Haynes Yamaha Xv V Twins Manual

							
6A-16 
Chapter 6 Part A Brakes, wheels and tires (XV535 models)

13.16b Drive out the bearings with a

long rod 
13.16c Lift out the spacer and collar (be

sure to reinstall both during assembly) 
13.16d Drive the clutch hub side bearing

into position with a bearing driver or

socket that bears on the outer race

14 Tubed tires - general information

1 Tires with tubes are used as standard equipment on this

motorcycle. They are generally easier to change than tubeless tires.

2 Before changing a tire yourself, check with your local dealership 
or repair shop to find out the labor charge for changing a tire. Although

the procedure is not complicated, it is time-consuming, and for safety,

it must be done correctly. For these reasons, it may be more practicai

to have the job done. Watching a professional technician do the job

before attempting it yourself can provide valuable information.

3 The accompanying illustrations can be used to replace a tubec

tire in an emergency.

13.16e Make sure the spacer and collar are in place, then drive in

the bearing on the opposite side 
13.16f Spin the bearings with a finger to make sure they

turn easily 
						

							
TIRE CHANGING SEQUENCE - TUBED TIRES

Deflate tire. After push-

ing tire beads away

from rim flanges push

tire bead into well of rim

at point opposite valve.

Insert tire lever next to

valve and work bead

over edge of rim.

Use two levers to

work bead over edge

of rim. Note use of

rim protectors

Remove inner tube

from tire

When first bead is clear,

remove tire as shown

To install, partially

inflate inner tube

and insert in tire

Work first bead over rim

and feed valve through

hole in rim. Partially

screw on retaining nut to

hold valve in place.

Check that inner tube

is positioned correctly

and work second

bead over rim using

tire levers. Start at a

point opposite valve.

Work final area of

bead over rim while

pushing valve inwards

to ensure that inner

tube is not trapped. 
						

							
6A-18 
Chapter 6 Part A Brakes, wheels and tires (XV535 models)

Notes 
						

							
6B-1

Chapter 6 Part B

Brakes, wheels and tires (XV700-1100 models)

Contents

Section

Brake caliper - removal, overhaul and installation 3

Brake disc - inspection, removal and installation 4

Brake hoses - inspection and replacement 7

Brake light switches - check and adjustment See Chapter 1

Brake pads - replacement 2

Brake system bleeding 8

Front brake master cylinder - removal, overhaul and installation.. 5

Front wheel - removal and installation 11 
Section

General information 1

Rear drum brakes - removal, overhaul and installation 6

Rear wheel - removal and installation 12

Tires - general information 14

Wheel bearings - inspection and maintenance 13

Wheels - alignment check 10

Wheels and tires - general check See Chapter 1

Wheels - inspection and repair 9

Specifications

Brakes

Brake fluid type See Chapter 1

Front brake disc thickness

1981 through 1983XV750

Standard 7 mm (0.28 inch)

Minimum* 6.5 mm (0.256 inch)

XV920 K and MK Not specified

All others

Standard 5.0 mm (0.20 inch)

Minimum* : 4.5 mm (0.18 inch)

Disc runout limit 0.15 mm (0.006 inch)

Front brake pad thickness

1981 through 1983 XV750

New 5.7 mm (0.224 inch)

Wear limit 1.2 mm (0.047 inch)

XV920K, MK Not specified

XV920 RH, RJ, RK

New 11.0 mm (0.433 inch)

Wear limit 6.0 mm (0.236 inch)

XV1000 chain drive (TR1)

New 6.5 mm (0.256 inch)

Wear limit 1.5 mm (0.059 inch)

1984-on (except 1994 UK)

New 5.5 mm (0.217 inch)

Wear limit 0.5 mm (0.020 inch)

1994 UK

New . 6.1 mm (0.24 inch)

Wear limit 0.8 mm (0.03 inch) 
						

							
6B-2 
Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models)

Brakes (continued)

Rear brake drum inside diameter

1981 through 1983XV750

Standard 180 mm (7.087 inch)

Maximum.... Not specified

All others

Standard 200 mm (7.87 inches)

Maximum 201 mm (7.91 inches)

Rear brake shoe lining thickness

Standard 4 mm (0.16 inch)

Minimum 2 mm (0.08 inch)

*Refer to marks stamped into the disc (they supersede information printed here)

Wheels and tires

Wheel runout

Radial (up-and-down) 2.0 mm (0.08 inch)

Axial (side-to-side).. 2.0 mm (0.08 inch)

Tire pressures See Chapter 1

Tire sizes

1981 through 1983 XV750 and XV920 shaft drive models

Front . 3.50H 19 4PR

Rear 130/90 16 67H

XV920 and XV1000 chain drive models

Front 3.25H19 4PR

Rear 120/90 18 65H

1984 and later models

Front 100/90 19 57H

Rear (except 1994 UK) 140/90 15 70H

Rear (1994 UK) 140/90 15 M/C 70H

Torque specifications

1981 through 1983 models

Front axle nut

XV750 107 Nm (77 ft-lbs)*

XV920J, K, MK . 110 Nm (80 ft-lbs)*

XV920 RH, RJ, RK 107 Nm (77 ft-lbs)*

Front axle pinch bolt 20 Nm (14 ft-lbs)

