Haynes Yamaha Xv V Twins Manual

2B-26

Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

15.7d Lift off the remaining rotor housing

and oil pump shaft... 
15.7e ... and separate the shaft from

the rotors 
15.7f Note the marks on the rotors; they

must face in the same direction when the

pump is assembled .

15.9a Measure oil pump clearances with a feeler gauge

15.9b Oil pump measurement points

1 Inner rotor B Outer rotor to housing

2 Outer rotor clearance

3 Pump housing C Side clearance

A Inner to outer...

Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

2B-27

15.13b Place the new sprocket on the

crankshaft with its teeth toward

the crankcase ... 
15.13c ... and drive the sprocket all the

way on with a hammer and piece of pipe 
15.15 Make sure the dowel and both

O-rings are in position

15.17 Install the chain on the drive

sprocket, engage it with the driven

sprocket and bolt the driven sprocket to

the oil pump 
15.18 Push the arm of the chain cover

against the chain to...

2B-28 
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

16.3 Bend back the metal tang on the

lever bracket and slip the end of the cable

out of the lever bracket 
16.9 Unhook the spring and remove the

nut from the operating lever 
16.10a Lift out the push screw .

16.10b ... and the thrust housing; the

locating pin on the thrust housing fits into

a hole in the alternator cover 
16.11 Pry out the old oil seal and install a

new one 
17.3 Remove the clutch cover; note the...

Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

2B-29

17.4b ... then take off the pressure plate 
12 Installation is the reverse of the removal steps.

13 Adjust clutch free-play (see Chapter 1).

17 Clutch and primary gears - removal, inspection and

installation

Removal

Refer to illustrations 17.3, 17.4a, 17.4b, 17.4c, 17.6. 17.7a. 17.7b

17.8, 17.9a through 17.9d, 17.11a, 17.11b, 17.12a, 17.12b and 17.13

1 Drain the engine oil and remove the oil filter (see Chapter 1).

2...

2B-30 
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

17.6 Remove the thrust washer and

thrust bearing 
17.7a Remove the push piece ... 
17.7b ... and the pushrod

17.8 Remove the clutch plates 
17.9a Bend the lockwasher tab away from

the nut 
17.9b Youll need a tool to keep the clutch

from turning; this is one type of Yamaha

special tool...

17.9c ... this is another type 
17.9d Hold the clutch housing so it wont turn and loosen the nut

6 Remove the thrust washer and thrust...

Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

2B-31

17.11a Remove the clutch boss ... 
17.11b ... and the thrust washer

17.12a With the primary gear nut loose.

slide off the clutch boss, then remove the

primary gear nut...

17.12b ... the lockwasher and the

special washer 
17.13 Take the primary drive gear and

Woodruff key off the crankshaft 
17.14 Push the ends of the wire ring

through the hole in the clutch boss

17.15 Inspect the clutch boss splines

17.16 Measure the...

2B-32

Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

17.17a Measure the free height of

the diaphragm spring with a

vernier catiper ...

1 Diaphragm spring 
17.17b ... and check it for warpage with a

feeler gauge 
17.18 Check the amount of wear on each

clutch friction plate

17.19 Check the metal plates for warpage

with a feeler gauge 
17.21 Check the slots in the clutch

housing for uneven wear 
17.22 Check the driven gear teeth for

wear or damage

17.23 Check the pressure...

Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

2B-33

17.24 Check the push piece, thrust bearing and washer for wear

and damage 
17.38 Several of the bottom clutch cover bolts secure wiring

harness clips

18.3 Loosen the pinch bolt and detach the shift lever from the

shift shaft (rearset shift linkage shown)

25 Clean all traces of old gasket material from the clutch cover and

ts mating surface on the crankcase.

Installation

Refer to illustration 17.38

26 Install the...

2B-34

Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

18.7a Pull the lever in the direction of the arrow until it clears the

shift cam, then slide the shift mechanism out of the engine 
18.7b Remove the C-clip at each end of the shaft and slide the

parts off for inspection

Shift mechanism removal

Refer to illustrations 18.7a and 18.7b

5 Disconnect the shift lever from the shaft (Steps 1 through 3).

6 Remove the alternator cover (see Chapter 8).

7 Pull the lever on the shift...

Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

2B-35

18.11 Check the stopper arm roller and

spring for wear and damage 
18.13 Pry the oil seal out of the cover and

tap a new one in 
18.15 The legs of the shaft return spring

should be on either side of the shift shaft

guide bar

20.8 Crankcase bolt TIGHTENING sequence

the shift cam. Replace the spring if its distorted.

12 Inspect the pins on the end of the shift cam. If theyre worn or

damaged, youll have to disassemble the...