Haynes Yamaha Xv V Twins Manual

							
2A-56 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

28.13 Measure the length of the gearset

on the main axle assembly and compare

to the Specifications 
28.14a Press the main axle out of second

pinion gear until its loose ... 
28.14b ... then remove the gear from

the shaft

28.15a Take off fifth pinion gear. .. 
28.15b ... and third pinion gear 
28.16a Remove the snap-ring .

28.16b ... the thrust washer ... 
28.16c ... and fourth pinion gear

main axle (see illustration). The length is determined by how far the

gears are pressed onto the shaft. Compare it to the value in illustra-

tion 28.3a.

14 Place the main axle in a press with a bearing splitter behind

second pinion gear (see illustration). Press the main axle out of

second pinion gear. Once the gear is loose, take it off the shaft (see 
illustration).

15 Take fifth pinion gear off the shaft (see illustration), then take off

third pinion gear (see illustration).

16 Remove the snap-ring and thrust washer, then take off fourth

pinion gear (see illustrations). 
						

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

2A-57

28.21 Check the shafts for runout with V-biocks and a

dial indicator 
28.22a Stake the bearing retainer screws ...

28.22b ... and the middle drive gear locknut 
28.23a The assembled main axle should look like this

28.23b Press second pinion gear onto the shaft until the gearset

is the specified length
Inspection

Refer to illustration 28.21

17 Wash all of the components in clean solvent and dry them off.

Rotate the ball bearing on the shaft, feeling for tightness, rough spots

and excessive looseness and listening for noises. If any of these

conditions are found, replace the bearing with a press.

18 Check the ball bearing that was removed from the other end of

the shaft and replace it if it has any of the conditions described in Step

6. The bearing should also be replaced if oil has been leaking from its

seal.

19 Check the gear teeth for cracking and other oovious damage.

Check the gear bushings and the surface in the inner diameter of each

gear for scoring or heat discoloration. If the gear or bushing is

damaged, replace it.

20 Inspect the dogs and the dog holes in the gears for excessive

wear. Replace the paired gears as a set if necessary.

21 Place the shafts in V-blocks and check runout with a dial indicator

(see illustration). Replace the shaft if runout exceeds the value listed

in this Chapters Specifications.

Assembly and installation

Refer to illustrations 28.22a, 28.22b, 28.23a, 28.23b, 28.24a, 28.24b,

28.24c, 28.24d, 28.25, 28.26a and 28.26b

22 If the middle gear and driveaxle were removed, reverse the

removal steps to install them. Be sure the short screw goes in the 
correct hole (see illustration 28.11a). Stake the screws (see

illustration). Install a new locknut, tighten it to the torque listed in this

Chapters Specifications and stake it (see illustration).

23 Reverse Steps 15 and 16 to assemble the main axle (see

illustration). Press second pinion gear onto the shaft (see illustration

28.23a and the accompanying illustration). 
						

							
2A-58

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

28.24a Install second wheel gear

28.24b ... the thrust washer ...

28.24c ... the snap-ring ...

28.24d ... and fifth wheel gear

28.25 Install third wheel gear on the main axle at the same time

you install the driveaxle in its bearing

28.26a When the gears are in the neutral position, the gear dogs

(arrows) are not engaged with the slots in the gears next to them

and the gears can be turned independently of each other

(driveaxle shown) 
24 Install the second wheel gear, thrust washer, snap-ring and fifth

wheel gear on the driveaxle (see illustrations).

25 Install the third wheel gear and main axle together (see

illustration).

26 Reverse Steps 3 through 5 to complete assembly. The assembled

gears should be in the neutral position (see illustrations).

27 The remainder of installation is the reverse of the removal steps.

29 Initial start-up after overhaul

1 Make sure the engine oil level is correct, then remove the spark

plugs from the engine. Place the engine kill switch in the Off position

and unplug the primary (low tension) wires from the coils.

