Haynes Yamaha Xv V Twins Manual

							
2A-6 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

5.24 Support the engine with a jack and a

block of wood 
5.25a Remove the lower rear

mounting bolt... 
5.25b ... and the upper rear

mounting bolts...

5.25c ... (theres an upper rear mounting

bolt on each side of the engine) 
5.25d Unbolt the front cylinder head

bracket from the frame 
5.25e Unbolt the rear cylinder head

mounting brackets from the frame ...

5.25f ... (theres one on each side of the engine)
23 Remove the starter motor (see Chapter 8).

24 Support the engine with a jack and wood block (see illustration).

Make sure the support is still in position under the swingarm pivot and

that the bike is still securely braced.

25 Remove the engine mounting bolts at the lower rear of the

crankcase, upper rear of the crankcase and at the top of each cylinder

(see illustrations).

26 Disconnect both battery cables from the battery. Warning:

Always disconnect the negative cable first and reconnect it last to

prevent a battery explosion.

27 Make sure no wires or hoses are still attached to the engine

assembly. Warning: The engine is heavy and may cause injury if it falls.

Be sure its securely supported. Have an assistant help you steady the

engine on the jack as you remove it.

28 Slowly and carefully lower the engine assembly to the floor, then

guide it out from under the right side of the bike.

Installation

29 Installation is the reverse of removal. Note the following points:

a) Dont tighten any of the engine mounting bolts until they all have

been installed.

b) Use new gaskets at all exhaust pipe connections.

c) Tighten the engine mounting bolts securely. 
d) Adjust the rear brake rod, clutch cable and throttle cable(s)

following the procedures in Chapter 1 and Chapter 2.

e) Be sure to refill the engine oil before starting the engine. 
						

							
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

2A-7

6.2a A selection of brushes is required for

cleaning holes and passages in the engine

components 
6.2b Type HPG-1 Plastigage is needed to

check the connecting rod oil clearances 
6.3 An engine stand can be made from

short lengths of lumber and lag bolts

or nails

7.1 a Loosen the tensioner cap bolt with a socket or wrench, then

unscrew it from the engine (if youre removing both tensioners at

the same time, its a good idea to label them F for front and R for

rear cylinder)...

7.1b ... then withdraw the cap bolt, sealing washer and spring
6 Engine disassembly and reassembly - general

information

Refer to illustrations 6,2a, 6.2b and 6.3

1 Before disassembling the engine, clean the exterior with a

degreaser and rinse it with water. A clean engine will make the job

easier and prevent the possibility of getting dirt into the internal areas

of the engine.

2 In addition to the precision measuring tools mentioned earlier,

you will need a torque wrench, a valve spring compressor, oil gallery

brushes, a piston ring removal and installation tool, a piston ring

compressor and a clutch holder tool (which is described in Section 16).

Some new, clean engine oil of the correct grade and type, some engine

assembly lube (or moly-based grease), a tube of Yamaha Quick Gasket

(part no. 11001-05-01) or equivalent, and a tube of RTV (silicone)

sealant will also be required. Although it may not be considered a tool,

some Plastigage (type HPG-1) should also be obtained to use for

checking connecting rod bearing oil clearances (see illustrations).

3 An engine support stand made from short lengths of lumber

bolted together will facilitate the disassembly and reassembly

procedures (see illustration). The perimeter of the mount should be

just big enough to accommodate the crankcase when its laid on its

side for removal of the crankshaft and transmission components. If you

have an automotive-type engine stand, an adapter plate can be made

from a piece of plate, some angle iron and some nuts and bolts. The

adapter plate can be attached to the engine mounting bolt holes.

4 When disassembling the engine, keep mated parts together

(including gears, cylinders, pistons, etc.) that have been in contact with

each other during engine operation. These mated parts must be

reused or replaced as an assembly.

5 Engine/transmission disassembly should be done in the following

general order with reference to the appropriate Sections.

