Haynes Yamaha Xv V Twins Manual

2A-26 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

12.4a Push the piston pin partway out, then grasp it and pull it the

rest of the way 
12.4b The piston pins should come out with hand pressure - if

they dont, this removal tool can be fabricated from readily

available parts

1) Bolt 5). Piston

2) Washer 6) Washer (B)

3) Pipe (A) 7) Nut(B)

4) Padding (A)

A Large enough for piston pin to fit inside

B Small enough to fit through piston pin bore

12.6 Remove the piston rings...

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

2A-27

12.14 Measure the piston diameter with a micrometer

A Specified distance from bottom of piston

B Piston diameter 
12.15 Slip the pin into the piston and try to wiggle it back-and-

forth; if its loose, replace the piston and pin

12.17a Slip the circlip into its bore with its

gap away from the removal notch in

the piston ... 
12.17b ... and push the circlip all the way

into its groove; make sure its

securely seated 
13.3...

2A-28 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

13.5 If the end gap is too small, clamp a

file in a vise and file the ring ends (from

the outside in only) to enlarge the

gap slightly 
13.9a Install the oil ring expander first 
13.9b Installing an oil ring side rail - dont

use a ring installation tool to do this

13.11a Install the middle ring with its

identification mark up 
13.11b The top and middle rings can be

identified by their profiles

Top ring Middle ring 
13.12 The...

Chapter 2 Part A Engine, clutch and transmission (XV535 models) 
2A-29

14.2 Pull off the shaft and no. 1 idler gear 
14.3a Pull out the Woodruff key... 
14.3b .. .take the no. 2 idler gear off the

crankshaft...

14.3c ... and locate the washer (it may

have stuck to the back of the no. 2

idler gear) 
15.1 Remove the cotter pin, disconnect

the cable from the release lever and

loosen the locknuts 
15.2a Loosen the free-play adjuster all

the way, align its slot with the cable and

pull the cable out...

2A-30 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

16.2a Loosen the cover bolts 1/4 turn at a time in a

criss-cross pattern; note that some of the bolts secure

wiring harness retainers

16.2b Separate the clutch cover from the crankcase .

16.2c ... if its difficult to remove, use the pry points at

the front... 
16.2d ... and at the rear

16.3 Remove the snap-ring (arrow) and take off the oil pump

driven gear 
16.4a Loosen the clutch spring bolts evenly

2 Loosen the right-hand...

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

2A-31

16.4b Clutch (XV535 models) exploded view

1) Pressure plate

2) Push plate

3) O-ring

4) Short pushrod

5) Steel ball

6) Metal plates

7) Friction plates

8) Wire circlip

9) Clutch damper plate 
10) Seat spring

11) Seat plate

12) Clutch boss

13) Retaining plate

14) Clutch housing

15) Long pushrod

16) Push lever assembly

17) Primary drive gear 

2A-32 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

16.5a Take off the pressure plate ... 
16.5b ... together with the push piece (A)

and short pushrod (B) 
16.5c The friction plates and metal plates

can be removed as a set

16.6a Pull out the steel ball with

a magnet... 
16.6b ... then pull out the long pushrod 
16.7a Bend back the lockwasher

16.7b Youll need a tool to keep the clutch hub from turning; this

is the Yamaha special tool...

1) Clutch boss nut 2) Holding tool...

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

2A-33

16.7d A holding tool can also be made by

bolting an old metal plate and friction

plate together 
16.7e Remove the nut... 
16.8 ... and the lockwasher

16.9a Pull the clutch boss off... 
16.9b ... and remove the holding plate 
16.10a Bend back the

lockwasher (arrow)...

16.10b ... then wedge a rag between the

drive and driven gears to keep them from

turning and loosen the nut 
16.11a Remove the lockwasher ... 
16.11b ... the...

2A-34

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

16.11c . . . the oil pump drive gear. .

16.12a ... the primary drive gear ...

16.12b ... and the Woodruff key

16.13a Pull one end of the wire circlip out

of its hole in the clutch boss ... 
16.13b ... and work the circlip out of

its groove 
16.13c Pull off the clutch damper plate ...

16.13d .... the seat spring ...

16.13e ... and the seat plate

16.15 Measure the clutch spring

free length

12 Remove the primary drive gear...

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

2A-35

16.16 Measure the thickness of the

friction plates 
16.17 Check the metal plates for warpage 
16.28 With the nut tightened to the

specified torque, bend the lockwasher

against one of the flats

6.29 Install the oil pump driven gear and

secure it with a new snap-ring 
16.30 Install the clutch boss lockwasher

16.31 Once the nut is tightened to the

specified torque, bend the lockwasher

against the nut

16 If the lining material...