2 Turn on the key switch and crank the engine over with the starter

several times to build up oil pressure. Reinstall the spark plugs,

connect the wires and turn the switch to On.

3 Make sure there is fuel in the tank, then turn the fuel tap to the On

position and operate the choke.

4 Start the engine and allow it to run at a moderately fast idle until it

reaches operating temperature.

5 Check carefully for oil leaks and make sure the transmission and

controls, especially the brakes, function properly before road testing

the machine. Refer to Section 30 for the recommended break-in

procedure.

6 Upon completion of the road test, and after the engine has cooled

down completely, recheck the valve clearances (see Chapter 1). 
						

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

2A-59

28.26b The assembled gears and shafts should look like this

30 Recommended break-in procedure

1 Any rebuilt engine needs time to break-in, even if parts have been

installed in their original locations. For this reason, treat the machine

gently for the first few miles to make sure oil has circulated throughout 
the engine and any new parts installed have started to seat.

2 Even greater care is necessary if the engine has been rebored or a

new crankshaft has been installed. In the case of a rebore, the engine

will have to be broken in as if the machine were new. This means

greater use of the transmission and a restraining hand on the throttle

until at least 500 miles have been covered. Theres no point in keeping

to any set speed limit - the main idea is to keep from lugging the

engine and to gradually increase performance until the 500 mile mark

is reached. These recommendations can be lessened to an extent

when only a new crankshaft is installed. Experience is the best guide,

since its easy to tell when an engine is running freely. The following

recommendations, which Yamaha provides for new motorcycles, can

be used as a guide:

a) 0 to 90 miles (0 to 150 km): Keep engine speed below 3,000 rpm.

Turn off the engine after each hour of operation and let it cool for

5 to 10 minutes. Vary the engine speed and dont use full throttle.

b) 90 to 300 miles (150 to 500 km): Dont run the engine for long

periods above 4,000 rpm. Rev the engine freely through the gears,

but dont use full throttle.

c) 300 to 600 miles (500 to 1000 km): Dont use full throttle for

prolonged periods and dont cruise at speeds above 5,000 rpm.

d) At 600 miles (1,000 km): Change the engine oil and filter. Full

throttle can be used after this point.

3 If a lubrication failure is suspected, stop the engine immediately

and try to find the cause. If an engine is run without oil, even for a short

period of time, severe damage will occur. 
						

							
2A-60 
Chapter 2 Part A Engine, clutch and transmission (XV535 models)

Notes 
						

							
2B-1

Chapter 2 Part B

Engine, clutch and transmission

(XV700-1100 models)

Contents

Section

Alternator rotor - removal and installation See Chapter 8

Cam chains and intermediate gears - removal, inspection

and installation . 14

Camshaft chain tensioners - removal and installation 7

Clutch and primary gears - removal, inspection

and installation 17

Clutch cable replacement and release mechanism removal

and installation 16

Compression test See Chapter 1

Connecting rod bearings - general note 24

Connecting rods and bearings - removal, inspection,

bearing selection and installation 25

Crankcase components - inspection and servicing 21

Crankcase - disassembly and reassembly 20

Crankshaft and main bearings - removal, inspection,

main bearing replacement and installation . 23

Cylinder head and valves - disassembly, inspection

and reassembly 10

Cylinder heads, camshafts and rocker arms - removal,

inspection and installation 8

Cylinders - removal, inspection and installation 11 
Section

Engine disassembly and reassembly - general information 6

Engine - removal and installation 5

External shift mechanism - removal, inspection

and installation 18

General information 1

Initial start-up after overhaul 27

Major engine repair - general note 4

Middle gears and shafts (shaft drive models) 19

Oil and filter change See Chapter 1

Oil pressure relief valve - removal, inspection and installation 22

Oil pump and pick-up - removal, inspection and installation 15

Operations possible with the engine in the frame 2

Operations requiring engine removal 3

Piston rings - installation 13

Pistons - removal, inspection and installation .......... 12

Recommended break-in procedure.... 28

Spark plug replacement See Chapter 1

Starter clutch - removal, inspection and installation See Chapter 8

Transmission shafts, shift cam and forks - removal,

disassembly, inspection, reassembly and installation. 26

Valves/valve seats/valve guides - servicing . 9 
						

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

Specifications

XV700 and XV750 models

General

Bore x stroke

XV700 80.2x69.2 mm (3.16x2.72 inches)