Remove the cylinder heads

Remove the camshafts

Remove the rocker arms

Remove the cylinders

Remove the pistons

Remove the idle gears

Remove the clutch

Remove the oil pump

Remove the external shift mechanism

Remove the middle driven gear

Separate the crankcase halves

Remove the crankshaft and connecting rods

Remove the shift cam/forks

Remove the transmission shafts/gears

6 Reassembly is accomplished by reversing the general

disassembly sequence. 
7 Camshaft chain tensioners - removal and installation

Removal

Refer to illustrations 7.1a, 7.1b, 7.2a and 7.2b

Caution: Once you start to remove the tensioner bolts, you must

remove the tensioner all the way and reset it before tightening the

bolts. The tensioner extends and locks in place, so if you loosen the

bolts partway and then retighten them, the tensioner or cam chain will

be damaged.

1 Remove the tensioner cap bolt and spring while the tensioner is

still installed on the engine (see illustrations). 
						

							
2A-8 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

7.2a Remove the tensioner Allen bolts , 
7.2b ... and remove the tensioner and gasket from the engine

7.3 Tensioner details

a) Cap bolt c) Spring

b) Sealing washer d) Tensioner body 
7.4 Lift the latch and compress the tensioner piston into the body

2 Remove the tensioner mounting bolts and take it off the engine

(see illustrations).

Installation

Refer to illustrations 7.3 and 7.4

3 Check the sealing washer on the cap bolt for cracks or hardening

(see illustration). Its a good idea to replace this washer whenever the 
tensioner cap is removed.

4 Release the one-way cam on the chain tensioner and compress

the tensioner piston into the tensioner body (see illustration).

5 Turn the tensioner so the one-way cam is up and install the

tensioner on the cylinder, using a new gasket (see illustration 7.2b).

6 Tighten the mounting bolts to the torque listed in this Chapters

Specifications.

7 Install the tensioner spring, sealing washer and cap. (see

illustration 7.1b). Tighten the cap to the torque listed in this Chapters

Specifications.

8.3a Remove four nuts (arrows); the front

of the engine is at the bottom of the

illustration ... 
8.3b ... and two washers (arrows), then

lift off the engine mounting bracket... 
8.3c ... and remove the four washers

from beneath the bracket 
						

							
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

2A-9

8.4a Cylinder head and cylinder (XV535 models) -

exploded view

1) Cylinder head side cover

2) Intake rocker arm cover

3) O-ring

4) Exhaust rocker arm cover

5) Spark plug

6) Oil baffle plate (rear cylinder only)

7) Gasket

8) Cylinder head (rear shown)

9) Cam sprocket cover

10) Long retainer bolt

11) Short retainer bolt

12) Lockwasher

13) Retainer

14) Dowel

15) Cylinder (rear shown)

8.4b Remove both Allen bolts ...

8.4c ... and take the cam sprocket cover

off the cylinder head 
8.4d Use a pointed tool to remove the O-

ring from the cam sprocket cover ...

C4e ... and on the rear cylinder, remove the oil baffle plate and

its O-ring 
8 Cylinder heads, camshafts and rocker arms - removal,

inspection and installation

Cylinder head removal

Refer to illustrations 8.3a, 8.3b, 8.3c, 8.4a through 8.4e and 8.5

1 Remove the engine from the frame (see Section 5).

2 Remove the ignition coil mounting bracket and ignition coils from

the rear cylinder (see Chapter 4).

3 Remove the engine mounting bracket, its washers and nuts from

the front cylinder head (see illustrations).

4 Remove the Allen bolts and take off the cam sprocket cover (see

illustrations). Stuff clean shop towels into the opening below the

sprocket so nothing is accidentally dropped into it. 
						

