Haynes Yamaha Xv V Twins Manual

							
2B-6 
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

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)

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 head 12 mm nuts

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)

7 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.

XV1000 models

General

Bore x stroke 95.0 x 69.2 mm (3.74 x 2.72 inches)

Displacement 981 cc

Compression ratio 8.3 to 1

Camshafts

Lobe height

Intake 39.17 mm (1.5421 inch)

Exhaust.... 39.20 mm (1.5433 inch)

Base circle

Intake 32.17 mm (1.2665 inch)

Exhaust 32.27 mm (1.2705 inch)

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

Journal diameter 24.96 to 24.98 mm (0.9432 to 0.9440 inch)

Bearing bore . 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 47.0 to 47.02 mm (1.850 to 1.858 inch)

Exhaust 39.0 to 39.2 mm (1.540 to 1.562 inch) 
						

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

2B-7

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 . 95.0 mm (3.740 inches)

Limit 95.1 mm (3.744 inches)

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 94.945 to 94.965 mm (3.738 to 3.739 inches)

First oversize 95.50 mm (3.76 inches)

Second oversize 96.00 mm (3.78 inches)

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

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

Top and second rings 1.5 mm (0.06 inch)

Oil ring (spacer and rails) 3.8 mm (0.15 inch)

Ring end gap

Top and second rings 0.30 to 0.50 mm (0.012 to 0.020 inch)

Oil ring 0.3 to 0.9 mm (0.012 to 0.035 inch)

Ring width

Top ring 3.8 mm (0.15 inch)

Second ring 4.0 mm (0.16 inch)

Oil ring 3.9 mm (0.153 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)

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)

Alternator rotor nut See Chapter 8 
						

							
2B-8 
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

Torque specifications (continued)

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

Cylinder head nuts (10 mm) 35 Nm (25 ft-lbs)

Cylinder head nuts (12 mm) 50 Nm (36 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.

XV1100 models

General

Bore x stroke 95.0 x 75.0 mm (3.74 x 2.95 inches)

Displacement 1063cc

Compression ratio 8.3 to 1

Camshafts

Lobe height

Intake 39.17 mm (1.5421 inch)

Exhaust 39.20 mm (1.5433 inch)

Base circle

intake 32.17 mm (1.2665 inch)

Exhaust 32.27 mm (1.2705 inch)

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

Journal diameter 24.96 to 24.98 mm (0.9432 to 0.9440 inch)

Bearing bore 25.00 to 25.021 mm (0.9483 to 0.9451 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 47.0 to 47.02 mm (1.850 to 1.858 inch)

Exhaust 39.0 to 39.2 mm (1.540 to 1.562 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) 
						

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

2B-9

Valve face width 2.1 mm (0.083 inch)

Valve inner spring free length 43.39 mm (1.708 inch)

Valve inner spring installed length 38.0 mm (1.496 inch)

Valve inner spring bend limit 1.9 mm (0.0748 inch)

Valve outer spring free length . 45.33 mm (1.785 inch)

Valve outer spring installed length 40.0 mm (1.575 inch)

Valve outer spring bend limit 1.9 mm (0.0748 inch)

Cylinders

Bore diameter

Standard . 95.000 to 95.005 mm (3.7402 to 3.7403 inches)

Limit 95.1 mm (3.744 inches)

Bore measuring point

Through 1987 Top. center and bottom of cylinder

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

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

Pistons

Piston diameter

Standard 94.93 to 94.98 mm (3.737 to 3.739 inches)

First oversize 95.50 mm (3.76 inches)

Second oversize 96.00 mm (3.78 inches)

Diameter measuring point

Through 1987 14.6 mm (0.575 inch) from bottom of skirt

1988-on 3 mm (0.12 inch) from bottom of piston skirt

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

Ring side clearance

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 Not specified

Ring thickness

Top ring 1.5 mm (0.06 inch)

Second ring 1.2 mm (0.0472 inch)1

Oil ring (spacer and rails) 2.5 mm (0.0984 inch)

Ring end gap

Top ring 0.3 to 0.5 mm (0.012 to 0.020 inch)

Second ring 0.3 to 0.45 mm (0.012 to 0.018 inch)

Oil ring 0.2 to 0.7 mm (0.008 to 0.0276 inch)

Ring width

Top and second rings 3.8 mm (0.15 inch)

Oil ring 3.4 mm (0.13 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)

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 1.9 to 2.1 mm (0,075 to 0.083 inch)

Steel plate warpage limit 0.1 mm (0.004 inch)

Pushrod bend limit 0.5 mm (0.02 inch)

Diaphragm spring height 7.2 mm (0.283 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)

Alternator rotor nut See Chapter 8 
						

							
2B-10 
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

Torque specifications (continued)

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

Cam chain clamper 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 head bolts (8 mm) 20 Nm (14 ft-lbs)

Cylinder head nuts (10 mm) 35 Nm (25 ft-lbs)

Cylinder head nuts (12 mm) 50 Nm (36 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.