XV750 . 83.0 x 69.2 mm (3.268 x 2.72 inches)

Displacement

XV700 ..... 699 cc

XV750.... 748 cc

Compression ratio

1981 though 1983 8.7 to 1

1984-on.. 9.0 to 1

Camshafts

Lobe height

Intake 39.17 mm (1.5421 inch)

Exhaust 39.20 mm (1.5433 inch)

Base circle

1981 through 1983

Intake . 32.00 mm (1.2598 inch)

Exhaust 32.00 mm (1.2598 inch)

1984-on

Intake 32.23 mm (1.2689 inch)

Exhaust 32.36 mm (1.2701 inch)

Bearing oil clearance 0.020 to 0.061 mm (0.0008 to 0.0024 inch)

Journal diameter (1981 through 1983)

Rear cylinder 24.976 to 24.980 mm (0.9830 to 0.9835 inch)

Front cylinder 23.976 to 23.9809 mm (0.9435 to 0.9440 inch)

Journal diameter (1984-on) 24.96 to 24.98 mm (0.9432 to 0.9440 inch)

Bearing bore (1981 through 1983)

Rear cylinder 25.000 to 25.021 mm (0.9843 to 0.9851 inch)

Front cylinder 24.000 to 24.021 mm (0.9448 to 0.9456 inch)

Bearing bore (1984-on) 25.00 to 25.021 mm (0.9448 to 0.9456 inch)

Camshaft runout limit 0.03 mm (0.0012 inch)

Rocker arm inside diameter 14.000 to 14.018 mm (0.5511 to 0.5518 inch)

Rocker arm shaft diameter 13.975 to 13.990 mm (0.5501 to 0.5507 inch)

Rocker arm to shaft clearance 0.010 to 0.043 mm (0.0004 to 0.0017 inch)

Cylinder head, valves and valve springs

Cylinder head warpage limit 0.03 mm (0.0012 inch)

Valve stem bend limit 0.03 mm (0.0012 inch)

Valve head diameter

Intake 43.0 to 43.02 mm (1.690 to 1.698 inch)

Exhaust 37.0 to 37.2 mm (1.460 to 1.468 inch)

Valve stem diameter

Intake . 7.975 to 7.990 mm (0.311 to 0.314 inch)

Exhaust 7.960 to 7.975 mm (0.3134 to 0.3140 inch)

Valve head edge thickness limit 1.3+/-0.2 mm (0.051 +/- 0.008 inch)

Valve guide inside diameter 8.000 to 8.012 mm (0.3150 to 0.3155 inch)

Valve seat width limit .... 1.3 +/- 0.1 mm (0.051 +/- 0.004 inch)

Valve face width 2,1 mm (0.083 inch)

Valve inner spring free length 45.3 mm (1.783 inch)

Valve inner spring installed length 38.0 mm (1.496 inch)

Valve inner spring bend limit 2.0 mm (0.0787 inch)

Valve outer spring free length 44.6 mm (1.756 inch)

Valve outer spring installed length 40.0 mm (1.575 inch)

Valve outer spring bend limit 2.0 mm (0.0787 inch)

Cylinders

Bore diameter (XV700) -

Standard 80.2 mm (3.157 inches)

Limit 80.3 mm (3.161 inches)

Bore diameter (XV750)

Standard 83.0 mm (3.267 inches)

Limit 83.1 mm (3.272 inches) 
						

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

2B-3

Bore measuring point

Through 1987 Top, center and bottom of cylinder

1988-on 35 mm (1.38 inch) from top of bore

Taper and out-of-round limit 0.05 mm (0.002 inch)