Rear axle nut 107 Nm (77 ft-lbs)*

Rear brake torque link nuts 20 Nm (14 ft-lbs)*

Brake disc mounting bolts 20 Nm (14 ft-lbs)**

Caliper mounting bolts

XV920J 35 Nm (25 ft-lbs)

All other 1981 through 1983 models 26 Nm (19 ft-lbs)

Fluid hose union bolts 26 Nm (19 ft-lbs)

Caliper bleed valve 6 Nm (4.3 ft-lbs)

Master cylinder clamp bolts 9 Nm (6.5 ft-lbs)

Rear brake cam lever bolt 9 Nm (6.5 ft-lbs)

1984-on models

Front axle or axle nut

XV700, XV1100 105 Nm (75 ft-lbs)*

XV750

US 110 Nm (80 ft-lbs)

UK 107 Nm (77 ft-lbs)

Front axle pinch bolt 20 Nm (14 ft-lbs)

Rear axle nut 105 Nm (75 ft-lbs)*

Rear brake torque link nuts 20 Nm (14 ft-lbs)*

Brake disc mounting bolts 20 Nm (14 ft-lbs)

Caiiper mounting bolts

All except 1994 UK models 35 Nm (25 ft-lbs)

1994 UK models Not specified

Fluid hose union bolts 26 Nm (19 ft-lbs)

Caliper bleed valve 6 Nm (4.3 ft-lbs)

Master cylinder clamp bolts 9 Nm (6.5 ft-lbs)

Rear brake cam lever bolt . 9 Nm (6.5 ft-lbs)

*Use new cotter pins.

**Use new lockwashers. 
						

							
Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models)

6B-3

2.2 On 1981 through 1983 XV750 and XV920 K and MK models,

remove the coil spring, then pull out the pad pin ... 
2.3a ... and lower the pads out of the caliper

1 General information

The models covered in this Chapter are equipped with a hydraulic

disc brake at the front and a mechanical drum brake at the rear.

Several different front brake designs are used, varying according to

model. They may be equipped with wire spoke wheels and tubed tires

or alloy wheels and tubetess tires.

Caution: Disc brake components rarely require disassembly. Do

not disassemble components unless absolutely necessary. If any

hydraulic brake line connection in the system is loosened, the entire

system should be disassembled, drained, cleaned and then properly

filled and bled upon reassembly. Do not use solvents on internal brake

components. Solvents will cause seals to swell and distort. Use only

clean brake fluid, brake cleaner or alcohol for cleaning. Use care when

working with brake fluid as it can injure your eyes and it will damage

painted surfaces and plastic parts. 
2 Brake pads - replacement

Warning: The dust created by the brake system may contain asbestos,

which is harmful to your health. Never blow it out with compressed air

and dont inhale any of it. An approved filtering mask should be worn

when working on the brakes.

1981 through 1983 XV750; XV920K, XV920MK

Refer to illustrations 2.2, 2.3a and 2.3b

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

procedure.

2 Remove the coil spring from the pad retaining pin at the bottom of

the caliper, then pull out the pin (see illustration).

3 Lower the padsout of the caliper (see illustrations).

2.3b Front brake caliper (1981 through

1983 XV750, XV920K and XV920 MK

models) - exploded view

1 Caliper assembly

2 Brake disc

3 Disc mounting bolts

4 Lockwashers

5 Nut

6 Lockwasher

7 Caliper body

8 Pivot sleeve

9 O-ring

10 Washer

11 Bleed valve

12 Bleed valve dust cap

13 Pad retaining pins

14 Spring

15 Cap

16 Pivot bolt

17 Washer

18 Piston

19 Piston seal

20 Dust seal

21 Retaining ring

22 Brake pads

23 Pad retainer

24 Anti-rattle spring 
						

							
6B-4 
Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models)

