaced with new ones.

14 To remove the upper race, drive it out of the steering head from

below with a hammer and punch (see illustration). A slide hammer

with the proper internal-jaw puller will also work.

15 The lower race can be removed in the same way as the upper

race if theres enough room for the punch to bear against the race. If

there isnt, use a puller tool which can hook the race and be locked into

position (see illustrations). Tap against the tool with a hammer and

punch to drive the race and tool out of the steering head (see

illustration).

16 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

hammer and punch or a large socket. Do not strike the bearing surface

or the race will be damaged.

17 Check the bearings for wear. Look for cracks, dents, pits in or flat

spots on the bearing rollers. Replace any defective parts with new

ones. If a new bearing is required, replace both of them as a set.

18 Dont remove the lower bearing unless it, or the grease seal

beneath it, must be replaced (see illustration). Remove the bearing 
5.15c ... then drive out the tool and race together

with a hammer and punch 
						

							
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models) 
5B-9

5.18 Remove the lower bearing and its

grease seal (arrow) if they need

to be replaced 
5.20 Work the grease completely

into the rollers 
6.2 Remove the plastic cap from the fork

6.4 Unscrewing the air valve core on models with separate air

valves will provide an opening to add fork oil

from the steering stem with a bearing splitter and puller setup. These

can be rented. Tap the lower bearing on with a hammer and piece of

pipe the same diameter as the bearing inner race. Dont tap against the

rollers or roller cage or the bearing will be ruined. As an alternative,

take the steering stem to a Yamaha dealer or motorcycle repair shop

and have the old bearing pressed off and a new one pressed on.

19 Inspect the steering stem lower triple clamp for cracks and other

damage. Dont attempt to repair any steering components. Replace

them with new parts if defects are found.

20 Pack the bearings with high-quality grease (preferably a moly- 
based grease) (see illustration). Coat the outer races with grease also.

21 Insert the steering stem/lower triple clamp into the steering head.

Install the upper bearing and lower ring nut. Refer to Chapter 1 and

adjust the bearings.

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

6 Fork oil change

Refer to illustrations 6.2, 6.4, 6.5a, 6.5b, 6.6, 6.7, 6.9, 6.12 and 6.14

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

procedure. Place it on the centerstand (if equipped). The front wheel

must be raised off the ground using a jack and wood support under the

crankcase, or with axle stands.

2 On all except XV920J models, remove the plastic fork caps (see

illustration).

3 On all except XV700 models, press on the air valve with a small

screwdriver or similar tool to release the fork air pressure.

4 If youre working on an XV920 K or MK, the easiest way to make

an opening for the new fork oil is to unscrew the air valve core with a

core removal tool (see illustration). As an alternative, unscrew the air

valve itself.

5 If youre working on a 1981 through 1983 XV750, a chain drive

XV920 or a TR1, press down the spring seat with a socket that will fit

over the air valve. Use an extension-on the socket so you can grip it (see

illustration). Remove the stopper ring, then slowly release the spring

pressure and lift out the spring seat and spring (see illustration).

6 Loosen the upper triple clamp pinch bolts (see illustration).

7 If youre working on an XV920J, unscrew the fork cap (see

illustration).

8 On all other models, unscrew the fork cap with an Allen bolt bit.

6.5a Push the fork cap down against the

spring pressure with an extension and a

socket big enough to fit over the air valve 
6.5b Remove the retainer, then remove

the fork cap and spring 
6.6 Loosen the upper triple clamp bolts

(arrow); 1994 1100 model shown 
						

							
5B-10 
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

6.7 On XV920J models, unscrew the fork

cap; it should sit like this before its

installed - if it sits higher, reposition

the end of the damping adjusting rod 
6.9 Remove the drain screw from the

bottom of the fork leg 
6.12 Add the specified amount of fork oil

6.14 Pour the specified amount of oil into the top of the fork - on

later models, measure the oil level and adjust it as needed 
7.7a Remove the trim screw (A); remove the trim caps (B), then

loosen the lower triple clamp bolts

Note: If you dont have an Allen bolt bit of the correct size, use a bolt with

a head size that fits into the fork cap. Turn the bolt with locking pliers.

9 Place a drain pan under the fork leg and remove the drain screw

(see illustration). Warning: Do not allow the fork oil to contact the tire,

brake disc or pads. If it does, wash off the tire, clean the disc with brake

system cleaner and replace the pads with new ones before riding the

motorcycle.