Pistons

Piston diameter (XV700)

Standard 80.135 to 80.185 mm (3.155 to 3.157 inches)

.First oversize 80.50 mm (3.17 inches)

Second oversize 81.00 mm (3.19 inches)

Piston diameter (XV750)

Standard 82.95 to 82.97 mm (3.266 to 3.267 inches)

First oversize ... 83.50 mm (3.278 inches)

Second oversize 84.00 mm (3.307 inches)

Diameter measuring point 9.5 mm (0.37 inch) from bottom of skirt

Piston-to-cylinder clearance. 0.040 to 0.060 mm (0.0014 to 0.0022 inch)

Ring side clearance (1981 through 1983)

Top and second rings 0.04 to 0.08 mm (0.0016 to 0.0031 inch)

Oil ring Not specified

Ring side clearance (1984-on)

Top ring 0.04 to 0.08 mm (0.0016 to 0.0031 inch)

Second ring 0.03to0.07 mm (0.0012 to 0.0028 inch)

Oil ring . Zero to 0.04 mm (zero to 0.0016 inch)

Ring thickness (1981 through 1983) Not specified

Ring thickness (1984-on)

Top and second rings 1.2 mm (0.05 inch)

Oil ring (spacer and rails) 2.5 mm (0.10 inch)

Ring end gap (1981 through 1983)

Top and second rings 0.3 to 0.5 mm (0.0118 to 0.0197 inch)

Oil ring 0.3 to 0.9 mm (0.0118 to 0.0351 inch)

Ring end gap (1984-on)

Top and second rings 0.20 to 0.40 mm (0.008 to 0.016 inch)

Oil ring 0.2 to 0.7 mm (0.0078 to 0.0276 inch)

Ring width (1981 through 1983) Not specified

Ring width (1984-on)

Top ring 3.2 mm (0.126 inch)

Second ring 3.6 mm (0.142 inch)

Oil ring 2.8 mm (0.110 inch)

Crankshaft, connecting rods and bearings

Connecting rod side clearance 0.370 to 0.474 mm (0.0146 to 0.0187 inch)

Connecting rod bearing oil clearance 0.030 to 0.054 mm (0.0012 to 0.0021 inch)

Crankshaft runout limit 0.02 mm (0.0008 inch)

Oil pump (1981 through 1983)

Inner to outer rotor clearance 0.03 to 0.09 mm (0.0012 to 0.0035 inch)

Crankshaft rotor thickness 6 mm (0.236 inch)

Transmission rotor thickness 4 mm (0.157 inch)

Oil pump (1984-on)

Inner to outer rotor clearance 0.03 to 0.09 mm (0.0012 to 0.0035 inch)

Outer rotor to housing clearance 0.03 to 0.08 mm (0.0012 to 0.0031 inch)

Rotor to straightedge clearance 0.03 to 0.09 mm (0.0012 to 0.0035 inch)

Clutch

Friction plate thickness

Standard 2.9 to 3.1 mm (0.116 to 0.124 inch)

Minimum 2.8 mm (0.11 inch)

Steel plate thickness 1.5 to 1.7 mm (0.059 to 0.067 inch)

Steel plate warpage limit 0.1 mm (0.004 inch)

Pushrod bend limit 0.5 mm (0.02 inch)

Spring length

Standard 41.2 mm (1.622 inch)

Minimum 40.2 mm (1.582 inch)

Transmission

Driveaxle and mainshaft runout limit 0.08 mm (0.0031 inch)

Torque specifications

Alternator cover bolts 10 Nm (7.2 ft-lbs)

Alternator cover screws 7 Nm (5.1 ft-lbs) 
						

							
2B-4 
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

Torque specifications (continued)

Alternator rotor nut See Chapter 8

Cam chain damper bolt 8 Nm (5.8 ft-lbs)

Cam chain damper bolt locknut 12 Nm ((8.7 ft-lbs)