1 General information

Note: Some of the procedures in this Chapter are listed as applying to

1981 through 1983 models. If youre working on a 1984 or 1985 TR1

model, use the 1981 through 1983 procedures.

The engine/transmission unit is an air-cooled V-twin. The valves

are operated by overhead camshafts which are chain driven off the

crankshaft. The engine/transmission assembly is constructed from

aluminum alloy. The crankcase is divided vertically.

The crankcase incorporates a wet sump, pressure-fed lubrication

system which uses a chain-driven oil pump and an oil filter mounted in

the right-hand side of the crankcase.

Power from the crankshaft is routed to the transmission via the

clutch, which is of the wet multi-plate type and is gear-driven off the

crankshaft. The transmission is a five-speed, constant-mesh unit.

2 Operations possible with the engine in the frame

The components and assemblies listed below can be removed without

having to remove the engine from the frame. If, however, a number of

areas require attention at the same time, removal of the engine is 
recommended.

Starter motor

Alternator

Oil pump

Starter clutch

Cam sprockets

Clutch and primary drive gear

External shift linkage

3 Operations requiring engine removal

It is necessary to remove the engine/transmission assembly from the

frame to gain access to the following components:

Cylinder heads, rocker arms and camshafts

Cylinders and pistons

Cam chains and intermediate gears

The crankcase halves must be separated to gain access to the

following components:

Crankshaft, connecting rods and bearings

Transmission shafts

Shift cam and forks

Oil pressure relief valve 
						

							
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models) 2B-11

5.9 Squeeze the clip, slide it down the hose and disconnect the

hose from the fitting

4 Major engine repair - general note

1 It is not always easy to determine when or if an engine should be

completely overhauled, as a number of factors must be considered.

2 High mileage is not necessarily an indication that an overhaul is

needed, while low mileage, on the other hand, does not preclude the

need for an overhaul. Frequency of servicing is probably the single

most important consideration. An engine that has regular and frequent

oil and filter changes, as well as other required maintenance, will most

likely give many miles of reliable service. Conversely, a neglected

engine, or one which has not been broken in properly, may require an

overhaul very early in its life.

3 Exhaust smoke and excessive oil consumption are both

indications that piston rings and/or valve guides are in need of

attention. Make sure oil leaks are not responsible before deciding that

the rings and guides are bad. Refer to Chapter 1 and perform a

cylinder compression check to determine for certain the nature and

extent of the work required.

4 If the engine is making obvious knocking or rumbling noises, the

connecting rod and/or main bearings are probably at fault.

5 Loss of power, rough running, excessive valve train noise and

high fuel consumption rates may also point to the need for an overhaul,

especially if they are all present at the same time. If a complete tune-up

does not remedy the situation, major mechanical work is the only

solution.

6 An engine overhaul generally involves restoring the internal parts

to the specifications of a new engine. During an overhaul the piston

rings are replaced and the cylinder walls are bored and/or honed. If a

rebore is done, then new pistons are also required. The main and

connecting rod bearings are generally replaced with new ones and, if

necessary, the crankshaft is also replaced. Generally the valves are

serviced as well, since they are usually in less than perfect condition at

this point. While the engine is being overhauled, other components

such as the carburetors and the starter motor can be rebuilt also. The

end result should be a like-new engine that will give as many trouble

free miles as the original.

7 Before beginning the engine overhaul, read through all of the

related procedures to familiarize yourself with the scope and

requirements of the job. Overhauling an engine is not all that difficult,

but it is time consuming. Plan on the motorcycle being tied up for a

minimum of two weeks. Check on the availability of parts and make

sure that any necessary special tools, equipment and supplies are 
obtained in advance.

