Haynes Yamaha Xv V Twins Manual

							
6B-18 
Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models)

12.11c Make sure the tire clears the swingarm 
13.4 If necessary, unbolt the clutch hub and remove it

d) Tighten the axle nut to the torque listed in this Chapters Specifi-

cations. Install a new cotter pin, tightening the axle nut an

additional amount, if necessary, to align the hole in the axle with

the castellations on the nut.

e) Tighten the axle pinch bolt to the torque listed in this Chapters

Specifications.

f) Make sure the tire clears the swingarm (see illustration).

11 Adjust the rear brake (see Chapter 1) and check its operation

carefully before riding the motorcycle.

13 Wheel bearings - inspection and maintenance

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

procedure and remove the wheel. See Section 11 (front wheel) or 12

(rear wheel).

2 Set the wheel on blocks so as not to allow the weight of the wheel

to rest on the brake disc or hub.

Front wheel bearings

3 Removal, inspection and installation of the front wheel bearings is

the same as for XV535 models (see Part A of this Chapter). Refer to

illustration 11.3a, 11.3b or 11.3c and the Part B Specifications.

Rear wheel bearings

Refer to illustrations 13.4 and 13.5a through 13.5e

4 If necessary for inspection, the dust seal and clutch hub can be

detached from the wheel (see illustration 12.3 and the accompanying 
13.5a Use non-permanent thread locking agent on the threads

of the clutch hub bolts

illustration). The rear wheel bearings can be removed and installed

these parts in place.

5 Rear wheel bearing removal, inspection and installation an

generally the same as for front wheel bearings (see part A of tr -

Chapter and the accompanying illustrations). On installation, be sure I

install the spacer and its collar between the bearings. Apply no-

permanent thread locking agent to the threads of the clutch hub bolts

(see illustration) and tighten them securely.

13.5b Drive the two bearings out of the let

side of the hub with a long bar ... 
13.5c ... and use the same tool to

remove the single bearing

from the right side 
13.5d Remove the spacer and collar

from the hub 
						

							
TIRE CHANGING SEQUENCE - TUBELESS TIRES

Deflate tire. After releasing beads, push tire bead into well of

rim at point opposite valve. Insert lever next to valve and work

bead over edge of rim.

When first bead is clear, remove tire as shown.

Work first bead over the rim flange. 
Use two levers to work bead over edge of rim. Note use of

rim protectors.

Before installing, ensure that tire is suitable for wheel. Take

note of any sidewall markings such as direction of

rotation arrows.

Use a tire lever to work the second bead over rim flange. 
						

							
6B-20 
Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models)

13.5e Drive in new bearings with a bearing driver or a socket

the same diameter as the bearing outer race 
14 Tires - general information

Tubed tires

1 Tires with tubes are used on models equipped with wire spoke

wheels. Information and tire changing procedures for tubed tires are

provided in Part A of this Chapter.

Tubeless tires

2 Tubeless tires are used as standard equipment on models with

cast wheels. They are generally safer than tube-type tires but if

problems do occur they require special repair techniques.

3 The force required to break the seal between the rim and the

bead of the tire is substantial, and is usually beyond the capabilities of

an individual working with normal tire irons.

4 Also, repair of the punctured tire and replacement on the wheel

rim requires special tools, skills and experience that the average do-it-

yourselfer lacks.

5 For these reasons, if a puncture or flat occurs with a tubeless tire,

the wheel should be removed from the motorcycle and taken to a

dealer service department or a motorcycle repair shop for repair or

replacement of the tire. The accompanying illustrations can be used to

replace a tubeless tire in an emergency. 
						

							
7A-1

Chapter 7 Part A

Frame and bodywork (XV535 models)

Contents

Section

Backrest and shock absorber cover - removal and installation 10

Footpegs and pads - removal and installation 3

Frame - inspection and repair 2

Front fender/mudguard - removal and installation 11

General information 1

Lower left frame cover - removal and installation 4 
Section

Rear fender - removal and installation 12

Seat - removal and installation 7

Side covers - removal and installation 9

Sidestand - maintenance 5

Sidestand - removal and installation 6

Top cover - removal and installation. 8

1 General information

The XV535 models use a steel frame composed of round-section

tubing and a pressed steel backbone which incorporates the air

cleaner housing.