Cam chain tensioner bolts 10 Nm (7.2 ft-lbs)

Cam sprocket bolt 55 Nm (40 ft-lbs)

Cam sprocket cover bolts 10 Nm (7.2 ft-lbs)

Camshaft retainer bolts 20 Nm (14 ft-lbs)

Clutch push screw locknut 12 Nm (8.7 ft-lbs)

Clutch boss nut 70 Nm (50 ft-lbs) (4)

Clutch cover bolts 10 Nm (7.2 ft-lbs)

Clutch pressure plate screws 8 Nm (5.8 ft-lbs)

Connecting rod nuts 48 Nm (35 ft-lbs) (2)

Crankcase bolts (6 mm) 10 Nm (7.2 ft-lbs)

Crankcase bolts (10 mm) 39 Nm (28 ft-lbs)

Cylinder bolts 10 Nm (7.2 ft-lbs)

Cylinder nuts (12 mm)

First stage 50 Nm (36 ft-lbs) (3)

Second stage 64 Nm (46 ft-lbs)

Cylinder head bolts (8 mm) 20 Nm (14 ft-lbs)

Cylinder head nuts (10 mm) 40 Nm (29 ft-lbs)

Intermediate gear stopper plate bolts 10 Nm (7.2 ft-lbs)

Oil line union bolts 20 Nm (14 ft-lbs) (1)

Oil pump bolts 10 Nm (7.2 ft-lbs)

Oil pump chain cover bolts 10 Nm (7.2 ft-lbs)

Oil pump sprocket bolts 12 Nm (8.7 ft-lbs)

Primary drive gear nut 110 Nm (80 ft-lbs) (4)

Rocker arm cover bolts 10 Nm (7.2 ft-lbs)

Rocker arm shaft holding bolts 38 Nm (27 ft-lbs) (1)

Shift fork guide bar stopper screws 7 Nm (5.1 ft-lbs) (5)

Shift pedal pinch bolt 10 Nm (7.2 ft-lbs)

1 Use new sealing washers.

2 Apply molybdenum disulfide grease to the threads and nut surfaces; follow special tightening procedure in the text.

3 Apply engine oil to the threads.

4 Use a new lockwasher.

5 Apply Loctite Stud n Bearing Mount or equivalent to the threads.

XV920 models

General

Bore x stroke 92.0 x 69.2 mm (3.622 x 2.72 inches)

Displacement 920 cc

Compression ratio 8.3 to 1

Camshafts and rocker arms

Lobe height

Intake 39.17 mm (1.5421 inch)

Exhaust 39.20 mm (1.5433 inch)

Base circle (intake and exhaust) 32.00 mm (1.2598 inch)

Bearing oil clearance 0.020 to 0.054 mm (0.0008 to 0.0021 inch)

Journal diameter

RH and RJ models

Rear cylinder 23.967 to 23.980 mm (0.9435 to 0.9440 inch)

Front cylinder 24.967 to 24.980 mm (0.9483 to 0.9491 inch)

J, K, MK models (both cylinders) 24.96 to 24.98 mm (0.9432 to 0.9440 inch)

Bearing bore

RH and RJ models

Rear cylinder 24.000 to 24.021 mm (0.9448 to 0.9456 inch)

Front cylinder 25.000 to 25.021 mm (0.9843 to 0.9851 inch)

J, K, MK models 25.00 to 25.021 mm (0.9448 to 0.9456 inch)

Camshaft runout limit 0.03 mm (0.0012 inch)

Rocker arm inside diameter 14.000 to 14.018 mm (0.5511 to 0.5518 inch)

Rocker arm shaft diameter 13.975 to 13.990 mm (0.5501 to 0.5507 inch)

Rocker arm to shaft clearance 0.010 to 0.043 mm (0.0004 to 0.0017 inch)

Cylinder head, valves and valve springs

Cylinder head warpage limit 0.03 mm (0.0012 inch)