							
2A-10 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

8.5 Unbolt the rocker arm covers and

take them off, together with their O-rings 
8.6a The line next to the T mark on the

alternator rotor should be aligned with the

notch in the timing window 
8.6b The punch mark on the sprocket

should be aligned with the arrowhead cast

in the cylinder head (arrows)

8.9 Hold the crankshaft turning bolt with

a socket and loosen the camshaft

sprocket bolt with another socket or a

box wrench (ring spanner) 
8.11 The* oil baffle plate (arrow) is used on

the rear cylinder only 
8.12 Label the rear cylinders cam

sprocket with an R, then slide it off -

make sure the dowel doesnt fall out of

the camshaft

8.13 Once the sprocket is removed, drape the cam chain over

the camshaft
5 Remove the rocker arm covers and their O-rings from the exhaust

side and intake side of the cylinder (see illustration).

Rear cylinder

Refer to illustrations 8.6a, 8.6b, 8.9, 8.11, 8.12, 8.13, 8.14a, 8.14b,

8.14c, 8.14d, 8.15a, 8.15b, 8.16a, 8.16b and 8.16c

6 Turn the engine so the rear cylinder is at top dead center on its

compression stroke (see Valve clearance - adjustment in Chapter 1).

When the rear cylinder is on its compression stroke, the line on the

alternator rotor with a T mark next to it will be aligned with the notch in

the timing window (see illustration). Also, the camshaft sprocket mark

will be aligned with the mark inside the sprocket housing on the

cylinder head (see illustration).

7 Remove the cam chain tensioner for the rear cylinder (see Sec-

tion 7).

8 Place a piece of wire where you can reach it easily during the next

steps.

9 Hold the engine from turning with a socket on the crankshaft

turning bolt (see illustration). If the engine is in the frame, you can also

keep it from turning by shifting the transmission into gear and having

an assistant hold the rear brake on.

10 While you hold the engine from turning, loosen the camshaft

sprocket bolt (see illustration 8.9).

11 Unscrew the sprocket bolt and remove the oil baffle plate (see

illustration).

12 Label the sprocket R (for rear cylinder) and slide it off the 
camshaft (see illustration). Make sure the camshaft dowel doesnt fall

out ofthe camshaft.

13 Drape the cam chain over the end of the camshaft (see

illustration). At this point, the camshaft dowel should be aligned with

the pointer cast in the cylinder head. 
						

							
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

2A-11

8.14a The cylinder heads are secured by two Allen

bolts (arrows)... 
8.14b ... and five nuts ...

a) Allen bolts c) Nut (in spark plug well)

b) Nuts

8.14c Use a socket and extension to

remove the nut in the spark plug well.. . 
8.14d ... and pull its washer out with

a magnet 
8.15a Lift the cylinder head off

8.15b If the head is stuck, tap it with a soft-faced mallet (dont tap

against the cooling fins or theyll break) 
8.16a There are three dowels, one with an O-ring (A) and two that

fit around studs (B)...

14 Loosen the cylinder head nuts and bolts evenly in several stages

(see illustrations). Remove the nuts, washer, bolts and engine

mounting brackets.

15 Lift the cylinder head off the studs (see illustration). If its stuck, 
tap it gently with a rubber or plastic mallet, being careful not to break

the cooling fins (see illustration). Dont pry against the gasket

surfaces or they will be gouged.

16 Remove the O-ring, dowels and exhaust side chain damper (see

illustrations). Tie up the cam chain with wire. 
						

							
2A-12 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

8.16b ... if theyre not in the cylinder,

they may have remained in the

head (arrow) 
8.16c Lift out the exhaust side chain

damper (arrow) 
8.22a Flatten the lockwasher tabs with a

hammer and chisel (take care not to strike

the cylinder head)...

8.22b ... undo the retainer bolts ... 
8.22c ... and remove the lockwasher

8.23a Pull the camshaft and bushing out

of the head ...

8.23b ... and take the bushing off the camshaft
17 Check the cylinder head gasket and the mating surfaces on the

cylinder head and block for leakage, which could indicate warpage.

Refer to Section 10 and check the flatness of the cylinder head.