Fenders and covers are steel, either painted or chrome plated.

2 Frame - inspection and repair

1 The frame should not require attention unless accident damage

has occurred. In most cases, frame replacement is the only 
satisfactory remedy for such damage. A few frame specialists have the

jigs and other equipment necessary for straightening the frame to the

required standard of accuracy, but even then there is no simple way of

assessing to what extent the frame may have been overstressed.

2 After the machine has accumulated a lot of miles, the frame

should be examined closely for signs of cracking or splitting at the

welded joints. Corrosion can also cause weakness at these joints.

Loose engine mount bolts can cause ovaling or fracturing of the

mounting tabs. Minor damage can often be repaired by welding,

depending on the extent and nature of the damage.

3 Remember that a frame which is out of alignment will cause

handling problems. If misalignment is suspected as the result of an

accident, it will be necessary to strip the machine completely so the

frame can be thoroughly checked. 
						

							
7A-2 
Chapter 7 Part A Frame and bodywork (XV535 models)

3.5 Remove the footpeg mounting bolts

(early models) 
3.6 Remove the clip, washer and clevis

pin (arrow) 
3.7 The rear footpegs are bolted to the

brackets; the brackets are bolted to

the frame

A Footpeg mounting bolt

B Bracket bolts

3.8a Make sure there are match marks on

the shift shaft and lever, then loosen the

pinch bolt (arrow); remove the rear

mounting nut... 
3.8b ... and front mounting bolt...

3.8c ... and detach the bracket from

the motorcycle

3 Footpegs and pads - removal and installation

Refer to illustrations 3.5, 3.6, 3.7, 3.8a, 3.8b, 3.8c, 3.8d, 3.9a, 3.9b and

3.9c

1 The front footpegs are mounted on a bracket that also serves to

protect the engine. The rear footpegs are mounted on brackets bolted

to the frame.

2 To remove a front or reaf footpeg pad on early models, work the

rubber pad off the end of the footpeg. The pad is a tight fit, so this may

be difficult. Cutting off the old pad, then heating the new pad in hot

yvater and lubricating it with soap, will make the job easier.

3 To replace a front footpeg pad on later models, remove the pad

securing nuts from the underside of the footpeg and lift the pad off.

Install the new pad and tighten the nuts securely.

4 To replace a rear footpeg pad on later models, remove the pad

securing screws and lift it off. Install the new pad and tighten the

screws securely.

5 To remove a front footpeg assembly (footpeg and pivot bracket),

remove the bolts that secure the pivot bracket to the main bracket (see

illustration).

6 To remove a front footpeg, remove the cotter pin, collar and clevis

pin and separate the footpeg from the pivot bracket (see illustration).

7 To remove a left rear footpeg assembly, unbolt the pivot bracket

from the main bracket (see illustration). To remove a right rear

footpeg assembly, support the exhaust system and unbolt the footpeg 
3.8d Remove the snap-ring to separate the shift pedal from

the bracket

from the frame (the same bolt also secures an exhaust bracket).

8 To remove the left front footpeg bracket, check for match marks

on the shift shaft and lever. Make your own marks if there arent any.

so the shift lever can be reinstalled in the correct orientation to the

shaft. Loosen the shift lever pinch bolt (see illustration) and remove

the bracket mounting bolt and nut (see illustrations). Take the bracket

off, turn it over and remove the snap-ring to separate the shift pedal

from the bracket (see illustrations). 
						

							
Chapter 7 Part A Frame and bodywork (XV535 models)

7A-3

3.9a Detach the pedal return spring,

disconnect the brake cable and remove

the snap-ring to detach the brake pedal

from the bracket 
3.9b Follow the wiring harness from the

brake light switch and disconnect the

connector; remove the mounting

nut (arrow)... 
3.9c ... and the mounting bolt at

the front

4.2a Remove the nut at the bottom ...

4.2b ... and the bolt at the top to detach

the lower left frame cover from the frame 
5.1 Make sure the sidestand spring is in

good condition and correctly installed

9 To remove the right front footpeg bracket, disconnect the

electrical connector for the brake light switch (see Chapter 8). Detach

the brake cable from the slots on the assembly (see Chapter 6). If

youre going to remove the brake pedal, disconnect its return spring

and remove the pedal snap-ring (see illustration). Remove the nut at

the rear of the bracket and the bolt at the front and take the assembly

off (see illustrations).