8 Most work can be done with typical shop hand tools, although a

number of precision measuring tools are required for inspecting parts

to determine if they must be replaced. Often a dealer service

department or motorcycle repair shop will handle the inspection of

parts and offer advice concerning reconditioning and replacement. As

a general rule, time is the primary cost of an overhaul so it doesnt pay

to install worn or substandard parts.

9 As a final note, to ensure maximum life and minimum trouble from

a rebuilt engine, everything must be assembled with care in a

spotlessly clean environment.

5 Engine - removal and installation

Warning: Engine removal and installation should be done with the aid

of an assistant to avoid damage or injury that could occur if the engine

is dropped. A hydraulic floor jack should be used to support and lower

the engine if possible (they can be rented at low cost).

Removal

Refer to illustrations 5.9, 5.20a, 5.20b and 5.20c

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

procedure. Place a support under the swingarm pivot and be sure the

motorcycle is safely braced.

2 Remove the seat and side covers (see Chapter 7). Disconnect the

battery cables from the battery (see Chapter 1). Warning: Always

disconnect the negative cable first and reconnect it last to prevent a

battery explosion.,

3 Remove the fuel tank and air cleaner housing (see Chapter 3).

4 If youre working on a 1981 through 1983 model,-remove the

battery (see Chapter 1).

5 Drain the engine oil (see Chapter 1).

6 Remove the exhaust system (see Chapter 3). If youre working on

a 1981 through 1983 model, remove the battery box together with the

right muffler/silencer bracket.

7 Remove the brake light switch (see Chapter 8). Remove the brake

pedal and the rear footpeg brackets (see Chapter 7). If youre working

on a 1981 through 1983 model, remove the front footpegs and

brackets as well.

8 Disconnect the mixture control valve hoses (see.Chapter 3). If

youre working on a 1984 or later model, remove the mixture control

valve case.

9 Disconnect the crankcase ventilation hose from the rear cylinder

head (see illustration).

10 Disconnect the throttle and choke cables from the carburetors

(see Chapter 3). Disconnect the fuel lines and plug or cap them to

prevent fuel leaks. If youre working on an XV1100, disconnect the

vacuum sensor hose.

11 Remove the ignition coil cover and disconnect the primary (low

tension) coil wires (see Chapter 4). If youre working on an XV1100,

disconnect the vacuum sensor hose and electrical connector.

12 Disconnect the clutch cable from the engine (see Section 16).

13 Remove the sidestand (see Chapter 7).

14 Disconnect the spark plug wires (HT leads) (see Spark plugs -

replacement in Chapter 1).

15 Disconnect the ground/earth wire from the engine.

16 If youre working on a 1981 through 1983 model, disconnect the

cable from the starter relay to the starter motor at the relay (see

Chapter 8).

17 Disconnect the wires for the alternator, sidestand switch, oil level

switch (if equipped), neutral switch and starter motor.

18 If youre working on a shaft drive model, pull the rubber driveshaft

boot away from the engine. If youre working on a chain drive model,

remove the engine sprocket (see Chapter 5).

19 Support the engine with a jack and wood block. Make sure the

support is still in position under the swingarm pivot and that the bike is

still securely braced. 
						

							
2B-12

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

5.20a Unbolt the front cylinder mounting

bracket from the frame 
5.20b Remove the rear cylinder bracket-

to-frame bolts (arrow); theres one on each

side of the bike 
5.20c Remove the mounting stud at the

rear on 1981 through 1983 models

5.23 Look through the viewing port to

align the driveshaft with the middle

driven gear 
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 2 x 4

lumber and lag bolts or nails 
7.1a If the engine has Type A tensioners, remove the Allen bolts

(arrows) and take the tensioner out

20 Remove the engine mounting bolts at the top of each cylinder

(see illustrations). If youre working on a 1981 through 1983 model,

remove the mounting stud at the rear of the engine (see illustration). If

youre working on a 1984 or later model, remove the mounting bolts at

the upper rear and lower rear of the engine.

21 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.

22 Slowly and carefully lower the engine assembly to the floor,

disengaging the driveshaft (if equipped) as you do so. Guide the engine

out from under the right side of the bike. 
						