Valve stem bend limit 0.03 mm (0.0012 inch) 
						

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

2B-5

Valve head diameter

RH models

Intake 43.0 to 43.02 mm (1.690 to 1.698 inch)

Exhaust 37.0 to 37.2 mm (1.460 to 1.468 inch)

J, K, MK models

Intake 47.0 to 47.2 mm (1.850 to 1.858 inch)

Exhaust 39.0 to 39.2 mm (1.540 to 1.548 inch)

Valve stem diameter

Intake 7.975 to 7.990 mm (0.311 to 0.314 inch)

Exhaust 7.960 to 7.975 mm (0.3134 to 0.3140 inch)

Valve head edge thickness limit 1.3 +/-0.2 mm (0.051 +/- 0.008 inch)

Valve guide inside diameter 8.000 to 8.012 mm (0.3150 to 0.3155 inch)

Valve seat width limit 1.3 +/- 0.1 mm (0.051 +/- 0.004 inch)

Valve face width 2.1 mm (0.083 inch)

Valve inner spring free length 45.3 mm (1.783 inch)

Valve inner spring installed length 38.0 mm (1.496 inch)

Valve inner spring bend limit 2.0 mm (0.0787 inch)

Valve outer spring free length 44.6 mm (1.756 inch)

Valve outer spring installed length 40.0 mm (1.575 inch)

Valve outer spring bend limit 2.0 mm (0.0787 inch)

Cylinders

Bore diameter

Standard 92.0 mm (3.622 inches)

Limit Not specified

Bore measuring point Top, center and bottom of cylinder

Taper and out-of-round limit 0.05 mm (0.002 inch)

Pistons

Piston diameter

Standard 92.0 mm (3.622 inches)

First oversize 93.25 mm (3.67 inches)

Second oversize 93.50 mm (3.68 inche.s)

Diameter measuring point 14.6 mm (0.575 inch) from bottom of skirt

Piston-to-cylinder clearance 0.045 to 0.065 mm (0.0018 to 0.0026 inch)

Ring side clearance (J, K, MK models)

Top ring 0.04 to 0.08 mm (0.0016 to 0.0031 inch)

Second ring 0.03 to 0.07 mm (0.0012 to 0.0028 inch)

Oil ring Zero

Ring thickness (J, K, MK models)

Top ring 1.5 mm (0.06 inch)

Second ring 2.0 mm (0.08 inch)

Oil ring (spacer and rails) 4.0 mm (0.16 inch)

Ring end gap (J, K, MK models)

Top and second rings 0.20 to 0.40 mm (0.008 to 0.016 inch)

Oil ring 0.3 to 0.6 mm (0.0012 to 0.0024 inch)

Ring width (J, K, MK models)

Top ring 3.8 mm (0.15 inch)

Second ring 4.0 mm (0.16 inch)

Oil ring 3.9 mm (0.15 inch)

Crankshaft, connecting rods and bearings

Connecting rod side clearance 0.370 to 0.474 mm (0.0146 to 0.0187 inch)

Connecting rod bearing oil clearance 0.030 to 0.054 mm (0.0012 to 0.0021 inch)

Crankshaft runout limit . . 0.02 mm (0.0008 inch)

Oil pump

Inner to outer rotor clearance 0.03 to 0.09 mm (0.0012 to 0.0035 inch)

Crankshaft rotor thickness 6 mm (0.236 inch)

Transmission rotor thickness 4 mm (0.157 inch)

Clutch

Friction plate thickness

Standard 2.9 to 3.1 mm (0.116 to 0.124 inch)

Minimum 2.8 mm (0.11 inch)

Steel plate thickness 1.5 to 1.7 mm (0.059 to 0.067 inch)

Steel plate warpage limit 0.1 mm (0.004 inch)

Pushrod bend limit 0.5 mm (0.02 inch)

Spring length

Standard 41.2 mm (1.622 inch)

Minimum 40.2 mm (1.582 inch)