10 Installation is the reverse of removal. Lubricate the footpeg pivots

(early models) (see Chapter 1).

4 Lower left frame cover - removal and installation

Refer to illustrations 4.2a and 4.2b

1 The lower left frame cover is secured by a nut at the bottom and a

bolt at the top.

2 To remove the cover, remove the nut and the bolt and lift it off

(see illustrations).

3 Installation is the reverse of the removal steps.

5 Sidestand -maintenance

Refer to illustration 5.1

1 The sidestand is attached to a bracket on the frame. An extension

spring(s) anchored to the bracket ensures that the stand is held in the

extended or retracted position (see illustration).

2 Make sure the pivot bolt is tight and the extension spring is in 
6.2 Remove the sidestand pivot nut and slide it off the post

good condition and not overstretched. An accident is almost certain to

occur if the stand extends while the machine is in motion.

6 Sidestand - removal and installation

Refer to illustration 6.2

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

procedure.

2 Unhook the sidestand spring (see illustration 5.1). Remove the

pivot nut and take the sidestand off the pivot shaft (see illustration).

3 Installation is the reverse of the removal steps. 
						

							
7A-4 
Chapter 7 Part A Frame and bodywork (XV535 models)

7.1 Remove one of the mounting bolts . . . 
7.2a ... pull out the clip, remove the

washer and separate the support from

its bracket... 
7.2b ... then remove the other mounting

bolt to detach the seat

7.4 Lift the passenger seat off... 
7.5 ... and remove the mounting bolts to

detach the riders seat 
8.2 Remove the front mounting bolt on

each side and detach the rear of the top

cover from the bike

9.1 Remove the bolt from the mounting tab (arrow), then

disengage the cover tabs from the slot and grommet

7 Seat - removal and installation

Single seat

Refer to illustrations 7.1, 7.2a and 7.2b

1 Unlock and lift the seat and remove one of the mounting bolts

(see illustration).

2 Remove the clip, washer and clevis pin, then remove the

remaining mounting bolt (see illustrations).

3 Installation is the reverse of the removal steps. 
Dual seat

Refer to illustrations 7.4 and 7.5

4 Unlock the passenger seat and lift it off the motorcycle (see

illustration).

5 Unbolt the riders seat (theres one bolt on each side at the rear)

(see illustration). Disengage it from the hole in the frame and lift it off

6 Installation is the reverse of the removal steps. Engage the tab

front of the riders seat with the hole in the frame.

8 Top cover - removal and installation

Refer to illustration 8.2

1 A top cover is used on models that dont have an upper fuel tank.

2 To remove the cover, lift the seat. Undo one mounting bolt on

each side at the front (see illustration). Slide the cover backwards to

unhook it from the frame and lift it off.

3 Installation is the reverse of the removal steps. Be sure the

mounting collars and grommets are in place on the front mountings

and that the rear mounting peg engages the grommet.

9 Side covers - removal and installation

Refer to illustrations 9.1, 9.2a, 9.2b, 9.3a and 9.3b

1 To remove a rear side cover, lift or remove the seat and undo the

mounting bolt at the top (see illustration). Disengage the tab at the 
						

							
Chapter 7 Part A Frame and bodywork (XV535 models) 
7A-5

9.2a Remove the mounting

bolts (arrows). . . 
9.2b ... and pull the hoses (if equipped)

off the fittings on the back side of

the bracket 
9.3a Remove the mounting bolt at the

upper rear ...

9.3b ... and at the lower front 
10.1a Remove the backrest mounting

bolts on each side ... 
10.1b ... dont lose the washer

and spacers

10.2a Remove the mounting bolt at the rear on each side ... 
10.2b ... these thread into special nuts that fit inside the

frame tubes

rear from the slot and the tab at the front from the grommet.

2 To remove either of the front side covers, remove the screws

around the edge of the cover and lift it off. To remove the left mounting

bracket, undo its bolts (see illustration). Disconnect the carburetor

hoses from the back side of the bracket (if equipped). Take the bracket

off, complete with the air induction system components (if equipped)

(see illustration).