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

2B-13

7.1b Camshaft, cam chains and tensioners

1

2

3

4

5

6

7

8

9

10

11

12

13

14 
Front cylinder camshaft

Camshaft bearing

Cam chain tensioner

Gasket

Bolt

Cam chain

Intermediate gear

Camshaft sprocket

Pin

Bolt

Washer

Gear spindle

retaining plate

Bolt 
15

16

17

18

19

20

21

22

23

24

25

26

27

28 
Chain guide

Tensioner side chain guide

Pivot shaft

Nut

Washer

Drive pinion

Pin

Spring

Rear cylinder camshaft

Camshaft bearing

Tensioner blade

Oil baffle plate

intermediate gear

Drive pinion

Installation

Refer to illustration 5.23

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

a) If youre working on a shaft drive model, engage the driveshaft

with the swingarm as the engine is moved into position. Some

models have a viewing port in the swingarm, covered by a plug

(see illustration).

b) Dont tighten any of the engine mounting fasteners until they all

have been installed.

c) Use new gaskets at all exhaust pipe connections.

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

following the procedures in Chapter 1 and Chapter 3.

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

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 17).

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 clutch and primary gear

Remove the alternator rotor and starter clutch (see Chapter 8)

Remove the oil pump

Remove the external shift mechanism

Remove the cam chains and intermediate gears

Separate the crankcase halves

Remove the crankshaft and connecting rods

Remove the shift cam/forks

Remove the transmission shafts/gears

Remove the oil pressure relief valve

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 If youre working on a model with Type A tensioners, remove the

Allen bolts and take the tensioner off (see illustrations). 
						

							
2B-14 
Chapter 2 Part B Engine, clutch and transmission (XV700-1100 models)

7.2a If the engine has Type B tensioners,

unscrew the tensioner from the body and

take it out 
7.2b Remove the Allen bolts and take the

tensioner body out of the cylinder 
7.3 Cam chain tensioner keeper

dimensions

7.5 Turn the screwdriver clockwise while pushing the tensioner

piston into the body 
8.3 engine mounting brackets

1 Front cylinder mounting

bracket

2 Rear cylinder mounting

bracket

3 Flange nuts (short)

4 Flange nuts (long)

5 Washers
2 If youre working on a model with hex-head (Type B) tensioners,

remove the tensioner cap bolt and spring while the tensioner is still

installed on the engine (see illustration). Remove the tensioner body

Allen bolts and take it off the engine (see illustration).

Installation

Type A tensioners

Refer to illustrations 7.3 and 7.5

3 Fabricate a keeper tool from steel 1 mm (0.039 inch) thick (see

illustration).

4 Pry the rubber plug out of the tensioner,

5 Insert a small screwdriver and turn it clockwise while pushing the

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

is all the way in, hold it there, remove the screwdriver and install the

keeper tool to hold the tensioner in position.

6 Install the tensioner on the engine, using a new gasket. Tighten

the mounting bolts to the torque listed in this Chapters Specifications.

Remove the keeper tool and install the rubber plug.

Type B tensioners

7 Install the tensioner body on the cylinder, using a new gasket, and

tighten its mounting bolts to the torque listed in this Chapters Specifi-

cations.

8 Check the sealing washer on the cap bolt for cracks or hardening.

Its a good idea to replace this washer whenever the tensioner cap is

removed.

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

the tensioner piston into the tensioner body (see Part A of this

Chapter). Install the tensioner on the cylinder, using a new gasket. 
10 Install the tensioner spring, sealing washer and cap. Tighten the

cap to the torque listed in this Chapters Specifications.

8 Cylinder heads, camshafts and rocker arms - removal,

inspection and installation

Cylinder head removal

Refer to illustrations 8.3, 8.4a, 8.4b, 8.4c 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 front cylinder (see Chapter 4). Remove the carburetors, intake

joints and air induction pipes (if equipped) (see Chapter 3).

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

the front cylinder head (see illustration).

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. 
						

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

2B-15

8.4a Cylinder heads (1981 through 1983 models) - exploded view

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17 
Front cylinder head

Rear cylinder head

Valve guide and snap-ring

Damping block

Locating dowel

Head gasket

Front cylinder stud

Rear cylinder stud

Stud

Nut

Copper washer

Cam chain tunnel O-ring

Nut

Domed nut

Washer

Bolt

Exhaust mounting stud 
18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33 
Cam chain sprocket cover

Cam chain sprocket cover

Oil baffle plate

Crankcase vent hose

Hose clamp

O-ring

Bolt

Rocker arm cover

Rocker arm cover

O-ring

Bolt

Lockwasher

Bolt

Oil pipe union bolt

Sealing washer

Spark plug