18 Clean all traces of old gasket material from the cylinder head and

block. Be careful not to let any of the gasket material fall into the

crankcase, the cylinder bores or the oil passages.

Front cylinder

19 Repeat Steps 6 through 18 to remove the front cylinder head,

noting that the front camshaft sprocket doesnt have an oil baffle and

that the front engine mounting bracket was removed in Step 3.

Camshaft removal

Refer to illustrations 8.22a, 8.22b, 8.22c, 8.23a, 8.23b and 8.23c

Note: You may need a 10 mm bolt for this procedure.

20 If you havent already done so, remove the rocker arm covers (see

illustrations 8.4c and 8.5).

21 Loosen the rocker arm locknuts and back off the adjusters.

22 Flatten the tabs on the camshaft bolt lockwasher (see

illustration). Remove the bolts, lockwasher and retainer (see

illustrations).

23 Try to pull the camshaft out with fingers (see illustration). If it

doesnt come easily, thread a 10 mm bolt into the end of the camshaft

and use it as a handle to pull out the camshaft. Once the camshaft is

out, remove the bushing (see illustrations). 
Rocker arm removal

Refer to illustrations 8.25a, 8.25b, 8.26a, 8.26b, 8.26c and 8.27

24 Remove the camshaft (see Steps 20 through 23).

25 Remove the rocker arm shaft retaining bolts and sealing washers

(see illustrations). 
						

							
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

2A-13

8.23c Camshaft, timing chain and valves (XV535 models) - exploded view

1) Valve adjuster locknut

2) Valve adjuster

3) Rocker arm shaft

4) Rocker arm

5) Valve keepers (collets)

6) Valve spring retainer

7) Valve springs

8) Oil seal

9) Valve spring seat

10) Valve 
11) Camshaft

12) Camshaft bushing

13) Camshaft dowel

14) Cam sprocket

15) Oil baffle plate (rear cylinder only)

16) Cam chain tensioner

17) Cam chain damper (intake side)

18) Cam chain

19) Cam chain damper (exhaust side)

2A

8.25a Remove the rocker arm shaft retaining bolts .

8.25b ... and their sealing washers 
						

							
2A-14 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

8.26a A slide hammer like this one is the

easiest way to remove the rocker shafts 
8.26b Pull the shaft partway out. 
8.26c ... then remove the rocker arm

8.27 Label the shafts according to

cylinder (front or rear) and side (intake

or exhaust) 
8.29a Check the lobes of the camshaft for

wear - heres a good example of damage

which will require replacement (or repair)

of the camshaft 
8.29b Measure the height of the cam

lobes with a micrometer

8.30 Measure the camshaft journal diameter with a micrometer

and compare it to the diameter of the bushing or the bearing

surface in the cylinder head
26 Thread a slide hammer into the end of the rocker shaft (see

illustration). If you dont have one, use along bolt, a large flat washer

and a short piece of pipe. Rap the pipe against the washer to pull the

rocker shaft out of the rocker arm. Once the rocker shaft clears the

rocker arm, take the rocker arm out (see illustrations).

27 Remove the remaining rocker shaft and arm, then label them

according to cylinder and position (for example, rear intake and rear

exhaust) (see illustration).

Camshaft, chain and cam sprocket inspection

Refer to illustrations 8.29a,. 8.29b, 8.30 and 8.32

Note: Before replacing camshafts because of damage, check with local

machine shops specializing in motorcycle engine work. It may be

possible for cam lobes to be welded, reground and hardened, at a cost

far lower than that of a new camshaft. If the bearing surfaces in the

cylinder head are damaged, it may be possible for them to be bored

out to accept bearing inserts. Due to the cost of a new cylinder head it

is recommended that all options be explored before condemning it as

trash!

28 Inspect the cam bearing surfaces of the head. Look for score

marks, deep scratches and evidence of spalling (a pitted appearance).