3 To remove the right bracket, disconnect the electrical connectors

from the components mounted on it. Undo the mounting bolts and

take the bracket off (see illustrations).

4 Installation is the reverse of the removal steps. 
10 Backrest and shock absorber cover - removal and

installation

Refer to illustrations 10.1a, 10.1b, 10.2a, 10.2b and 10.3

1 If youre working on a model with a backrest, lift the seat and

remove the forward mounting screw on each side, then remove the

washer and spacers (see illustrations).

2 Remove the Allen bolt and special nut at the rear of the backrest

on each side and detach it from the motorcycle (see illustrations). 
						

							
7A-6 
Chapter 7 Part A Frame and bodywork (XV535 models)

10.3 Remove the screw and washer to

detach the shock absorber cover 
11.2a The fender mounting bolts are

accessible from inside the fender 
11.2b Lift the fender off toward the front

of the motorcycle

12.3a Unbolt the inner rear fender panel at the bottom ... 
12.3b ... and disengage the tabs at the top

3 The shock absorber covers are retained by two screws and

washers on each side. On models with a backrest, the rear screw

forms the backrest front mounting (see illustration).

4 Installation is the reverse of the removal steps.

11 Front fender/mudguard - removal and installation

Refer to illustrations 11.2a and 11.2b

1 If the upper fender/mudguard bolts will come all the way out

without striking the wheel rim, it wont be necessary to remove the

front wheel. If they wont, remove the front wheel (see Chapter 6).

2 Unbolt the fender/mudguard from the forks and take it off (see

illustrations). Note that one left fender/mudguard bolt secures the

speedometer cable retainer and one right fender/mudguard bolt

secures the brake hose retainer.

3 Installation is the reverse of the removal steps. Tighten the bolts

securely. 
12 Rear fender/mudguard - removal and installation

Refer to illustrations 12.3a and 12.3b

1 Lift the seat (single seat models) or remove it (dual seat models)

(see Section 7).

2 Remove the screw at the bottom of the toolbox and disengage

the rear end of the toolbox from the tab on top of the fender.

3 Unbolt the inner rear fender/mudguard panel from the frame (see

illustration). Disengage the tabs at the top of the panel from the rear

fender and take the panel out (see illustration).

4 Follow the wiring harnesses for the brake/taillights and rear turn

signals forward to their connectors. These are all single cpnnectors, so

labeling them will speed re-connection.

5 Remove the fender/mudguard mounting bolts and take it off the

motorcycle.

6 Installation is the reverse of the removal steps. 
						

							
7B-1

Chapter 7 Part B

Frame and bodywork (XV700-1100 models)

Contents

Section

Footpegs and pads - removal and installation 3

Frame - inspection and repar 2

Front fender/mudguard - removal and installation . 8

General information 1

Rear fender/mudguard - removal and installation 9 
Section

Seat - removal and installation 4

Side covers - removal and installation 7

Sidestand and centerstand - maintenance 5

Sidestand and centerstand - removal and installation 6

3.2a On early shaft drive models, the front footpeg brackets

are secured by two nuts 
1 General information

1981 through 1983 models use a pressed steel backbone frame

with a bolt-on rear section made of round-section steel tubing. The

frame on later models is similar, but the rear section is welded to the

backbone.

Fender/mudguards are steel, either painted or chrome plated.

2 Frame - inspection and repair

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

Chapter.

3 Footpegs and pads - removal and installation

Refer to illustrations 3.2a, 3.2b, 3.2c and 3.2d

1 To remove a footpeg from its pivot bracket, remove the cotter pin,

clevis pin and torsion spring and separate the footpeg from the

bracket.

2 To remove a footpeg assembly on shaft drive models, unbolt the

pivot bracket from the main bracket (see illustrations). If youre

3.2b The right rear footpeg bracket bolt

on early shaft drive models (arrow) also

secures the muffler/silencer bracket 
3.2c The front footpeg pivot brackets on

later shaft drive models are secured

by two bolts 
3.2d The passenger footpeg pivot

brackets on later shaft drive models

are secured by two bolts (arrows)