2.4a On chain drive XV920 and TR1

models, remove the bolt and detach

the caliper from the bracket... 
2.4b ... remove the brake pad retaining

screw and the pads 
2.5a Remove the anti-rattle spring

2.5b Front brake caliper (XV920 chain drive

and TR1 models) - exploded view

1 Right brake disc

2 Left brake disc

3 Disc mounting bolts

4 Lockwashers

5 Right caliper assembly

6 Left caliper assembly

7 Caliper mounting bolts

8 Lockwashers

9 Washers

10 Caliper body

11 Caliper bracket

12 Anti-rattle shim

13 Caliper-to-bracket bolt

14 Sleeve

15 Boot

16 Inspection window

17 Pad retaining screw

18 Bleed valve cap

19 Bleed valve

20 Piston

21 Piston seal

22 Dust seal

23 Retaining ring

24 Brake pads

25 Anti-rattle spring 
						

							
Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) 
6B-5

2.7 Front brake caliper (XV920J) - exploded view

7 Right caliper assembly

2 Left caliper assembly

3 Caliper body

4 Mounting bracket

5 Shim

6 Retaining plate

7 Screw

8 Bleed valve and cap

9 Pad retaining pin

10 Pad retaining pin

11 Cotter pin

12 Spring clip

13 Anti-rattle spring

14 Brake pads

15 Piston seals

16 Piston

17 Caliper mounting bolts

18 Lockwashers

19 Washers

20 Brake disc mounting bolts

27 Lockwashers

22 Right brake

23 Left brake disc

XV920 chain drive models and TR1

Refer to illustrations 2.4a, 2.4b, 2.5a and 2.5b

4 Remove the single bolt that secures the caliper body to its

bracket (see illustration). Remove the single screw that secures the

pads, then lift the caliper off the bracket to expose the pads (see

illustration).

5 Note carefully which pad is on which side of the disc, then

remove the anti-rattle spring and the pads (see illustrations). 
XV920J

Refer to illustration 2.7,

6 Remove the front wheel (see Section 11).

7 Remove the pad pin clips, then pull out the pad pins (see

illustration).

8 Remove the anti-rattle spring, pads and shim. 
						

							
6B-6

Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models)

1984 and later models (except 1994 UK)

Refer to illustrations 2.9a and 2.9b

9 Remove the pad cover (see illustration). Remove the pad pin

clips, then pull out the pad pins and remove the anti-rattle spring (see

illustration).

10 Pull out the pads.

1994 UK models

Refer to illustration 2.11

11 Remove the lower caliper bolt and pivot the caliper upward (see

illustration).

12 Remove the pad spring and pull out the pads.

All models

13 Measure the amount of friction material left on the pads and

replace them as a pair if worn, fouled with oil or damaged in any way. If

youre working on a 1994 UK model, replace the pads if the grooves in

the friction material are worn away.

14 Check the condition of the brake discs (see Section 4). If they are

in need of machining or replacement, follow the procedure in that

Section to remove them. If they are okay, deglaze them with sandpaper

or emery cloth, using a swirling motion. 
2.9a Caliper mounting details (1984 and later models

except 1994 UK)

A Pad cover

B Pad pin clips 
C Pad pins

D Caliper mounting bolts

2.9b Front brake caliper (1984 and later models

except 1994 UK) - exploded view

1 Bleed valve and cap

2 Pad springs

3 Pad retaining pins

4 Piston, piston seal and dust seal

5 Caliper assembly

6 Brake pads

7 Sealing washers

8 Union bolts

9 Master cylinder piston assembly 
						

							
Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models) 
6B-7

15 Connect a length of rubber or plastic tubing to the caliper bleed

valve and place the other end in a container. Open the bleed valve and

push the pistons into the caliper as far as possible; displaced brake

fluid will flow through the tubing into the container. If you cant depress

the pistons with thumb pressure, try using a C-clamp (G-clamp). If the

piston sticks, remove the caliper and overhaul it as described in

Section 3. Once the pistons are pressed in, close the bleed valve,

remove the tubing and install the bleed valve cap.

16 Warning: This step is necessary to ensure that the pads move

freely in the calipers. Because a large amount of salt is used on roads in

the UK, special lubrication of the pads and calipers is required. Before

installing the pads on UK models, apply a thin film of Duckhams

Copper 10 or equivalent to the following areas (see illustrations 2.6a

and 2.6b in Part A of this Chapter):

a) To the edges of the metal backing on the brake pads

b) To the areas of the caliper where the pads rub

c) To the threads of the caliper mounting bolts.

Apply a thin film of Shin-Etsu G-40M or equivalent silicone grease to

the following:

d) Exposed areas of the caliper pistons

e) The areas of the pad backing plates that contact the pistons. 
Caution: Dont use too much Copper 10. Make sure no Copper 10

contacts the brake discs or the pad friction surfaces.

17 Install the pads and springs in the caliper. The rounded edge of

the pad faces the rear of the motorcycle (see illustration 2.3a).

18 Check fluid level in the master cylinder reservoir (see Chapter 1)

and add fluid if necessary.

19 Operate the brake lever several times to bring the pads into

contact with the disc. Check the operation of the brakes carefully

before riding the motorcycle.

3 Brake caliper - removal, overhaul and installation

Warning: If a caliper indicates the need for an overhaul (usually due to

leaking fluid or sticky operation), all old brake fluid should be flushed

from the system. Also, the dust created by the brake system may

contain asbestos, which is harmful to your health. Never blow it out

with compressed air and dont inhale any of it. An approved filtering

mask should be worn when working on the brakes. Do not, under any

circumstances, use petroleum-based solvents to clean brake parts.

Use brake cleaner or denatured alcohol only!

2.11 Front brake caliper (1994 and later UK models) -

exploded view

1 Bleed valve and cap

2 Pad springs

3 Pad retaining pins

4 Pistons, piston seals and dust seals

5 Caliper assembly

,. 6 Brake pads

7 Sealing washers

8 Union bolts

9 Master cylinder piston assembly