10 After most of the oil has drained, slowly compress and release the

forks to pump out the remaining oil. An assistant will most likely be

required to do this.

11 Check the drain screw gasket and spring seat O-ring (if equipped)

for damage and replace them if necessary. Clean the threads of the

drain screw with solvent and let it dry, then install the screw and

gasket, tightening it securely.

12 Pour the type and amount of fork oil, listed in this Chapters

Specifications, into the fork tube through the opening at the top (see

illustration).

13 Remove the jack from under the engine and slowly pump the

forks a few times to purge the air.

14 If fork oil level is specified for the bike youre working on, measure

the level of the oil in the fork with the fork fully compressed and without

the spring in position (see illustration). Compare it to the value listed

in this Chapters Specifications. Add or remove oil as necessary, then

install the spring.

15 If youre working on a 1981 through 1983 XV750, coat the O-ring

on the spring seat with a thin layer of multi-purpose grease. Install the

spring seat and stopper ring (see illustrations 3.4a and 3.4b in Part A

of this Chapter). 
16 If youre working on an XV920J, install the cap bolt assembly (see

illustration 6.7). Caution: The cap bolt should sit as shown in the

illustration before you try to screw it in. If it sits higher, the damping

adjusting rod is out of position. Turn the cap bolt so the bottom end at

the damping adjusting rod engages the semicircular hole in the top o

the damper rod inside the fork. Forcing the cap bolt in when it sits too

high will ruin the damping adjuster.

17 On all other models, install the fork cap and tighten it to the

torque listed in this Chapters Specifications.

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

Tighten all fasteners to the torque listed in this Chapters Specifications.

19 On models with air valves, adjust fork air pressure (see Chapter 1).

7 Forks - removal and installation

Removal

Refer to illustrations 7.7a through 7.7e

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

procedure. Place it on the centerstand (if equipped).

2 Place a jack under the engine and raise it slightly to lift the fron:

tire off the ground.

3 Remove the brake caliper and front wheel (see Chapter 6).

4 Remove the front fender (see Chapter 7).

5 Remove any wiring harness clamps or straps from the fork tubes.

6 If the fork will be disassembled after removal, read through the

disassembly procedure (see Section 8), paying special attention to the

damper rod bolt removal steps. If you dont have the necessary specia 
						

							
Chapter 5 Part B Steering, suspension and final drive (XV700-1100 models)

5B-11

7.7b Front forks (XV750 and XV920 K and MK models) - exploded view

1 Outer fork tube 17 O-ring (XV750)

2 Drain screw 18 Air valve (XV750)

3 Gasket 19 Cap (XV750)

4 Oil seal 20 Bolt

5 Retainer 21 Nut

6 Dust seal 22 Lockwasher

7 Damper rod seat 23 Bolt

8 Inner fork tube 24 Air charging hose (XV920)

9 Damper rod 25 O-ring (XV920)

10 Rebound spring 26 Air valve (XV920)

11 Fork spring 27 O-ring (XV920)

12 O-ring (XV920) 28 Left air hose union

13 Top bolt (XV920) 29 O-ring (XV920)

14 Plastic cap (XV920) 30 Seal (XV920)

15 Fork cap (XV750) 31 Retainer (XV920)

16 Retainer (XV750) 32 Right air hose union

tool or a substitute for it, you can remove the damper rod bolt before

the fork is disassembled, while the spring tension will keep the damper

rod from spinning inside the fork tube. This is also a good time to

loosen the fork top bolt (if equipped), as it will eliminate the need to

clamp the fork tube in a vise after its removed.

7 Loosen the upper triple clamp bolts (see illustration 6.5b).

Remove the trim cover and loosen the lower triple clamp bolts (see

illustrations), then slide the fork tubes down and remove the forks

from the motorcycle.

7.7c Front forks (chain drive XV920 and XV1000/TR1 models) -

exploded view

1 Outer fork tube 16 Steering stem/lower

2 Oil seal triple clamp

3 Retainer 17 Bolt

4 Damper rod seat 18 Washer

5 Inner fork tube 19 Lockwasher

6 Dust seal 20 Nut

7 Rebound spring 21 Bolt

8 Damper rod 22 Washer

9 Spring 23 Lockwasher

10 O-ring 24 Nut

11 Top plug 25 Damper rod bolt

12 Retainer 26 Copper washer

13 O-ring 27 Drain plug

14 Air valve 28 Gasket

15 Cap