29 Check the camshaft lobes for heat discoloration (blue

appearance), score marks, chipped areas, flat spots and spalling (see

illustration). Measure the height of each lobe with a micrometer (see

illustration) and compare the results to the minimum lobe height listed

in this Chapters Specifications. If damage is noted or wear is

excessive, the camshaft must be replaced.

30 Next, check the camshaft bearing oil clearances. Measure the

outer diameter of the camshaft journals and the inner diameter of the

bearing surface in the cylinder head and the camshaft bushing (see 
illustration). Subtract the journal diameter from the bearing or bushing

bore diameter to obtain the clearance. If its greater than that listed in

this Chapters Specifications, replace the cylinder head, bushing or

camshaft, whichever is worn.

31 Check the visible portion of the cam chain for obvious wear or

damage. Except in cases of oil starvation, the chain wears very little. If

the chain has stretched excessively, which makes it difficult to

maintain proper tension, replace it with a new one (see Section 17).

32 Check the cam sprockets for wear, cracks and other damage,

replacing them if necessary (see illustration). If the sprockets are

worn, the chain is also worn, and also the sprocket on the crankshaft

(which can only be remedied by replacing the crankshaft). If wear this 
						

							
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

2A-15

8.32 Check the sprockets for wear

and damage 
8.34 Check rocker arms for wear on the

adjuster surface, inside the bore and on

the cam contact surface (arrows) 
8.36 Hold the rocker arm in the installed

position and install the shaft, using a bolt

8.40a Slide the camshaft into its bearing

in the cylinder head ... 
8.40b ... then install the bushing and

align it as shown 
8.41a Install the retainer...

8.41b ... and the lockwasher and bolts; the long bolt goes on the

exhaust side and the short bolt on the intake side

severe is apparent, the entire engine should be disassembled for

inspection.-

13 Check the cam chain damper for wear or damage. If it is worn or

damaged, the chain may be worn out or improperly adjusted. Refer to

Section 17 for cam chain replacement.

Rocker arm inspection

Refer to illustration 8.34

34 Clean all of the components with solvent and pry them off. Blow

though the oil passages in the rocker arms with compressed air, if

available. Inspect the rocker arm faces for pits, spalling, score marks

and rough spots (see illustration). Check the rocker arm-to-shaft

contact areas and the adjusting screws, as well. Look for cracks in 
each rocker arm. If the faces of the rocker arms are damaged, the

rocker arms and the camshafts should be replaced as a set.

35 Measure the diameter of the rocker arm shafts, in the area where

the rocker arms ride, and the inside diameter of the rocker arms.

Calculate the difference and compare the results with this Chapters

Specifications. If the clearance is beyond the specified limits, replace

them as a set.

Rocker arm installation

Refer to illustration 8.36

36 Coat the rocker shafts and the rocker arm bores with clean engine

oil. Thread a bolt into the threads in the end of the exhaust rocker shaft

to use as a handle. Position the exhaust rocker shaft partway into its

hole with the threaded end facing out (see illustration). Install the

exhaust rocker arm and slide the shaft into the rocker arm. Dont install

the holding bolt yet.

37 Repeat Step 36 to install the intake rocker arm.

Camshaft installation

Refer to illustrations 8.40a, 8.40b, 8.41a, 8.41b, 8.42a, 8.42b and 8.42c

38 Apply a light coat of engine assembly lube or moly-based grease

to the camshaft journals. Position the camshaft bushing on the

camshaft.

39 Apply a light coat of engine assembly lube or moly-based grease

to the cam lobes.

40 Slide the camshaft into the cylinder head, then install the bushing

(see illustrations). Dont let the bushing tilt sideways and jam in its

bore. Position the bushing cutout flush with the cylinder head and align

the camshaft dowel with the timing mark (see illustration 8.13).

41 Install the retainer (see illustration). Install a new lockwasher and

the retainer bolts (the exhaust side bolt is longer than the intake side

bolt) (see illustration). Tighten the bolts to the torque listed in this